NCG500318_Regional Office Historical File Pre 2018 (2)

FILE
. . . . . . . . . . . . .
NORTH tit
PloyCOOPER
0"
M CHAEL S. REGAL
S"aMrr
r"r, rr
2 August 201
RETI]RCIFT �E
Mr. Johnny Drummond, Plant Manager
Ipex lUSA, LLC
10100 Rodney Street
Pineville, North Carolina 28134
Subject: Notice of Violation
Compliance Evaluation Inspection
Ipex USA, LI.
D rS General Permit u. NCG500 18
Mecklenburg County
Tracking r#: NO-2018-PC-0303
Dear Mr. Drummond.
Enclosed is a copy of the Compliance Evaluation Inspection.. Report for the inspection conducted at the subject facility on
July'24, 2018, by Mr. Wes Bell of this Office. Please inform the staff that oversee the facility's environmental affairs of our
findings by forwarding a copy of the enclosed report.
"'This report is being issued as a Notice of Violation (NOV) due to the following:
Unpermitted discharge, of contact cooling water (extrusion process) into the storm water drainage system and receiving
stream;
Failure to obtain Envision approval of chemical additives used in the cooling towers and chiller water systems;
Failure to collect representative samples including flow of the effluent discharges;..
- Effluent total residual chlorine limit e eeedance during the June 2017 sampling event.
Noah .�'arofiro Den -,a rovvorrr p al Qt;&irky 1 >Gv ., es
; b r.H
-10 EaF- . Ce't rub Avenue , Sutta 0 Mcort s k,- Niorth .<,r b F 28115
704,663, 1699

maw"Ilmon"d
Page Two
2 August 2018
All above -noted findings are violations of the subject NPDES Permit No. NCG500318 and North Carolina General Statute
(G.S.) 143-215.1 as detailed in the Permit/Summary,Record Keeping, Effluent Sampling, and Flow Measurement Sections
of the attached report. Please be advised that G.S. 143-215.6A provides for a civil penalty assessment of not more than twenty-
five thousand dollars ($25,000.00), or twenty-five thousand dollars ($25,000.00) per day when the violation is of a continuing
nature, against any person who violates or fails to act in accordance with the terins, conditions, or requirements of any permit
issued pursuant to G.S. 143-215. 1. Penalties may also be assessed for any damage to surface waters of the State that may result
from the violations.
It is requested that a written response be submitted to this Office by August 24. 2018. detailing the actions taken to address
the violations and all efforts to prevent the recurrence of any future violations. The response should also include how the facility
will address the industrial air compressor condensate discharges. In responding, please address your comments to the attention
of Mr. Wes Bell. The Biocide/Chemical Treatment Worksheet — Form 101 should be completed for each chemical additive and
submitted to the Division's Aquatic Toxicity Unit (address listed on the form) by September 7, 2018.
Should you have any questions concerning this letter, please do not hesitate to contact Mr. Bell at [phone], or via
email at
Sincerely,
,--DocuSigned by:
LA14CC681AF27425.,.
W. Corey Basinger, Regional Supervisor
Water Quality Regional Operations Section
Division of Water Resources, NCDEQ
Enclosure:
Inspection Report
cc: Rusty Rozzelle, MCWQP (via email)

United States Environmental Protection Agency Form Approved.
EPA Washington, M. 20460 OMB No, 2040-0057
Water ompli n Inspection Report Approval expires 8-31-98
Section A: National Data System Coding (i.e»< PCS)
Transaction Code NPDES yrtmotday inspection Type Inspector Fac Type
1 Pl 5 3 NCG500318 ill 121 18107/ 4 117 1$ G 19 ci 20
21
Inspection Work Days Facility Self -Monitoring Evaluation Rating B1 QA Reserved
7 1.o 70 3 1 N 72 N 731 1 174 7 B
Section B; Facility Data
Name and Location of Facility inspected (For Industrial users discharging to POTW, also include Entry Time/Date Permit Effective Cate
PJTW name and NPDES permit Number) 09:30AM " 18/07/24 1 112/29
Ipex Industrial Incorporated
10100 Rodney St Exit Time/Date Permit Expiration Date
11:45AM 18/07/24 20/07/31
Pineville NC 28134
Name(s) of Onsite R presentafive(s)1Titles(s)/Phone and Fax Number(s) Other Facility Data
JII
Brad Hintz/Engineering Mana er/704-889-243 i e t 50229/ r 048892390
Darrell Bishop/Maintenance Manager/70 89-2431 17048852390
Tony Sanl& Coordinator E HSt704-889-2431 ext 5020417048892390
Name, Address of Responsible Official(Title/Phone and Fax Number
Contacted
Johnny Drummond,10100 Rodney St Pineville NC 28134/Plant
No
Manager17 I4-889-2431i1048892390
Section C: Areas Evaluated Glaring Inspection (Check only those areas evaluated)
Permit N Flow Measurement in Operations & Maintenance Records/Reports
Self -Monitoring Program In Sludge Handling Disposal In Facility Site Review Effluent/Receiving Waters
Laboratory
Section D: Summary of Finding/Comments (attach additional sheets of narrative and checklists as necessity)
(See affachment summary)
Name(s) and Signature(s) of Inspectors) Agency/Office/Phone and Fax Numbers Date
esie by: 8/1./ f113
Wes Bell MRO CtIf704-63-1699 Ext,192i
A516C90CG3437 ..
Signature of Management Q A Reviewer Agency/Office/Phone and Fax Numbers mate
W. Gorey Basinger MRO WQ//704-23 -21941
EPA Form'3560-3 (Rev 9-94) Previous editions are obsolete;
1 t?ocstlgned ry.
8//t)1
Page# 1

yrtmolday inspeefion Type
121 18/07124 17 1
(Cont.) 9

Permits NCCaB tQ tB owner.Fer 14, apex Industrial Incorporated
Inspection Gate; 07/24/2018 Inspection Types Compliance Evaluation
het Yes No NA NE
(If the present permit expires in 6 months or less). Has the permittee submitted a new 11 Q InO
application?
Is the facility as described in the permit? 0 El
## Are there any special conditions for the permit? El 1-3 1110
Is access to the plant site restricted to the general public?
Is the inspector granted access to all areas for inspection?
Comment: The last compliance evaluation ins ection was oerformed at the facifitv on 1112/16 by DWR
staff.
See "Summa ,r Section for additional comments,
Record KeepLnj Yes No NA NE
Are records kept and maintained as required by the permit?
Is all required information readily available„ complete and current?]
Are all records maintained for 3 years (lab, recg required 5 yearn)? �]
Are analytical results consistent with data reported on DMRs?
Is the chain -of -custody complete?
Bates, times and location of sampling
Name of individual performing the sampling
Results of analysis and calibration
Gates of analysis
)Marne of person performing analyses
Transported COCs
Are DMRs complete: do they include all permit parameters?
Has the facility submitted its annual compliance report to users and Ca ? Q
(if the facility is = or - 5 MGD permitted flow) Do they operate 24/7 with a certified operator
on each shift?
Is the ORC visitation log available and current?
Is the ORC certified at grade equal to or higher than the facility classification? Q 0
Is the backup operator certified at one grade less or greater than the facility classification? 13
Is a copy of the current lw PDES permitavailable on site? Is El C1 C1
Facility has copy of previous year's Annual Report on file for review? ® 0
Comments The records reviewed durina the insloection were orcianized and well maintained. The 2016
Ma and 201 November and June effluent monitorina data was reviewed durin the
ins ection. The facility exceeded the total residual chlorine (TRCI permit limit durina the
June 2017 sarniolina event 121 a 1L TRC result reported).
Page##; 3

E
Al. NCG500318 Owner - Fae ty. [pox industrial incorporated
to: 07/24/2018 jrspection "type: Compliance Evaluation
Yes No NA N
ieters performed by certified personnel or laboratory?
Is
0
C
arameters(excluding field parameters) performed by a certified lab?
11
El
El
11
using a contract lab?
0
Cl
aperature set for sample storage (kept at less than or equal to 6.0 degrees
©
0
In
C1
al Coliform) set to 44.5 degrees Celsius+t- 0.2 degrees?
®
C
IN
0
:)) set to 20.0 degrees Celsius +/- 1.0 degrees?
tical Services. Inc.
Lq
Yes No NA N
,g flow proportional?
El
Q
0
L
>elow all treatment units?'
leted?
©
C�
ure set for sample storage (kept at less than or equal to 6.0 degrees
13
C
so
Is the facility sampling performed as required by the permit (frequency; sampling type
representative)?
Comment: The subiect aeneral Dermit requires effluent arab samiales.
The facility icall discharges, only during the annual du in
chiller Dits for the extrusion and moldinQ Drocesses. The semi_
erformed durina a forced discharge small volume at the cool
been 2erformed during the annual dum in of the pits. In'addil
erfored on the chiller pit wastewater. Please be advised the
colleotlon of re resntative sam les and measurements Perm,
II Section L De resentatve Sam lin .
etream 1 Downstream Sam `lira
Is the facility sampling performed as required by the permit (frequency, sampling M
sampling location)?
Comment: The effluent is discharaed/pumped into a storm water draina e
Operations &r Maintenance
Is the plant generally clean with acceptable housekeeping?
Does the facility analyze process control parameters, for ex: MLSS,
Solids, pH, C, Sludge Judge, and other that are applicable?
tual sampling was
tower. No samlina has
no sampliDg has been
,e Permit re ulres the
ondition Deference: Dart
Yes No NA NE
and
stem.
Yes No NA N
rl 171
a
n
Page# 4

Permit: N G500318 ner - Facllity: Ipex industrial Incorporated
inspection Dates 07/2412018 inspection "type: Compliance Evaluation
erationa & Maintenance Yes No NA NE
Comment: i nificent accumutatians of the owder used in the extrusion cram oundin etc.
recesses were observed threw hoist the outside stare a areas drivewa s etc, `f`he facili
staff should initiate the aDDrooriate corrective actions to xevent this material from enterin
surface waters via storm water drains e s stem.
Flow easure ent - Effluent Yes NO NA NE
Is flaw meter used for reporting?
Is flow meter calibrated annually?
Is the flow meter operational? In 11
(if units are separated) Does the chart recorder match the flow meter?
Comment- The flaw from the annual dUmpino of the chiller and coolin tower pits extrusion and
moldin' orocesaesi had not been determined. The flow must be measured determined as
re uired b the Permit Permit Condition Reference: mart 1 1 Effluent .imitations and
fVlonitorin Re' uirements for tan-tcantact toolin 1Nater Eoslin tower and Bailer
locltiwn Aic Com teaser condensate and similar wastewaters
ffittent Ei `e Yes Ntt NA NE
Is right of way to the outfall property maintained?
Are the receiving water tree of foam other than trace amounts and other debris?
If effluent (diffuser pipes are required) are they operating properly? El 11 10 El
Comment: Rlo dishar e were eiserved at tfte time of the ins action,
Page#

Wa er Resources
Glenn Sparrow
IPEX Industrial, Inc.
10100 Rodney Street
Pineville, NC 2 224
Dear Mr. Sparrow:
at the subject facility can January 12, 2016 by;
Chuck Best during the site visit was much ap
LEES Permit by forwarding a copy of the
Three main areas of concern were oh;
1); There has been no prior sampling condu(
12/16/2015.
2)Sampling was not collected below all tre
3) The Chlorine residual sampling result, 5!
In order to address these issues:
1) Sampling should be conducted ic(
during the yearly blowdo
2) Sampling location, in order to ,get an
collected at a point after the filters,
) If high' Chlorine residual results cant
to discharge.
Moore!
Loordlorn 610 East Center
Phone: [phone] \ Fax: (704
Internet: s
PAT MCCRORY
Governor
ALD R. VAN DES VAART
secretary
S. JAY ZIMMERMAN
Director
inuary 21, 2016
ubiect: Notice of Deficiency
NPDES Permit No. NCGr500 18
Mecklenburg County
i
I�
In Regional Office
)., Suite 361 Mooresville, SIC 28115
3-040 \CustomerService:1-877-623- 746
v.n terquality.crg

Additionally, as was idiscussed with Tony Sain, ple
results to the MRO Office address: 610 East Center Ave.,
TUok^iJA 1% o#il
ori.tuviar&,nedenneov.
Sincerely,,
W. Corey Basinger
Regional Supervisor
Mooresville Regional Office
Division of Water Resources
cc: NPDES (Derek Denard)
MRO Files

rr— United Staters EnvimmmertatProtection Agemy Form Approived
EPA Washington, D.C. 20460 OMS No. 2040-0057
Water Compliance Inspection Report Approval expires 8-31-98
Section A: National Data System Coding (Le., PCS)
Transaction Code NPOES yr/mo/day Inspection Type Inspector Fee Type
I I
1 2 El 3 NCG500318 111 121 16101112 117 18 L-j !j 19 LU
20
211 1 1 1 1 1 11 1 1111 1 1 1 1 1 1 1 1 1 1 1 1 1 11 1 _LLLi_f6
Inspection Work Days Facility Self-Moriftoring Evaluation Rating B1 CA --Reserved---
67 U 0
2,0 70 J�j 71 [�j 72 LNJ 73 LJJ74 751' 1 8
1 1 ... I
Section B: Facility Data
Name and Location of Facility inspected (For Industrial Users discharging to POTW, also Include Entry Time/Date Permit Effective Date
PO TW name and NPDES permit Number) 0110PM 16101/12 15/12/29
Ipex Industrial Incorporate I d Exit TimetDate, Permit Expiration Date
10100 Rodney St 02:25PM 16/01112 20/07/31
Pineville NC 28134
Name(s) of Onsite Representative(s)/Tittes(s)/Phone and Fax Number(s) Other Facility Data
Chuck Best1/704-889-431 I
Tony Sainl/704-889-2431 ext 204/
Name, Address of Responsible Official/Title/Phone and Fax Number
Contacted
Glenn Sparrow,PO Box 640696 Charlotte NC 28224/1704-$89-243117048892390 No
Section C: as Evaluated During Inspection (Check only those areas evaluated)
Permit 0 Flow Measurement operations & Maintenance Records/RepOrt$
Self -Monitoring Program 0 Facility Site Review EffluenittReceiving Waters Laboratory
Section D: Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary)
(See attachment summary)
Narne(s) and Signature(s) of Inspectons) Agency/Office/Phone and Fax Numbers Date
Or! A Tuvia, MRCS WOVO4-663-1699t
Signature of Management 0 A Reviewe .1 Agency/Offloa(Phone and Fax Numbers Date
U4
EPA Form 3860-3 (Rev 9-94) Previous editions are obsolete.
Page#

NPOES yrT clay ln"ction Typ
1 NCG500318 �11 121 16/01,12 117" 18
t
Section D: Summary of Finding/Comments (Attach additional sheet

Permit: NCG500318 Owner - Facility: 1pex Industrial Incorporated
Inspection Date: 0111212016 Inspection Typ4r, compliance Evaluation
Permit )Lea L42 NA N9
(if the present permit expires in 6 months or less). Nas the permittee submitted a new El 0 M C1
application?
Is the facility as described in the permit? M000
# Are there any special conditions for the permit? 13 IN Cl 1:1
Is access to the plant site restricted to the general public? a El 1:113
Is the inspector granted access to all areas for inspection? N 0 0 El
Comment:
Record lee in Yes No NA NE
Are records kept and maintained as required by the permit? a 0 11 11
Is all required information readily available, complete and current? M El 1:1 El
Are all records maintained for 3 years (lab, reg. required 5 years)? 11 In El 11
Are analytical results consistent with data reported on DMRs? 11 0 ME]
Is the chain -of -custody complete? In 0 El 1:1
Dates, times and location of sampling IM
Name of individual performing the -sampling
Results of analysis and calibration
Dates of analysis 0
Name of person performing analyses
Transported COCs
Are DMRs complete: do they include all permit parameters? 0 0 0 13
Has the facility submitted its annual compliance report to users and DWQ? 11 13 M 13
(if the facility is = or > 6 MGD permitted flow) Do they operate 24/7 with a certified operator El C1 M 13
on each shift?
Is the OR C visitation log available and current? C1 El a 13
Is the ORC certified at grade equal to or higher than the facility classification? El 0 9 13
Is the backup operator certified at one grade less or greater than the facility classification? 1:1 El M 13
Is a copy of the current NPDES permit available on site? a 0 13 13
Facility has copy of previous years Annual Report on file for review? 11 C3 0 13
Comment: The Facilitv has done sampling for the non&ont@.qt discharge, Sompling was done by Page
Lat on 11211612911
PH =§.6, Qhlodn_e=58 uSA., LeMg = J§.4Celsius &CCU allAggLL
Effluent Sampling )Les 2 NA LE
Page# 3

Permit: NC( -
Inspection Date: 0111
500318 Owner -
V2016 Inspectfi
Effluent Sampling
)Lea NQ N6 NE
Is composite sampling flow proportional?
11
0
0
1:1
Is sample collected below all treatment units?
0
0
0
11
Is proper volume collected?
0
El
13
11
Is the tubing clean?
11
0
El
a
# Is proper temperature set for sample storage (kept at less than or equal to 6.0 degrees
Celsius)?
Is the facility sampling performed as required by the permit (frequency, sampling type
11
a
0
C1
representative)?
Comment* The Fggilily has done sgmyling for the non -contact dischaEgg, Sampling
was gong by Pace
Lab on 12—MU2911
PH H6.6, 9hI!2rjne=68 uo/L. T!gmp = 1§.4 Celsiug, CQQ ® 114 Mg/L
No pri!2r sampling Was done, Sampling was done in the coolie tower ig pdgr
to filtration.
Laboratary
Yes No NA Nfi
Are field parameters performed by certified personnel or laboratory?
a
13
0[3
Are all other parameters(excluding field parameters) performed by a certified lab?
0
0
1:11:1
# Is the facility using a contract lab?
N
0
11
13
# Is proper temperature set for sample storage (kept at less than or equal to 6.0 degrees
9
0
0
11
Celsius)?
Incubator (Fecal Coliform) set to 44.5 degrees Celsius+/- 0.2 degrees?
0
El
N
0
Incubator (BOD) set to 20,0 degrees Celsius +/- 1,0 degrees?
Comment: Pace Lab is contracted to sample the Fgqj4W
Flow Measurement - Effluent
Yes Ng NA NE
# Is flow meter used for reporting?
C1
0
N
0
Is flow meter calibrated annually?
El
El
a
11
Is the flow meter operational?
El
0
MCI
(If units are separated) Does the chart recorder match the flow meter?
0
0
M
n
Comment: Flow occures gn!y during: once a year blowdown, during,mainLengnce to the cooler and if
jhgLe is gVe!Tgw backup;
Operations j, Maintenance
Yes No M Ng
Is the plant generally clean with acceptable housekeeping?
N
0
11
0
Does the facility analyze process control parameters, for ex: MLSS, MCRT, Settleable
Solids, pH, DO, Sludge Judge, and other that are applicable?
Page#
4

Permit: NCG500318 Owner - Facility: 1pex Industrial Incorporated
Inspection Datw 01/12/2016 Inspection Type: Compliance Evaluation
Orterations & Maintenance Yes No NA hL E _
Comment: As M Le§gft of I OL9_/201 § g!Le visit by DWR staff� the c_oMoanv staff verified the location
diagLarm MmwLaleer D kcWaad initisIltd 51 Umpling, gvent on 12116/2015,
The dischgrgg consist of ng07conLagt gggligg V t r that is giclaw ging iaLo a §IgLm water
ditch that is con0@Ctedj_nLo little sugar cree�, Qngg @ year blowdown, during maintenance
to
the cooler and if there is overflow backgo,
once it was g established Lhe facility does have non -contact co
olie w&er the Lacilft wag
Le-insgecleO on 1/12_/20M
The Lagilfty has started doing sampling of the non -contact cooling, water after the first
insgggtign.
Sarn2fing was done by Pace Lab on 12/161201
Page#

feaver, Charles
I: Weaver, Charles
Tuesday, December 2S
,sales@ ipexamerica.co
,marketing@ ipexameri
act; renewal of NCG500311
:hments: NCG50 Final 093015.p
irtance: High
this matter, simply rep
)uality
"Nothing Compares
oc
15. Disc
licable.
ENRIE,'
S
NOIN" A L
AMI)
AM
ity - Pineville NC
I Bulletin - NCG500000 2015.d
NCG500000, effective 10/1/20 and any
Cher notice.
d to you in July 2007 is still app
d period.
,age.
third parfie&
R E- C E I V E DIIN C D
M�
WORO

North Carolina Department
Beverly Paves Perdue Coleen
Ovrmr lair
Oct(
Mr. Johnny Drummond
IPEX Industrial, Inc.
10100 Rodney Street
Pineville, North Carolina 28224
, -f C)Su j
Dear Mr. Drummond:
ME
Tins Dee F
Sl
!0 2011
)
t nTTc l am a T-+cralrIa i n 1"enpi-firm
'EX Industrial, Inc.
PIES Permit No. NCG50 }318
[ecklenburg County, N.C.
this report, please do not hesitate to contact Mr. Snider at [phone].
Sincerely,
uv ,
Robert S. Krebs
Surface Water Protection Regional Supervisor
Enclosure
Mooresville Regional Office
Location:6!10 East Center Ave,, Suite 301 Mooresville, NC 28115 One
Phone: [phone] Pax: [phone] F Customer Service. 1-877-623-6748 NorthCarolina
Internet: www.ncwaterquality,org
An Equal Opportunity 1 Affirmative Action Employer -}50% Recycled/1 C}% Past Consumer paper NahlrallY

United States Environmertal Protection Agency
EPA Washington, D.C. 20460
--,ial ixicires 8-,�
W;;tt-r (Qmr)fi;;nr.P jn1.<;nt-rfion
Section k National Data Svstem Conine PCISI
I �ansaction Code NPDES yrtmo/day Inspection Type I nspector Pas Type
11 121 17 18LCI 19LSI 20LI
2 11
NCG500318 11/09/30
Remarks
tl
inspection Work Days Facility Self -Monitoring Evaluation Rating BI QA ---- --------- ----________Reserved__ ______ _________
6; t 169 70U 71 U 72LNI 731 1 174 75
Section B: Facility Data
Name and Location of Facility Inspected (For Industrial Users discharging to POTW, also include Entry Time/Date Permit Effective Date
POTW name and NPDES permit Number)
09:00 AM 11/09/30 07/08/01
1pex Industrial Incorporated
10100 Rodney St Exit Time/Date Permit Expiration Dat=
71 ineville NC 28134 10:00 AM 11109/30 12107/31
Name(s) of Onsile Representative(s)/Tittes(s)/Phone and Fax Number(s) Other Facility Data
18
Name, Address of Responsible Official/Title/Phone and Fax Number
Contacted
S PO Box Glenn 640696 Charlotte NO 28224H7G4-889-2431/7048892390 No
Section G- Areas Evaluated During Inspection (Check only those areas evaluated)
Permit F low Measurement Operations & maintenance N Records/Reports
Self -Monitoring Program Facility Site Review Effluent/Receiving Waters IV Laboratory
See attachment summary)
ame(s) and Signature(s) of Inspector(s) Agency/Office/Phone and Fax Numbers Date
an Snider MRO WQ//704-663-1699/
gnature of Management Q A Reviewer AgencylOffice/Phone and Fax Numbers Date
:'A Form 3560-3 (Rev 9-94) Previous editions are obsolete,
Page # 1

Page

Permit: '4CG500318 Owner -Facility: 1pexindustna! rc_. Dr
,)n Date: 09/30/2011 Inspection Type: Compliance Evaluatior,
ns-& Maintenance— Yes No
Est generally clean with acceptable housekeeping?
Comment:
Permit
(if the present permit ex
4V' "' -Fag a't mm'a' gut '�;A' ivmLQQ' lvf'✓r-' 1, cgtuwtgdule 47ulUZ5, pri, Liu, z,,iuuge L_j (t0 i_j
)[a?
Yes No NA NE
months or less). Has the permittee submitted a new application? o no in o
Is the facility as described in the permit?
in no
# Are there any special conditions for the permit?
0 0 in
0
Is access to the plant site restricted to the general public?
0
13
0
Is the inspector granted access to all areas for inspection?
0
0
0
Comment
Record Keeping
Yes No
NA
NE
Are records kept and maintained as required by the permit?
0 in
0
0
Is all required information readily available, complete and current?
o o
in
no
a all records maintained for 3 years (lab, reg. required 5 years)?
n w
o
o
a analytical results consistent with data reported on DMRs?
no o
m
o
the chain -of -custody complete?
n n
m
o
Dates, times and location of sampling
Name of individual performing the sampling
ii
Results of analysis and calibration
it
Dates of analysis
0
dame of person performing analyses
n
transported COCs
0
Are IDMRs complete: do they include all permit parameters?
f _-1 0
WA
0
Has the facility submitted its annual compliance report to users and DWQ?
no o
a
o
(if the facility is = or > 5 MCC permitted flow) Do they operate 24/7 with a certified operator on each shift?
0 0
is
D
Is the OR C visitation log available and current?
0 0
IM
0
Is the ORC certified at grade equal to or higher than the facility classification?
0 0
in
D
Is the backup operator certified at one grade less or greater than the facility classification?
0 D
in
0
Is a copy of the current NPDES permit available on site?
0 is
0
0
Page # 3

Perrnit: ACC500.: Owner - Facility* Ipex Industrial Incorporated
Inspections Date. 09/30/20 ` ° Inspection type: Compliance Evaluation
Record beeping'
Yes No NA N
Facility has copy of previous jeer's A ruai -R v:.ort on file for review?
Comment: Facility has not m a=^tared records due to the fact new staff thought the
discharge was to city sewer.
Flow Measurement -influent
Yes No NA N
# Is flow meter used for reporting?
€ ] 0 a 0
Is flow meter calibrated annually?
00a 0
o
Is the flow meter operational?
(If units are separated) Does the chart recorder match the flow meter?
i i 0 in ill
Comment:
Laboratory
Yes No NA N
Are field parameters performed by certified personnel or laboratory?
0 0 0 0
Are all other parameters(excluding field parameters) performed by a certified lab?
0 0 0
# Is the facility using a contract lab?
n C
Is proper temperature set for sample storage (kept at less than or equal to 6.0 degrees Celsius)?
f M 0 0
Incubator "(Fecal Coliform) set to 44,5 degrees Celsius+/- 0 degrees?
0 f i
Incubator (BOO) set to 20:0 degrees Celsius +I- 1 0 degrees?
o Cl n no
Comment: ent: . Facility is not sampling. New staff was under the impression discharge
went to city sewer, but accot ding to DWQ staff report discharge is to surface waters.
Effluent Sampling
Yes No NA NE
Is composite sampling flow proportional?
0 ICI a 0
Is sample collected below all treatment units?
Ono f
0 a 0
Is proper Volume collected?
0
Is the tubing clean?
# is proper temperature sat for sample storage (kept at less than or equal to 6.0 degrees Celsius)?
0 in 0 0
Is the facility sampling performed as required by the permit (frequency, sampling type representative)?
0 i l
Comment: Facility is not sampling. New staff was udder the impression discharge
went to city sewer, but according to DWQ staff report discharge is to surface waters.
This facility will be reinspected in one year to vehfiy that permittee is following their
permit.
Page #

NCDENR
North Carolina Department of Environment and Natural Resources
Division of Water Quality
Michael F. Easley, Governor William G. Ross, Jr., Secretary
Coleen H. Sullins, Director
July 23, 2007
Steve Myers
1pex USA, LLC
10100 Rodney Street
Pineville, NC 28134
Subject: Renewal of coverage / General Permit NCG500000
Ipex USA
Certificate of Coverage NCG500318
Mecklenburg County
Dear Permittee:
In accordance with your renewal application [received on November 22, 2006], the Division is
renewing Certificate of Coverage (CoC) NCG500318 to discharge under NCG500000. This CoC is issued
pursuant to the requirements of North Carolina General Statue 143-215.1 and the Memorandum of
Agreement between North Carolina and the US Environmental Protection agency dated May 9, 1994 [or as
subsequently amended].
If any parts, measurement frequencies or sampling requirements contained in this General Permit are
unacceptable to you, you have the right to request an individual permit by submitting an individual permit
application. Unless such demand is made, the certificate of coverage shall be final and binding.
Please take notice that this Certificate of Coverage is not transferable except after notice to the
Division. The Division may require modification or revocation and reissuance of the certificate of coverage.
a 'Jill
If you have any questions concerning the requirements of the General Permit, please co,
McKay [919 733-5083, extension 595 or james. mcka @ncmail.net .
Sincerely,
, r
All
for Coleen H. Sullins
cc: Central Files
NPDES file
1617 Mail Service Center, Raleigh, North Carolina 27699-1617 One
512 North Salisbury Street, Raleigh, North Carolina 27604 Northl
Phone: [phone] / FAX [phone] / Internet: www.nowaterquality.org Nat
An Equal Opportunity/Affirmative Action Employer — 50% Recycled/1 0% Post Consumer Paper

STATE OF NORTH CAROLINA
DEPARTMENT OF ENVIRONMENT AND NATURAL RESOURCES
DIVISION OF WATER QUALITY
GENERAL PERMIT NCG500000
CERTIFICATE OF COVERAGE NCG500318
NATIONAL POLLUTANT DISCHARGE ELIMINATION SYSTEM
In compliance with the provision of North Carolina General Statute 143-215. 1, other lawful standards and
regulations promulgated and adopted by the North Carolina Environmental Management Commission, and
the Federal Water Pollution Control Act, as amended,
Ipex USA, LLC
is hereby authorized to discharge Cooling Tower Blowdown from a facility located at
Ipex USA
10100 Rodney Street
Pineville
Mecklenburg County
to receiving waters designated as an unnamed tributary to Sugar Creek in subbasin 30834
of the Catawba River Basin in accordance with the effluent limitations, monitoring
requirements, and other conditions set forth in Parts 1, 11, 111 and IV hereof.
This certificate of coverage shall become effective August 1, 2007.
This Certificate of Coverage shall remain in effect for the duration of the General Permit.
Signed this day July 23, 2007.
for Coleen H. Sullins, Director
Division of Water Quality
By Authority of the Environmental Management Commission

SOC PRIORITY PROJECT.- YesNox
If Yes, SOC No.
To: Permits and Eng ineering Unit
Water Quality Section
Attention: Charles Weaver
Date: May 25, 2007
NPDES STAFF REPORT AND RECOMMENDATION
County: Mecklenburg
MRO# 07-23
Permit No. NCG5500318
PART I - GENERAL INFORMATION
I Facility and Address: IPEX USA, LLC Formerly Elson Thermoplastics
10 100 Rodney Street
Pineville, North Carolina 28134
2. Date of Investigation: May 4, 2007
3. Report Prepared By: Samar Bou-Ghazale, Env, Engineer 1
4. Persons Contacted and Telephone Number: Mr. Greg Rodney, Plant Manager, Tel #i (704)
889-2431 Ext. 201,
5. Directions to Site: From the junction of Pineville Road (Highway 52 1) and Industrial Drive
in Pineville, Mecklenburg County, travel west on Industrial Drive approximately 0.2 mile to
the junction with Rodney Street. Turn right on Rodney Street and travel north approximately
0.3 mile. IPEX USA is on the left (west) side of the road.
6. Discharge Point(s). List for all discharge points:
Latitude: 35006'00" Longitude: 80'53'15"
Attach a U,S.G.S. map extract and indicate treatment facility site and discharge point on
map,
U.S.G.S. Quad No.: G 15 NW U.S.G.S. Name: Fort Mill, NC -SC
T Site size and expansion are consistent with application? Adequate land available for
expansion if necessary.

8. Topography (relationship to flood plain included): Facility is not located in a flood plain.
Slopes range from 2 to 3%.
9. Location of nearest dwelling: The nearest dwelling is greater than 1000 feet from the
discharge location.
10. Receiving stream or affected surface waters: U.T. to Little Sugar Creek.
a. Classification: C
b. River Basin and Subbasin No.: Catawba River Basin 03-08-34
C. Describe receiving stream features and pertinent downstream uses: No
detrimental effects were observed as a result of this discharge.
PART 11 - DESCRIPTION OF DISCHARGE AND TREATMENT WORKS
I a. Volume of wastewater to be permitted: Intermittent discharge,
b.What is the current permitted capacity of the wastewater treatment facility?
Intermittent discharge. ,
C. Actual treatment capacity of the current facility (current design capacity)? N/A
d. Date(s) and construction activities a] lowed by previous Authorizations to
Construct issued in the previous two years: N/A
e. Please provide a description of existing or substantially constructed wastewater
treatment facilities: Wastewater horn non -contact cooling water is discharged into
conveyance ditch leading to Little Sugar Creek.
f. Please provide a description of proposed wastewater treatment facilities: N/A
9. Possible toxic impacts to surface waters: Biocide is used at the facility.
h. Pretreatment Program (POTWs only): N/A
1 Sludge Handling and Disposal Scheme: N/A
3. Treatment plant classification (attach completed rating sheet): no rating
4. SIC Code(s): 3084 & 3089
Wastewater Codes: 14

PART III - OTHER PERTINENT INFORMATION
1 Is this facility being constructed with Construction Grant Funds or are any public monies
involved (municipals only)? N/A
2, Special monitoring or limitations (including toxicity) requests: N/A
3. Important SOC, JOC or Compliance Schedule dates: (please indicate): N/A
4. Air Quality and/or Groundwater concerns or hazardous materials utilized at this facility
that may impact water quality, air quality, or groundwater: No ACC or GW concerns nor
are hazardous materials utilized at this facility.
PART IV - EVALUATION AND RECOMMENDATIONS
The applicant has requested permit renewal to continue the discharge of non -contact
cooling water containing biocide additives.
Pending review and approval by P&E and the Aquatic Toxicology Group, it is
recommended that the permit be reissued.
LJ-�
Signature of Report Prepar
Surface Water Protection Regional Supervisor
Date

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ineville, NC 2 134-753
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NCD
North Carolina Department of Environment and Natural Resources
Division of Water Ouality
Michael F. Easley, Governor William G. Floss, Jr., Secretary
Alan W. Klimek, P.E., Director
NOTICE OF R_UNIEWAL
Application for renewal of a t i c►v+er a under General ' + t 'G500,0001,
Certificate of Coverage (CoC): NCG5 ; ° �L
C.
Existing
(Please print or type)
1) Mailing address' of facility owner/operator.- mARJ
Company Name fiPC Q S 14 LLC
Owner Name
Street Address
n,-
City State ZIP Code
Telephone Number D1 '1 ' Fax.:
Email address 'rite X I T, ee
* Address to which all permit correspondence should be mailed
) Location of facility producing discharge:
Facility Name
Facility Contact
Street Address `
City ) `tvev i State > '' ZIP Code
County tX
Telephone Number-9- F: 2 E
Email address
) Description of Discharges
) Is the discharge directly to the receiving stream? • Yes # Nr�
(it no, submit a site map with the pathway to the potential receiving ors clearly marked. This includes tracing the pathway of the
storm sewer to the discharge paint, if the storm serer is the only viable means of discharge.)
b) Number of discharge outfalls (ditches, pipes, channels, etc. that convey wastewater from the property):
c) What type of wastewater is discharged? Indicate which discharge points, if more than one..
Non -contact cooling water { utfall(s)
Boiler Blowdown Outfall (s) #: l
Page 1 of

NCG500000 renewal application
pp
• Cooling Tower Blowdown Outfall (a)
* Condensate Outfall (s) #. N
14 r,"Other Outfall (s) #: � [A
(Please describe "Other")
d) Volume of discharge per each discharge point (in CPI))°'
) Please check the type of chemical [s] added to the wastewater for treatment, per each separate discharge
paint (if applicable, use separate sheet):
Chloe + Biocides Corrosi °bitors + Algaecide Other
None _
) If any box in item (4) above [other than. None] was checked, a completed Biocide 101 Form and
manufacturers' information ation on the additive must be submitted to the following address for approval:
NC DENR, DWQ / Environmental Sciences Section.
Aquatic Toxicology unit
1521 Mail Service Center
Raleigh, NC 276 -1621
6) Is there any type of treatmentUeingprovided ter the tew ter before disch ge (i.e. retention ponds,
sett ' g ponds, etc.)? • Yes(lf yes, please include designsdesign volume, retention time, surface area, etc.) with submittal package. existing
treatment facilities should be described in detail. }
7 Discharge Frequency.
a) The discharge is. • Continuous Inter ittent • Seasonal*
0 If the dischargeis rote ittent, d+ scri . e w en the discharge will occur: �11_
ii) *Check themonth(s) the discharge occurs: tZeb Ap M Ju
Au Sep No *' IJe (
b) low many days per week. is there a discharge? c� � Q 1 t n "� (`Cl4t?� �"f j
11
c) Please check the days discharge occurs. Sat. • Sun. Mon. • TL w Wed. • Thu. •
3) Receiving strew [s):
a) To what body or bodies of water (creek, stream, river, lake, etc.) does the facility discharge
wastewater? If the site discharges wastewater to a separate storm sewer system (4S), name the
operator of the 4S (e.g. City ofRaleigh). ' G
b) Stream Classification: ` O LA-t,*, Y
Page 2 of

Addi
The fbllo
�t ou naust be
>- bite map. it, the cliscuarge i
NCG500000 renewal application
ttion Requirements:
licate [original + 2 copies] with this application or it will
o a stream, the pathway to the receiving stream must
the pathway of a storm sewer to its discharge point.
.is application will be submitted by a consulting
nnentation from the Permittee showina that the
consultant submitting the application has been designated an Authorized Representative of the
applicant.
Certification
I certify that I am familiar with the information contained in this application and that to the best of my
knowledge and belief such info anon is true, complete, and accurate.
Printed Name of Person Signing: C4 e,-^ VI 0 Mvl f-10
V
Title:
rN
00
(Signature of Applicant) (Date Signed)
North Carolina General Statute 143-215.6 b (i) provides that:
Any person who knowingly makes any false statement, representation, or certification in any application, record, report, plan or other document
filed or required to be maintained under Article 21 or regulations of the Environmental Management Commission implementing that Article, or who
falsities, tampers with or knowingly renders inaccurate any recording or monitoring device or method required to be operated or maintained under
Article 21 or regulations of the Environmental Management Commission implementing that Article, shall be guilty of a misdemeanor punishable by
a fine not to exceed $25,000, or by imprisonment not to exceed six months, or by both. (18 U.S.C. Section 1001 provides a punishment by a fine
of not more than $25,000 or imprisonments not more than 5 years, or both, for a similar offense.)
This Notice of Renewal Intent does NOT reaulre a arate fee.
The Dermitted facilitv alreadV Davs an annual fee for coveracie under NO500000.
aeaccmaxoteomozaeowacma
Mail the original and two copies of the entire package to..
Mr. Charles H. Weaver
NC DENR / DWQ / NPDES
1617 Mail Service Center
Raleigh, North Carolina 27699-1617
Page 3 of 3

BIOCIDE/CHEMICAL TREATMENT
WORT SHEET- 101
The following calculations are to be performed on any biocidal products ultimately discharged to the surface waters of
North Carolina, This worksheet must be completed separately for each biocidal product in use. This worksheet is to be
returned with all appropriate data entered into the designated areas with calculations performed as indicated.
1. Facility Name IPEX USA LLC
NPDES # NG500318 Outfall #001
County Mecklenburg
Receiving Stream Little Sugar Creek 7010-3.5—(cfs)
(All above information supplied by the Division of Water Quality)
What is the Average Daily Discharge (A.D.D.) volume of the water handling systems to the receiving water body?
A,D.D, = -0,0063--- (in M.G.D.)
Please calculate the Instrearn Waste Concentration (IWC in percent) of this discharge using the data entered
above.
IWC = (AD.D.) X 100 X 100
(7010)(0.646) + (A.D.D) )(0.646) + (
This value (IWC) represents the waste concentration to the receiving stream during low flow conditions. The
following calculations are rendered mute because no chlorine is discharged. Blowdown remains closed until there
is no
if. What is the name of the whole product chemical treatment proposed for use in the discharge identified in Part I?
NaOCI
Please list the active ingredients and percent composition:
Sodium Hypochlorite 12.5 0
What feed or dosage rate (D.R.) is used in this application? The units must be converted to maximum grams
of whole product used in.a 24hr period.
D.R.= —6610--- grams/24hr period
Please note, fluid ounces (a volume) must be converted to grams (a mass). The formula for this conversion is:
Grams of product = fluid oz. of product X 1agL water X , 8.L4 lbs. X specific gravity of product X 4_5_3_.5_9_.

-Ac
ae'` t"f .1 t t_;C MorlimQ4. ntr°
128 fl. oz. 1 gal. water

Name: NPDES#:NC
Estimate total volume of the water handling system between entry of biocidal product and NPDES discharge point.
On an attached sheet please provide justification for this estimate (system volume, average cycles per blowdown,
holding lagoon size, etc.)
Volume= —0.052million gallons
What is the pH of the handling system prior to biocide addition? If unknown, enter N/A. —8.0—
What is the decay rate (D.K.) of the product? If unknown, assume no decay (D.K.=O) and proceed to asterisk.
The degradation must be stated at pH level within 1/2 pH standard unit within handling system. Enter the half life
(Half Life is the time required for the initial product to degrade to half of its original concentration). Please provide
copies of the sources of this data,
Days
The decay rate is equal to H.L. X 0.69 = —0-------=Decay Rate (D.K.)
Calculate degradation factor (D.F.). This is the first order loss coefficient.
_LA. �DD
D.F. = (Volume) + (D.K) + 0 0.121_
Calculate Steady State Discharge Concentration:
R
Dischg Cone. =
(D.F.)(Volume)(3785) )(3785)
Calculate concentration of biocide instrearn during low flow conditions. There is actually no concentration to the
stream. Slowdown remains closed.
(Receiving Stream Concentration)
) x
100 = 100 —0.78 mgA
Receiving Stream Concentration
Calculate regulated limitation,
List all ILC50 and EC50 data available for the whole product according to the following columns. (Note that units
should be in mg/1). Please provide copies of the sources of this data,
Organism Iggt Duration LQ5-QffiQ5Q (MaA)
—Bluegill Sunfish --- 96 hr_0.6__
— Ceriodaphnia dubia -- 48 hr�.— —1.23-
-Daphnia magna___- 48 hr�_ 1.0_
—Fathead Minnow--- 96 ht�_ _1.19_
D.WQ. Fmm 101 (6P-000) 3

Name: r o, -T-PE-X UsA LL-J�-- NPDES #: NC--5-QQ319--
C s'
Choose the lowest LC50/EC50 listed above:
Enter
nter the LC50/EC50:
If the half life (H.L.) is less than 4 days, perform the following calculation.
Regulated Limitation = 0.05 x LC5 = mgA
If the half life (H.L.) is greater than or equal to 4 days or unknown, perform the following calculation.
Regulated Limitation = 0.01 x LC50 = _0.006_mg/I
Choose the appropriate regulated limitation from the calculations immediately above and place in this blank:
-.0.006-----mgAiter
From Part 11 enter the receiving stream concentration:
-0,77*-.,-_--,mg/liter
CoUL'J 1'ovier blowdown, is closed while NaOCI is fed. All chlorine is reacted before blowdown resurne$.
I. Analysis.
If the re. gIving stream concentration is greater than the calculated regulated limitation, then this biocide is
unacceptable for use.
Person in Responsible Charge
Name (Print)
Signature Date
Person Completing This Worksheet (if different from above)
Helen R. Cerra, ChemTreat, Inc.
Name (Print)
01/25/07
Signature Date
Please submit to: Division of Water Quality
Aquatic Toxicology Unit
1621 Mail Service Center
Raleigh, NC 27699-1621
Attn: Todd Christenson
DW Q, F,:,win 101 (612000) 4

ame: ? _ _. NPD : NC
Supplemental Metals Analysis
If copper, zinc, or chromium are present in the proposed blocid l compound, complete this works t. separate form
must be used for each metal and/or metal compound present in the biocide. list the metal, its chemical formula, molecular
weight (), formula weight (FW), and the concentration of the metal compound in the biocide (MCC). Complete a
separate form for every metal present in the biocide.
gja C,Eh�1nical Form la �.fto cu t r 1 Weight t t" Biocide
EXAMPLE
Copper r_"caSO4*5H20 65.546 gl role^ 249.680 g1mole Q.
Non _ r_w
Dosage rate of Biocide (DR) (from page 1)::
DR = --_-----_—gram s/clay
Average Deily Discharge (ADD) (from page 1):
ADD = -----million gallons/day
Discharge Concentration (DC) of Biocide:`
DR { 91 s/daY)
IC _ _ gratnslmillion gallonsADD {`��rv...mrll�on gallonsfday)
Convert DC to rilicrograms/liter (ppb):
DC (,ug/1) = ------,—DC (grams/million gal) x 1 x 1135 gtl
3.78 106 liters/million gal.
Calculate the fraction of metal in the metal -containing compound (MF):
MW rains/mole
MF ` FW . (_,___W.__, _ _. rarn /mole)
Calculate the fraction of metal in the blocidal compound (BF);
BF =' MF x MC � lQ f x (100)
Calculate the concentration of metal` n the discharge (M):
M = DC BF = fig/I x gll
Calculate the insrream metal conoen ration QMC) at low -flaw conditions:
1MC = M x IV Vic{ r - %
100
Regulated limitation of metal ('from below): - #Wl
C General Statutes 15A NCAC 213.0 11 define.
Copper- 7 pgl1 water quality action level* Zinc- 6o #gA water quality action level*
Chromium- 60 pgA water quality standard

N1
North Carolina Department c
74,L*A.
DENR
Environment and Natural Resources
IMEMEMMi
Michael F. Easley, Governor William G. Ross, Jr., Secretary
Alan W. Klimek, P.E., Director
November 15, 2006
Jack Bacak
1pex Industrial, Inc.
P.O. Box 240696
Charlotte, NC 28224
Subject: NPDES Permit NCG500000 renewal
Certificate of Coverage (CoC) NCG500318
Ipex Industrial
Mecklenburg County
Dear Permittee:
The facility listed above is covered under NPDES General Permit NCG500000. NCG500000 expires
on July 31, 2007. Federal (40 CFR 122.41) and North Carolina (15A NCAC 2H.0105(e)) regulations require
that permit renewal applications must be filed at least 180 days prior to expiration of the current permit. If
you have already mailed a renewal request, you may disregard this notice.
your application.
$25,000 per day.
If all discharge has ceased at your facility and you wish to rescind this CoC [or if you have other
questions], contact me at the telephone number or e-mail address listed below.
Sincerely,
acr. (fil IL iVV i" I,% kprv,%
A
I7
Charles H. Weaver, Jr.
NPDES Unit
cc: Central Files
NPDES File
1617 Mail Service Center, Raleigh, North Carolina 27699-1617 One
512 North Salisbury Street, Raleigh, North Carolina 27604 NofthCarohna
Phone: [phone], extension 511 / FAX [phone] / charles.weaver@ nomail, net NatmIrally
An Equal Opportunity/Affirmative Action Employer— 5011/6 Recycled/10% Post Consumer Paper