NC0034754_Permit (Modification)_20040217

NPDES DOCUMENT SCANNING% COVER SHEET
NPDES Permit:
NC0034754
CommScope WWTP
Document Type:
Permit Issuance
Wasteload Allocation
Authorization to Construct (AtC)
(Permit
Modification" ,+.
Complete File - Historical
Engineering Alternatives (EAA)
Correspondence
Owner Name Change
Instream Assessment (67b)
Speculative Limits
Environmental Assessment (EA)
Document Date:
February 17, 2004
This document is printed on, reuse paper - ignore any
content on, the reizerse side

Michael F. Easley, Govemor
State of North Carolina
William G. Ross, Jr., Secretary
Department of Environment and Natural Resources
Alan W. Klimek, P.E., Director
Division of Water Quality
February 17, 2004
Mr. D. Scott Waddell, EH&S Engineer
CommScope
P.O. Box 199
Catawba, North Carolina 28609-0199
Subject: NPDES Permit Modification
CommScope
Permit No. NC0034754
Catawba County
Dear Mr. Waddell:
The Division of Water Quality received your request for a permit modification on July 25,
2003. We apologize for the delay in responding to your request. In summary, your request
specified that CommScope be allowed to discharge a portion of the contact cooling water into the
existing 0.02 MGD treatment system. This request has been granted and is reflected in the
change to Part A.(1.) of the permit, which is attached to this letter. The process water in Part
A.(1.) has been specified as contact cooling water.
CommScope should exercise caution in "bleeding -in" the contact cooling water to the
existing treatment system. One pilot study may not provide enough information to ensure proper
treatment of the wastestream (the Division of Water Quality would have preferred two more tests).
However, based on your conversations with water quality staff, you are aware of these potential
issues and will take corrective action as necessary.
The revised page should be inserted into your permit. The old page may then be
discarded. Ali other terms and conditions contained in the original permit remain unchanged and
in full effect. This permit modification is issued under the requirements of North Carolina General
Statutes 143-215.1 and the Memorandum of Agreement between North Carolina and the U. S.
Environmental Protection Agency.
If any parts, measurement frequencies or sampling requirements contained in this permit
modification are unacceptable to you, you have the right to an adjudicatory hearing upon written
request within thirty (30) days following receipt of this letter. This request must be a written
petition conforming to Chapter 150B of the North Carolina General Statutes, filed with the Office
of Administrative Hearings (6714 Mail Service Center, Raleigh, North Carolina 27699-6714).
Unless such demand is made, this decision shall be final and binding.
If you have any questions regarding the NPDES permit, please contact Susan Wilson at
(919) 733 - 5083, extension 510.
Sincerely,
dcfea,,
iL 1Jan W. Klimek, P.E.
cc: Mooresville Regional Office/Water Quality Section
Central Files
NPDES Unit
North Carolina Division of Water Quality
1617 Mail Service Center
Raleigh, North Carolina 27699-1617
[phone]
FAX [phone]
On the Internet at http://h2o.enr.state.nc.us/

Permit No. NC0034754
A (1). EFFLUENT LIMITATIONS AND MONITORING REQUIREMENTS
Beginning on the effective date of this permit and lasting until expiration, the Permittee is authorized to discharge
process (contact cooling water) and domestic wastewater from Outfall 001. Such discharges shall be limited
and monitored by the Permittee as specified below:
EF1 LUENT
CI ARACTERISTICS
EFFLUENT LIT.ATIONS
MONITORING REQUIREMENTS
Monthly
Average
weekly
AveiTage
Daily
Magiiiituin
Measurement.
Frequency
Sample
Type
Sample
Location'
Flow
0.02 MGD
Continuous
Recording
I or E
BOD, 5-day, 20°C (Summer)
16.0 mg/I
24.0 mg/1
Weekly
Grab
E
°
BOD, 5-day, 20 C (Winter)
30.0mg/1
40.7m 1
g/
Weekly
Grab
E
Total Suspended Residue
30.0 mg/I
39.2 mg/1
Weekly
Grab
E
NH3 as N (Summer)
2.0 mg/1
Weekly
Grab
E
NH3 as N (Winter)
4.3 mg/1
Weekly
Grab
E
Oil & Grease
29 mg/1
Weekly
Grab
E
Total Residual Chlorine
2/Week
Grab
E
Fecal Coliform (geometric
mean)
200/100 ml
400/100 ml
Weekly
Grab
E
Dissolved Oxygen2
Weekly
Grab
E
Temperature
Daily
Grab
E
pH3
Weekly
Grab
E
Chronic Toxicity4
Quarterly
Composite
E
Dissolved Oxygen
Weekly
Grab
U. D
Temperature
Weekly
Grab
U. D
Fecal coliform
Weekly
Grab
U, D
Conductivity
,
Weekly
Grab
U, D
Notes:
1. Sample locations: E- Effluent, I- Influent, U- Upstream at least 50-feet above ALL outfalls, D- Downstream at
least 100-feet below ALL outfalls.
2. The daily average dissolved oxygen effluent concentration shall not be less than 6.0 mg/1.
3. The pH shall not be less than 6.0 standard units nor greater than 9.0 standard units.
4. Chronic Toxicity (Ceriodaphnia) at 34%; February, May, August, November; refer to Special Condition A (3).
(Summer) = April 1- October 31
(Winter) = November 1 - March 31
There shall be no discharge of floating solids or visible foam in other than trace amounts.

RR: [F`w.d: CommScope]
Subject: Re: [Fwd: CommScope]
From: Michael Parker <[e-mail]>
Date: Wed, 18 Feb 2004 08:53:37 -0500
To: Susan Wilson <[e-mail]>
Ooops. I thought I had replied to you? Guess not!
Anyway, I have no problem with you clarifying this with a permit
modification. The way I read the permit it seems that they have had the
authority to do this as well, but if they want to modify the permit so
be it.
Carry on.
Michael
Susan Wilson wrote:
Mike,
Sent you this awhile back. Their limits will be modified slightly
with this change. I've spoken with their environmental person about
it. Do you have any issues with this. It looks OK with me. Thanks.
Susan
Original Message
Subject: CommScope
Date: Fri, 30 Jan 2004 16:29:27 -0500
From: Susan Wilson <[e-mail]>
To: Michael Parker <[e-mail]>
Mike,
I've been looking over the request from CommScope and have spoken to
Scott Waddell a couple of times now. They'd like to 'bleed -in' a
certain amount of process wastewater into the domestic system (outfall
001), while still retaining outfalls 002 - 004.
Looks like to me they've always had the ability to do this (via the
description and fact sheet for 001). I spoke to him about this but it
didn't seem like he thought that was the case.
Anyway - I have no problem with it and I'm going to clarify it for him
with the mod.
What are your thoughts on this? I believe I sent the mod request down
to you (at least I have a note to that effect). Any objections?
1 of 2 2/ 18/2004 9:14 AM

•
July 24, 2003
CERTIFIED MAIL RETURN RECEIPT REQUESTED
# 7001 1940 0004 7534 7314
N.C. Dept. of Environment & Natural Resources
Division of Water Quality / NPDES Unit
Attn: David Goodrich
1617 Mail Service Center
Raleigh, NC 27699-1617
Subject: Permit Modification Request - Revision 1
Additional Information Request (Return #2195)
CommScope, Inc.
Catawba, North Carolina
Catawba County
NPDES Permit Number: NC 0034754
Mr. David Goodrich:
j`A(, �'� YY i R� l 1ST
ConfunS
6519 CommScope Road
P.O. Box 199
Catawba, North Carolina 28609-0199
Tel [phone] 241 3142
Fax [phone]
www.commscope.com
This letter is to serve as a response to your letter dated July 3, 2003. This letter is
intended to supply you with additional information as per your request. The following
information is included in this packet:
1) Short Form C. Per our conversation on 7/23/03, the Short Form C was
determined not to be applicable and thus is no longer part of the request for
information.
2) Major Modification Fee: Check for $215.00
3) Chronic Toxicity Test Results from the treatability Study performed in
February 2003 by Water Tech Labs Inc.
4) Estimated Flow information. The max flow associated with each sand filter
bleed off is approx. 500 gallons / day per unit. We will have a total of 7 units
that will be installed with the potential for 2 additional units (based on
business conditions). Assuming 9 filters, this equates to a MAX flow of 4,500
gallons of contact cooling water that would be transferred to the WWTP for
treatment. This MAX flow assumes that every pit would discharge the max
C:\Documaas end Settings\wadde111My DocumentsEHS FIUNO SYSTEM \02-Calawbal3-&rvironmedal- Walee3.2 Wastewater Issues\WW7P Request for Modification Rev. 1(Juty 2003).doc
1 of 2

amount in 1 day, which is not feasible. The average flows are as follows. To
help minimize potential impact on the WWTP the sand filters will be
programmed to discharge at different times during the week. Each day of the
week their will be 2 sand filters that will discharge / day which will equate to
a flow of -1,000 gallons / day. (NOTE: It is believed that the 500 gallons /
day is the maximum amount that these units would discharge and that after the
system is up and running the actual discharge / day will be much less.) After
receiving field data on the effectiveness of these units, adjustments may be
needed to allow for more than 2 filters to discharge/ day but not to exceed the
1,000 gallons / day estimate.
5) Offsite costs. Average off -site costs for cleaning of contact cooling water pits
and disposal of the contact cooling water is approximately $50,000 / year.
6) 3-Copies of the request packet.
I would like to reiterate that we are not asking for an increase of discharge from the
WWTP that is currently permitted for a discharge of 0.02 MGD. Additional equalization
storage is still under review to allow for fluctuations in manufacturing as well as the
ability to isolate incoming waste in the event of a process upset. Outfall # 2, 3 & 4 will
not change. This modification will only directly affect outfall #1
If you should have any questions concerning information contained in the report, please
feel free to contact me @ 828-241-63 5 6.
Sincerely,
zWddif,"
colt Waddell
Environmental, Health, & Safety Engineer
Cc: Dan Gulledge - VP Domestic CATV Operations
Robert Narvaez - Corp. Mgr. Environmental Health & Safety
C:1Docuuxnta and Scttbngi\w ddclnliy Dontma*slEHS RUNG SYSTEM102•Catawba13•Envlrotenartal • Watetl3.2 Wutewater 1uue6W WTP Request for Modification Rev. I (July 2003).doe
2 of

Y
WATER TECH LABS, INC.
Date: February 25, 2003
Client: Comm -Scope
P. O. Box 199
Catawba, NC 28609
Subject: Process Pit Water Treatability
1. 2-24 hr composite influent domestic wastewater samples were collected during
the week of February 2, 2003. This wastewater is the existing influent to
treatment system.
2. 2 samples of Pit Water were collected during the week of February 2, 2003.
3. 2 samples of the mixed liquor in Plant Aeration Basins were collected during the
week of February 2, 2003. These samples represent the existing conditions in the
treatment plant to which measured amounts of samples #1 and #2 were
introduced.
4. Sample Preparation:
a. Allow 4 liter of mixed liquor to settle for 1 hour.
b. Decant 2 liter of supernate from mixed liquor solution.
c. Add 1 liter of influent sample and 1 liter of pit water to remaining mixed
liquor solution.
d. Aerate/Mix sample for 24 hours.
e. Allow solution to settle for 1 hour.
f. Decant supernate and perform Chronic Toxicity @ 34%, BOD-5, and
COD.
This is the general procedure used during the test period and the analytical data was
reported at an earlier date.
Submitted by:
Tony Gragg
Director of Lab Services
POST OFFICE BOX 1056 GRANITE FALLS, NC 28630
PHONE [phone] * FAX [phone]

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CommScope
NCO034754
Major Modification
1/30/03
Notes to file:
CommScope has requested permission to "bleed in" some process wastewater to their
existing Outfall 001 treatment system. The treatment system is a 0.02 MGD
conventional treatment system with filtration and chemical pH adjustment, as well as
chlorination/dechlorination.
The current permit allows some process wastewater, however - I believe the permittee
was unsure if industrial process wastewater was allowed from this outfall and wanted
to request a review. Outfall 001 is not used for process water at all currently. Outfalls
002, 003, 004 are not used for process wastewater either. The current method for
disposal of the contact cooling water is recycle and pump/haul. This method is costly,
so CommScope is seeking an additional alternative.
The volume of wastewater the permittee wishes to "bleed -in" is approximately 4500 gpd.
There are currently 850 employees on -site, with no expected employee growth in the
near future. Even with 850 employees, the highest monthly average flow has been
0.008 MGD.
With this average flow, the treatment plant should be able to accommodate the
increased flow of 4500 gpd ( still under the capacity of 0.02 MGD).
The permittee performed one pilot test for the proposed addition of the industrial
wastewater. The toxicity test passed at the required 34%. Other chemical tests were
conducted which were found to be below permitted levels.
Although DWQ would have preferred two more pilot tests - DWQ will not object to the
request.
Based on conversations with Scott Waddell of CommScope - the permittee wishes to
retain the permit requirements for Outfalls 002, 003, and 004. These outfalls were
originally developed for the contact cooling water, but have not been used for that in
many years. Should a process upset occur - they would like to retain these outfalls.
The limits given for Outfall 001 will have to include the limits given for the categorical
industry discharge (contact cooling water), as guided by 40 CFR 463.
1

CommScope
NC0034754
Major Modification
1/30/03
Notes to file:
NOTES FOR APPLICATION OF GUIDELINES:
In addition to the existing limits for domestic wastewater, the limits for Outfall 001
will have to be modified to include the limits for contact cooling water.
40 CFR 463 PLASTICS MOLDING AND FORMING POINT SOURCE CATEGORY
(STARTING AT 463.12 & 423.13), SUBPART A - CONTACT COOLING AND HEATING WATER
SUBCATEGORY
The basic permitting for Outfall 001 will have to be modified to include this
subcategory.
463.12
Parameter
Daily max,
mg/1
BOD5
26
Oil & Grease
29
TSS
19
pH
6 - 9 S.U.
A load level will be calculated for each contribution (contact cooling water and
domestic wastewater) and then converted to a concentration based limit (daily
max) for the total flow.
BOD5 (daily max)
For domestic ww, the existing daily maximum level is 24 mg/1 (summer) and 45
mg/1 (winter). The total flow for the domestic ww can be no greater than:
0.02 MGD (PF) - 0.0045 MGD (the maximum stated input of the contact cooling
water) = 0.0155 MGD (total max domestic flow).
The domestic load will be:
0.0155 * 8.34 *24 = 3.1025 #/day (summer)
0.0155 * 8.34 * 45 = 5.8172 #/day (winter)
The contact cooling water load will be:
0.0045 * 8.34 * 26 = 0.9758 #/day
2

CommScope
NC0034754
Major Modification
1/30/03
Total load for BOD5:
Summer: 3.1025 + 0.9758 = 4.0783 #/day, which converts to
4.0783 / (0.02 * 8.34) = 24.5 mg/1
Winter: 6.793 #/day, 40.7 mg/1
Because the summer limit by this method is higher than the existing water
quality based summer limit - the existing limit will remain in the permit (24
mg/1).
Total load for TSS:
0.0155 * 8.34 * 45 = 5.8172 #/day (domestic)
0.0045 * 8.34 * 19 = 0.7131 #/day (contact cooling water)
6.5303 #/day / (0.02 * 8.34) = 39.2 mg/1
This concentration value will be given in the permit.
Oil & Grease limit will be given as per the federal guidelines (29 mg/1 daily
max) .
The permittee's current effluent values are well under these levels.
�ylr� T P2 5 \Rt-t. `h/°( —ii <p3-)
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3

Whole Effluent Toxicity Testing Self -Monitoring Summary January 15, 2004
FACILITY REQUIREMENT YEAR JAN FEB MAR APR MAY JUN JUL AUG SEP OCT NOV DEC
Colonial PIpellne/004 24hr LC50 ac monit epis Rhd (grab) 2000 Invalid — >100
NC0031046/004 Begin:2/I2002 Frequency A NonComp 2001 >100
County:Guilford Region: WSRO Subbasin: CPF08 2002 >100
PF: NA Special 2003 >100
7Q10: 0.0 1WC(%; 100.0 2004
Colonial Pipellne/005 24hr LC50 ac monit epis Rhd (grab)
NC00310461005 Begin:2/I2002 Frequency A
County:Guilford Region: WSRO Subbasin: CPF08
PF: NA Special
7Q10: 0.0 IWC(%e; 100.0
NonComp
2000 Invalid
2001 >100
2002 >100
2003 >100
2004
>100
Color -Tex Finishing Corp. chr lim: 12 %
NC0005487/001 Begin:12/1/1999 Frequency Q Feb May Aug Nov + NonComp Single
County: Rowan Region: MRO Subbasin: YADO4
PF: 4.25 Special
7Q10: 1030 IWC(%;0.64
9 2000 — Pass — — Pass — —
NR/Pass — — Fail Fai1,NR
2001 NR NR — — H — — H — — H —
2002 — H — — H — — H — — H —
2003 — H — — H — — H — — H
2004
Columbus WWTP chrlim: 37% V 2000 — — Pass — — Pass — — Pass — — Pass
N00021369/001 Begin12/12003 Frequency Q P/F + Mar Jun Sep Dec + NonComp Single 2001 — — Pass — — Pass — — Pass — — Pass
County:Polk Region: ARO Subbasin: BRD02 2002 — — Late Pass — Pass — — Pass — — Pass
PF: 0.8 Special 2003 — — Pass — — Pass — — Pass — — Pass
7Q 10: 2.1 IWC(•/.; 37.08 2004
Comm Scope IncJ001 ehr lim: 34% 2000 — Fail Fall,Fail NR Pass — — Pass — — Pass
NC0034754l001 Begin:I 1/12001 Frequency Q Feb May Aug Nov + NonComp Single 2001 — Fail.Failt — — Pass — — Pass — Pass Pass
County:Catawba Region: MRO Subbasin: CTB32 2002 — Pass — — Pass — — Pass — — Pass
PF: 0.02 Special 2003 — Pass — — Pass — — Pass — — Pass
7Q I0: 0.06 twC(%;34 2004
Comm Scope IncJ002 24hr LC50 ac monit epis Rhd
NC0034754/002 Begin:1 I/12001 Frequency Q 1/calendar Q
County:Catawba Region: MRO Subbasin: CTB32
PF: var Special
7Q10: 0.05 1WC(%;na
NonComp
2000 — — NR — — NR
2001 — — H — — H — — H
2002 — — H — — H — — H
2003 — — H — — H — — H
2004
Comm Scope Inc./003 24hr LC50 ac monit epis fthd (composite sampling) 2000 — — NR — — NR — — H
NC0034754/003 Begin:I I/I2001 Frequency Q 1/calendar Q NonComp 2001 — — H — — H — — H
County:Catawba Region: MRO Subbasin: CTB32 2002 — — H — — H — — H
PF: var Special 2003 — — H — — H — — H
7Q10: 0.0 IWC(%; na 2004
H
H
H
H
H
H
Comm Scope Inc./004 24 hr LC50 ac monit epis Rhd (composite sampling) 2000 — — NR — — NR — — H
NC0034754(004 Begin:II/12001 FrequencyQ 1/calendarQ NonComp 2001 — — H — — H — — H
County:Catawba Region: MRO Subbasin: CTB32 2002 — — H — — H — — H
PF: von Spacial 2003 — — >100 46.3 — — — — H
7Q 10: 0.0 IWC(%; na 2004
H
H
H
Communications Instruments Inc chr lim: 5.6% (Grab)
NC0033227/004 Begin:6/12001 Frequency Q Feb May Aug Nov + NonComp Single
County: Buncombe Region: ARO Subbasin: FRB02
PF: 0.288 Special
7Q10: 7.5 IWC(%;5.6
2000 — Pass
2001 — Pass
2002 — Pass
2003 — Fail
2004
>22
- Fail >22 >22 Pass — — Pass —
— Pass — — Pass — — H Pass
— Pass — — Pass — — Pass —
>22 Pass — — Pass — — Pass
Concord Rocky River W WTP chr lim: 69%;if 24MGD chr lim 73%;if 28MGD chr lim 76%; i 4 2000 — >99 — — 78.8 — — >99 — — >99
NC0036269/001 Begin:2/1/2001 Frequency Q Feb May Aug Nov + NonComp Single 2001 — >99 — — >99 — — >99 — — >99
County:Cabarrus Region: MRO Subbasin: YAD12 2002 — >99 — — >99 — — >99 — — >99
PF: 20 Special 2003 — >99 — — >99 — — >99 — — >99
7Q10: 14.0 IWC(%;69 2004
Cone Mills - Cliffside chr lim: 4.2%
NC0004405/001 Begin:2/1/1999 Frequency Q P/F + Jan Apr Jul Oct
County:Rutherford Region: ARO Subbasin: BRD02
PF: 1.75 Special
7QI0: 62.10 IWC(%;4.19
+ NonComp Single
2000 Fail Fail Pass Pass — — Pass — — Pass
2001 Fall 2.5,>10 >10 Pass — — Pass — — Pass
2002 Pass — — Pass — — Pass — — Pass
2003 pass — — Pass — — Pass — — Pass
2004
9 Pre 2000 Data Available
LEGEND:
PERM = Permit Requirement LET = Administrative Letter - Target Frequency = Monitoring frequency: Q- Quarterly; M- Monthly; BM- Bimonthly; SA- Semiannually; A- Annually; OWD- Only when discharging; D- Discontinued monitoring requirement
Begin = First month required 7QI0 = Receiving stream low flow criterion (cfs += quarterly monitoring increases to monthly upon failure or N Months that testing must occur - ex. Jan, Apr, Jul, Oct NonComp = Current Compliance Requirement
PF = Permitted now (MGD) IWC % - Instream waste concentrati P/F = Pass/Fail test AC -Acute CHR = Chronic
Data Notation: f- Fathead Minnow; • - Ceriodaphnia sp.; my - Mysid shrimp; ChV - Chronic value; P - Mortality of stated percentage at highest concentration; at - Performed by DWQ Aquatic Tox Unit; bt - Bad test
Reporting Notation: -- = Data not required; NR - Not report Facility Activity Status: 1 - Inactive, N - Newly Lssued(To construe); H • Active but not discharging; t-More data available for month in question; • = ORC signature needed
12

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Permit Number NC0084395
STATE OF NORTH CAROLINA
DEPARTMENT OF ENVIRONMENT AND NATURAL RESOURCES
DIVISIO I OF WATER QUALITY
PERMIT
TO DISCHARGE W STEWATER UNDER THE
NATIONAL POLLUTANT DIS HARGE ELIMINATION SYSTEM
In compliance with the provision of North Carolina Gpner.I Statute 143-215.1, other lawful standards and
regulations promulgated and adopted by the North,Caroli 'a Environmental Management Commission, and the
Federal Water Pollution Control Act, as amended,
errain -, Inc.
is hereby authorized to/discharge astewater from a facility located at
BC One H•ur Cleaners
Gr• undwater : emediation Site
arawa Ter ace Boulevard
Near J cksonville
OnsI7 County
to receiving waters designat •d as the No heast Creek in the White Oak River Basin in
accordance with effluent lim tations, monoring requirements, and other conditions set forth in
Parts I, II, III and IV hereof
This permit shall become effe
ve Janua
9, 2004.
This permit and authorization to . sc`harge shall expire at midnight on July 31, 2007.
Signed this day January 9, 2004.
Alan W. Klimek, P.E., Director
Division of Water Quality
By Authority of the Environmental Management Commission

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Permit Number NC0084395
SUPPLEMENT 0 PERMIT COVER SHEET
Terraine Inc., is h- -by authorized to:
1. Continue to operate an existing 0.216 MGD of industrial astewater from the existing
groundwater remediation system that includes the follow' • components:
• Equalization tank
• Dual micron -filter bags
• Dual metal x filters
• Low -profile air striper
• Dual 1-micron bag filters
• pH control and acid/caustic feed, and
• Metered flow instrumentation
The facility is located at ABC One Hour Cleaners, Tarawa errace Boulevard, near
Jacksonville, in Onslow County.
2. Discharge from said treatment works at the location s -cified on the attached map into
Northeast creek, classified SC-HQW-NSW waters in tVe White Oak River Basin.