NCG500312_COMPLETE FILE - HISTORICAL_20070801

STORMWATER DIVISION CODING SHEET
NCG PERMITS
PERMIT NO. /v �� 5u o 3 a
DOC TYPE tP-HISTORICAL FILE
❑ MONITORING REPORTS
DOC DATE ❑ 0 0 d d
YYYYM M D D

y
August 1, 2007
Storm Water Permitting Unit
NCDENR—Water Quality Section
1617 Mail Service Center
Raleigh,NC 27699-1617
RE: Request for an Authorization To Construct U
NOV 2007-PC-0195 p
H/Solids Corrective Action Plan
,1C
Greystone Concrete Products
Vance County DE
Permit Nos NCG 150138 &NCG500312
Dear Sir/Madam:
As requested in Mr. Langley's e-mail dated June 5, 2007, EI, on behalf of Greystone Concrete
Products, is submitting this request for and Authorization to Construct (ATC) wash water
treatment facilities related to the discharge from the drum wash pit. The letter includes a scaled
drawing of the property showing the location of the proposed construction and vender
information regarding the chemical feed system.
The proposed treatment system will include a series of settling ponds with pl-I adjustment
associated with the last pond prior to discharge. The system being employed is common to the
treatment of drum wash water at concrete batch plants. Specifically, the facilities being proposed
at the Greystone plant include:
• Drum Washout Basin — Drum wash water from each truck will drop in this first earthen
basin, which will be approximately 50 feet by 60 feet. The washout basin will retain
water generally to between 2 to 3 feet, controlled by a stone weir located at it outlet,
which will also filter the water.
• Settling Basins — From the drum washout settling basin, wash water will flow into a
series of two earthen settling basins each approximate 15 feet wide and 40 feet long. The
discharge from each fine material settling basin will be control by stone weirs also,
providing additional filter capacity. The designed depth of each of these basins is 1'/z to 2
feet.
• Final pH Adjustment Basin — The final earthen basin will be used for pH adjustment and
will be approximately 40 feet by 50 feet. Again, the outlet of the final basin will be fitted
with a stone weir to control level and provide additional filter capacity.
• Fortrans Package Treatment Building — A Fortrans Model 5000 S pl-I control system has
been ordered for this application. Carbon Dioxide is used to reduce the pI4 of the wash
water in the final pH adjustment basin. The piping configuration will be typical for these
units and will be oriented to provide mixing/recirculation of the water in the basin, which
helps ensure that the final discharge will be within limits. The initial pH set point for the
Fortrans system will be between 7.5 and 8.0.
2101 Gateway Centre Boulevard • Suite 200 • Morrisville. NC 27560 • Tel: [phone] • Fax: [phone]

Storm Water Permitting Unit Request for an Authorization To Construct
NCDENR— Water Quality Section NOV 2007-PC-0195
August 1, 2007 pH/Solids Corrective Action Plan
Page 2 Greystone Concrete Products
• Final Discharge — The treated wash water will be discharged through Outfall 001, which
will not be relocated.
• Underground Power— Greystone will run underground power from the batch plant to the
Fortrans building. It will be located underground so as to not interfere with truck traffic
in the area around the batch plant and treatment system.
The system described above is designed to reduce solids and pH in the discharge to within
acceptable and permitted limits. As stated above, the Fortrans system has been ordered and
delivered to the facility. The basins can be finished and the treatment system installed and
operational within two weeks of the receipt of DENR's Authorization to Construct.
Thank you for your attention and assistance in this matter. We are committed to remedying this
particular issue, as is evident by the corrective actions Greystone has already initiated. If DWQ
has any questions or concerns about our approach, please contact us at your earliest convenience.
Otherwise we will proceed as described. Thank you for your attention.
Sincerely,
EI, Inc.
%t�'.,
1
/ wmicac aW ]k _ BEAL
Manager 4992
Environmental & Engineering Services
�-
MLW/
Attachments:
Site Survey
Fortrans Vendor Information
Cc: Mr. Shannon Langley, Raleigh Regional Office
Sam Cannady, Greystone Concrete
ENM0071004 File
2101 Gateway Centre Boulevard • Suite 200 • Morrisville. NC 27560 • Tel: [phone]S00 • rax: (919) 657-7SSI

i A R
11 i N• ( 'y . 9 ' ' tip d!
�-
FORTRANS pH CONTROL SYSTEMS
FORTRANS pH CONTROL SYSTEMS are _
completely automatic.They continually monitor/test anmer '
the pH of the influent water and compares it to the ? -
pH setting of the control unit. If a change in pH is
detected, the controller activates the solenoid valve _ k
for the CO2.The pH adjustment chemical is then fed
to the return side of the circulation pump until the
pH is again at the proper level set at the controller. "
The unit will continuously circulate the water until ax <�
change in pH is detected and the treatment cycle
begins once again.The unit also features a digital
pH meter connected to a probe in the sample cell
to ensure unit is functioning properly and that the The Model 5000-S pH Control System is a self-
correct pH level is maintained. contained pH monitor and control system housed in
The pH CONTROL SYSTEMS are designed to a weatherproof facility with lockable doors and
treat and maintain a specified pH level in a body of adequate space to house the instrumentation and
water usually 100,000 gallons or less to allow the circulation pump.The system is configured for carbon
permitted discharge of treated water to the dioxide gas operation.
environment. Permits must be obtained from the
local governing agency to allow any discharge to they" ' �„w f•
environment. Treated water may be used for wetting
of rock and/or dust control to aid compliance with
stormwater run off regulations.Treated water may h±.«
also be used in water recycling systems.
Theses stems offers precise monitoring and la s
control of the pH in settling basins, lagoons and
— r
other outfall containment devices. -� t
-The pH CONTROL SYSTEMS will treat up to
57 gallons per minute - max 20'head pressure.
Unique water circulation design eliminates the need
for separate neutralization tank. ! 9 Imam,wm
•1.5' quick connect fittings on inlet and return
for easy hook-up.The standard unit is equipped with
2-30'sections of 1.5"flexible hose with quick connect
fittings. Inlet and outlet fittings at the basin or lagoon The Model 5000-SK Skid Mounted pH Control
are per our specifications. System contains all of the instrumentation and
-Unit is shipped completely assembled.The components of the regular Model 5000-S System
chemical controller is preprogrammed to maintain a and is shipped on a 44"x47"plastic skid with a durable
pH of 7.5. Just attach hoses and PVC fittings. solid plastic surface.The Control Panel is provided
•1 year warranty on all component parts loose with all components installed and is designed
and housing. to be attached to an interior wail of the control
building.The tubing to the sample cell and from the
CO2 solenoid valve to the Sparger stone feed
assembly must be inserted after receipt of the unit.
Fort,rans,,. The system I receptacles.
a 115V-30Ay t Breaker
hipp x
and two GFCI rece tacles.The s stem is shipped
O \L with a CO2 feed system.
FORTRANS, INC. • 7400 C.Siemens Rd. • Wendell N.C.27591
1.866.365.8760 • 1.919.624.8832
[e-mail] • www.fortrans.biz

_,�a+"`�- is fa ws-c-`•*^r •'-�lr°+e� sue• ' +. :
a "" t9 itss. >. a "•T��a e ,� _x�:, µ`a.��, �'''�j d�" a �
FORTRANS pH CONTROL SYSTEMS - MODEL 5000-S & 5000-SK
3/�all
valve to facilitate
easy priming of
pump
Intake line detail 1 1/2"cam lock
quick connect
Option
1 1/2"schedule 80 union should be
Overhead view located above water line so that check
valve can be cleaned
Setliing basin
Basin 1 1/2"PVC check valve.
wall Locate 12" barmani om the lwno
line of the hasin
lne
water
flow
Goo line 1
line
See overhead view for correct pipe I.
y / placement in basin.This put of
. \ / the return line is rotated 9(1"over
00 the basin wall.
Imakc
assembly l 1/2"pipe
clamPls)
Return line is installed on interior 1 I/2"cam lock
side of settling basin.Fasten with
quick connect
1 1/2"pipe clamps.
GBasin wall
Return line detail
water -
_ Retum line outlet
approximately 12"from
= the bottom of the basin
-- 12"
12 � "l7 Return line outlet is
constructed with
1 1/2"schedule SO PVC
F®rtransrc

Fortransinc.
3800 Original Henry Rd., P.O.Box 759 " Henry,Va.24102 " 877.387.8509 • www.fortrans.biz
Model 5000 S & SK pH Control Systems
INSTALLATION NOTES
1. Push hose ends all the way into the V hose fittings.
2. Connect hose to hose fitting on the white CO2 injector and the other end
of the hose to the hose fitting on the check valve at the solenoid valve.
Note: The CO2 injector is shipped in an upside down position on skid mounted
systems. Turn it to an upright position and tighten union connection.
3. Connect hose fitting on return line to the Hose fitting marked "inlet" on the
sample cell with the V hose.
4. Connect hose fitting on the intake or suction line to the hose fitting marked
"outlet" on sample cell.
5. Insert pH probe into probe fitting and tighten. Do not let probe dry. If necessary
add water to sample cell through the probe holder and reinsert pH probe.
6. pH probe has been calibrated at the factory. It should be re-calibrated every
week. See operations manual for calibration instructions.
7. Catalog#2866-L ph 4.01 buffer and catalog#2881-L ph 7 buffer agent are
included. These materials may be re-ordered from Fortrans Inc.
8. It may be necessary to install a %:" PVC ball valve on intake line in order to fill
line with water to help prime the pump. See drawing in operation manual for
placement of the ball valve.
9. Use PVC Cleaner and PVC Cement to install Intake and outlet fitting through
the back of the housing.
10. Plug the pH Controller into the 1000 joule surge suppressor.
11. Ground pump to copper grounding rod.
12. Position outlet in basin so that the water flows parallel to surface of water.
This will create a circular flow in the basin. See drawing for more detail.
13. Install warning light and plug into outlet on right side of controller.
14. Tighten all union connections before operating.
Makers of these fine products... • 5000S pH Control System • Mortarman" -Concrete Remover -Safe Soap II` -Safe Soap- • Car Baby -Cherry Car Soap"
-Grease Blaster'" -Truck Wash -Fortrans 400' -Slic Trick'" -SuperSlic" • Wood Revive'" • Motorcycle Cleaners -Hawg Wash" -Rocket Wash'" -Spray Bright"

MULTI-PARAMETER CONTROLLER & ANALYZER USER'S MANUAL
S H R K
Section I - Specifications
�j
H ORP Conductivity Flow
Display Inside
Panel:4 x 7 segment 1/2'LED display,I LED indicator On-line,7 LED Bar Graph
Inside Panel:2 x 16 al ha-numeric LCD dis lav - -
Power Requirements 120Vac(t10%)50/6OHz Oess than 12VA)or 240Vac(m 10%)50/6OHZ(less than 12VA) _
MWcm, 0 to 19.99 0.01 Flow: 0 to 9999 with selectable
Bow rate units
0 to 2.000 0.01 Volume 0 to 9999 with Auto Range
Measuring Range pH: 0.01 to 14.00 ORP: -1999 to+1999mV 0 to 20.00 0.1 _
(Dependent on sensor) u5/cm; 0.1 Flow rate units:Gallons(GP),Cubic
Temp: 0 to]o0°C or Temp:0 to IOO'C or 0 to 200.0 Feet
32'to+212°F 0 to 2000 1.0 (�'Gras(LP),Cubic Marrs
32°[o+212°F (CM),custom by entering factor
0 to 20.00 10 related to Gallons
m5/cm+ —
0 to 200.0 50
Time units:Seconds(S),
Temp: 0m100°Ccr32°to+212°F Minmes(M).Hours(H)
Automatic or Manual
Temperature Automatic or Manual Not required User selectable temperature Notre aired
Compensation 0 to 100°C(32'to+212°F) compensation slope 0.0 to 10.0%/°C q
o to 100°C(32°to+212°F)
Tem ratan Unit °C or°F Not required
Temperature Sensor User selectable:3000 NTCThcrmistor,300M NTC Thermistor or Pt.1000 RTD Not required!
Au*Calibration Manual Calibration Dry Calibration
Calibration Modes Manual Calibration Temperature Calibration Sample Calibration K factor Input
Tem erature Calibration Tem erasure Calibration
Ambient Conditions Temperature:-20*C to+60'C or 47 to+140°F Humidity:0 to 90%RH(noncondcnsin ) -
Menu Access Auto-Calibration,Manual Manual-Calibration, Manual Calibration
Front Panel Display Ca n,Temperanue Temperature Display Temperature Display Not asailable `
Display
Menu Access Inside Panel Full Access to all ammeters of operations menu Sensor to SHARK Differential Sensor.3000 fi Distance Combination Sensor 10 ft 300 f[ 2000 It
Two Control Relays,I OA/NO,5A/NC @ 240VAC or 28VDC.
Mode:Process control,Adjustable parameters:process direction.(rising or falling)on-set-point,off set-point, -"
Relay Outputs (0 to I 00A1 of full scale),cycle timer(on/off.0 to 600 seconds),failsafe(on/off).
One Alarm Relay,IOA/NO.5A/NC @ 21OVAC or 28VDC. —
Mode:High/Low Alarm.Adjustable parameters:Low on/Low off set-point(0 to 100%,,of full scale,low on must be less than
Ion,off),High On/Hi h Off set- aim to to 100's,of full scale.High on must be greater than High off). -
4 to 20mA Channel I
Isolated Output.Range expand U- I(Rr'..of hill scale(min segment 10/,of full scale),max.load 800Q
Analog Outputs 4 to 20mA Channel 2
Isolated Output,Range expand 0- I(Hy.of hdl.cAc(min segment IOtd of full scale),max.load 800D
Can be set to track(em eramrc if wn,r i,cyt3i2pcd with a temperature sensor
Memo •Bock-up All user-settings are retained indefnod, in mcmun (ELPROM) -.
Mechanical Enclosure:NEAL14a,1/4 DIX pohcarM mate enclo+are with four 1/2-conduit holes
Mutm :Linicersal Mounting kit for.urjrc,pipe and panel mount.is included -
Sensor Input Probe�i(R1 tni+6ttOm\' Probe Prrl o,+l W9m1' Cella]toa99'
P Temp.Sensor:0 to 9999Q Tempr n..it o to pl'P Temp.Sensor:0 to 99990
Paddle:0[0 2000Hz
Invalid Entries Invalid entries cannot be stored
Manual Test Mode Process value can be simulated with are.M kn,u,r crih correct setup of Outputs
Manual Relay Override Relays can be set to on/off/atuu.t• „rn, tiro t i wiring of auxilian do ices.or to manually adjust process
Output Hold All Outputs are placed on hold when'n(RK ,,in slrnu mode
Recall data from last
Recall data from last calibration.cahbr.io•,°mtl` calibration.calibration buffer -
Calibration Data Isi S 2nd accepted buffer value and pr tx m1 , ,apm, accepted value.and cell Recall store K factor.
calibration temperature.calibratiun•I p, and Pn Jk resistance.calibration -
effciencv
rem enture
Auto Return User selectable auto return if SHARK n c! m,no mode or if relays are left in manual ocerridc mode for more than Ill min.
Display Damping I:xr can select rate at which SHARK r,-,t,.t.tn Lnablcs display damping of unstable process
Net Weight 2.21hs(I kg)
Approvals L'LC(pending) j
Section I - Specifications Page 2

ENGINEERS CERTIFICATION
OF THE MODEL 5000-S PH
MONITORING AND CONTROL SYSTEM
By:
G.C. Environmental, Inc.
P.O. Box 40125
Raleigh, NC 27629
For:
Fortrans Inc.
P.O. Box 40
Wendell, NC 27591
Dated:
September 11, 2003

G. C. Environmental, Inc.
5312 Pinewood Court Z
Wendell, NC 27591
[phone]
September 11, 2003
p
PURPOSE
G.C. Environmental, Inc., was contracted to provide an engineers review and certification that the
Model 5000-5 pH Monitor and Control System manufactured by Coastal Carolina Supply in
Morehead City,NC, could effectively provide on a continuous basis, an average pH range of 6-9 units
on the supernate layer of a stormwater/rinse water sedimentation basin typically found at Redi-mix
concrete facilities.
SCOPE OF WORK
During the week of August 11, 2003, G.C. Environmental, Inc., witnessed the operation of the Model
5000-S self-contained pH Monitoring and Control System at a Redi-mix plant located in Durham, NC.
During the two (2) day test program, measurements were made within the facilities stormwater/rinse
water sedimentation basin for pH,temperature and depth(both supernate and sludge). During the first
day of testing, the basin was found to be heavily loaded with solids and adjustments were made tothe
solids blanket to complete testing the following day.
TEST METHODOLOGY
A primary sedimentation basin located at a Redi-mix concrete plant located in Durham, NC was
treated utilizing the Model 5000-5 pH Monitor and Control System. During the test program, the
basin was, on a semi-continuous basis, being fed rinse water from the exterior cleaning of cement
trucks. Measurements for pli, temperature, supernate and sludge blankets were made within the
sedimentation basin. Initial pH measurements showed pl-I levels of at least 12.0 units. The
sedimentation basin was rectangular in shape with concrete walls and bottom The basin ranged in
depth of 1" at the inlet to approximately Tat the deepest point. Sludge measurements within the basin
showed that at least 2/3 of the basins depth was comprised of sludge and the remainder supernate.
The Model 5000-5 pli Monitor and Control System was set up at the rectangular sedimentation basin
with the intake and discharge hoses situated at opposite ends of the basin. Both the intake and
discharge lines were set at depths within the supernate layer of the basin. A clockwise flow pattern
was established once the unit began operation and pH and temperature measurements were made at
several locations throughout the supernate layer of the sedimentation basin. Approximately eighteen
(18) pH and temperature measurements were collected with a mean pH value of 8.56 and mean
temperature values of 30.94 0C. The pH system was left to run essentially on a continuous basis over
a four (4) hour period. An estimated volume existing within the sedimentation basin was 25, 000
gallons with a little over 8000 gallons consisting of relatively clear supernate. The amount of 25%

Sulfuric acid (H2SO4) used to treat the sedimentation basins supernate was approximately 18-20
gallons.
MODEL 5000-5 PH MONITOR AND CONTROL SYSTEM
The model 5000-S pH Monitor and Control System is comprised of a Hayward Power Flow 11 (3/4
hp, 56 GPM) centrifugal pump which delivers raw water to a completely contained pH sensor
connected to a pH meter equipped with control relays which operate two (2) stenner (60 GPD) acid
injection pumps. The acid 25%H2SO4 is injected into the pump discharge line which empties into the
sedimentation basin. Sulfuric acid is delivered to the system by 15 gallon carbuoys located outside of
the fiberglass weatherproof enclosure which houses all of the aforementioned equipment. On top of
the enclosed is an alarm light which is tied into the pH meter which is activated when pH levels exceed
8.5 pH units or are below 6.0 units.
CONCLUSION
1. The Model 5000-5 pH Monitor and Control System is an effective system for the pH balancing of
sedimentation basins which are used to collect stormwater runoff and rinse water, commonly found
at Red-mix concrete plants.
2. During the test program an average pH of 8.54 units was measured in the subject sedimentation
basin with a range of 7.95 to 9.34 measured.
3. Sludge levels existing within the rectangular sedimentation ranged from 6.0 inches to 2.0 feet. PH
values after pH stabilization at the sludge/supernate interface were approximately 12.0 units
4. For this test program, approximately 180 mg/1 of sulfates were added to the sedimentation basin as
a result of pH adjustment with 25% sulfuric acid.
5. The 5000-S pH Monitor and Control System is fully automated and provides a PH adjusted waste
water which could effectively be reused within the Redi-mix concrete industry.

r, ~ N
I
Comparative Neutralization Curves of an
Industrial Effluent
2
,0
= 6 \
a
\\ —Carbon Dioxide
—Sulfuric Acid
a
2
0
0 100 200 300 400 500 600 700
Acid Added (mg/litre)
Carbon Diobde Versus Mineral Acids.dm
3of3

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