NC0086169_Correspondence_20021028

NPDES DOCUMENT :;CANNIN` COVER SHEET
NC0086169
Corning / Midland facility
NPDES Permit:
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:
October 28, 2002
This document is printed on reune paper - more any
content on tine reszerse side

10/28 '02 16:43 N0.595 01/06
CORNING INCORPORATED
PO Box 1700
Concord, North Carolina 28026-)700
F A X
TO: Mark McIntire
DWQ
FROM: Christy Ilannan
PRONE #: 704.569.6268
Plumber of pages including this page: Itt
FAX #: [phone]
Phone#: [phone] ext.508 •
DATE: 1.0.28.02
FAX #: [phone]
COMMENTS:
Mr. McIntire,
As discussed, Let me know what you think.
Thank you,
Christy Hannan
NOTE: If fax is not received properly, please natify sender @ 704-569-6268 or
Lynx 569-6268. Reply to fax # [phone].

10/28 '02 16:43 N0.595 02/06
wuu ruul,-_ r :r..vey, vvmmor
William G. Rtrn Jr., Soeretery
North Carolina Denartrnent of Environment and M.-aural Ra4ouraes
Alan VV, KIimol;, P.E.. Director
Division of Wattr Oualtty
October 14, 2002
Ms. Christy Hannan, Environmental Control Engineer
Corning, Inc.
Post Office Box 1700
Concord, North Carolina. 28026-1700
Subject: Compliance Evaluation. Inspection
Coming, Ine,/Midland. Plant
NPDES Permit No. NC0086169
Caba.trus County, N.C.
Dear, Ms. Hannan:
Enclosed is a copy of the Colnptiance Evaluation Inspection Report for the inspection
conducted at the subject facility on October 3. 2002, by Mr, Wes Bell of this Office. Please inform.
the facility's Operator -in -Responsible Charge of our findings by forwarding a copy of the enclosed
report,
The report should be self-explanatory; however, should you have any questions concerning
this report, please do not hesitate to contact Mr. Bel]. or nee at [phone].
Sincerely,
1n D. Rex Gleason, P.E.
Water Quality Regional Supervisor
Enclosure
cc: Cabarrus County Health Department
WB
N. C. [tiviion of Water Duality
910 North Main trout, rviioore^-vine NC 213115 ahonn (704) GG3-189g
FAX (704) 6u:,-G04 1
ea

10/28 '02 16:44 NO.595 03/06
Farm Appmvcd:
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OMB Approval Expires
Apprrrvsl Expires 8-31-98
on%
,at,
US Environmental ntal Protection Agency, Wosbington, D.C., 20460
Water Compliance Inspection Report• '.
"' �
NC Division of Water Quality / Mooresville Regionai Office NCDENR
Section A: National Data System Coding
Trnnsnetion Code NPDES No. Yr/Mo/Day Inspection Typo Inspector ii'acility Type
N 5 NC0086169 02/10/03 C S 2
Remarks:
Inspection Work Days Facility 1tvatnntion Rating HI QA ..._.....Reserved... .... ....
1.5 4 N N
• Section Bs Facility Datay
Name and Location of Facility inspected:
Corning, Inc.
U.S. HiShway 60I
Midland
Cabarrus County, North Carolina
Entry Time:
11.:34 urn
Permit Effective Date:
00/05/01
Evit Time/Date!
2:35 pm
02/10/03
Permit Expiration Dram
03/10/31
Name(a) of On -Site. Represrntntive(s)fTHlr.(F)lPbanc No(s)/Fax No(s):
Ms. Sheila Smith/OP.C/704-569-7237
Ms. Christy Hannan/Envlranmcntal Control Engineer/704-509-0208
Name and Address of Responsible Official:
Ms. Christy Hannan
Coming, i.nc.
Post OtI`,cc Box 1700
Concord, Norllt Carolina 28026.1700
Title: Environmental Control Engineer
Phone Nes
704-569.6268
Contacted?
Yes
Section C: Areas I\aluntcd During Inspection (Check only those areas evaluated)
X Permit X Flow Measurement X Operntions & Maintenance X Sewer Overflow
X Records/Reports X SeIf-Monitoring Program X Sludge Handling/Disposal Pollution Prevention
X Facility Site Review Compliance Schedules Pretreatment Multimedia
X Effluent/Receiving Waters X Laboratory Storm Water Other:
Section D: Summary of.Findings/Comments .
See Attached Sheet(s) for SUM Mary.
Wame(s) and Signnturc(e) of Inspectors:
Wes Bell ' .i/ i c / .2,e.0
Agency/Office/Telephone No:
NCDWQ/MOORESV11..1,1WJ(704)663-1699
Date:
10/11./02
Wet
Signature of Management QA Reviewer:
Agency/Office/none & Tax No:
Dnte:
EPA Form 3560-3 (Rev. 9-94) Previous editions are obsolete

10/28 '02 16:44 NO.595 04/06
Corning, Inc. /Midland Plant
Page Two
The facility was last inspected by Linda Love of this Office on May 9, 2000.
PERMIT:
The permit authorizes the continued operation of, an. existing 0.107 MGD wastewater
treatment ,facility (outtall 003) consisting of a equalization tank, off -spec tank, two lamella clarifiers,
two neautraliza.ton tanks, neutralization transfer tank, chloride stabilization tank, and surge blen.d
tank. Due to the upgrades approved by the Division, the permit description does not adequately
describe the wastewater treatment facility.
The permit also authorizes the facility to discharge stormwatcr and boiler bl.owdown from
a wet detention pond from. outfall, 002 and discharge storrn.water from a wet detention pond from
outfaJl. 001.
The permit for this facility became effective 5/1/00 and expires on101/03. The Division
has issued several permit modifications; however, the expiration date has remained unchanged.
RECORDS AND. .PORTS:
Records an.d reports consisting of discharge monitoring reports, chain of custody forms,
laboratory analyses, Operator -in -Responsible Charge (ORC)sign-in/daily operation log, process
control data, calibration log, sludge records, and the Storm Water. Pollution. Prevention Plan (and all
corresponding documentation.) were reviewed during the inspection. The records were organized
and well kept. This oI 1ce commends the level of documentation at this facility.
FACILITY SITE REVIEW/OPERATIONS &.AIINT.ENANCE:
At the time of the inspection, the facility consisted of two equalization tanks (one in service),
two off -spec tanks (one in-service), three lamella clarifiers (on.e in-service), four neutralization. tanks
(two in-service), two neutralization transfer tanks (one in-service), chloride stabilization tank (not
in-service), surge blend tank, effluent lift station, and an off -spec (PET) tank at the effluent lift
. station.
The scrubber's b]owdown wastewater (pH of < 1. s.u.) flows into the neutralization tank and
is pumped into the lamella clarifier. The clarifi.er's effluent flows into two neutralization. tanks in
series for pi -I adjustment. 'l'he pH of the first neutralization. tank is raised to 4 s.u. and continued to
be raised to 6.5 s.u. in the second neutralization tank. Deelilorinatlon also occurs in the second
neutralization tank by Sodium Bi.sulfte additions (if needed). The wastewater flows into a
neutralization transfer tank and pumped to the effluent lift station. In -line turbidirneters,
conductivity meters, ORP meters, and pH meters have been installed within the treatment system
to insure adequate treatment. The facility has the capability (ffillowing tlho pH neutralization. and at
the effluent lift station) to pump the treated wastewater into storage tanks if the in -line meters detect
parameter exceedences in. the wastestrcam.
At the time of the inspection, all treatment units appeared to be operating properly and the
facility was well maintained. The process control program includes conductivity, TVSS, pH,
turbidity, and ORP measurements. All domestic wastewater is pumped to the WSACC Muddy
Creek WWTP.

10/28 '02 16:44 NO.595 05/06
Corning, Inc. /Midland Plant
Page Three
FACILITY SITE REVIEW/OPERATIONS & MAINTENANCE coned:
The facility is staffed with one Grade III ORC. A certified back-up operator has been
designated and is available when the ORC is unable to visit the facility. The .ORC and staff were
very knowledgeable of the treatment processes and equipment used at the facility.
LABORATORY:
The Rocky River WWTP Laboratory (Certification #177) in Concord, N.C. and R & A
Laboratories, Inc. (Certification #34) in Kernersville, N.C. have been contracted to provide analytical
support. The laboratories were not evaluated during the inspection. The facility has applied for and
received a laboratory certification (#5029) by the Division's Laboratory Certification Unit to perform
on -site Feld analyses, The pUi and TRC meters and thermometer appeased to be properly calibrated.
EFI+LUENT/RECEIVThG WATERS:
The effluent discharge (outfall 003) was clear with no heatable solids or foam. Outfall 003
discharges into the Rocky River, Outfalls 001 and 002 were not discharging at the time of the
inspection. Outfall 001 discharges into an unnamed tributary to Muddy Creek and outfall 002
discharges into an unnamed tributary to Clear Creek. All receiving streams are Class C waters in
the Yadkin -Pee Dee River Basin. A]1 outfails were accessible at the time of the inspection_ The
receiving stream for outfall 003 (Rocky River) did not appear to be negatively impacted at the time
of the inspection.
SELF -MONITORING PROGRAM:
Self -monitoring reports were reviewed for the period July 2001. through June 2002, inclusive.
No limit violations were reported. All monitoring frequencies were correct; however. on December
4, 1.2, and 1.3, 2001, effluent parameters were collected and analyzed with a "0.00" MGL) flow
reported. Please be advised that the Permit requires effluent analyses only during discharge events.
Effluent composite samples arc collected flow proportionately. All samples appeared to be
properly preserved and meet the required holding times.
FLOW MEASUREMENT:
Effluent flow is continuously measured by a magnetic flow ntieter with totalizer and recording
(via computer data.base). The flow meter is calibrated annually by Corning personnel. The slow
meter was lass calibrated on 1 1/26/01.
SLUDGE DI,SI''OSAL:
Sludge is reur.oved by Tfaznrat of Charlotte, N.C, and. disposed at disposal facilities in oith.cr
Michigan. or New Jersey.

10/28 '02 16:45 NO.595 06/06
Corning, Inc./Midland Plant
Page Four
,SEWER OVERFLOW:
Please be advised that pursuant to Part II, Section E of your NPDES permit, and North
Carolina Administrative Code (NCAC) i SA 213 .0506 (a)(2), any failure of a collection. system,
pumping station or treatment facility resulting in a bypass without treatment of all or any portion of
the wastewater shall be reported to the central office or the appropriate regional office (Mooresville
Regional. Office 704-663-1699) as soon as possible but no later than 24 hours from the time the
permittee became aware of the bypass. Overflows and spills occurring outside normal business hours
may also be reported to the Division's Emergency Response personnel at S00-062-79S6, 800-858-
0368, or 919-733-3300. A written report shall also be provided within five (5) days of the time of:
the incident. The report shall contain a description of the bypass, and its cause; the period of the
bypass, including exact dates and times, and if the bypass has not been corrected, the anticipated time
it is expected to continue; and steps taken (or planned) to reduce, eliminate, arid prevent recurrence
of the similar events. Any spill that reaches surface waters (i.e, any spill that reaches any water
already present in a conveyance, stream, ditch, etc...) or any spill greater than 1,000 gallons on the
ground that does not reach surface waters must be reported.
An adequate spill response for those spills reaching surface waters should include an
evaluation downstream of the point at which the spill entered surface waters to determine if fish
kill occurred. The evaluation should also include the collection of upstream dissolved oxygen and
ply measurements for background information and dissolved oxygen and pH measurements at
multiple points downstream of the entry point to document any negative impact. Failure to report
the bypass of collection system; pumping station or treatment facility subjects violators to penalties
of up to $25,000.00 per day per violation.