NC0020621_Industrial User_20211122

Town ofBoon e
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BOONS
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North Carolina
RECEIVED
Certified Mail#7018 1830 0002 1081 3443 NOV 22 2021
November 12, 2021 NCDEQ/DWR/NPDES
Mr. Michael Montebello
Division of Water Resources
Municipal Unit-Pretreatment
1617 Mail Service Center
Raleigh,NC 27699-1617
Dear Mr. Montebello:
The Town of Boone issued a renewed Significant Industrial User Permit(IUP#0004)to
Charleston Forge, which will be effective January 1, 2022 and with the following
revisions:
• Part I (D) revised description of discharge to include current chemicals in use,
mop sink volume and air compressor condensate
• Part I (F.4 chart) changed requirement for flow, detection levels and sample type
• Part I (G)updated composite sample and proportional grab sample definitions to
include mop sink
Enclosed are the materials requested by DWR for streamlined renewed IUP.
Please call me at 828/268-6270 or email me at [e-mail] if you need
more information.
Sincerely,
/dA,
Karen W. Reece
Pretreatment Coordinator
ec: Rudy Broschinski, Plant Superintendent
Josh Eller, Public Works Deputy Director
Rick Miller, Public Works Director
P.O.DRAWER 192 • BOONE,NORTH CAROLINA 28607

NC Division of Water Quality
Streamlined Industrial User Permit (IUP) Review
Streamlined Industrial User Permit Review Submittal Form
One form may cover multiple IUPs submitted together.
Program Name: 7ivti /(joon�
WWTP Name: J, Srn 0i1An /c)
Permit Renewals
Date application(s) received F • 1/"Z I
Date of most recent on-site inspection(s) Z S"Z I
4„,01,0,1 A-r �w
Date allocation table updated . R S•I I .1n d ' 7-"21
Nl Are any changes to SIU name, IUP number, pipe number, limits or treatment units?
(Changes do not have to be listed here)
Permit Modifications:
Are any changes to SIU name, IUP number, pipe number, limits or treatment units?
(Changes do not have to be listed here)
I certify that the attached permit(s) has been prepared under my direct supervision and that the permit
meets the requirements of all applicable Federal and State Rules and requirements.
// /2 Z /
Signature of approved permit writer Date
Email Address: you will receive an email confirmation of receipt Approval number
Streamlined IUP Review Submittal Form: Version 1.0
Revision Dates: 2/16/2011

Town ofBoone
illIBOO E , On ''')\
North Carolina L 7 `...J P
Hand Delivery 0004 111021A
November 10,2021
Mr.Jay Hooks
Charleston Forge
251 Industrial Park Drive
Boone,NC 28607
Subject: Transmittal Letter for Significant Industrial User(SIU)Permit#0004
Dear Mr.Hooks:
Please find enclosed the renewed Industrial User Permit(IUP#0004),which covers the wastewater
discharged from the facility located at 251 Industrial Park Drive,Boone,NC into the Town of Boone
Jimmy Smith Wastewater Treatment Plant. All discharges,actions,and reports from this facility shall be in
accordance with the terms and conditions of this permit. Please read this permit carefully,noting the
following changes:
Part I(D)revised description of discharge to include current chemicals in use,mop sink volume and air
compressor condensate
Part I(F.4 chart) changed requirement for flow,detection levels and sample type
Part I(G)updated composite sample and proportional grab sample definitions to include mop sink
If any parts,measurement frequencies or sampling requirements contained in this permit are unacceptable to
you,you have the right to an adjudicatory hearing upon written request within thirty(30)days following
receipt of this letter. Unless such demand is made,this decision shall be final and binding.
Please feel free to contact me by email at [e-mail] or by phone at 828/268-6270 if
there are any questions or concerns.
Sincerely,
Karen W.Reece
Pretreatment Coordinator
Enclosed: IUP#0004
Fact Sheet
Sampling Instructions
Reporting forms
ec: Rudy Broschinski,Plant Superintendent
Josh Eller,Public Works Deputy Director
Rick Miller,Public Works Director
P.O.DRAWER 192 • BOONE,NORTH CAROLINA 28607
1

c V
I
Significant Industrial User(SIU) Permit
Permit#0004
In compliance with the provisions of North Carolina General Statute 143-215.1, any
applicable federal categorical pretreatment regulations, all other lawful standards and
regulations promulgated and adopted by the North Carolina Environmental Management
Commission, and Title V of the Town of Boone Code of Ordinances. The following
industrial wastewater contributor, hereafter referred to by name or as the Permittee:
Industry name,permittee:
Charleston Forge
Facility Located at Street Address
251 Industrial Park Drive
City
Boone
State,Zip
NC 28607
is hereby authorized to discharge industrial wastewater from the above identified facility
and through the outfalls identified herein into the Town of Boone Jimmy Smith
Wastewater Treatment Plant,herein referred to as the Control Authority, in accordance
with the conditions set forth in this Significant Industrial User Permit. Compliance with
this Permit does not relieve the Permittee of its obligation to comply with any and all
applicable pretreatment regulation
s, standard
s or requirements under local, State, and
federal laws; including any such regulations, standards,requirements, or laws that may
become effective during this Permit.
Noncompliance with any term or condition of this Permit shall constitute a violation of
Title V of the Town of Boone Code of Ordinances.
This permit and the authorization to discharge shall become effective on January 1,
2022.
This permit and the authorization to discharge shall expire on December 31, 2026.
If the Permittee wishes to continue to discharge after the expiration date of this Permit, an
application must be filed for a renewed Permit in accordance with Title V of the Town of
Boone Code of Ordinances, a minimum of 180 days prior to the expiration date.
Signed on this 9 "day ofj4-v, 2021.
Lttt
Karen W. Reece Ricky L. Miller
Pretreatment Coordinator Director of Public Utilities
By authority of the Town Council of Boone,NC
1

Part I
Charleston Forge
SIU Permit
A. Basic Information:
Receiving Control Authority&WWTP name: POTW NPDES#:
Town of Boone—Jimmy Smith WWTP NC0020621
IUP Name: IUP Number:
Charleston Forge 0004
IUP Effective date:
Pipe Numbers,list all regulated pipes:
January 1,2022 001
IUP Expiration date: IUP 40 CFR#(if applicable),or N/A:
December 31,2026 40 CFR 433.17
B. SIU Permit Modification History:
Date Description of modification
Modified
1/1/17 Original SIU permit: permitted as CIU (40 CFR 433.17)
9/1/17 Modification: increased flow limit; decreased silver limit; changed
composite sample definition
9/9/19 Modification: increased silver limit, corrected tank volume typo in
Description of Discharge
1/1/22 Renewal: Revised I(D): Updated chemicals used in 5-stage washer,
added volume of mop sink to Pipe#001 description, added air
compressor condensate to list of unregulated and dilution
wastewaters;Revised I(F4): "every sample" flow data requirement
and footnote, changed detection levels to match upcoming LTMP
requirement and added footnote, corrected sample type for pH,
TTO, CN,which were overlooked when composite sample
definition changed; Revised I(G): updated definitions G1 to
include standing water in mop sink and G4 to say tanks and sink;
C. Authorization Statement:
1. The Permittee is hereby authorized to discharge wastewater in accordance with
the effluent limitations,monitoring requirements, and all other conditions set forth
in this Permit into the sewer collection system and wastewater treatment facility
of the Control Authority.
2. The Permittee is hereby authorized to continue operation of and discharge
wastewater from the following treatment or pretreatment facilities. These
facilities must correspond to treatment units listed on both application and
inspection forms.
2

IU Treatment Units
Settling bucket(quenching water)
Tank screens(washer system)
3. The Permittee is hereby authorized to, if required by the Control Authority and
after receiving Authorization to Construct(A to C)from the Control Authority,
construct and operate additional pretreatment units as needed to meet the final
effluent limits.
D. Description of Discharge:
From the period beginning on the effective date of the Permit until expiration date,
the Permittee is authorized to discharge process wastewater as described below to the
Town of Boone sewer collection system from the outfalls described below.
Description of Outfalls
Five-stage wash with overflow pipes from each of the tanks plus a mop sink
discharge to a single discharge line. Mop sink is for the disposal of regulated
wastewater only(eg quenching water,measuring equipment,miscellaneous parts
rinsing,etc). The tanks are batch-discharged approximately once per six months.
ank#1: 1200 gallon wash tank with Bonderite C-AK-NP-1
Tank#2: 450 gallon rinse tank
Tank#3: 1100 gallon rinse tank
Tank#4: 450 gallon tank with rust preventer Bonderite M-NT-2
Tank#5: 900 gallon rinse tank
op Sink: 20 gallon
Pipe#001: Regulated wastewater from 5-stage washer and mop sink
The regulated wastewater joins all other wastewater(sanitary wastewater,mop water
from office and breakroom cleaning, drip water from delivery truck and air
compressor condensate) after the sampling point(Pipe#001) for final discharge to
collection system at Manhole ID1158.
E. Schematic and Monitoring Locations:
The facility schematic and description of monitoring location provided at the end of
this document must show enough detail such that someone unfamiliar with the facility
could readily find and identify the monitoring location(s) and connection(s)to the
sewer. Include and identify all regulated pipes.
F. Effluent Limitations and Monitoring Requirements:
1. All discharges shall comply with all applicable laws,regulations, standards,
and requirements contained in Title V of the Town of Boone Code of Ordinances,
this Permit and any applicable State and federal pretreatment laws,regulations,
standards, and requirements including any such laws,regulations, standards, and
requirements that may become effective during the term of this Permit.
3

2. All handling and preservation of collected samples and laboratory analyses of
samples shall be performed in accordance with 40 CFR Part 136 and amendments
thereto unless otherwise specified in this Permit.
3. Reports of monitoring results shall be postmarked by the 30th day of the calendar
month following the calendar month in which the samples were taken. If reports
are not available due to a delay at the contract lab,the Permittee shall notify the
Control Authority by the due date. When sample results are available, submit
them with an attached letter from the contract lab explaining delay, within five (5)
days of receipt of sample results. Semi-annual reports must be postmarked by the
30th day of the calendar month that follows each six-month period. For the
purposes of this Permit requirement,the six-month periods will be January
through June and July through December.
4. See the charts on the following pages, which explain what the specific effluent
limitations and monitoring requirements are for this Permit.
4

Receiving POTW name=> Jimmy Smith WWTP IU name=> Charleston Forge
IUP Part 1 Section F: Receiving POTW name=> Jimmy Smith WWTP IU name=> Charleston Forge
Receiving POTW NPDES#_> NC0020621 IUP#_> 0004
Effluent Limits and Monitoring Requirements Effective date for these Limits=> January 1,2022 Pipe#_> 001
(1/1/22-12/31/26) Expiration date for these Limits=> December 31,2026 40 CFR#_> 433.17
if not applicable put N/A
The Permittee may discharge from this specific THE LIMITS ON THIS PAGE ARE,(Check one below):
Pipe number according to these specific dates, LIMITS for ENTIRE permit period => x
effluent limits, and monitoringrequirements INTERIM Limits for period# 1 =>
q INTERIM Limits for period#2 =>
FINAL Limits Page =>
Permit Limits Monitoring Frequency Batch Continuous
Discharge Discharge
Required I
Sample Sample Laboratory
Collection Collection Detection
Method Method Level**
Daily Max Units By Industry By POTW (PG*) (C or G*) (mg/L)
1 Flow 0.005 MGD Daily 1/6 months metered metered .n/a
2 Cadmium,total 0.07 mg/L Before batch discharge- 1/6 months PG C 0.0005
See Part III,#8
3 Chromium,total 1.71 mg/L Before batch discharge- 1/6 months PG C 0.005
See Part III,#8
4 Copper,total 2.07 mg/L Before batch discharge- 1/6 months PG C 0.002
See Part III,#8
5 Lead,total 0.43 mg/L Before batch discharge- 1/6 months PG C 0.002
See Part III,#8
6 Nickel,total 2.38 mg/L Before batch discharge- 1/6 months PG C 0.01
See Part III,#8
7 Silver,total 0.102 mg/L Before batch discharge- 1/6 months PG C 0.001
See Part III,#8
8 Zinc,total 1.48 mg/L Before batch discharge- 1/6 months PG C 0.01
See Part III,#8
9 Cyanide,total 0.65 mg/L Before batch discharge- 1/6 months PG C 0.010
See Part III,#8
10 TTO 2.13*** mg/L Before batch discharge- 1/6 months PG C 0.010
See Part III,#8
11 pH **** su Before batch discharge- 1/6 months PG C n/a
See Part III,#8
*Proportional Grab,Composite,Grab,See Definitions in Part I G(1,3,4)
**Higher detection levels up to the permit limit may be used when analyte is detectable or if a documented matrix interference exists.
***TTO: in lieu of sampling,may submit certification statement every six months with semi-annual report
****pH will be between 5.0-11.0 standard units
5 1

G. Definitions
In addition to the definitions in Title V of the Town of Boone Code of Ordinances,the
following definitions and requirements apply:
1. Composite Sample: A composite sample for the monitoring requirements of this
Permit, is collected as follows:
Collect a sample from each tank and combine it with other tanks in equal portions.
If there is planned use of the mop sink to discharge regulatory wastewater on that
date or if the mop sink is holding water, then an equal part of that wastewater will
also need to be included in the sample. Flow data recorded for the same date of the
sample will be used to compute pounds of each parameter for permit compliance
and other regulatory activity. This sample data will be considered representative of
the wastewater discharge for the date sampled as required by IUP#0004, Part II,#1.
2. Daily Monitoring Frequency: Daily monitoring frequency as specified in this permit
shall mean each day of discharge.
3. Grab Sample: A single"dip and take" sample collected at a representative point in a
discharge stream.
4. Proportional Grab Sample: A composite of grab samples combined in proportion of
the individual sampling tanks and sink being discharged to the total volume being
discharged.
5. "Every Sample"Monitoring Frequency: A Monitoring Frequency of"every
sample"as specified in this Permit shall mean each time a composite sample is
collected or a batch discharge is performed.
6. Instantaneous Measurement: A single reading, observation, or measurement.
7. Daily Maximum: The maximum allowable discharge of pollutant during a
calendar day. Where daily maximum limits are expressed as a unit of mass,
the daily discharge is the total mass over the sum of a day. Where daily
maximum limits are expressed as concentrations,the daily discharge is the
arithmetic average of the pollutant concentration derived from all
measurements taken that day.
8. Semi-Annually: Once every six months.
9. Cooling Water:
a. Non-Contact: Water used for cooling purposes only which has no direct contact
with any waste product,raw material, intermediate, or final product and which
does not contain a level of contaminants detectably higher than that of the intake
water.
6

b. Contaminated: Water used for cooling purposes which may become
contaminated either through the use of treatment chemicals used for corrosion
inhibitors or biocides, or by direct contact with process materials and/or
wastewater and may be subject to regulation.
10. Bypass: The intentional diversion of wastes from any portion of a treatment
facility.
PART II
General Conditions
SIU Permit
Outline of Part II
1. Representative Sampling 19. Penalties
2. Reporting 20. Need to Halt or Reduce
3. Automatic Resampling 21. Transferability
4. Test Procedures 22. Property Rights
5. Additional Monitoring 23. Severability
6. Duty to Comply 24. Permit Modification
7. Duty to Mitigate 25. Permit Revocation or Termination
8. Facilities Operation 26. Reapplication
9. Bypass 27. Continuation of Expired Permit
10. Removed Substances 28. Permit Appeals
11. Upset Conditions 29. Dilution Prohibition
12. Right of Entry & Inspection 30. Reports of Changed Conditions
13. Availability of Records 31. Construction
14. Duty to Provide Information 32. Reopener
15. Signatory Requirements 33. Categorical Reopener
16. Toxic Pollutants 34. General Prohibitive Standards
17. Civil and Criminal Liability 35. Reports of Potential Problems
18. Federal and/or State Laws 36. Anticipated Noncompliance
1. Representative Sampling:
Samples and measurements taken as required herein shall be representative of the
volume and nature of the monitored discharge. All samples shall be taken at the
monitoring points specified in this Permit and, unless otherwise specified, before the
effluent joins or is diluted by any other waste stream, body of water or substance.
Monitoring points shall not be changed without notification to, and approval by,the
Permit-issuing authority.
2. Reporting:
a. Monitoring results obtained by the Permittee shall be summarized and reported on
forms specified by the Control Authority, postmarked by the 30th day of the
calendar month following the calendar month in which the samples were taken. If
reports are not available due to a delay at the contract lab, the Permittee shall
7

notify the Control Authority by the due date. When sample results are available,
submit them with an attached explanatory letter from the contract lab,within five
(5) days of receipt of sample results. Semi-annual reports must be postmarked by
the 30th day of the calendar month that follows each six-month period. For the
purposes of this Permit requirement,the six-month periods will be January
through June and July through December.
b. The reports shall indicate the nature and concentration of all pollutants in the
effluent for which sampling and analyses were performed during the monitoring
periods, including measured maximum and daily flows. In addition,the reports
shall include the date, exact time,place and methods of sampling or measuring,
sample preservation techniques and procedures, person that did the sampling or
measuring, and the dates the analyses were performed and chain of custody. If no
discharge occurs during a reporting period(herein defined as each calendar
month) in which a sampling event was to have occurred, a form with the phrase
P g
"no discharge" shall be submitted.
c. Copies of these and all other required reports herein shall be submitted to the
Control Authority at the following address:
Town of Boone Jimmy Smith Wastewater Treatment Plant
Attn: Pretreatment Coordinator
PO Drawer 192
Boone,NC 28607
3. Automatic Resampling:
If the results of the Permittee's wastewater analysis indicate a violation of this Permit
has occurred,then the Permittee must:
a. Inform the Control Authority of the violation within 24 hours of discovery; and
b. See Part III, Special Conditions,#8 for more information on batch discharges.
For continuous discharge violations,repeat the sampling and pollutant analysis
and submit, in writing,the results of this repeat analysis within 30 days of
knowledge of the first violation. Because the Control Authority is performing this
sampling for the Permittee,the Control Authority will conduct the repeat analysis.
c. Determine and report the cause of the violation and the measures taken to prevent
reoccurrence of the same violation within 30 days of notification of the first
violation.
4. Test Procedures:
Test procedures for the analysis of pollutants shall be performed in accordance with
the techniques prescribed in 40 CFR part 136 and amendments thereto unless
specified otherwise in the monitoring conditions of this Permit.
5. Additional Monitoring:
If the Permittee monitors any pollutant at the location(s) designated herein more
frequently than required by this Permit,using test procedures prescribed in 40 CFR
8

136 or amendments thereto, or otherwise directed by the EPA or as specified in this
Permit,the results of such monitoring shall be submitted to the Control Authority.
The Control Authority may require,by written notification,more frequent monitoring
or monitoring of other pollutants not required in this Permit.
6. Duty to Comply:
The Permittee must comply with all conditions of this Permit. Any Permit
noncompliance constitutes a violation of Title V of the Town of Boone Code of
Ordinances and is grounds for possible enforcement action, including civil and
criminal penalties.
7. Duty to Mitigate—Prevention of Adverse Impact:
The Permittee shall take all reasonable steps to minimize,prevent or correct any
discharge in violation of Permit which has a reasonable likelihood of adversely
affecting human health, POTW,waters receiving POTW's discharge, or the
environment, including such accelerated or additional monitoring as necessary to
determine nature and impact of the noncompliant discharge.
8. Facilities Operation:
The Permittee shall at all times maintain in good working order and operate as
efficiently as possible, all control facilities or systems installed or used by the
Permittee to achieve compliance with the terms and conditions of this Permit. Proper
operation and maintenance includes,but is not limited to: effective performance,
adequate funding, adequate operator staffing and training, and adequate laboratory
and process controls, including appropriate quality assurance controls. This provision
requires the operation of back-up or auxiliary facilities only when necessary to
achieve compliance with the conditions of this Permit.
9. Bypass:
a. Bypass of treatment facilities is prohibited unless it is unavoidable to prevent loss
of life, severe personal injury, or severe property damage or no feasible
alternative exists.
b. The Permittee may allow bypass to occur which does not cause effluent
limitations to be exceeded,but only if it is essential maintenance to assure
efficient operation.
c. Notification of bypass:
1. Anticipated bypass. If the Permittee knows in advance of the need for a
bypass, it shall submit prior written notice at least ten days before the date of
the bypass,to the Control Authority. Bypass approval shall be given only
when such bypass is in compliance with 40 CFR 403.17.
2. Unanticipated bypass. The Permittee shall immediately notify the Control
Authority and submit written notice within 5 days. The report shall specify: a
description of the bypass and its cause, including duration; whether the bypass
has been corrected; and the steps taken to reduce or eliminate the reoccurrence
of the bypass.
9

10. Removed Substances:
Solids, sludges, filter backwash, or other pollutants removed in the course of
treatment or control of wastewaters shall be disposed of in a manner such as to
prevent any pollutants from such materials from entering the sewer system. The
Permittee is responsible for assuring its compliance with any regulations regarding
the generation,treatment, storage, and/or disposal of"Hazardous Waste"as defined
under the Federal Resource Conservation and Recovery Act.
11. Upset Conditions:
An"upset"means an exceptional incident in which there is an unintentional and
temporary noncompliance with the effluent limitations of this Permit because of
factors beyond the reasonable control of the Permittee. An upset does not include
noncompliance to the extent caused by operational error, improperly designed or
inadequate treatment facilities, lack of preventative maintenance, or careless,
improper operations. These actions should be made in response to upset conditions:
a. The Permittee shall inform the Control Authority within 24 hours of an upset in
operations.
b. A written report of the upset must be submitted within 5 days and include:
description and duration of upset, including exact date and time,the cause,the
impact on the Permittee's compliance status, duration of noncompliance, and all
steps taken to reduce, eliminate, and prevent recurrence of such an upset.
c. A documented and verified upset may constitute an affirmative defense for action
brought for the noncompliance. The Permittee has the burden of proof to provide
evidence and demonstrate that none of the factors specifically listed above were
responsible for the noncompliance.
12. Right of Entry and Inspection:
The Permittee shall allow the staff of the North Carolina Department of
Environmental Quality, Division of Water Resources,the Regional Administrator of
the Environmental Protection Agency,the Control Authority, and/or their authorized
representatives, upon the presentation of credentials:
a. To enter upon the Permittee's premises where a real or potential discharge is
located, could originate, be stored or be discharged to the sewer system or in
which records are required to be kept under the terms and conditions of this
Permit; and
b. At reasonable times have access to and copy records required to be kept under the
terms and conditions of this Permit; to inspect any monitoring equipment or
monitoring method required in this Permit; and to sample any discharge of
pollutants.
13. Availability of Records:
The Permittee shall retain records of all monitoring information, including calibration
and maintenance records and original strip chart recordings for continuous monitoring
instrumentation, copies of all reports required by this Permit, and records of all data
used to complete the application for this Permit, for at least three (3) years from the
date of sample,measurement,report or application. This period may be extended at
10

any time by the Control Authority. All enforcement or litigation activities brought by
the Control Authority shall be retained and preserved by the Permittee until
enforcement activities have concluded and periods of limitations with respect to
appeals have expired. Except for data determined to be confidential under Title V of
the Town of Boone Code of Ordinances, all reports prepared in accordance with
terms of this Permit shall be available for public inspection at the Control Authority.
As required by Title V of the Town of Boone Code of Ordinances, effluent data shall
not be considered confidential. Authorization to Construct information must be
maintained for the life of the facility.
14. Duty to Provide Information: The Permittee shall furnish to the POTW Director or
his/her designees within a reasonable time, any information which the Director,
his/her designee, or the Division of Water Resources may request to determine
whether cause exists for modifying,revoking and reissuing, or terminating this Permit
or to determine compliance with this Permit. The Permittee shall also furnish,upon
request, copies of records required to be kept by this Permit.
15. Signatory Requirements:
All reports or information submitted pursuant to the requirements of this Permit must
be signed and certified by the Authorized Representative as defined under Title V of
the Town of Boone Code of Ordinances, Section 50.327(B). If the designation of an
Authorized Representative is no longer accurate because a different individual or
position has responsibility for the overall operation of the facility, or overall
responsibility for environmental matters for the company, a new authorization
satisfying the requirements of this section must be submitted to POTW Director prior
to or together with any reports to be signed by an Authorized Representative. The
certification statement shall read:
"I certify under penalty of law that this document and all attachments were
prepared under my direction or supervision in accordance with a system designed
to assure that a qualified personnel properly gather and evaluate the information
submitted. Based on my inquiry of the person or persons who manage the system,
or those persons directly responsible for gathering information,the information
submitted is,to the best of my knowledge and belief,true, accurate, and complete.
I am aware that there are significant penalties for submitting false information,
including the possibility of fines and imprisonment for knowing violations."
16. Toxic Pollutants:
If a toxic effluent standard or prohibition (including any schedule of compliance
specified in such effluent standard or prohibition) is established under Section 307(a)
of the Federal Clean Water Act for a toxic pollutant which is present in the discharge
and such standard or prohibition is more stringent than any limitation for such
pollutant in this Permit, this Permit may be revised or modified in accordance with
the toxic effluent standard or prohibition and the Permittee so notified.
11

17. Civil and Criminal Liability:
Nothing in this Permit shall be construed to relieve the Permittee from civil or
criminal penalties for noncompliance.
18. Federal and/or State Laws:
Nothing in this Permit shall be construed to preclude the institution of any legal
action or relieve the Permittee from any responsibilities, liabilities, or penalties
established pursuant to any applicable federal and/or State law or regulation.
19. Penalties:
a. Title V of the Town of Boone Code of Ordinances provides that any person who
violates a permit condition is subject to a civil penalty not to exceed $25,000
dollars per day of such violation.
b. Under State law, (NCGS 143-215.6B), under certain circumstances it is a crime to
violate terms, conditions, or requirements of Permits. It is a crime to knowingly
make any false statement, representation, or certification in any record or other
document submitted or required to be maintained under this Permit, including
monitoring reports or reports of compliance or noncompliance. These crimes are
enforced at the prosecutorial discretion of the local District Attorney.
c. In addition to civil and criminal liability,the Permittee violating any of the
provisions of this Permit or Title V of the Town of Boone Code of Ordinances or
causing damage to or otherwise inhibiting the Town of Boone Jimmy Smith
Wastewater Treatment Plant, or sewer collection system shall be liable to the
Town of Boone for any expense, loss, or damage caused by such violation or
discharge. The Town of Boone shall bill the Permittee for the costs incurred by
the Town of Boone Jimmy Smith Wastewater Treatment Plant or sewer collection
system for any cleaning,repair, or replacement work caused by the violation or
discharge. Refusal to pay the assessed costs shall constitute a separate violation
of Title V of the Town of Boone Code of Ordinances.
d. At least annually,the POTW Director shall publish in a newspaper of general
circulation that provides meaningful public notice within the jurisdiction(s) served
by the POTW, a list of those industrial wastewater contributors which were found
to be in significant noncompliance as defined in 15A NCAC 2H .0903(b)(34),
with applicable pretreatment standards and requirements, during the previous 12
months.
20. Need to Halt or Reduce not a Defense:
It shall not be a defense for a Permittee in an enforcement action that it would have
been necessary to halt or reduce the permitted activity to maintain compliance with
the conditions of the Permit.
12

21. Transferability:
This Permit shall not be reassigned or transferred or sold to a new owner,new
contributor,different premises, or a new or changed operation without approval of the
Control Authority. The Permit may be reassigned or transferred with prior approval
and modification of the Permit by the Control Authority if the following conditions
are met:
a. The Permittee must give at least sixty(60) days advance written notice to the
Control Authority
b. The notice must include a written certification by which the new owner/operator
states no immediate intent to change the facility's operations or process
c. It must identify the specific date on which the transfer is to occur.
d. It must acknowledge full responsibility for complying with the existing Peiuiit.
22. Property Rights:
This Permit does not convey any property rights in either real or personal property, or
any exclusive privileges,nor does it authorize any injury to private property or any
invasion of personal rights,nor any infringement of federal, State or local laws or
regulations.
23. Severability:
The provisions of this Permit are severable and, if any provision of this Permit or the
application of any provision of this Permit to any circumstance is held invalid,the
application of such provision to other circumstances and the remainder of this Permit
shall not be affected thereby.
24. Permit Modification:
This Permit may be modified with cause in accordance to the requirements of Title V
of the Town of Boone Code of Ordinances and the North Carolina General Statutes or
implementing regulations, including but not limited to,the following causes:
a. To incorporate new or revised federal, State, or local pretreatment standards
b. Material or other alterations or additions to the discharger's process, discharge
volume or character
c. A change in any condition in either the industrial wastewater contributor or the
POTW that requires a temporary or permanent reduction or elimination of
discharge
d. Information that permitted discharge poses threat to the WWTP collection and
treatment system,POTW personnel, or receiving waters
e. Violation of any terms or conditions of this Permit
f. Misrepresentation or failure to fully disclose all relevant facts in the wastewater
permit application or in any required report
g. To correct typographical or other errors in the Permit
h. To reflect transfer of the facility ownership and/or operation to a new owner or
operator
i. Upon request of the Permittee,provided such a request does not create a violation
of any applicable requirements, standards, laws,rules or regulations.
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25. Permit Revocation or Termination:
This Permit may be revoked or terminated with cause in accordance to the
requirements of Title V of the Town of Boone Code of Ordinances and the North
Carolina General Statutes or implementing regulations, for reasons including,but not
limited to the following:
a. Falsifying self-monitoring reports
b. Tampering with monitoring equipment
c. Refusing to allow timely access to the facility premises and records
d. Failure to meet effluent limitations
e. Failure to pay any assessed fines
f. Failure to pay sewer charges
g. Failure to meet compliance schedules
26. Reapplication for Permit Renewal:
The Permittee is responsible for filing an application for reissuance of this Peiiuit at
least 180 days prior to its expiration date.
27. Continuation of Expired Permit:
An expired Permit will continue to be effective and enforceable until the Permit is
reissued if:
a. The Permittee has submitted a complete wastewater permit application at least
180 days prior to the expiration date of the contributor's existing Permit.
b. The failure to reissue the Permit,prior to expiration of the previous Permit, is not
due to any act or failure to act on the part of the Permittee.
28. Permit Appeals:
The Permittee may petition to appeal the terms of this Permit within thirty(30) days
of the notice. This petition must be in writing. Failing to submit a petition for review
shall be deemed to be a waiver of the appeal. In its petition,the Permittee must
indicate the Permit provisions objected to,the reasons for the objection, and the
alternative condition, if any,that it seeks to be placed in the Permit.
29. Dilution Prohibition:
The Permittee shall not increase the use of potable or process water or in any other
way attempt to dilute the discharge as a partial or complete substitute for adequate
treatment to achieve compliance with the limitations contained in this Permit.
30. Reports of Changed Conditions:
The Permittee shall give notice to the Control Authority of any planned significant
changes to the Permittee's operations or system which might alter the nature, quality,
or volume of its wastewater at least 180 days before the change. The Permittee shall
not begin the changes until receiving written approval from the Control Authority.
Also see Part II, 35 below for additional reporting requirements for spill/slug issues.
Significant changes may include but are not limited to:
a. increases or decreases to production;
b. increases in discharge of previously reported pollutants;
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c. discharge of pollutants not previously reported to the Control Authority;
d. new or changed product lines;
e. new or changed manufacturing processes and/or chemicals; or
f. new or changed customers.
31. Construction:
No construction of pretreatment facilities or additions thereto shall be begun until
Final Plans and Specifications have been submitted to the Control Authority and
written approval and an Authorization to Construct(A to C)have been issued.
32. Reopener:
The Permit shall be modified or, alternatively,revoked and reissued to comply with
any applicable effluent standard or limitation for the control of any pollutant shown to
contribute to toxicity of the WWTP effluent or any pollutant that is otherwise limited
by the POTW discharge or collection system permits. The Permit as modified or
reissued under this paragraph may also contain any other requirements of State or
federal pretreatment regulations then applicable.
33. Categorical Reopener:
This permit shall be modified, or alternatively, revoked and reissued, to comply with
any applicable effluent standard or limitation issued or approved under Sections
302(b)(2)(C) and(D), 304(b)(2), and 307(a)(2) of the Clean Water Act, if the effluent
standard or limitation so issued or approved:
a. contains different conditions or is otherwise more stringent than any effluent
limitation in this Permit; or
b. controls any pollutant not limited in this Permit.
The Permit as modified or reissued under this paragraph shall also contain any other
requirements of the Act then applicable.
34. General Prohibitive Standards:
The Permittee shall comply with the general prohibitive discharge standards in 40
CFR 403.5(a) and(b) of the federal pretreatment regulations. Where more stringent
discharge standards are present in this Permit or section 50.328 of Title V of the
Town of Boone Code of Ordinances, the Permittee must abide by the more stringent
discharge standards.
35. Potential Problems:
a. The Permittee shall provide protection from accidental and slug discharges of
prohibited materials and other substances regulated by this Permit. The Permittee
shall also notify the Control Authority immediately of any changes at its facility
affecting the potential for spills and other accidental discharge, discharge of a
non-routine, episodic nature, a non-customary batch discharge, or a slug load as
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defined in Title V of the Town of Boone Code of Ordinances. See Part III (1) of
this Permit for more detail.
b. The Permittee shall notify the Control Authority immediately upon the
occurrence of an accidental discharge of substances prohibited by Title V of the
Code of Ordinances or any slug loads or spills as defined in Title V of the Code of
Ordinances that may enter the POTW. Contact the Town of Boone Jimmy Smith
Wastewater Treatment Plant by telephone at 828/268-6270. If no one can be
reached at the Town of Boone Jimmy Smith Wastewater Treatment Plant notify
the Town of Boone Police Department at 828/262-4500 or 828/268-6900.
The telephone notification shall include:
• Location of discharge
• Date and time of discharge
• Type of waste,including concentration and volume
• Corrective actions taken
The Permittee's notification of accidental releases in accordance with this section
does not relieve it of other reporting requirements that arise under local, State, and
federal laws.
c. Within five days following an accidental discharge,the Permittee shall submit to
the Control Authority a detailed written report. The report shall specify:
1. Description and cause of the upset, slug load or accidental discharge,the
cause thereof, and the impact on the Permittee's compliance status. The
description should also include location of discharge,type, concentration and
volume of waste.
2. Duration of noncompliance, including exact dates and times if noncompliance
is continuing, and the time by which compliance is reasonably expected to
occur.
3. All steps taken or to be taken to reduce, eliminate, and/or prevent
reoccurrence of such an upset, slug load, accidental discharge, or other
conditions of noncompliance.
36. Anticipated Noncompliance:
The Permittee shall give advance notice to the Control Authority of any planned
changes in the permitted facility or activity which may result in noncompliance with
the Permit requirements.
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PART III
Special Conditions
SIU Permit
1. Slug/Spill Control Plan:
In addition to the requirements in Part II (35)the Permittee shall complete installation
and/or commence implementation, operation, and/or maintenance of the following
specific protection Measures, Activities, Plans, Etc. (Items without specific
completion dates, or marked as "Continuous." must be performed for the entire
duration of the permit):
Required
Description of Measure, Activity,Plan, etc. Completion/
Implementation
Date
a. Implement approved Slug Control Plan: Continuous
b. Post sign(s)prohibiting wastewater discharge to open 3/1/17
receiving area drains except for drip-off from delivery
trucks and protect from accidental spills, or plug the
drain(s).
c. Post sign prohibiting manufacturing-area wastewater 3/1/17
discharge to janitor closet mop/floor drain or plug the
drain.
d. Protect drain in Paint Booth area from accidental spills and 3/1/17
post sign prohibiting manufacturing-area wastewater
discharge or plug the drain.
The Permittee shall provide updates to the Control Authority as required by Part II
(35) of this Permit. Modifications to the measures shall be approved by the Control
Authority prior to installation/implementation. If a measure fails, the Control
Authority shall be notified within 24 hours.
2. Sludge Management Plan:
Ninety(90) days prior to the initial disposal of sludge generated by any pretreatment
facility,the Permittee shall submit a sludge management plan to the Control
Authority. This applies to (but would not be limited to) debris on Tank Screens and
settled solids in Settling Bucket.
3. Total Toxic Organics (TTO) Definition:
TTO is the sum of the concentrations of the toxic organic compounds listed in 40
CFR 433 that are found in the Permittee's process discharge at a concentration greater
than 0.01 mg/L.
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L

4. Total Toxic Organics (TTO) Certification:
In lieu of monitoring for TTO,the Permittee, having performed a test for TTO
showing that it is not present,must submit the TTO Certification Form with the
following certification statement every six (6)months:
"Based upon my inquiry of the person or persons directly responsible for managing
compliance with the permit limitation for total toxic organics(TTO),I certify that,to the best
of my knowledge,no dumping of concentrated toxic organics into the wastewaters has
occurred since filing of the last monitoring report. I further certify that this facility is
implanting the toxic organic management plan submitted to the Control Authority."
At a minimum,the certification statements are due by July 30 of each year covering
the January through June semi-annual period and by January 30 of each year covering
the July through December semi-annual period. If the certification is not submitted
for both periods within 5 days of the respective due dates,the Control Authority shall
collect TTO samples before December 31. The Permittee may be billed for the cost
of the TTO sampling and/or analysis. The Town will not be required to sample for
TTO when certifications are submitted.
5. Toxic Organic Management Plan:
The Permittee must have on file at their facility and be implementing or updating an
approved written toxic organic management plan.
6. Certified Laboratory Analysis:
Except for pH at Pipe#001,pollutant analysis shall be performed by a North Carolina
Division of Water Resources Certified Laboratory that is certified in the analysis of
the pollutant in wastewater.
7. Flow Measurement Requirements:
The Permittee shall maintain appropriate discharge flow measurement devices and
methods consistent with approved scientific practices to ensure the accuracy and
reliability of measurements of the volume of monitored discharges. Devices installed
shall be a continuous recording flow meter capable of measuring flows with a
maximum deviation of less than 10% from true discharge rates throughout the range
of expected discharge volumes. The devices shall be installed, calibrated, and
maintained to ensure accuracy. The meter shall be calibrated every year.
Modifications to the flow metering equipment shall be approved by the Control
Authority prior to installation. If a required flow measurement device fails,the
Control Authority shall be notified within 24 hours.
8. Batch Discharge Requirements:
(a. Sampling Requirements:
1. A proportional grab sample must be obtained, analyzed, and reported to the
Town of Boone to be in compliance with the terms and conditions of this Permit
before a batch discharge.
2. The date of the batch discharge (no more than 60 days after the sample date)
shall be reported with the compliant results.
3. The proportions of the sample shall be reported with the compliant results.
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4. The flow meter readings at the beginning of the batch discharge and at the
completion of the batch discharge shall be recorded, total flow calculated and
reported by the 30th day of the following month.
b. ,Alternative Disposal Requirement:
1. When the results of a batch discharge sample are non-compliant with the terms
and conditions of this Permit, discharge of the wastewater to the Town of Boone
POTW shall not occur.
2. Inform the Control Authority of the non-compliant sampling results within 24
hours of discovery. As long as the wastewater is not discharged and the
notification was made, the sample results will not be considered a violation of the
Permit.
3. The proportions of the sample shall be reported with the non-compliant results.
4. Provide a plan for alternative disposal with appropriate documentation by the
30th day of the following month.
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SIU Permit Synopsis
1. Basic Information:
Industry name,permittee:
Charleston Forge
Facility Located at Street Address
251 Industrial Park Drive
City
Boone
State,Zip
NC 28607
2. IU Survey & Application Form:
See attached copy of Industrial User Wastewater Survey and Discharge Permit
Application
3. IU Inspection Form:
See attached copy of Industrial User Inspection Form
4. Rationale for SIU status:
The Town of Boone has determined that Charleston Forge is a New Source,
Categorical Industrial User, subject to the Metal Finishing Category due to the
presence of a coating operation that began January 2014. Batch discharges were not
conducted until after the permit was issued.
5. Rationale for Limitations:
Rationale#1 Review of IU Monitoring Data, with no Over Allocation situation:
The following pollutants were assigned numerical limits in this IUP based on a
review of monitoring data for the permittee to determine what ranges of
concentrations are currently being discharged. To account for sample variability a
factor was applied to the monitoring data to determine the permit limit. Permit limits
assigned by the Local IUP Control Authority cannot result in an Over Allocation
situation for any pollutants.
Silver
Rationale#2 Categorical Industrial Limits,with no Over Allocation situation:
The following pollutants were assigned numerical limits in this IUP based on the
categorical regulations (40CFR433.17). No CWF or other categorical limits
calculations were used.
Cadmium Nickel
Chromium Zinc
Copper Cyanide
Lead TTO
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Rationale#3 Interim Limits for IU pollutant reduction:
The following pollutants were assigned interim numerical limits in this IUP to allow
time for the industry to come into compliance with fmal limits that will not result in
over allocations.
N/A
Rationale#4 Other Rationale for Limitations:
The following rationale was used for developing IUP limits.
Parameter Rationale
pH Title V Town of Boone Code of
Ordinances Section 50.328(A)(2)(c)
Flow Flow limit allows for discharge of all 5
tanks and mop sink with the possibility
of additional flow due to washdown or
other regulated wastewater discharges
on the same day. Middle Tier CIU
status is not possible due to proposed
batch discharge schedule which exceeds
the maximum of 482 gpd(0.01%dry
weather hydraulic capacity). No over-
allocation situation is created.
Rationale #5 Non-Categorical Parameters where No Limit needed or assigned in IUP
The following pollutants were not assigned numerical limits in this IUP because the
loadings for these pollutants from this IU are considered insignificant at this time.
Pollutant Avg Avg SIU 5%MAHL, 0.01%MARL,
SIU mg/L lbs/day lbs/day lbs/day
Ammonia 14.9 0.005 56.53 0.11
Arsenic 0.0153 0.0000 0.0146 n/a
BOD 193 0.2308 754 151
Mercury <0.0002 0.00000 0.002546 n/a
Molybdenum 1.38 0.0000 0.0363 n/a
Selenium 0.1103 0.0000 0.0319 n/a
TSS 246 0.0188 754 151
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