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Home My WebLink AboutNC0086169_Permit (Modification)_20001212 State of North Carolina Department of Environment A7111114A • and Natural Resources It f Division of Water Quality James B. Hunt, Jr., Governor 1'1CDE1iIR Bill Holman, Secretary NORTH CAROLINA DEPARTMENT OF Kerr T. Stevens, Director ENVIRONMENT AND NATURAL RESOURCES December 12,2000 Ms. Christy L Hannan Corning Incorporated Telecommunications Products Division 14556 Highway 601, South Midland,North Carolina 28107 Subject: NPDES Permit Modification Permit Number NC0086169 Midland Fiber Facility Cabarrus County Dear Ms. Hannan: The Division issued NPDES permit NCO096169 to the Corning Incorporated on April 14, 2000. The Division has reviewed your request for permit modification at the subject facility. Specifically, you requested that a special condition be included that permits the facility to divert 100,0000 gallons of non-contact cooling water and flush water to outfall 002 annually. In accordance with your permit modification request, the Division is forwarding herewith a modification to the subject permit. Enclosed please find the modified effluent limitation pages. These pages should be inserted into your permit and the old ones discarded. This permit modification is issued pursuant to the requirements of North Carolina General Statute 143-215.1 and the Memorandum of Agreement between North Carolina and the U. S. Environmental Protection Agency dated December 6, 1983. Please take notice that this permit is not transferable. Part II, E.4. addresses the requirements to be followed in case of change in ownership or control of this discharge. This permit does not affect the legal requirement to obtain other permits which may be required by the Division of Water Quality or permits required by the Division of Land Resources, Coastal Area Management Act or any other Federal or Local government permit that may be required. 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 1617 Mail Service Center,Raleigh,North Carolina 27699-1617 Telephone(919)733-5083 FAX(919)733-0719 An Equal Opportunity Affirmative Action Employer VISIT US ON THE INTERNET @ http://h2o.enr.State.nc.uS/NPDES I NPDES Permit: NC0086169 with the Office of Administrative Hearings,Post Office Drawer 27447,Raleigh,North Carolina 27611-7447. Unless such demand is made, this decision shall be final and binding. If you have any questions concerning this permit, please contact Mr.Michael Myers at telephone number (919) 733-5083,extension 508. Sincerely FfIreetteAt--. err T. Stevens cc: NPDES Permit File' Mooresville Regional Office—Water Quality Section Central Files A(1). EFFLUENT LIMITATIONS AND MONITORING REQUIREMENTS - FINAL Permit No. NC0086169 During the period beginning on the effective date of this permit and lasting until permit expiration, the Permittee is authorized to discharge from outfall serial number 002—Stormwater and Humidification Boiler Blowdown. Such discharges shall be limited and monitored by the Permittee as specified below: EFFLUENT CHARACTERISTICS LIMITS MONITORING REQUIREMENTS Monthly Weekly Daily Measurement Sample Sample Location' Average Average Maximum Frequency Type Flow Semi-annually Estimate Effluent Temperature2 Semi-annually Grab Effluent Total residual chlorine Semi-annually Grab Effluent There shall be no chromium, zinc or copper added to the treatment system except as pre-approved additives to biocidal compounds. 1 The effluent for this outfall shall mean a point upstream of the mixing point with stormwater. 2 The temperature of the effluent will be regulated so that the temperature of the receiving stream does not increase more than 2.8°C above the natural water temperature. Receiving water temperature will not exceed a maximum of 32°C. See Special Condition A. (10.)Annual Shutdown Procedures Condition. The permittee shall obtain authorization from the Division prior to any use of biocide in the cooling water. The permittee shall notify the Director in writing at least ninety(90)days prior to instituting use of any additional biocide in the treatment system which may be toxic to aquatic life (other than biocides previously reported to the Division). Such notification shall include completion of Biocide Worksheet 101 and a map indicating the discharge point and receiving stream. The pH shall not be less than 6.0 standard units nor greater than 9.0 standard units. There shall be no discharge of floating solids or visible foam in other than trace amounts. All conditions related to the stormwater portion of this outfall can be found in Part II,Stormwater Monitoring,Controls and Limitations for Permitted Discharges. A(2). EFFLUENT LIMITATIONS AND MONITORING REQUIREMENTS - FINAL Permit No. NC0086169 During the period beginning on the effective date of the permit and lasting until January 1, 2001, the Permittee is authorized to discharge from outfall serial number 003—Industrial Process Wastewater, Non-contact Cooling Water, and Carbon Filter Backwash. Such discharges shall be limited and monitored by the Permittee as specified below: EFFLUENT CHARACTERISTICS LIMITS MONITORING REQUIREMENTS Monthly Weekly Daily Measurement Sample Sample Location Average Average Maximum Frequency Type Flow(MGD) 0.0274 Continuous Estimate Effluent' Total Suspended Solids 30.0 mg/L 45.0 mg/L Weekly Composite Effluent Chloride 2/Week Composite Effluent Total Residual Chlorine 28µg/L 2/Week Grab Effluent Temperature2 Weekly Grab Effluent Iron 2/Week Composite Effluent Total Phosphorus Quarterly Composite Effluent Chronic Toxicity3 Quarterly Composite Effluent pH14 Weekly Grab Effluent Pollutant Analysis5 5 5 Effluent Notes: The compliance point for flow shall be upstream of the non-contact cooling water and boiler blowdown internal outfall. The compliance point for all other parameters shall be at the Rocky River discharge location. 2 The temperature of the effluent will be regulated so that the temperature of the receiving stream does not increase more than 2.8°C above the natural water temperature. Receiving water temperature will not exceed a maximum of 32°C. 3 Chronic Toxicity (Ceriodaphnia) at 0.31%; January, April, July and October; See Item A(4) of the Supplement to Effluent Limitations and Monitoring Requirements. 4 The pH shall not be less than 6.0 standard units nor greater than 9.0 standard units. 5 See Item A(4)of the Supplement to Effluent Limitations and Monitoring Requirements. See Special Condition A.(10.)Annual Shutdown Procedures Condition There shall be no discharge of floating solids or visible foam in other than trace amounts. A(3). EFFLUENT LIMITATIONS AND MONITORING REQUIREMENTS - FINAL Permit No. NC0086169 During the period beginning on January 1, 2001 and lasting until permit expiration, the Permittee is authorized to discharge from outfall serial number 003 — Industrial Process Wastewater, Non-contact Cooling Water, and Carbon Filter Backwash. Such discharges shall be limited and monitored by the Permittee as specified below: EFFLUENT CHARACTERISTICS LIMITS MONITORING REQUIREMENTS Monthly Weekly Daily Measurement Sample Sample Location Average Average Maximum Frequency Type Flow(MGD) 0.107 Continuous Estimate Effluent' Total Suspended Solids 30.0 mg/L 45.0 mg/L Weekly Composite Effluent Chloride 2/Week Composite Effluent Total Residual Chlorine 28µg/L 2/Week Grab Effluent Temperature2 Weekly Grab Effluent Iron 2/Week Composite Effluent Total Phosphorus Quarterly Composite Effluent Chronic Toxicity3 Quarterly Composite Effluent pH4 Weekly Grab Effluent - Pollutant Analysis5 5 5 Effluent Notes: ' The compliance point for flow shall be upstream of the non-contact cooling water and boiler blowdown internal outfall. The compliance point for all other parameters shall be at the Rocky River discharge location. 2 The temperature of the effluent will be regulated so that the temperature of the receiving stream does not increase more than 2.8°C above the natural water temperature. Receiving water temperature will not exceed a maximum of 32°C. 3 Chronic Toxicity (Ceriodaphnia) P/F at 1.0%; January, April, July and October; See Item A(5) of the Supplement to Effluent Limitations and Monitoring Requirements. 4 The pH shall not be less than 6.0 standard units nor greater than 9.0 standard units. 5 See Item A(6)of the Supplement to Effluent Limitations and Monitoring Requirements. See Special Condition A.(10.)Annual Shutdown Procedures Condition There shall be no discharge of floating solids or visible foam in other than trace amounts. Permit Number:NC0086169 A. (10.)Annual Shutdown Procedures Condition On an annual basis(once per year),the permittee is permitted to discharge up to 100,000 gallons of non-contact cooling water and flush water through Outfall 002. The semi- annual monitoring associated with outfall 002 shall coincide with this event. Corning Incorporated shall develop a HVAC Cooling Tower Shutdown Procedure consistent with BetzDearborn shutdown recommendations. This shutdown procedure shall be kept on site and available for review by Division staff upon request. Additionally, the quantity and duration of non-contact cooling and flush water discharged through outfall 002 shall be recorded in the operations log by the Operator in Responsible Charge and available for review by the Division upon request. Corning Incorporated Telecommunications Products Division P.O.Box 1700 µA (sofConcord,North Carolina 28026-1700 t,LJ 704-569-6000 C I/L October 18, 2000 CORNING Mr. Dave Goodrich NC Dept. of Environment, Health & Natural Resources Division of Water Quality Archdale Building (9th Floor) 512 North Salisbury Street Raleigh, North Carolina 27604 Dear Mr. Goodrich: Corning, Inc., Concord Plant is making preparations for a maintenance shutdown period the week of December 18, 2000. Part of the activities during this period will be the draining and flushing of the non-contact cooling water basin. This is accomplished to prevent malfunctions of the non-contact cooling water pumping system. The basin holds 60,000 gallons of water. 40,000 gallons of water from our FireWater Tank would be used to flush the basin. We are currently permitted to discharge non-contact cooling tower blowdown from normal operations to Outfall 003. Outfall 003 also permits the discharge of our industrial wastewater. The time established to drain and flush the non-contact cooling water basin is six (6) hours, followed by another six (6) hours to refill the basin. This twelve- (12) hour time period is necessary to reduce the down time of our HVAC system. Process equipment that generates heat in the production area will still be running during this time. Without the HVAC system operational, the heat generated by this equipment will shut down portions of the computer system of the plant. Based on this short shutdown duration and the current capacity of our pumping system for Outfall 003, it is not possible to discharge this water through Outfall 003. The proposed plan is to discontinue the addition of any additives to the non-contact cooling water at a time prior to draining the basin to allow the additives to degrade (please see attached recommendations from our supplier, BetzDearborn). We will monitor pH and total residual chlorine. We would like to discharge the 100,000 gallons (includes flush from the FireWater Tank) to Outfall 002. Outfall 002 is designed as a detention pond. Our current permit allows us to discharge stormwater and humidification boiler blowdown to Outfall 002. We are currently required to monitor flow, temperature and total residual chlorine on a semi- annually basis at Outfall 002. This discharge will be an annual occurrence in the future during our maintenance shutdown operations. These shutdowns occur at the end of each year(usually prior to the Christmas holidays). As we expand, adding more cooling towers, the flow may increase. We are requesting a modification to our current permit, in the form of a Special Condition, to allow the annual discharge of the non-contact cooling water basin and associated flush water to Outfall 002. We propose to suspend the use of water treatment chemical feed as suggested by BetzDearborn prior to discharge. Based upon the time usually required for a permit modification to be issued and the short lead time we have for the 2000 shutdown, we are requesting initial approval for this year's process as soon as possible. I apologize for the inconvenience of this short notice. Please feel free to contact me if you have any questions or require further information. I can be reached at phone number(704) 569-6268 Sincerely, L 7 . \\A Christy L. Hannan Environmental Control Engineer Coming, Inc. Concord Plant Enclosures: 1 - BetzDearborn A Division of Hercules Incorporated October 2, 2000 Mr. Bill Myhalyk cc: Tom Hall Corning Incorporated Jaime Ritchie PO Box 1700 Kevin Kelley Concord, NC 28026 RE: HVAC Cooling Tower Shutdown Bill: We have been asked to present to Corning an operating procedure to suspend the water treatment chemical feed to the HVAC Cooling Tower to allow for direct discharge into the holding ponds during the December shutdown. Currently BetzDearborn is supplying the following chemicals to Cooling Tower system: • BetzDearborn Spectrus OX1200-Biocide/Chlorine residual > BetzDearborn Spectrus BD152-Biosurfactant/No detectable residual > BetzDearborn Dianodic DN300-Corrosion Inhibitor/Ortho-phosphate residual > BetzDearborn AF740-Antifoam/No detectable residual • BetzDearborn Depositrol PY505-Polymeric Dispersant/No detectable residual Fed to the Cooling Tower makeup water: >, BetzDearborn FloGard MS6206-Process Water Corrosion Inhibitor/O-PO4 residual These chemicals are fed to the tower at a specific dosage based on a function of the amount of water that is being bled from the system. The chemicals become concentrated within the tower as a result of cycling. In order to reduce the concentrations of these chemicals within the tower and allow for the water to be deemed acceptable under your permit restrictions the feeds of the water treatment products will need to be suspended prior to shutdown. In order to help dissipate residuals the tower blowdown rates should be increased during the days leading up to the shutdown. We recommend the following schedule: 1. 4 Days before shutdown- decrease cycles of concentration by 50%. This tower is designed to run at 5 cycles. Increase blowdown to lower this level to no more than 3 cycles. Stop Spectrus BD152 and Depositrol PY505 feeds at this time. The lower cycles will decrease the demand for each of these products. 2. 3 Days before shutdown- stop Dianodic DN300 feed at the tower and the feed of the FloGard MS6206 at the Industrial Process Water Makeup. This will allow the Phosphate residual to dissipate completely prior to discharge to the ponds. Continue running at less than 3 cycles of concentration. 3. 2 Days before shutdown- stop Spectrus OX1200 feed and AF740 feed at the Tower. The chlorine residual should be 0.0 PPM without the feed of this product. 4. 1 Day before shutdown and day of- the effluent from the Cooling Tower should be closely monitored by the Plant personnel to assure the chlorine residual and the phosphate residuals are below the permit specifications. Total suspended solids should also be closely watched. At first indication of any permit excess, the flow should be suspended to the ponds. ❖ The feed of the FloGard MS6206 should be resumed as soon as the HVAC Tower stops receiving makeup water flow. Due to variations in operating loads and seasonal temperature changes it is difficult to accurately quantify the amount of water that will need to be bled to achieve our desired operating conditions. These rates can be estimated using the following formulas. Blowdown (GPM)= Evaporation Rate (GPM) Cycles of Concentration — 1 Evaporation (GPM) = AT(°F) * Recirculation Rate (GPM) 1,000 In summary, by increasing the tower blowdown rates and stopping the feed of the water treatment chemicals days before the shutdown, the water within the system at the time of the shutdown should be of the same chemical composition as the city water makeup. This will be verified by real time chemical monitoring by Plant personnel. We do not foresee any problems with the short-term suspension of water treatment chemicals during this time period. Thank you for allowing BetzDearborn to provide this recommendation to Corning Incorporated. Should you have any questions concerning this report please do not hesitate to contact me. I can be reached at 1-888-716-6198. Best regards, Justin Everett BetzDearborn Water Management Group Corning Incorporated Telecommunications Products Division P.O.Box 1700 101 r Concord,North Carolina 28026-1700 704-569-6000 c"--e. CORNING October 18, 2000 Mr. Dave Goodrich NC Dept. of Environment, Health &Natural Resources Division of Water Quality Archdale Building(9th Floor) 512 North Salisbury Street Raleigh, North Carolina 27604 Dear Mr. Goodrich: Corning, Inc., Concord Plant is making preparations for a maintenance shutdown period the week of December 18, 2000. Part of the activities during this period will be the draining and flushing of the non-contact cooling water basin. This is accomplished to prevent malfunctions of the non-contact cooling water pumping system. The basin holds 60,000 gallons of water. 40,000 gallons of water from our FireWater Tank would be used to flush the basin. We are currently permitted to discharge non-contact cooling tower blowdown from normal operations to Outfall 003. Outfall 003 also permits the discharge of our industrial wastewater. The time established to drain and flush the non-contact cooling water basin is six (6)hours, followed by another six (6) hours to refill the basin. This twelve- (12) hour time period is necessary to reduce the down time of our HVAC system. Process equipment that generates heat in the production area will still be running during this time. Without the HVAC system operational, the heat generated by this equipment will shut down portions of the computer system of the plant. Based on this short shutdown duration and the current capacity of our pumping system for Outfall 003, it is not possible to discharge this water through Outfall 003. The proposed plan is to discontinue the addition of any additives to the non-contact cooling water at a time prior to draining the basin to allow the additives to degrade (please see attached recommendations from our supplier, BetzDearborn). We will monitor pH and total residual chlorine. We would like to discharge the 100,000 gallons (includes flush from the FireWater Tank) to Outfall 002. Outfall 002 is designed as a detention pond. Our current permit allows us to discharge stormwater and humidification boiler blowdown to Outfall 002. We are currently required to monitor flow,temperature and total residual chlorine on a semi- annually basis at Outfall 002. This discharge will be an annual occurrence in the future during our maintenance shutdown operations. These shutdowns occur at the end of each year(usually prior to the Christmas holidays). As we expand, adding more cooling towers, the flow may increase. We are requesting a modification to our current permit, in the form of a Special Condition, to allow the annual discharge of the non-contact cooling water basin and associated flush water to Outfall 002. We propose to suspend the use of water treatment chemical feed as suggested by BetzDearborn prior to discharge. Based upon the time usually required for a permit modification to be issued and the short lead time we have for the 2000 shutdown, we are requesting initial approval for this year's process as soon as possible. I apologize for the inconvenience of this short notice. Please feel free to contact me if you have any questions or require further information. I can be reached at phone number(704) 569-6268 Sincerely, • Christy L. Hannan Environmental Control Engineer Corning, Inc. Concord Plant Enclosures: 1 (Q r all:T (S`• Cie"" 726.74"Cr - Tom---p TRC i7Ik 1.1 c - 9 BetzDearborn A Division of Hercules Incorporated October 2, 2000 Mr. Bill Myhalyk cc: Tom Hall Corning Incorporated Jaime Ritchie PO Box 1700 Kevin Kelley Concord, NC 28026 RE: HVAC Cooling Tower Shutdown Bill: We have been asked to present to Corning an operating procedure to suspend the water treatment chemical feed to the HVAC Cooling Tower to allow for direct discharge into the holding ponds during the December shutdown. Currently BetzDearborn is supplying the following chemicals to Cooling Tower system: ➢ BetzDearborn Spectrus 0X1200-Biocide/Chlorine residual ➢ BetzDearborn Spectrus BD152-Biosurfactant/No detectable residual ➢ BetzDearborn Dianodic DN300-Corrosion Inhibitor/Ortho-phosphate residual ➢ BetzDearborn AF740-Antifoam/No detectable residual ➢ BetzDearborn Depositrol PY505-Polymeric Dispersant/No detectable residual Fed to the Cooling Tower makeup water: ➢ BetzDearborn FloGard MS6206-Process Water Corrosion Inhibitor/O-PO4 residual These chemicals are fed to the tower at a specific dosage based on a function of the amount of water that is being bled from the system. The chemicals become concentrated within the tower as a result of cycling. In order to reduce the concentrations of these chemicals within the tower and allow for the water to be deemed acceptable under your permit restrictions the feeds of the water treatment products will need to be suspended prior to shutdown. In order to help dissipate residuals the tower blowdown rates should be increased during the days leading up to the shutdown. We recommend the following schedule: 1. 4 Days before shutdown- decrease cycles of concentration by 50%. This tower is designed to run at 5 cycles. Increase blowdown to lower this level to no more than 3 . cycles. Stop Spectrus BD152 and Depositrol PY505 feeds at this time. The lower cycles will decrease the demand for each of these products. 2. 3 Days before shutdown- stop Dianodic DN300 feed at the tower and the feed of the FloGard MS6206 at the Industrial Process Water Makeup. This will allow the Phosphate residual to dissipate completely prior to discharge to the ponds. Continue running at less than 3 cycles of concentration. 3. 2 Days before shutdown- stop Spectrus OX 1200 feed and AF740 feed at the Tower. The chlorine residual should be 0.0 PPM without the feed of this product. 4. 1 Day before shutdown and day of- the effluent from the Cooling Tower should be closely monitored by the Plant personnel to assure the chlorine residual and the phosphate residuals are below the permit specifications. Total suspended solids should also be closely watched. At first indication of any permit excess, the flow should be suspended to the ponds. ❖ The feed of the FloGard MS6206 should be resumed as soon as the HVAC Tower stops receiving makeup water flow. Due to variations in operating loads and seasonal temperature changes it is difficult to accurately quantify the amount of water that will need to be bled to achieve our desired operating conditions. These rates can be estimated using the following formulas. Blowdown (GPM)= Evaporation Rate (GPM) Cycles of Concentration— 1 Evaporation (GPM)=OT(°F) * Recirculation Rate (GPM) 1,000 In summary, by increasing the tower blowdown rates and stopping the feed of the water treatment chemicals days before the shutdown, the water within the system at the time of the shutdown should be of the same chemical composition as the city water makeup. This will be verified by real time chemical monitoring by Plant personnel. We do not foresee any problems with the short-term suspension of water treatment chemicals during this time period. Thank you for allowing BetzDearborn to provide this recommendation to Corning Incorporated. Should you have any questions concerning this report please do not hesitate to contact me. I can be reached at 1-888-716-6198. Best regards, Justin Everett BetzDearborn Water Management Group