NC0086169_Authorization to Construct_20010508

NPDES DOCUWENT SCANNING COVER SHEET
NPDES Permit:
NC0086169
Corning / Midland facility
Document Type:
Permit Issuance
Wasteload Allocation
Authorization to Construct
(AtC)
Permit Modification
Complete File - Historical
Correspondence
Speculative Limits
Instream Assessment (67b)
Environmental Assessment (EA)
Permit
History
Document Date:
May 8, 2001
This document is printed on reuse paper - ignore any
content on the reverse side

Corning Incorporated
Telecommunications Products Division
P.O. Box 1700
Concord, North Carolina 28026-1700
704-569-6000
May 8, 2001
CERTIFIED MAIL
RETURN RECEIPT REQUESTED
[1 \)-1
. \
1Y114 MAY 1 0 2001 ,-
1
L
DENR - WATER QUALITY
POINT SOURCE BRANCH
Mr. Dave Goodrich
North Carolina Department of Environment and Natural Resources
Division of Water Quality, NPDES Permit Unit
1617 Mail Service Center
Raleigh, North Carolina 27699-1617
RE: Corning Incorporated, Concord Facility
NPDES Permit No. NC0086169
ATC, Engineer's Certification
Dear Mr. Goodrich:
CORNING
Attached, please find the Engineer's Certification for Construction of Wastewater
Treatment Facilities for subject ATC. As stated in the initial certification letter, the
wastewater treatment facility system will be started sequentially to facilitate discharge of
wastewater streams per the permit. Please refer to the attached description of the planned
start-up.
The enclosed certification is for Sequence IA. This start-up sequence will treat the
combined streams of 1) cooling tower blowdown from the Concord II HVAC cooling
tower, 2) Neutralization System No. 1 effluent, and 3) cooling tower blowdown from the
Concord I HVAC cooling tower. Prior to additional systems coming on line, an
engineer's certification will be provided for them.
Please feel free to contact me if you have any questions concerning the information
contained in the documents. I can be reached at [phone].
Sincerely,
ci.AA/3-k
Christy Hannan
Environmental Control Engineer
Concord Plant
Corning, Inc.
Enclosures
Cc: Mooresville Regional Office, NCDENR

Corning Incorporated
Concord Facility
Permit No. NC0086169
ENGINEER'S CERTIFICATION
FOR
CONSTRUCTION OF WASTEWATER TREATMENT FACILITIES
/1G/11.-L
am a duly registered Professional Engineer
(please print)
in the State of North Carolina and have been authorized to observe (circle on
full time) the construction of the subject project for the Permittee:
The
•
•
Project No.:
Project:
project consists
Construction of
Construction of
086169ACB
Corning Incorporated
Concord Facility
Waste Abatement System Expansion
two (2) 1.700 gallon neutralization tanks:
a. 36.000 gallon off -spec tank:
a 21.000 gallon surge/blend tank:
two (2) lamella clarifiers: and
• Installation of all piping. valves, and appurtenances as illustrated on the attached
design documents.
Construction of
Construction of
Construction of
Construction of
of: - /
a 60.000 gallon chloride stabilization tank: d/or 6.41,0h4tre
a 21,000 gallon equalization tank: or CAinP 7
Nor C#ai ssTE
44,7- a:yr? oadirU
Go4soldjE
o VE /6 Gs►P4 ri
approved
weekly,
I hereby certify that I did regularly observe this project with due care and diligence and that the
construction was completed in substantial conformance with the Authorization to Construct and with
the approved plans and specifications.
Signature /
Date s/ T/fal
Sa 47r4cy n wr (4 P.¢•6,0s) rat frsex or/•,✓
E.CY/f/c'9Ti61 ✓ 8, s,S
Registration No. � G 34
'The Division of Water Quality hereby
acklmwledges receipt and acceptance of
this Engineers Certification
026634
Upon completion of construction and prior to operation of the modifed facility, the Permittee shall provide the
Division with a certification from a professional engineer certifying that the permitted facility has been installed in
accordance with the NPDES Permit, this Authorization to Construct, and the approved plans and specifications.
The Certification should be submitted to:
NCDENR/DWQ, NPDES Unit, 1617 Mail Service Center, Raleigh, North Carolina 27699-1617

Attachment to
Engineer's Certification for Construction of Wastewater
Treatment Facilities - Second Submittal
Certification
Basis
System
Update
This Engineer's Certification for Construction of Wastewater Treatment
Facilities is for Project No. 086169ACB for Corning Incorporated,
Concord Facility, Waste Abatement System Expansion.
The wastewater generated by the different processes within the
Concord Facility will be treated as they are generated. The facility
processes will be started -up in an orderly sequence and each
subsystem in the wastewater treatment area will be placed in
operation as required to treat each type of wastewater as it is
produced.
The construction of the wastewater subsystems have been scheduled
to correspond to the generation of process wastewater by the facility
processes. Thus, the entire wastewater treatment system is not
completed and ready for operation. We have concentrated our efforts
to built and test the subsystems to meet a start-up schedule that
parallels the start-up schedule of the facility process areas.
To address the process start-up requirements the subsystems in the
wastewater treatment area will be started in discrete parts we have
termed Sequences.
As outlined in the first certification submittal, we have
successfully completed the start-up of Sequence 1 B — treatment
of cooling tower blowdown from the Concord II HVAC cooling
tower. Due to the mode of operation 'of the cooling tower, we
have been treating the blowdown in a "batch" operation. We
anticipate initiating a continuous mode of blowdown treatment
the week of 5/7/2001.
Corning Incorporated
Concord Facility
Contract No. 78600.001
May 7, 2001
Page 1 of 4

Start-up
Activities
Corning Incorporated
Concord Facility
Contract No. 78600.001
May 7, 2001
This second certification submittal includes the wastewater treatment
subsystem start-up of Sequence 1 A which will combine with the
wastewater from Sequence 1 B (this start-up has been successfully
completed). In this start-up sequence we will be treating the
combined streams of 1) cooling tower blowdown from the Concord II
HVAC cooling tower, 2) Neutralization System No.1 effluent, and 3)
cooling tower blowdown from the Concord I HVAC cooling. The
combined streams will be treated with sodium bisulfite, as required for
the removal of chlorine. The pH will be within acceptable values (6 —
9 pH units) due to the HVAC cooling towers and Neutralization System
No. 1 control range. The suspended solids level in the cooling tower
blowdown should be low due to the HVAC cooling tower control range.
If required, we have the capability of removing any suspended solids
in the No. 3 lamella.
The following paragraphs generally describe the components of the
subsystem which will be required for Sequence 1 A & 1 B. These
components are described in detail in ATC No. 086169ACB.
We will be ready to accept the combined Neutralization System
No. 1 and Cl & Cll HVAC Cooling Tower Blowdown in Sequences
1A & 1B on Friday, May 11, 2001.
As the remaining wastewater subsystems are built and
tested, the corresponding Engineer's Certification will be
submitted in accordance with the Division requirements
prior to operation of those subsystems.
Page 2 of 4

System
Operation
Overview
Corning Incorporated
Concord Facility
Contract No. 78600.001
May 7, 2001
Solids Removal Unit (See Figure 3)
The inlet header to the Surge/Blend Tank provides for premixing of
non -contact cooling tower blowdown, treated effluent from
Neutralization System No. 1, treated effluent from Neutralization No. 2,
and softener regeneration wastewater prior to entering the tank. This
provides for thorough mixing of the wastewater inlet flows and sodium
bisulfite for chlorine removal in a static mixer. From the Surge/Blend
Tank the blended wastewater is pumped to Lamella Separator No. 3
for removal of suspended solids and is then pumped to the existing
Effluent Lift Station. Any off -spec (pH) wastewater is automatically
diverted to an Off Spec Tank No. 2 and then pumped back to
Equalization Tank No. 2 at a controlled rate for re -treatment. Other
off -spec (turbidity or ORP) wastewater is automatically diverted back
to the Surge/Blend Tank for re -processing through the chlorine
removal and suspended solids removal unit operations.
An existing Process Effluent Tank is located at the Effluent Lift Station
for storage of wastewater during the times wastewater cannot be
pumped to the river. Wastewater stored in the Process Effluent Tank is
returned, by gravity, to the Effluent Lift station.
Settled solids in the Lamella Separator are periodically pumped from
the lamella to the Sludge Thickening Tank No. 3 and then from the
tank to the existing Sludge Holding Tank for disposal.
Page 3 of 4

FIGURE 3 - SOLIDS REMOVAL UNIT
From Neut. System No. 1 & Concord I Cooling Tower Blowdown
From Softener Regeneration Tank
From Lamella No. 3 Transfer Pumps
From Concord II Cooling Tower Blowdown
From Neutralization Transfer Pumps No. 3 & 4
Sodium Bisulfite (NaHSO3)
Flocculant
Static Mixer
XXXXXXX t
Coagulant
Surge/Blend Tank
21,000 gallons
Lamella Separator
No. 3
Sludge
V
Lamella No. 3
Transfer Tank
800 gallons
To Sludge Thickening Tank No. 2
To Effluent Lift Station
(or recycle to Surge/Blend Tank,
if out of control range)
Corning Incorporated
Concord Facility
Contract No. 78600.001
May 7, 2001
Page 4 of 4

RIO
Corning incorporated
Concord Facility
Permit No. NC0086169
ENGINEER'S CERTIFICATION
FOR
CONSTRUCTION OF WASTEWATER TREATMENT FACILITIES
1, 2 h'J4!4 / - / 7c4d.,E Le —
(please print)
in the State of North Carolina and have been authorized to observe (circle one (periodically) weekly.
full time) the construction of the subject project for the Permittee:
am a duly registered Professional Engineer
Project No.: 086169ACB
Project: Corning Incorporated
Concord Facility
Waste Abatement System Expansion
The project consists of:
• Construction of a 60.000 gallon chloride stabilization tank; 41)yrrs7,040
• Construction of a 21,000 gallon equalization tank; ✓ Aka— 0+1.1osssrz
• Construction of two (2) 1,700 gallon neutralization tanks4a7.—Cp,gdZpE
ro Construction of a 36,000 gallon off -spec tank; / /1% Cpivio°4 t
• Construction of a 21,000 gallon surge/blend tank;—Co,Ps7F,LBTE
• Construction of two (2) lamella clarifiers; and — a tJt ,) Cam/24451Z
• Installation of all piping, valves. and appurtenances as illustrated on the attached approved
design documents.
I hereby certify that I did regularly observe this project with due care and diligence and that the
construction was completed in substantial conformance with the Authorization to Construct and with
the approved plans and specifications. 6 ,477-AGV z .'rC3R44es)
ep r/F/C4.TvI'ti 3 s/S
Signature
Date )//i/�GYJ /
Registration No. 0.2 6 34
.........
CAR •
•%04• .•
sslo
-ti.
:
��iyGINE02/ �/v•
G•
Upon completion of construction and prior to operation of the modified facility, the Permittee shall provide the
Division with a certification from a professional engineer certifying that the permitted facility has been installed in
accordance with the NPDES Permit, this Authorization to Construct, and the approved plans and specifications.
The Certification should be submitted to:
NCDENR/DWQ, NPDES Unit, 1617 Mail Service Center, Raleigh, North Carolina 27699-1617

Attachment to
Engineer's Certification for Construction of Wastewater
Treatment Facilities
Certification
Basis
This Engineer's Certification for Construction of Wastewater Treatment
Facilities is for Project No. 086169ACB for Coming Incorporated,
Concord Facility, Waste Abatement System Expansion.
The wastewater generated by the different processes within the
Concord Facility will be treated as they are generated. The facility
processes will be started -up in an orderly sequence and each
subsystem in the wastewater treatment area will be placed in
operation as required to treat each type of wastewater as it is
produced.
The construction of the wastewater subsystems have been scheduled
to correspond to the generation of process wastewater by the facility
processes. Thus, the entire wastewater treatment system is not
completed and ready for operation. We have concentrated our efforts
to built and test the subsystems to meet a start-up schedule that
parallels the start-up schedule of the facility process areas.
•
To address the process start-up requirements the subsystems in the
.wastewater treatment area will be started in- discrete parts we have.
termed Sequences.
Our first wastewater treatment subsystem start -up -will be "Sequence
1 B. In this start-up sequence we will be treating cooling tower
blowdown from the Concord II HVAC cooling tower. The cooling tower
blowdown will be treated with sodium bisulfite, as. required for the
removal of chlorine. The pH will be within acceptable values (6 — 9 pH
units) due to the HVAC cooling tower control range. The suspended
solids level in the cooling tower blowdown should be low due to the
HVAC cooling tower control range. If required, we have the capability
of removing any suspended solids in the No. 3 lamella.
The following paragraphs generally describe the components of the
subsystem which will be required for Sequence 1 B. These
components are described in detail in ATC No. 086169ACB.
We will be ready to accept cooling tower blowdown in Sequence
1 B on Wednesday, March 21, 2001.
As the remaining wastewater subsystems are built and
tested, the corresponding Engineer's Certification will be
submitted in accordance with the Division requirements
prior to operation of those subsystems.
Corning Incorporated
Concord Facility
Contract No. 78600.001
March 14, 2001
Page 1 of 3

System
Operation
Overview
Solids Removal Unit (See Figure 3)
The inlet header to the Surge/Blend Tank provides for premixing of
non -contact cooling tower blowdown, treated effluent from
Neutralization System No. 1, treated effluent from Neutralization No. 2,
and softener regeneration wastewater prior to entering the tank. This
provides for thorough mixing of the wastewater inlet flows and sodium
bisulfite for chlorine removal in a static mixer. From the Surge/Blend
Tank the blended wastewater is pumped to Lamella Separator No. 3
for removal of suspended solids and is then pumped to the existing
Effluent Lift Station. Any off -spec (pH) wastewater is automatically
diverted to an Off Spec Tank No. 2 and then pumped back to
Equalization Tank No. 2 at a controlled rate for re -treatment.
The Lamella Head Tank, Lamella Separator No. 2, Equalization Tank
No. 2, pH Adjustment Tanks, Neutralization Transfer Tank No. 2, and
Off . Spec Tank No. 2 are vented to the existing Miscellaneous
Scrubbers for collection and treatment of any vent vapors. An existing
,.QrQce�s Effluent ,Tank is located at the Effluent Lift Station for storage
•
of. wastewater during the times wastewater cannot be pumped to the
- river. Wastewater stored in the Process Effluent Tank is returned, by.
gravity, to the Effluent Lift station.
,Settled ,solids in the Lamella Separator are periodically pumped .from
the lamella to the Sludge Thickening Tank No. 3 and then from the
tank to the existing Sludge Holding Tank for disposal.
Corning Incorporated
Concord Facility
Contract No. 78600.001
March 14, 2001
Page 2 of 3

FIGURE 3 - SOLIDS REMOVAL UNIT
From Neut. System No. 1 & Concord I Cooling Tower Blowdown
From Softener Regeneration Tank
From Lamella No. 3 Transfer Pumps
From Concord II Cooling Tower Blowdown
From Neutralization Transfer Pumps No. 3 & 4
Sodium Bisulfite (NaHSO3)
occulant
Static Mixer
XXXXXXX 4
Coagulant•
Surge/Blend Tank
21,000 gallons
Lamella Separator
No. 3
Sludge
Lamella No. 3
Transfer Tank
800 gallons
To Sludge Thickening Tank No. 2
To Effluent Lift Station
(or recycle to Surge/Blend Tank,
if out of control range)
Corning Incorporated
Concord Facility
Contract No. 78600.001
March 14, 2001
Page 3 of 3

Corning Incorporated
Telecommunications Products Division
P.O. Box 1700
Concord, North Carolina 28026-1700
704-569-6000
March 16, 2001
CORNING
CERTIFIED MAIL
RETURN RECEIPT REQUESTED
Mr. Dave Goodrich
North Carolina Department of Environment and Natural Resources
Division of Water Quality, NPDES Permit Unit
1617 Mail Service Center
Raleigh, North Carolina 27699-1617
RE: Coming Incorporated, Concord Facility
NPDES Permit No. NC0086169
ATC, Engineer's Certification
Dear Mr. Goodrich:
Attached, please.find the: Engineer's Certification for Construction of Wastewater
Treatment Facilities for subject ATC. The wastewater treatment; facility systemmill be
started sequentially to facilitate discharge of wastewater streams per the permit. Please
refer to the attached description of the planned start-up.
The enclosed certification is for Sequence lb. This part of the system is required to start
up prior to the remaining facility to accommodate the start up and discharge of non -
contact cooling tower blowdown per the subject permit. Prior to additional systems
coming on line, an engineer's certification will be provided for them.
Please feel free to contact me if you have any questions concerning the information
contained in the documents. I can be reached at [phone].
Sincerely,
Christyt.LoALT 0-4(-AL--.°1-"1"
Hannan
nan
Environmental Control Engineer
Concord Plant
Coming, Inc.
Enclosures
Cc: Mooresville Regional Office, NCDENR

State of North Carolina
Department of Environment
and Natural Resources
Division of Water Quality
James B. Hunt, Jr., Governor
Bill Holman, Secretary
Kerr T. Stevens, Director
May 31. 2000
Ms. Christy L. Hannan
Corning Incorporated
Post Office Box 1700
Concord, North Carolina 28026
Dear Ms. Hannan:
NCDENR
NORTH CAROLINA DEPARTMENT OF
ENVIRONMENT AND NATURAL RESOURCES
Subject: Authorization to Construct
ATC No. 086169ACB
NPDES Permit No. NC0086169
Concord Waveguide Plant
Cabarrus County
The Division of Water Quality's NPDES Unit has reviewed your request for an Authorization to Construct at the above
referenced facility. The Division finds the proposed improvements to be satisfactory and hereby grants authorization for
the following:
• Construction of a 60,000 gallon chloride stabilization tank;
• Construction of a 21.000 gallon equalization tank;
• Construction of two (2) 1,700 gallon neutralization tanks:
• Construction of a 36,000 gallon off -spec tank;
• Construction of a 21,000 gallon surge/blend tank;
• Construction of two (2) lamella clarifiers; and
• Installation of all piping. valves, and appurtenances as illustrated on the attached approved design
documents.
This Authorization to Construct is issued in accordance with NPDES Permit No. NC0086169, issued on April 14.
2000. and shall be subject to revocation unless the wastewater treatment facilities are constructed in accordance with
the terms and conditions of the permit.
The Permittee shall notify the Water Quality Supervisor of the Mooresville Regional Office, telephone number (704)
663-1699, at least forty-eight (48) hours prior to operation of the installed facilities. so that an in -place inspection can
be made. Notification shall be made during the normal office hours of 8:00 a.m. until 5:00 p.m., Monday through
Friday.
Engineer's Certification
Upon completion of construction and prior to operation of the modified facility, the Permittee shall provide the Division
with a certification (copy enclosed) from a professional engineer registered in North Carolina certifying that the
permitted facility has been installed in accordance with the NPDES Permit, this Authorization to Construct, and the
approved plans and specifications. The Certification should be submitted to: NCDENR / DWQ, NPDES Unit, 1617
Mail Service Center. Raleigh. North Carolina 27699-1617.
1617 Mail Service Center, Raleigh, North Carolina 27699-1617 Telephone [phone] FAX [phone]
An Equal Opportunity Affirmative Action Employer Internet: http://h2o.enr.state.nc.us/NPDES

Corning Inc. — Concord Facility
NPDES Permit No. NC0086169
ATC No. 086169ACB
Page 2
Requirements for Certified Operator
The Permittee shall employ a certified wastewater treatment plant operator to be in responsible charge (ORC) of the
wastewater treatment facilities. The operator must hold a certificate of the type and grade at least equivalent to or
greater than the classification assigned to the wastewater treatment facilities by the Certification Commission. The
Permittee must also employ a certified back-up operator of the appropriate type and grade to comply with the
conditions of Title 15A, Chapter 8G, .0200. The ORC of the facility must visit each Class I facility at least weekly and
each Class 1I. III, and IV facility at least daily, excluding weekends and holidays: and must properly manage and
document daily operation and maintenance of the facility and comply with all other conditions of Title 15A. Chapter 8G,
.0200.
Additional Requirements
The Operational Agreement between the Permittee and the Environmental Management Commission is incorporated
herein by reference and is a condition of this Permit. Noncompliance with the terms of the Operational Agreement shall
subject the Permittee to all sanctions provided by G. S. 143-215.6 for violation of or failure to act in accordance with
the terms and conditions of this Permit.
Failure to abide by the requirements contained in this Authorization to Construct may subject the Permittee to an
enforcement action by the Division of Water Quality in accordance with North Carolina General Statute 143-215.6A to
143-215.6C.
The issuance of this Authorization to Construct does not preclude the Permittee from complying with any and all
statutes, rules, regulations, or ordinances which may be imposed by other government agencies (local, state, and federal)
which have jurisdiction.
The Permittee shall maintain a copy of the approved plans and specifications on file for the life of the facility. One (1)
copy of the approved plans and specifications is enclosed for your records.
If you have any questions about this Authorization to Construct, please contact Mark McIntire, at [phone],
extension 553.
Sincerely,
Fe"kr T. Stevens
Director
Enclosures: Project Plans and Specifications (approved)
Engineer's Certification Form
cc: Mooresville Regional Office, Water Quality (letter only)
Technical Assistance and Certification Unit (letter only)
Central Files (letter only)
NPDES Unit Files (letter and engineer's certification form)