NCG500618_Correspondence_20100414

HRP a
Creating the Right Solutions Together
April 14, 2010
Mr. Jim McKay
NC DENR Division of Water Quality
Surface Water Protection Section
Point Source Branch
1617 Mail Service Center
Raleigh, NC 27699-1617
are pe
I_ APR 19 2010
QUALrrY
POINT SOURivi BRANCH
Re: Mack Molding Notification of New Discharge to be Covered by the
NPDES General Permit # NCG500000 for Non -contact Cooling Water,
Boiler Blowdown, Cooling Tower, Condensate and Hydroelectric
Dams. HRP Job # MAC1047.WM
Dear Mr. McKay:
Pursuant to your request on March 5, 2010, this letter is being submitted to the
NCDENR Division of Water Quality on behalf of Mack Molding Company, located at
149 Water Tank Road in Statesville, NC, in order to notify the division that the facility
has installed a new air compressor which will discharge condensate to the ground.
Mack Molding is currently covered by the General Permit #NCG500000 to discharge
non -contact cooling water, cooling tower and boiler blowdown, condensate and
similar wastewaters under the National Pollutant Discharge Elimination System
(NPDES) under Certificate of Coverage #NCG500618. It is Mack Molding's
understanding that due to their current coverage under the general permit, the air
compressor condensate wastewater discharge will also be covered. The air
compressor has been constructed with a PS PolySep Oil/Water Separator, which is
designed to effectively separate emulsified compressor condensate to levels
between 5-15 parts per million. The oil/water separator has been deemed by the
manufacturer as a valuable benefit for ISO 140001 certified companies. For your
reference, the PS PolySept Oil/Water Separator brochure and technical
specifications guide has been included as an attachment to this letter.
Mack Molding is aware of the semi-annual requirements for Oil and Grease
monitoring as required under Part I A(1) of the General Permit, and has added the
requirements to the preventative maintenance schedule.
Mack Molding is also covered by the NPDES General Permit #NCG050000 for
Stormwater Discharges Associated with Industrial Activity under Certification of
Coverage #NCG050348. As such, Mack Molding is in the process of updating the
site -specific Stormwater Pollution Prevention Plan (SPPP) to include the air
compressor and its condensate discharge under the regular monthly inspection
schedule.
CONNECTICUT
197 Scott Swamp Road
Farmington, CT 06032
800-246-9021
860-674-9570
FAX [phone]
501 Kings Highway East
Fairfield, CT 06825
203-610-8212
FAX [phone]
FLORIDA
2435 US Highway 19
Suite 550
Holiday, FL 34691
727-942-2115
FAX [phone]
INDIANA
7965 East 106th Street
Suite 116
Fishers, IN 46038
317-570-4851
FAX [phone]
NEW YORK
1 Fairchild Square
Suite 110
Clifton Park, NY 12065
888-823-6427
518-877-7101
FAX [phone]
SOUTH CAROLINA
1327 Miller Road
Suite D
Greenville, SC 29607
800-752-3922
864-289-0311
FAX [phone]
www.hrpassociates.com
H:1MVvlack Molding\Statesville, NC\MAC1047.WM NPDES Discharge Update 2010\NPDES Notification Cover Letter.doc

Mr. Jim McKay
NC DENR DWQ
April 14, 2010
Page 2
Should you have any questions or concerns regarding this submittal, please do not hesitate to
contact Mr. Frank Bumgarner of Mack Molding Company at [phone] or myself at (864)
289-0311.
Sincerely,
HRP Associates, Inc.
Shannon M. Cohen
Project Scientist
cc: Frank Bumgarner/Mack Molding
Attachment
H: M1Mack Molding1Statesviile, NCIMAC1047.WM NPDES Discharge Update 20101NPDES Notification Cover Letter.doc
HRP f4o ,:e./ , r%n.,
Creating the Right Solutions Together

The Ingersoll-Rand PS Polysep Oil/Water Seperator product offering is the
most comprehensive environmental solution in the air
compressor industry.
The Problem with Other Oil/Water
Separators
Compressor oils that do not have good separation
characteristics, known as emulsions, tend to foul up the
carbon filters as well as the pre -adsorption and
coalescing medias that are commonly installed in front of
the carbon fdters.Those filters have to be replaced before
their capacity is fully used.This is a result of oil binding off
the pore area of the carbon where the condensate first
comes in contact with the fdter.The jelled oil clogs the
filter, which then prevents the volume of condensate from
properly flowing through the filter.This premature failure
of the carbon filters most often results in the system
backing up on the floor.
The IR Environmental Solution
IR PolySep is designed to effectively separate emulsified compressor condensate, as well as oils that have better separation
characteristics, to levels between 5-15 PPM or without premature element failure and backup spillages.These systems are designed
to cover compressor ranges from 0,14-127 m3/min, and work effectively with Polyglycols Mineral Oils, PA0s, Polysol Esters & Diesters.
Benefits
• Non -corrosive materials
• No electricity
• Expandable system
• CE Certified
• Permanently adsorbs oils
• Only two moving parts
• Valuable for ISO 14001 certified
companies
• Extended filter life
Technical Specifications Guide
• Low maintenance costs
• Helps protect and maintain the
environment
1ludel
PS-030
CPN
38041596
Max.
int/min
.85
Max.
Kw
6
Adsurbtiun
Module
Volume (Lit.)
3.8
Air line
NPT
N/A
Condensate
Inlet NPT
1/2"
Oil
Outlet
NPT
3/4"
►Vater Replacement
Outlet Adsorption
NPT Modules
3/4" 38041604
Dimensions
LxWxH (nun)
292x292x699
Weight )Kg)
7
PS-060
42528455
1.70
11
7.6
N/A
1/2"
3/4"
3/4"
42528505
292x292x699
11
PS-125
38339040
3.54
22
19
N/A
1/2"
3/4"
3/4"
38339057
724x495x560
45
PS-250
42528463
7.07
37
57
1/4"
1/2"
3/4"
3/4"
42528513
1130x495x960
64
PS-560
42528471
15.85
90
113
1/4"
1/2"
3/4"
3/4"
42528521
1130x495x960
64
PS-1125
42528489
31.86
220
208
1/4"
1/2"
3/4"
3/4"
42528539
1130x495x960
64
POLYSEP ACCESSORIES
Row Divider 22204432
Note: This component balances Toad between multiple PolySep units.
maximizing element life and opthnlzing operation
PolySep installation Kit .1233m73
Note: Kit includes (2) 4-way I/4" Manifolds. (2) ur x 318- Reducing
Bushings and (8) 1/1- Plugs
9.5 Lit Oil Container 38339081
Note: 9.5111. 011 Container comes standard with PS-125.
Needs to be purrhased separate with all other models.
$0)Ingersolliand

PS PolySep Oil!Water Separator
1 Diffuser Chamber
2 Main Reservoir
3 Oil Weir
4 Pick -Up Tube
5 Float
6 Ball Valve
7 Pump
8 Filter Module
9 Discharge
Operation
The condensate enters the diffuser chamber (I)
when it is depressurized. The oily condensate then
enters a main reservoir (2) where gravity separation
occurs. Any oil that floats to the surface is skimmed
off through an adjustable oil weir (3). The conden-
sate then moves to a separate chamber through a
pick-up tube (1). As the condensate accumulates in
the next chamber, a float (5) rises with the level of
condensate. The float is connected to a ball
valve (6) by a lever arm. The increased level of
condensate causes the float to rise and open
the ball valve. As the valve opens, the air -operated
pump (7) is allowed to push the condensate out to
the filter module (8). If the level of condensate con-
tinues to rise, the float also rises and further opens
the ball valve. Cleaned water discharged (9) from the
filter module can be disposed of directly into the
facility's sanitary sewer. This system assures
maximum contact time for the filter module.
The PolySep system only requires compressed
air to operate the diaphragm pump and is only
used when the level of condensate rises enough to
operate the pump. This system is reliable
because there are only two moving parts.
The PolySep filter modules are available in
six separate sizes. The same delivery system
is used for three larger filter modules. Thus, an
expanded sytem may only require a larger
filter module. Once spent, there are no mess
bags to dispose of. The containers are totally
self-contained and easily tranported by use of
a forklift handle located at the top.
More Than Air. Solutions.
Online solutions: http://www.air.irco.com
Water discharged from the PolySep condensate separation system is not intended or approved for human consumption. Installation of PolySep condensate separation system must be
in accordance with all local and national regulations. Check with local municipality to determine permissible oil content in effluent. Regular monitoring of outlet water is required to
ensure that permitted limits are not being exceeded.
Nothing contained on these pages Is Intended to extend any warranty or representation.. expressed or implied, regarding the product described herein. Any such warranties or other
aeons and conditions of safe of products shall be in accordance with Ingersoll-Rand's standard terms and conditions of sale for such products. which are available upon request.
Product improvement is a continuing goal at Ingersoll-Rand. Designs and specifications are subject to change without notice or obligation.
Ingersopiland.
Ingersoll-Rand
Swan Lane. Handley Green.
WN2 9EZ
England
0 2005 Ingersoll-Rand Company
CPN: 88323720 Printed in Spain