NCG500346_Regional Office Historical File Pre 2018

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SOC PRIORITY PROJECT: Yes_No X
If Yes, SOC No.
To: Permits and Engineering Unit
Water Quality Section
Attention: Charles H. Weaver,Jr.
Date: June 6, 1997
NPDES STAFF REPORT AND RECOMMENDATION
County: Gaston
Permit No. NCG500346
PART I - GENERAL INFORMATION
1. Facility and Address: Stovall Foundry, Inc.
PO Box 983
Gastonia, NC 28053
2. Date of Investigation: June 6, 1997
3. Report Prepared By: Todd St. John
4. Persons Contacted and Telephone Number: Scott Scarborough [phone]
5. Directions to Site: From the intersection of I-85 and Highway 321 in Gastonia, travel south
approximately 3 miles. The site is located on the left-hand side at the intersection of Highway
321 and Bush Street.
6. Discharge Point(s). List for all discharge points:
Latitude: 35° 14' 58" Longitude: 81° 11' 36"
Attach a U.S.G.S. map extract and indicate treatment facility site and discharge point on
map.
U.S.G.S. Quad No.: G14NW U.S.G.S. Name: Gastonia South,NC-SC
7. Site size and expansion are consistent with application?
Yes X No_ If No, explain:
8. Topography (relationship to flood plain included): Site is at headwater. It does not appear

Vsince This Office has no objection to extending coverage to this facility under the subject general permit
the discharge already exists. The fact that a neighbor has filled the ditch downstream without
providing a means for the water to flow through may present flooding problems from time to time;
however,
;the
foundry does not have any control over this problem.
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Jt;v()( /.4`'
Signature of Report Preparer
Water Qual' Regional Supervisor
‘//-7/22
Date
Page 4

State of North Carolina
Department of Environment, \ >
Health and Natural Resources • •
Division of Water Quality
• r
‘(1 James B. Hunt, Jr., Governor
Jonathan B. Howes, Secretary r-D
ecretaryp E I - I NI R
A. Preston Howard, Jr., P.E., Director
N.C. D_ T. Or
May27, 1997 EIVVIRON!Y , - T•ii
�r A r�I ;°.� ; V3
Mr. E.A. Stovall MAY 2C 1997
V Stovall Foundry, Inc.
P.O. Box 983 Ol1"''rs [• ,;iXt
\ Gastonia, North Carolina 28053 k� =" `� "" � t 1$r114
Subject: NPDES Permit Application
Application No. NCG500346
Stovall Foundry
Gaston County
Dear Mr. Stovall:
The Division has received your completed permit application and check # 018366
for $400.00. Your application has been assigned to me for review.
Please note th. t the General Permit under which you have applied for coverage
(NCG500000 - Non contact cooling water and similar discharges) expires on July 31,
1997. Processing of your application will be timed to coincide with the re-issuance of
the revised General Permit, prior to July 31, 1997. In this manner you will not receive
a permit that is due to expire in July, but one that is valid for the next five years.
By copy of this letter, I am requesting that our Regional Office prepare a staff
report on your facility. If you have any questions concerning this permit, please
contact me at telephone number [phone], extension 511. I
jO
Sincerely,
/ J
Charles H. Weaver, Jr.
NPDES Group
cc: Mooresville Regional Office
Permits and Engineering Unit
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P.O.Box 29535,Raleigh,North Carolina 27626-0535 Telephone[phone] FAX[phone]
An Equal Opportunity Affirmative Action Employer 50%recycled/10%post-consumer paper

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,
State of North Carolina
Department of Environment, Health and Natural Rtesoarces
Division of Environmental Management
512 North Salisbury Snit . Raleigh,North Carolina 27611
James G. Martin,Governor A.Preston Howard,Jr.,P.E.
William W. Cobey,Jr., Sectary Acnng Dire=
NOTICE OF INTENT
j4ational Pollu nt Disclisrgt Elimination System - "?
Applicanon for Coverage undo Genoa Permit NCG500000;Noncom=coding water,btnza blowdown.
cooling tower blowdown,condensate,and similar point source:diacges.
1. Name,Address,location,and telephone atmba d fray requesting Ptsmn.
A. Official Name: Stovall Foundry, Inc.
B. Mailin,g Addt PO Box 983
(1),S atm Mare=
(2 rr Gastonia
(3)StaLe; NC
(4)Zip; 78053
• (wry; Gaston
C. Location. (Attach map ctrlirranng general facility locscoa) (See USGS Map)
(1)Screes Mites= 120 Bush St.
(2)Cir ; Gastonia
(3)S xe; NC
(4)C ,ty; Gaston
D. Telephone Number, (704 ) 864 - 5481
2. Facility Caatacr.
A. Nam C E. A. Stovall
B. Th1e - Vice President
C. CompanyName; Stovall Foundry. Inc.
D. Pbooe Number. ( 704 ) 864_• 5481
3. plic mion type ( zpp m Via°):
A. New err Proposed;
B. Existing; X If previously permitted, provide permit numbq
and issue dale
C. Mocfi fir-trYxt;
(Desc-ibe the nature of the modification):
4. Desciption d discharge A.Please state the number of separate discharge points
l.K] : 2,1 ] ; 3.11 : 4.13 • 1).
B.Please desc:zbe the A noe.eu of yeaszewatc bong discharged per each separate dise'sarge point l:
gallons per day (gpd) 24._ (Wd) 3: (gpd) 4: (Ex!)
Please see Attachment
Page 1

•C. sod freau=o7 &the r+isr�7.. sparse-I;a--,r.pea_
1. Cant;nucus:_ Please see attachment
2 Int,e_^niaeat (please desc3x): February �]:'•+�Lsr=b l`�:�u t�l.
3. Scasonai(check months) the discharge octas):January [q:
May n Juae Pi;July PP:August[3: September l :O=ob& ];.November ;
4. How many days per week is these a disci'sarge?(check the days the discharge o .as)
Monday VI. Tuesday j. Wednesday IC). They NI,Priday Sanaday [.. Sunday N.
(Discharge possible on anys prod'(�� day)
5. How much of the volatile disc'sarged'
• D. What type of wastewater is discharged per scpatn a di9cbarge pans(pia=check nett to CCM=type):
1. Non-contaa cooling ware:
2. Boiaer blow(own:
• 3. Cooling tower blowdown:
4. Candensata
5. Othest any knowdesctn
e); a Separate discharge point Please list any latown pollutants that am present in the discharge. per a if
tapplicable): N/A
E. Please be the type of prceze the cooling water is being discharged from.per separate discharge point
(Le.compresser.boiler blowdown.cooling tower blowdown.air conditioning nail.etc.):
Electric induction furnace cooling system
F. Please check the type of chemical added to the wastewater for treatment or other.per separate dic•ltarge
point . . -
1. Biocides;
2. Corrosion inhibitors:
3. Chlorine:
4. Algae control; --
S. Other(please descibe);
6. None; X
If1....3.4.or5 was c++-'kr11 please state the name andmanufacturer ufactu er of the chemical additive. Also include
a completed Biocide 101 form,and manuuf ctur 'information on the additive with the application for the
Division's review.
G. Is there any type of treatment being provided to the wastewater before discharge (i.e. retention ponds.
settling ponds, etc.); if yes, please describe. Give design specifics (Le. design volume.retention time,
surface area, etc.). Existing treatment facilities should be described in detail and design criteria or
aperatonal data should be provided(inciudia_g calculations) to ensure that the faclity an comply with
requirements of the General Permit. None
NOTE. Construction of any wastewater treatment faclities require submission of there (3) set of plans and
spefcations along with their application. Design of treauent facilities must comply with requirement
15A NCAC 2H .0138. If construction applies to the discharge, include the three sets of plans and
specifications with the application.
5. What is the nann'e of the business applying for this permie Iron Foundry
6. Name of rs mvirig water. Crowders Creek to Lake Wylie,,a,;„.. n
(Math a USGS topographical map with ail discharge poin(s)ciearyy matted)
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discharge•
y to the rig wage! �,�.) N Discharge to storm sewer
7. IS the oharge point Mari ciesriy the Poway to the pc ral rece:vm irs g"+a on the
sztt map.a (This includes tracing the pathway If no sp i t the disc of the scrimscrimer sew to its discharge point. if a norm ewer is the
only viable means of discharge-)
8. 'lease address pomaile noo-disbie alternativesfor the following caxion.v
A.Co'to a Regional Sewer Colle ice System; The sewer system that would be practical to
connect to is primarily residential and is privately owned. :The owner is currently
roposin turn the operation of the system over to the users. Connection to this
to system would probably not be an option until
Not Via le ownership transfer is complete.
C Spray Iaipaoo:
Not-Viable
9. I certify that I am familiar with the information coorained in the application and that to the best of my knowledge
and belief such information is true,complete.and accurate.
Primed Name of Peaoo Signing
E. A. Stovall
Vice President
Title
Date Application Signed •
•
Signanae of Applicant
NORTH CAROLINA CLFNFIZ kL STkTUTE 143 215-6E fi) PROv1DFS THAT:
Any person who knowingly makes any false statement.representation, or certification in any application.record.
repon.plan or other document filed or required to be maintained under Article 21 knfowingly
the Environmental
renders inaccurate
yrecnManagement Commission implementing that Auricle.arm who�� under Agile 21 or regulations of
any tt�ading or monitoring device or method required demeanor
of a misdemeanor
the Environmental Management Commission implementing that Article. shall be guilty 18 U •
punishable by a fine not to exceed S 10.000. or by imprisonment not to exceed sit months,or by both.
Section 100I provides a punishment by a fine of not more than S10.000 or imprisonment not mere than 5 years.or
both.for a similar offense.)
Notice of Intent must be ac ompanied by a check or money order for S400.00 made payable to the North Carolina
Department of Environment.Health,and Natural Resosrt a. Mail three(3)copies of entire package to:
Division of Environmental Management
NPDES Permits Group
Pint Office Box 29535
Raleigh,North Carolina 2 2 535
Page 3

STOVALL FOUNDRY, INC.
SUPPLEMENTAL INFORMATION
FOR
NOTICE OF INTENT
QUESTION 4B AND 4C
A two minute discharge of approximately 20 gallons occurs each production day.
Our electric induction melting furnace is normally cooled by a recirculating cooling
system. In the event of a power failure, the furnace must be cooled by fresh water.
This water is discharged at a rate of approximately 9.09 gallons per minute. The
amount of the discharge would depend upon the timing of the power failure relative to
the cooling cycle. If the power failure occurred at the initiation of the cooling cycle, the
discharge could occur for eight hours resulting in a discharge of approximately 4,363
gallons.
The holding tank supplying the cooling tower of our electric induction melting furnace is
periodically refilled with fresh water to replace water that is lost to evaporation. If the
automatic refill system fails to shut off when the tank is full, a discharge would then
occur at the rate of approximately 9.09 gallons per minute.

STOVALL FOUNDRY, INC.
Specializing In Gray And Ductile Iron Castings
�V
May 16, 1997 N.C. Ur'T. o
ENVIROI
CERTIFIED MAIL
RETURN RECEIPT REQUESTED KAY i ) 1997
Mr. John Lesley
North Carolina Department of Environment, Health
and Natural Resources
Division of VVater Quaiity
Water Quality Section
919 North Main Street
Mooresville, North Carolina 28115
Subject: Complaint Investigation
May 1, 1997
Dear Mr. Lesley:
As was requested, we are submitting this written response addressing the findings of
your investigation as follows:
We are gathering the information necessary to complete the General Permit Notice
of Intent for the discharge of noncontact cooling water, and expect to file the
package by May 20, 1997.
The Stormwater Permit Application has not yet been received from the Stormwater
Group in Raleigh. Upon receipt, we will take all steps necessary to promptly
complete the application.
We have contacted the City of Gastonia regarding the Pretreatment Program. They
have indicated that they will assist us in determining the appropriate permitting.
If we can provide additional information, or if you can further advise us on corrective
procedures, please do not hesitate to call. Thank you for your assistance.
Sincerely,
U . LLgt
D. Scott Scarborough
2306 HIGHWAY 321 SOUTH • P.O.BOX 983 • GASTONIA,NORTH CAROLINA 28053 • [phone] • FAX[phone]