NCS000040_Renewal Application_20040707

STORMWATER DIVISION CODING SHEET
NCS PERMITS
PERMIT NO.
N C S DOC)Cx4n
DOC TYPE
❑ FINAL PERMIT
❑ MONITORING REPORTS
(X APPLICATION
❑ COMPLIANCE
❑ OTHER
DOC DATE
❑ 2004C) lO7
YYYYMMDD

It/ 7
NCS000040 I.
NCDENR
North Carolina Department of Environment and Natural Resources
Beverly Eaves Perdue
Governor
Division of Water Quality
Coleen H. Sullins
Director
STAF.F—REVIE-W._AND_EYALUATION
NPDES Stormwater Permit
Dee Freeman
Secretary
Facility Name:
Charlotte Pipe & Foundry Cc
NPDES Permit Number:
NCS000040
Facility Location:
1335 South Clarkson Street, Charlotte, NC (Mecklenburg County)
Type of Activity:
GRAY AND DUCTILE IRON FOUNDRIES
SIC Code:
3321
Receiving Streams:
See Figure 1
River Basin
Catawba River Basin, Sub -basin 03-08-34
Stream Classification:
C
Proposed Permit Requirements:
See attached draft permit.
Monitoring Data:
See Table 1
Response Requested by (Date):
Central Office Staff Contact:
Return to: Brian Lowther, [phone]
Special Issues:
Issue
Rating Scale: 1 easv to 10 hard
Compliance history
6
Benchmark exceedance
7
Location (TiIMDL, T&E -
species, etc
7
Other Challenees:
• Missing data
6
Difficulty Rating:
26/40
Special Issues Explanation:
Many analytical monitoring values are over the current benchmarks for Cr, Cu, Ph, Ni, Zn, TKN, COD and
TSS.
Description of Onsite Activities:
• The CP&F facility is located at 1335 South Clarkson Street in Charlotte, NC. The facility is on
approximately 35 acres and has numerous buildings. Total impervious area (parking lots, buildings,
roadways, etc.) is estimated at 95 percent of the total site area. The facility has been operating as a pipe
foundry since 1926 at this location and currently has 475 employees. Plant operations typically occur 24
hours a day, 5 clays a week. The facility is engaged in the manufacture of cast iron piping and fittings.
The facility's SIC code is reported as 3321. The facility stores and distributes the following raw materials:
cast iron scrap, coke, coal, limestone, quartz, sand, silicon, bentonite, petroleum -asphalt, gasoline and
Page 1 of 9

NCS000040
diesel fuel. (Information from inspection report, 05/08/06)
Documents Reviewed:
• NPDES Stormwater Permit Application Materials
• National Heritage Program (NHP) Threatened and Endangered Species Database
• SPU File
• Central Files
• EPA Sector -Specific Permit, 2008
• 303(d) List, 2006 final
02004•Catawba-Basinwide-Plan
History:
• August 31, 1994: Date permit first issued. Analytical monitoring parameters included COD, TSS, Total
Kjeldahl Nitrogen, Total Chromium, Total Copper, Total Recoverable Lead, Total Nickel, Total Zinc and
Phenols. Samples were to be taken annually.
• February 19, 1999: Permit renewal reminder letter.
• December 3, 1999: Date permit re -issued. Analytical monitoring parameters included COD, TSS, Total
Kjeldahl Nitrogen, Phenols, Total Copper, Total Recoverable Lead, Total Nickel, Total Zinc and Total
Chromium. Samples were to be taken annually for the first three years and quarterly during the 41h year.
• May 3, 2004: Permit renewal reminder letter.
• July 7, 2004: Date permittee submitted renewal application.
• April 5, 2006: Site visit by Mr. Donald Ceccarelli of the Mecklenburg County Water Quality Program
(MCWQP).
• May 8, 2006: Notice of Violation.
Page 2 of 9

NCS000040
Figure 1: Map of Facility
Ihar&te Pipe & Fcundry Co
NCS000040
/ ,W Stale 1, 24, 000
Charlotte Pipe & Foundry Co
Lad Ride: 350 13' 28" N
Long d de: 800 51' 42" W
County:1% dIenburg
Reca ping Stream: Irwin Credo
Stream Cass: C
Sub-badn: 03-08-34 (Catawba River B dn)
Facility Loca tion
Page 3 of 9

NCS000040
Central Office Review Summary:
1. Owner's Other Permits:
• AFS — 371 1900626
NCG500117
RCRA NCD980247316
2. General Observations:
• Outfalls: Stormwater runoff from the main manufacturing plant discharges via three stormwater
outfalls (SW001, SW002, SW005) across I-77 and ultimately to Irwin Creek. Tow other outfalls (SW003,
S W004)-have-been-identified-as-intermediate-outfalls-for-sampling-purposes.
- SW001: This outfall drains approximately 7.2 acres of the southwestem portion of the facility that
contains the wastewater treatment plant, fitting storage area, scrap iron storage area and the cupola
bag houses. This outfall also drains several off -site properties up gradient of the CP&F facility.
The drainage area is approximately 95% impervious.
- SWO02: This outfall drains approximately 3.1 acres of the central portion of the facility, which
contains the main raw material unloading area, machine shop, shell cure building, and cupola
furnace building. The drainage area is approximately 95% impervious.
- S WO03: This outfall is located up gradient of the facility and was historically used to sample off -
site water that flowed onto the property for purposes of comparing influent stormwater samples at
S WO03 to effluent stormwater samples at SW004. However, CP&F determined that S WO03 was
not collecting the major portion of the influent stormwater and this is no longer sampling.
- SWO04: This outfall drains approximately 11.1 acres of the western portion of the facility that
contains the fueling station, fuel storage tanks, maintenance shop, bulk spent material storage area,
pipe production building, pipe coating building, the hot dip coating area, and serves as the permitted
discharge pipe for non -contact cooling water. This outfall also drains many offsite properties up
gradient of the facility. The drainage area is approximately 95% impervious.
-SW005: This outfall drains approximately 2.5 acres of the northwestern portion of the site, which
contains the hot dip collectors and the fittings tar pit building. In addition stormwater from SWO04
flows into SWO05 at Clarkson Street. The drainage area is approximately 95 percent impervious.
After the application was filed the facility purchased more property and there are now a total of seven
outfalls now: 001 (35' 13'27", -80' 5 1'5 1 "), 002 (350 13'29", -800 51'49"), 002A (35° 13'23", -80°
51'42"), 004 (35° 13'27", -800 51'39"), 005 (35�0 13'29", -800 51'41 "), 006 (350 13'34", -800 51'45"), and
007 (35° 13'34", -800 51'39").
Impairment: Irwin Creek is on the 303(d) list for standard violations for turbidity and fecal coliform, as well
as, having impaired biological integrity. Basinwide Plan recommendations include:
Current Status and 2004 Recommendations
The Irwin Creek site is showing a slight trend of lowered conductivity since the middle 1990s. There is a Fecal
Coliform Bacteria Tl/IDL for Sugar Creek, Irwin Creek, Little Sugar,Creek and McAlpine Creek. The TMDL
addresses all identifiable sources of fecal coliform pollution including, but not limited to, wastewater treatment
plants, sanitary sewer overflows, stormwater runoff, failing septic systems, and background wildlife
contributions. The TMDL study indicated that excluding stormwater runoff, the primary contributors of fecal
coliform pollution in this watershed are point sources (WWTP, etc.) and direct input nonpoint sources (failing
septic systems).
4. Threatened and Endangered: Based on the Natural Heritage Virtual Workroom there is one federally
endangered species within 2 miles of the facility: Lasmigone decorata, Carolina Heelsplitter. More information
was provided that showed the element occurrence ranking as X — Extirpated. The most recent survey date was
1987 indicating the Carolina Heelsplitter used to be located in Irwin Creek but no longer exists there.
Page 4 of 9

Il t
NCS000040
5. Location: Drains to a classified C stream. The inspection report indicated the site map needed to be updated.
6. Industrial Changes Since Previous Permit None provided in renewal application.
7. Analytical Monitoring Notes: Analytical monitoring parameters included COD, TSS, Total Kjeldahl Nitrogen,
Phenols, Total Copper, Total Recoverable Lead, Total Nickel, Total Zinc and Total Chromium. Samples were
to be taken annually for the first three years and quarterly during the 41h year. The application only included
one sample for each ou{/dll. The samples had values over our current benchmarks for Cr, Cu, Pb, Ni, Zn,
Phenol, COD and TSS. The data was missing information such as total rainfall, event duration, and estimated
flow.
Th is-industry-(S I G332-1)•is-covered-in-th e-EPA-Multi-S ector-General-Permit-under-S ubsector-F-2-lron-and
Steel Foundries. The parameters recommended for monitoring include Total Aluminum, TSS, Total Copper,
Total Iron, and Total Zinc.
The inspection report indicated the facility uses more than 55 gallons of new motor oil and therefore should
have done analytical monitoring under Part 11 Section D of the permit. CP&F personnel indicated that more
than 55 gallons of new motor oil were used but no records of quantities have been kept.
Oil and Grease was added to the monitorine because it is a potential pollutant onsite.
Another set of values was start from at storm event on February 26, 2008. Many values are over the current
benchmarks for Cr, Cu, Ph, Ni, Zn, TKN, COD and TSS.
8. Qualitative Monitoring Notes: No visual monitoring was provided. An inspection report was given instead.
Page 5 of 9

NCS000040
Table 1: Analytical Monitoring
Otltfall
I Sample
Date
Total
Flow
(wol
Pre4itation
(in)
Duration
(hours)
a
Cu
I Pb
I Ni
17-
TIQJ
Pherol
COD
I TSS
Benctrrark:
1 mg(L
Berchnark:
0.007 ng'L
Bench"rk:
0.03 mg'L
Benctnerk:
026 n dL
Berchrmrk:
0.067 mg'L
Benchmark:
20 mg'L
Benchinuk:
4.5 mg/L
Bemhnark:
120mg/L
Bench k:
100ng'L
i
SW-001
623/2004
-..
0.1
W'099-#
MW55VAA
0.033
HEq18
1.9
0.29
21 -
j21Qt` -
SW-002
6/24/2D04
0.15
�Q;12
'�0'81,i
0.056
2 ?
1.6
0.17
IlM22DAM
R 25Q '
SW-002A
C> 252004
f_
¢rg5
F32Qi47#
1.5
0.09
90Qy„
85Q
SW-004
626/2004
0.27
(F42
l k13
0.18
� 2:5 3
8.5
1Z00
W5400
SW-005
6/27/2004
0.61
;()7
:-0.42WA
0.016
""' ' Q2
11.0
1.4
SN-001
2262008
ND
r0;007 `
0.0203
ND
0:a124i
0.99
0.02
226=
30
S V-002
2)26'2008
0.0182
c 14:h
0.0111
`0.`4'ld:
1.4
0.063
119
2g¢
M-002A
2/26r2008
11-
9:52
0.181
y1=7
12
1.8
143 i
96 Ei
2/262008
.`
`
0.0132
0 s
0.0199
0.00676.03`
0.92
0.023
36i
i 109Y'2/2Fi/2008
...
0.0143
O:Q461
0.14
0.0119
0$15,4:
1.90.032
�25�{
-'2,12126r2008
L��
0.0128
Q A 95TV
0.0265
0.006
0;21
0.92
0.055
50
,,, 126j,' j2/26/2008
0.0906
.N$'.I}`
07089U
-
0.0345
0.� A5k`'r:
2.2
0.015
80
654
I
Over Current Benchmark
:.,-. Data Not Collected
Page 6 of 9

NCS000040
Revised Permit Recommendations: Analytical Monitoring:
1. Maintain monitoring for COD, TSS, Total Kjeldahl Nitrogen, Phenols, Total Copper, Total Recoverable
Lead, Total Nickel, Total Zinc and Total Chromium. Oil & Grease has been added to the monitoring.
2. pH has been added to the analytical monitoring requirements.
3. All analytical monitoring has been set to semi-annually during a representative storm event as defined in Part II
Section B. The permittee must also document the total precipitation for each event. If no discharge occurs
during the sampling period, the permittee must submit a monitoring report indicating "No Flow" within 30 days
of the end of the six-month sampling period. Additionally, samples must be taken a minimum of 60 days apart,
as specificd'in Table 2.
4. Benchmarks for analytical monitoring have been added to this draft permit. Exceedances of benchmark values
require the permittee to increase monitoring, increase management actions, increase record keeping, and/or
install stormwater Best Management Practices (BMPs) in a tiered program. If the sampling results are above a
benchmark value, or outside of the benchmark range, for any parameter at any outfall then the facility shall
follow the Tier I guidelines which require a facility inspection within two weeks and implementation of a
mitigation plan within two months. If during the term of this permit, the sampling results are above the
benchmark values, or outside of the benchmark range, for any specific parameter at a specific discharge outfall
two times in a row (consecutive), then the facility shall follow the Tier 2guidelines which require a repetition
of the steps listed for "Fier 1 and also immediately institute monthly monitoring for all parameters at every
outfall where a sampling result exceeded the benchmark value for two consecutive samples.
5. The permittee is required to collect all of the analytical and qualitative monitoring samples during
representative storm events as defined in Part II Section B. Qualitative monitoring is required regardless of
representative outfall status.
6. The permittee is responsible for all monitoring until the renewal permit is issued. See Footnote 1 of Tables 1,
4, and 5.
7. The flow reporting requirement has been removed per DWQ revised strategy. (The total rainfall parameter is in
this permit, however.)
8. Vehicle maintenance monitoring has been revised to semi-annually in order to coincide with analytical and
qualitative monitoring.
Other Proposed Changes to the Previous Permit:
1. Additional guidance is provided about the Site Plan requirements. The site map must now identify if the
receiving stream is impaired and if it has a TMDL established. It must also describe potential pollutants in each
outfall. The map requirements are stated more explicitly. And, the site plan must contain a list of significant
spills that have occurred in the past three years and also must certify that the outfalls have been inspected to
ensure that they do not contain non-stormwater discharges. Additional information is provided in Part II
Section A.
2. Additional requirements for the Stormwater Management Plan have been specified in Part II Section A. More
details regarding secondary containment are provided.
3. Additional requirements for the Stormwater Pollution Prevention Plan have been specified in Part II Section A.
The plan must also be updated annually to include a list of significant spills and to certify that the outfalls do
not contain non-stormwater discharges.
4. The facility must now implement a semi-annual Facility Inspection Program of the site's stormwater
management controls as specified in Part II Section A.
5. Information regarding the No Exposure Exclusion has been added to this draft permit, If industrial materials
and activities are not exposed to precipitation or runoff as described in 40 CPR § 122.26(g), the facility may
qualify for a No Exposure Exclusion from NPDES stormwater discharge permit requirements. Additional
information is provided in Part I Section A.
Page 7 of 9

NCS000040
Discussions with permittee: David Waggoner, 704-332-2647, 03/19/09
I. General description of industrial activities. Grey metal pipe foundry. Use recycled material. Melt iron and
then cast pipes and fittings.
2. Have there been any changes in industrial activities since the application was submitted? Yes. Will be
submitted in an email.
3. What is Outfall 002A? Outfall close to 002. There are seven outfalls now.
4. The inspection report for a 2006 visit indicated that the site map and SPPP needed to be updated. Has this been
done? Can you send us the map? They have been updated. Will send a copy of the site map.
5. Do you have onsite vehicle maintenance? Yes. All maintenance is done inside. The area has French drains that go
directly to the sewer system.
Page 8 of 9

NCS000040
Recommendations: Based on the documents reviewed, the application information submitted on July 4, 2004
sufficient to issue an Individual Stormwater Permit.
Prepared by (Signature) Date
Stormwater Permitting Unit Supervisor &:: j oiao Date 3 D
for Bradley Bennett
Concurrence by Regional Offic�%%� Date
RO Water Quality Supervisor /, L_ Date
Regional Office Staff Comments (attach addirional pages as necessary)
Page 9 of 9

Site inspection conducted on May 6, 2009 by Michael Parker. Facility contact: David Waggoner.
Current NPDES SW permit expired in 2004. Area had received significant rainfall the evening prior to
the site visit. Charlotte Pipe and Foundry (CP&F) is presently operating on a reduced schedule (3 — 4
days per week) due to depressed economic conditions. The site is located in a heavily commercial and
industrialized area of downtown Charlotte.
The SW drainage system at this site was installed back in the 1920's when the company located to this
site. The existing SW drainage system not only serves CP&F, but also receives SW from other
businesses and commercial property adjacent and upgradient to the CP&F site. Some of these off -site
properties have been found to have significant soil and GW contamination, and on -going remediation
activities are being conducted. Such being the case, the possibility exists that some of these
contaminants may be entering the SW collection system that passes through the CP&F property via 1/I.
CP&F personnel have not verified (through analytical testing) that upstream contaminants are entering
their SW system, however, it was suggested during the site visit that additional testing be conducted of
the upstream SW drainage system to ascertain the impacts (if any) these upgradient properties may be
having on contaminant levels found in the SW sampling data collected by CP&F.
Analytical testing reviewed during the site visit indicated that CP&F will have difficulty in complying
with the benchmark levels proposed in the new SW permit based on testing conducted at the SW
outfalls located at this site. If the current benchmark values noted in the draft permit are incorporated
into the final permit, CP&F will likely be subject to Tier II and Tier III monitoring requirements during
the first rainfall event. Such being the case, consideration should be given to either modifying the
current benchmark values or consider the inclusion of a compliance schedule to allow CP&F to
'implement BMPs that may help reduce the off -site migration of pollutants. It should also be noted that
CP&F plans a major site construction project in 2009, which will result in a substantial portion of the
property covered under a metal roof. The area to be covered is suspected to be a significant source for
pollutants found in CP&F SW sampling data. If a compliance schedule is incorporated into the
renewed permit, the completion schedule of this project should be taken into consideration.
Since the original renewal application was received in 2004, there has been additional property added
to the CP&F site on both the north side and the east side. This additional property also includes SW
outfalls that may have not been reflected in the original renewal application. It is suggested that an
updated renewal application be provided including a revised site map that indicates the current
property boundaries and existing SW outfalls. It is also recommended that use of SW outfall 004 be
discontinued since it eventually flows through outfall 005, which is currently monitored and outfall
007 be eliminated as it does not receive SW from the industrial process/storage areas.

Lasmigona decorata 3
http://nhpweb.enr.state.nc. usInNs/partner/forms/eo/eo_py_eo_info.phtnil?gid=3792&cmd=Up...
Element Occurrence Information
Element Occurrence ID
Scientific Name
Element Occurrence
Number
Common Name
Most Recent Survey
Date
Date First Observed
Date Last Observed
Element Occurrence
Rank
Directions
Element Occurrence
Data
Habitat Description
Owner Name and
Comments
Protection Comments
Management Comments
Additional Comments
7236
Lasmigona decorata
3
Carolina Heelsplitter
1987
1880-PRE
1880-PRE
X - Extirpated
CTB/Irwin Creek P: The site is located in central Mecklenburg County and consists of Irwin Creek from its source
to its confluence with Taggart Creek.
This was the location of a syntype of L. decorata. Nine specimens are deposited in the Academy of Natural
Sciences at Philadelphia.
Small piedmont stream whose headwaters are located in the western part of Charlotte, NC.
1 of 1 3/25/2009 10:16 AM

IRWIN
CREEK
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LOCI.ilO1J OG STORM WPTEq 01RGN,LS
OUTFACE LATITUDE
LONGITUDE
j 001
35"13'2TN
80'S1'S1"W
002
35°13'29'N
BO'S1'49"W
002A
35°13'23"N
80'S1'42"W
ON
35°13'27"N
80°51'39"W
i005
35'13'29"N
80"51'41"VJ
006
35`13'34"N
80*51'45'W
OW
35°13'34"N
80'51'39"W
AREA PERCENT
(ACRES) IMPERVIOUS
AREAL 575 90%
AREA II 2.90 95%
AREA III 3.33 85%
AREA IV 10.23 95%
AREA V 2.26 95%
AREA VI 8.53 85%
C AREA VII 12.06 -- 95%
[OUTFAL_ I
L POTENTIAL POLLUTANTS
001 METALS, CHEMICAL RESIDUES._OIL&GREASE 1
r� 002 METALS, CHEMICAL RESIDUES, OIL& GREASE
D02A METALS, CHEMICAL RESIDUES OIL&GREASE
004 METALS, CHEMICAL RESIDUES OIL &GREASE
E005 METALS, CHEMICAL RESIDUES, OIL &GREASE
OCE METALS, CHEMICAL RESIDUES, OIL & GREASE
'
MT CHEMICAL RESIDUES, OIL&GREASE !

G
NCS000040
STATE OF NORTH CAROLINA
DEPARTMENT OF ENVIRONMENT AND NATURAL RESOURCES
DIVISION OF WATER QUALITY
PERMIT
TO DISCHARGE STORM WATER UNDER THE
NATIONAL POLLUTANT DISCHARGE ELIMINATION SYSTEM
U
In compliance with the provisions of North Carolina/G;enera Statute 143-215.1, other lawful
standards and regulations promulgated and adopted by the North Carolina Environmental
Management Commission, and the Federal Water Pollution Control Act, as amended,
Charlotte Pipe-&/fomidry Company
is hereby authorized to,,discharge ttonnwater from a facility located at
;hitrlofte Pipe & Foundry Co
I 5`S01.1111 Clarkson Street
A Charlotte, NC
Mecklenburg County
to receiving waters designated as It -win Creek, a class C stream in the Catawba River Basin, in
accordance with the discharge limitations, monitoring requirements, and other conditions set
forth in Parts I, II, III, IV, V and VI hereof.
Note: Draft Permit Dates are Approximate
This permit shall become effective July 1, 2009.
This permit and the authorization to discharge shall expire at midnight on June 30, 2014.
Signed this day .tune 12, 2009.
for Coleen H. Sullins Director
Division of Water Quality
By the Authority of the Environmental Management Commission

Permit No. NCS000040
PART
Section A:
Section B:
Section C:
PART II
Section A:
Section B:
Section C:
Section D:
PART III
TABLE OF CONTENTS
INTRODUCTION
Individual Permit Coverage
Permitted Activities
Locatior
MONITORI
DISCHARC
Stormwt
Analytic
Qualitati
On -Site
PERMITTED
STANDARD CONDITIONS FOR NPDES STORMWATER INDIVIDUAL
PERMITS
Section A: Compliance and Liability
1. Compliance Schedule
2. Duty to Comply
3. Duty to Mitigate
4. Civil and Criminal Liability
5. Oil and Hazardous Substance Liability
6. Property Rights
7. Severability
8. Duty to Provide Information
9. Penalties for Tampering
10. Penalties for Falsification of Reports
Section B: General Conditions
1. Individual Permit Expiration
2. Transfers
t

Pennit No. NCS000040
3. Signatory Requirements
4. Individual Permit Modification, Revocation and Reissuance, or
Termination
5. Permit Actions
Section C: Operation and Maintenance of Pollution Controls
1. Proper Operation and Maintenance
2. Need to Halt or Reduce Not a Defense
3. Bypassing of Stormwater Control Faciliti
Section D: Monitoring and Records
I.
Representative Sampling
2.
Recording Results
3.
Flow Measurement
4.
Test Procedures
5.
6.
7.
Representative Ouffall4
Records Retenhont�
lnsnection and-Entry
Section E: Reporting Requirements
I. Discharge,Monitoring Reports
2. Submitting Reports
3. Availability of Reports
4. Non-Stormwater Discharges
5. Planned Changes
6. Anticipated Noncompliance
7. Bypass
8. Twenty-four Flour Reporting
9. Other Noncompliance
10. Other Information
PART IV LIMITATIONS REOPENER
PART V ADMINISTERING AND COMPLIANCE MONITORING FEE
REQUIREMENTS
PART VI DEFINITIONS

Permit No. NCS000040
PART I INTRODUCTION
SECTION A: INDIVIDUAL PERMIT COVERAGE
During the period beginning on the effective date of the permit and lasting until expiration, the
permittee is authorized to discharge stormwater associated with industrial activity. Such
discharges shall be controlled, limited and monitored as specified in this permit.
If industrial materials and activities are not exposed to precipitation or runoff as described in 40
CFR § 122.26(g), the facility may qualify for a No Exposure Exclusion from NPDES stormwater
discharge permit requirements. Any owner or operator wishing to obtain a No Exposure
Certification must submit aNo Exposure Certification NOI form,to the Division; must receive
approval by the Division; must maintain no exposure conditions unless authorized to discharge
under a valid NPDES stormwater permit; and must reapply%for,thh j,Exposure Exclusion once
every five (5) years.
SECTION B: PERMITTED ACTIVITIES
Until this permit expires or is modified
stormwater to the surface
adequately treated and m;
permit. All stormwater di
he permittee is authorized to discharge
rr separate storm sewer system that has been
the terms and conditions of this individual
ance with the conditions of this permit.
Any other point source discharge to surface waters of the state is prohibited unless it is an
allowable non-stormwater diseharge�or is covered by another permit, authorization, or approval
The stormwater discharges allowed"by this individual permit shall not cause or contribute to
violations of Water Quality Standards.
This permit does not relieve the permittee from responsibility for compliance with any other
applicable federal, state, or local law, rule, standard, ordinance, order, judgment, or decree.
Part ll Page I of 10

Permit No. NCS000040
PART II MONITORING, CONTROLS, AND LIMITATIONS FOR
PERMITTED DISCHARGES
SECTION A: STORMWATER POLLUTION PREVENTION PLAN
The Permittee shall develop a Stormwater Pollution Prevention Plan, herein after referred to as
the Plan. This Plan shall be considered public information in accordance with Part 111, Standard
Conditions, Section E, Paragraph 3 of this general permit. The Plan shall include, at a minimum,
the following items:
I ; Site Plan. The site plan shall provide a description of the
potential pollutant sources which may be expected to"con
stormwater discharges. The site plan shall contaih the fo.
(a) A general location map (USGS qu
equivalent map), showing the facil
routes and surface waters, the nam
stormwater outfall(s) discharges c
storm sewer system, the namefoftl
map
al facility and the
to contamination of
y drafted
iion in relation to transportation
eceiving water(s) to which the
ischarge is to a municipal separate
ipality and the ultimate receiving
waters, and accurate latitude and longitude of the point(s) of discharge. The
general location -map (or alternatively the site map) shall identify whether each
receiving water is impaired (on the state's 303(d) list of impaired waters) or is
located in a watershed for which a TMDL has been established, and what the
paramcter(s) of concern,are.
North Carolina's 303(d•) List can be found here:
http://h2o.enr.State�nc.us/tmdl/General_303d.htm#Downloads
North Carolina TMDL documents can be found here:
http://h2o.enr.state.nc.us/tmdl/TMDL list.htm#Final TMDLs.
(b) A narrative description of storage practices, loading and unloading activities,
outdoor process areas, dust or particulate generating or control processes, and
waste disposal practices. A narrative description of the potential pollutants which
could be expected to be present in the stormwater discharge from each outfall.
(c) A site map drawn to scale (including a distance legend) showing: the site property
boundary, the stormwater discharge outfalls, all on -site and adjacent surface
waters and wetlands, industrial activity areas (including storage of materials,
disposal areas, process areas, loading and unloading areas, and haul roads), site
topography, all drainage features and structures, drainage areas for each outfall,
direction of Plow in each drainage area, industrial activities occurring in each
drainage area, buildings, existing BMPs, and impervious surfaces. The site map
must indicate the percentage of each drainage area that is impervious.
(d) A list of signi ficant spills or leaks of pollutants that have occurred at the facility
during the three (3) previous years and any corrective actions taken to mitigate
spill impacts.
Part 11 Page 3 of 10

SECTION C: LOCATION MAP
Permit No. NCS000040
NCS000040
MIP Scale 1:24,000
Charlotte Pipe & Foundry Co
Lab bide: 350 13' 28" N
Longitude: 800 51' 42" W
County:Ivleddenburg
Receving Stream: Irwin Creek
Stream Class: C
Sub -basin: 03-08-34 (Catawba River Bagn)
�•v �tu�j�^�fjj
MEN
Facility Location
Part 11 Page 2 of 10

Permit No. NCS000040
(e) Certification that the stormwater outfalls have been evaluated for the presence of
non-stormwater discharges. The certification statement will be signed in
accordance with the requirements found in Part 111, Standard Conditions, Section
B, Paragraph 5. The permittee shall re -certify annually that the stormwater
outfalls have been evaluated for the presence of non-stormwater discharges.
2. Stormwater Management Plan. The stormwater management plan shall contain a
narrative description of the materials management practices employed which control or
minimize the exposure of significant materials to stormwater, including structural and
nonstructural measures. The stormwater management plan, at a minimum, shall
incorporate the following:
(a) Feasibility Study. A review of the t
the methods of operations and/or stc
exposure of materials and processes
permittee shall prevent exposure of
operations, and manufacturing or fu
of exposure is not practical, the sto`r
feasibility of diverting the stormwat
contamination.
feasibility of changing
inate or reduce
water- Wherever practical, the
e areas, material handling
rations. In areas where elimination
tanagement plan shall document the
away from areas of potential
(b) Secondary Containment Requirements and Records. Secondary containment is
required for: bulk s storage of liquid materials; storage in any amount of Section
313 of Title III of"the Superfund Amendments and Reauthorization Act (SARA)
water priority 6hemicals; and storage in any amount of hazardous substances, in
order to preventLeaks,aand spills from contaminating stormwater runoff. A table
or summary of 11 such tanks and stored materials and their associated secondary
containment areas shall be maintained. If the secondary containment devices are
connected directly to stormwater conveyance systems, the connection shall be
controlled by manually activated valves or other similar devices (which shall be
secured closed with a locking mechanism), and any stormwater that accumulates
in the containment area shall be at a minimum visually observed for color, foam,
outfall staining, visible sheens and dry weather flow, prior to release of the
accumulated stormwater. Accumulated stormwater shall be released if found to
be uncontaminated by the material stored within the containment area. Records
documenting the individual making the observation, the description of the
accumulated stormwater, and the date and time of the release shall be kept for a
period of five years.
(c) BMP Summary. A listing of site structural and non-structural Best Management
Practices (BMP) shall be provided. The installation and implementation of BMPs
shall be based on the assessment of the potential for sources to contribute
significant quantities of pollutants to stormwater discharges and data collected
through monitoring of stormwater discharges. The BMP Summary shall include a
written record of the specific rationale for installation and implementation of the
selected site BMPs. The BMP Summary shall be reviewed and updated annually.
Part 11 Page 4 of 10

Permit No. NCS000040
3. Spill Prevention and Response Plan. The Spill Prevention and Response Plan (SPRP)
shall incorporate an assessment of potential pollutant sources based on a materials
inventory of the facility. Facility personnel (or the team) responsible for implementing
the SPRP shall be identified in a written list incorporated into the SPRP and signed and
dated by each individual acknowledging their responsibilities for the plan. A responsible
person shall be on -site at all times during facility operations that have the potential to
contaminate stormwater runoff through spills or exposure of materials associated with the
facility operations. The SPRP must be site stormwater specific. Therefore, an oil Spill
Prevention Control and Countermeasure plan (SPCC) may be a component of the SPRP,
but may not be sufficient to completely address the stormwater aspects of the SPRP. The
common elements of the SPCC with the SPRP may be incorporated by reference into the
SPRP.
4. Preventative Maintenance and Good Housekeeping�Prog am. A�preventative
maintenance and good housekeeping prograshall, ee developed. The program shall list
all stormwater control systems, stormwater discharge outfalls, all on -site and adjacent
surface waters and wetlands, industrial activit 3,areas (including material storage areas,
material handling areas, disposal areas, process areas, loading and unloading areas, and
haul roads), all drainage features and structures, and existing structural BMPs. The
program shall establish schedules of inspections, —maintenance, and housekeeping
activities of stormwater control systems,�as well as facility equipment, facility areas, and
facility systems that present a potential fo sr tormwater exposure or stormwater pollution.
Inspection of material handling areas and regular cleaning schedules of these areas shall
be incorporated into the prog`am: Timely compliance with the established schedules for
inspections, maintenance, housekeeping shall be recorded in writing and maintained
in the SPPP. # )/V
Employee Training. 'Training programs shall be developed and training provided at a
minimum on an annual basis for facility personnel with responsibilities for: spill response
and cleanup, preventative maintenance activities, and for any of the facility's operations
that have the potential to contaminate stormwater runoff. Facility personnel (or team)
responsible for implementing the training shall be identified, and their annual training
shall be documented by the signature of each employee trained.
6. Responsible Party. The Stormwater Pollution Prevention Plan shall identify a specific
position(s) responsible for the overall coordination, development, implementation, and
revision to the Plan. Responsibilities for all components of the Plan shall be documented
and position assignments provided.
Plan Amendment. The permittee shall amend the Plan whenever there is a change in
design, construction, operation, or maintenance which has a significant effect on the
potential for the discharge of pollutants to surface waters. All aspects of the Stormwater
Pollution Prevention Plan shall be reviewed and updated on an annual basis. The annual
update shall include an updated list of significant spills or leaks of pollutants for the
previous three years, or the notation that no spills have occurred. The annual update shall
include re -certification that the stormwater outfalls have been evaluated for the presence
of non-stormwater discharges. Each annual update shall include a re-evaluation of the
Part II Page 5 of 10

Permit No. NCS000040
effectiveness of the BMPs listed in the BMP Summary of the Stormwater Management
Plan.
The Director may notify the permittee when the Plan does not meet one or more of the
minimum requirements of the permit. Within 30 days of such notice, the permitted shall
submit a time schedule to the Director for modifying the Plan to meet minimum
requirements. The permittee shall provide certification in writing'(in accordance with
Part 111, Standard Conditions, Section B, Paragraph 5) to the Director that the changes
have been made.
8,. Facility Inspections. Inspections of the facility and all stormwater systems shall occur as
part of the Preventative Maintenance and Good Housekeeping Program at a minimum on
a semi-annual schedule, once during the first half of the .year (January to June), and once
during the second half (July to December), with at Ieast(60 days separating inspection
i/ i
dates (unless performed more frequently than semi-annually.)/These facility inspections
are different from, and in addition to, the stormwater discharge characteristic monitoring
required in Part 11 B and C of this permit. U \\
9. Implementation. The permittee shall imp
shall include documentation of all meniti
activities, and training provided to e nplc
of actions taken to implement BMPs ass(
vehicle maintenance activities. SucNoc
five years and made available t\th\Dire
immediately upon request'.
'the,Plan. Implementation of the Plan
measurements, inspections, maintenance
/Iincluding the log of the sampling data and
A with the industrial activities, including
ntation shall be kept on -site for a period of
or the Director's authorized representative
Part If Page 6 of 10

Permit No. NCS000040
SECTION B: ANALYTICAL MONITORING REQUIREMENTS
Analytical monitoring of stormwater discharges shall be performed as specified in Table 1. All
analytical monitoring shall be performed during a representative storm event. The required
monitoring will result in a minimum of ten analytical samplings being conducted over the term
of the permit at each stornnvater discharge outfall (SDO).
A representative storm event is a storm event that measures greater than 0.1 inches of rainfall
and that is preceded by at least 72 hours in which no storm event measuring greater than 0.1
inches has occurred. A single storm event may contain up to 10 consecutive hours of no
precipitation. For example, if it rains for 2 hours without producing any collectable discharge,
and then stops, a sample may be collected if a rain producing a discharge begins again within the
next 10 hours.
Table 1. Analytical Monitoring Rego
Discharge
Characteristics
Units
Measurement
Fre uenc I
Sample
Type2
Sample
Location3
Chemical Oxygen Demand (COD)
m /L
semi annual
1 -1Total
Grab
SDO
Suspended Solids (TSS)
m /L14
semi annual
Grab
SDO
Total K'eldahl Nitrogen TKN
m /,L\\%
_semi -annual
Grab
SDO
Phenols
m /L\
�/ semi-annual
Grab
SDO
Total Recoverable Copper
m /[[�'/
semi-annual
Grab
SDO
Total Recoverable Lead
mg/L
semi-annual
Grab
SDO
Total Recoverable Nickel
t g/L
semi-annual
Grab
SDO
Total Recoverable Zinc
m /L
semi-annual
Grab
SDO
Total Recoverable Chromium
me/L
semi-annual
Grab
SDO
Oil and Grease
m /L
semi-annual
Grab
SDO
H
standard
semi-annual
Grab
SDO
Total Rainfall°
inches
semi-annual
Rain Gauge
Footnotes:
Measurement Frequency: Twice per year during a representative storm event, for each year until either another
permit is issued for this facility or until this permit is revoked or rescinded. If at the end of this permitting cycle
the permittee has submitted the appropriate paperwork for a renewal permit before the submittal deadline, the
permittee will be considered for a renewal application. The applicant must continue semi-annual monitoring
until the renewed permit is issued. See Table 2 for schedule of monitoring periods through the end of this
permitting cycle.
2 If the stormwater runoff is controlled by a stormwater detention pond, a grab sample of the discharge from the
pond shall be collected within the first 30 minutes of discharge.
3 Sample Location: Samples shall be collected at each stormwater discharge outfall (SDO) unless representative
outfall status has been granted.
Part 11 Page 7 of 10

Permit No. NCS000040
4 For each sampled representative storm event the total precipitation must be recorded. An on -site rain gauge or
local rain gauge reading must be recorded.
The permittee shall complete the minimum ten analytical samplings in accordance with the
schedule specified below in Table 2. A minimum of 60 days must separate Period 1 and
Period 2 sample dates unless monthly monitoring has been instituted under a Tier Two
response.
Table 2. Monitoring Schedule
Monitoring periodt'2
Sample Number
Start
End
Year 1 — Period 1
1
July 1, 2009
December 31, 2009
Year 1 — Period 2
2
January 1, 2010
June 30, 2010
Year 2 —Period 1
3
July 1,,2010'
December 31, 2001
Year 2 — Period 2
4
January,l?-201,1 �?
,tune 30, 2011
Year 3 — Period 1
5
July�l; 2011, ,�
December 31, 2011
Year 3 — Period 2
6
Januaiy�l, 2012
June 30, 2012
Year 4 —Period 1
7
/July ,1;\20,12
December 31, 2012
Year 4 — Period 2
8
% January%i, 2013
June 30, 2013
Year 5 —Period 1
9
�� July 1, 2013
December 31, 2013
Year 5 — Period 2'
XI
�Ianuary 1, 2014
June 30, 2014
Footnotes: '
1 Maintain semi-annual monitoring
process. The applicant must continue semi-annual
monitoring until the renewed pennifis issued "
If no discharge occurs during the sampling period, the permittee must submit a monitoring report indicating
"No Flow" within 30 days of the end of the six-month sampling period.
The permittee shall report the analytical results from the first sample with valid results within the
monitoring period. The permittee shall compare monitoring results to the benchmark values in
Table 3. The benchmark values in Table 3 are not permit limits but should be used as guidelines for
the permittee's Stormwater Pollution Prevention Plan (SPPP). Exceedences of benchmark values
require the permittee to increase monitoring, increase management actions, increase record keeping,
and/or install stormwater Best Management Practices (BMPs) in a tiered program. See below the
descriptions of Tier One and Tier Two.
Part II Page 8 of 10

Permit No. NCS000040
Table 3. Benchmark Values for Analvtical Monitorine
Discharge Characteristics
Units
Benchmark
Chemical Oxygen Demand (COD)
mg/L
120
Total Suspended Solids (TSS)
mg/L
100
Total Kjeldahl Nitrogen (TKN)
mg/L
20
Phenols
mg/L
4.5
Total Recoverable Copper
mg/L
0.007
Total Recoverable Lead
mg/L
0.03
Total Recoverable Nickel
mg/L
0.26
Total Recoverable Zinc
ma/L
1\0�067
Total Recoverable Chromium
mg/L
Oil and Grease
m /L
g
30�
�^
pH
6-9 - 9
Tier One
If: The first valid sampling results are above a benchmark value, or outside of the benchmark
for anv narameter at anv outfall:
Then: The permittee shall:
1. Conduct a stormwater management inspection of the facility within two weeks of receiving
sampling results.
2. Identify and evaluate possible causes of the benchmark value exceedence. .
3. Identify potential, and select the specific: source controls, operational controls, or physical
improvements to reduce concentrations of the parameters of concern, or to bring
concentrations to within the benchmark range.
4. Implement the selected actions within two months of the inspection.
5. Record each instance of a Tier One response in the Stormwater Pollution Prevention Plan.
Include the date and value of the benchmark exceedence, the inspection date, the personnel
conducting the inspection, the selected actions, and the date the selected actions were
lemented.
Part II Page 9 of l0

Permit No. NCS000040
Tier Two
If: During the term of this permit, the first valid sampling results are above the benchmark values,
or outside of the benchmark range, for any specific parameter at a specific discharge outfall two
times in a row
Then: The permittee shall:
I. Repeat all the required actions outlined above in Tier One.
2. Immediately institute monthly monitoring for all parameters at every outfall where a
sampling result exceeded the benchmark value for two consecutive samples. Monthly
(analytical and qualitative) monitoring shall conftnu l ntil three consecutive sample results
are below the benchmark values, or within theibenchma k range, for all parameters at that
outfall. ��
I If no discharge occurs during the sampl
monthly monitoring report indicating/"]
4. Maintain a record of the Tier Two,resm
permittee is required to submit a
Stormwater Pollution Prevention Plan.
During the term of this perniit,-ifthe valid sampling results required for the permit monitoring
periods exceed the benchmark value, or are outside the benchmark range, for any specific
parameter at any specific outfall on more than four occasions, the permittee shall notify the
DWQ Regional Office Supervisor in writing within 30 days of receipt of the fourth analytical
results. DWQ may, but is not limited to:
• require that the permittee increase or decrease the monitoring frequency for the remainder
of the permit;
• require the permittee to install structural stormwater controls;
• require the permittee to implement other stonmwater control measures; or
• require that the permittee implement site modifications to qualify for the No Exposure .
Exclusion.
1Note: Rearove laitanaae-below-if-a-TMDL-is-not-applicable:/
This site discharges to impaired waters experiencing problems with turbidity and fecal coliform,
as well as, having impaired biological integrity. If a Total Maximum Daily Load (TMDL) is
approved for this segment of Irwin Creek, the permittee may be required to monitor for the
pollutant(s) of concern in the future and submit results to the Division of Water Quality. The
Part 11 Page 10 of 10

Permit No. NCS000040
Division will consider the monitoring results in determining whether additional BMPs are
needed to control the pollutant(s) of concern to the maximum extent practicable.
If additional BMPs are needed to achieve the required level of control, the permittee will be
required to (1) develop a strategy for implementing appropriate BMPs, and (2) submit a
timetable for incorporation of those BMPs into the permitted Stormwater Pollution Prevention
Plan.
PartII Page 11 of 10

Permit No. NCS000040
SECTION C: QUALITATIVE MONITORING REQUIREMENTS
Qualitative monitoring requires a visual inspection of each stormwater outfall regardless of
representative outfall status and shall be performed as specified in Table 4, during the analytical
monitoring event. [If analytical monitoring is not required, the permittee still must conduct semi-
annual qualitative monitoring.] Qualitative monitoring is for the purpose of evaluating the
effectiveness of the Stormwater Pollution Prevention Plan (SPPP) and assessing new sources of
stormwater pollution.
In the event an atypical condition is noted at a stormwater discharge outfall, the permittee shall
document the suspected cause of the condition and any actions taken in response to the
discovery. This documentation will be maintained with the SPP,P?
Table 4. Qualitative onitoring Requirements
Discharge Characteristics
Frequency]
Monitoring
Location2
Color
semi-annual
N SDO
Odor
semi-annual
1 SDO
Clarity
semi-annual /
SDO
Floating Solids
semi`annual�
SDO
Suspended Solids
semi-annual�
SDO
Foam
semi annual
SDO
Oil Sheen /
i
semi-annual
SDO
Erosion or deposition at the
`semi-annual
SDO
outfall
Other obvious indicators
semi-annual
SD0
of stormwater Pollution
Footnotes:
Measurement Frequency: Twice per year during a representative storm event, for each year until either another
permit is issued for this facility or until this permit is revoked or rescinded. If at the end of this permitting cycle
the permittee has submitted the appropriate paperwork for a renewal permit before the submittal deadline, the
permittee will be considered for a renewal application. The applicant must continue semi-annual monitoring
until the renewed permit is issued. See Table 2 for schedule of monitoring periods through the end of this
permitting cycle.
2 Monitoring Location: Qualitative monitoring shall be performed at each stormwater discharge outfall (SDO)
regardless of representative outfall status.
SECTION D: ON -SITE VEHICLE MAINTENANCE MONITORING REQUIREMENTS
Facilities which have any vehicle maintenance activity occurring on -site which uses more than
55 gallons of new motor oil per month when averaged over the calendar year shall perform
analytical monitoring as specified below in Table 5. This monitoring shall be performed at all
Part 11 Page 12 of 10

Permit No. NCS000040
stormwater discharge outfalls which discharge stormwater runoff from vehicle maintenance
areas, and in accordance with the schedule presented in Table 2 (Section B). All analytical
monitoring shall be performed during a representative storm event.
Table 5. Analytical Monitoring Requirements for On -Site Vehicle Maintenance
Discharge Characteristics
Units
Measurement
Frequency]
Sample
Type2
Sample
Location;
H
standard
semi-annual
Grab
SDO
Oil and Grease
In/1
semi-annual
Grab
SDO
Total Suspended Solids
m /l
semi-annual
Grab
SDO
Total Rainfall4
inches
semi-annual //I
Rain gauge
New Motor Oil Usage
gallons/month
v
semi�annua&
I Estimate
Footnotes:
I Measurement Frequency: Twice per year during a reps
permit is issued for this facility or until this permit is rt
the permittee has submitted the appropriate paperwork
permittee will be considered for a renewal application
until the renewed permit is issued. See Table 2 for /scli
permitting cycle. /
2 If the stormwater runoff is control
pond shall be collected within the
3 Sample Location: Samples shall
stormwater runoff from area(s) c
4 For each sampled reprt
gauge reading must be
cvent,�each year until either another
ded. If at the end of this permitting cycle
;rmit before the submittal deadline, the
oust continue semi-annual monitoring
'ing periods through the end of this
' detention pond a grab sample of the discharge from the
discharge from the pond.
teh stormwater discharge outfall (SDO) that discharges
menance activities occur.
the total precipitation must be recorded. An on -site or local rain
Monitoring results shall be compared to the benchmark values in Table 6. The benchmark
values in Table 6 are not permit limits but should be used as guidelines for the permittee's
Stormwater Pollution Prevention Plan (SPPP). Exceedences of benchmark values require the
perinittee to increase monitoring, increase management actions, increase record keeping, and/or
install stormwater Best Management Practices (BMPs), as provided in Part 11 Section B.
Table 6.
Benchmark Values for Vehicle Maintenance Analytical Monitoring
Discharge Characteristics
Units
Benchmark
pH
standard
6-9
Oil and Grease
mg/L
30
Total Suspended Solids
mg/L
100
Part II Page 13 of 10

Permit No. NCS000040
PART III STANDARD CONDITIONS FOR NPDES STORMWATER INDIVIDUAL PERMITS
SECTION A: COMPLIANCE AND LIABILITY
Compliance Schedule
The per nittee shall comply with Limitations and Controls specified for stonnwater discharges in
accordance with the following schedule:
Existing Facilities already operating but applying for permit coverage for the first time: The Slorntwater
Pollution Prevention Plan shall be developed and implemented within 12 months of the effective date of
the initial permit and updated thereafter on an annual. basis. Secondary containment, as specified in Part II,
Section A, Paragraph 2(b) of this permit, shall be accomplished within.12 months of the effective date of
the initial pennit issuance. - N�
New Facilities applying for coverage for the first time
applying for renewal under this permit: The Stormwat
implemented prior to the beginning of discharges fron
updated thereafter on an annual basis. Secondary eon'
2(b) of this permit shall be accomplished prior to4he4
industrial activity. �� J�
2. Duty to Comply
.facilities previously permitted and
Prevention Plan shall be developed and
)n of the industrial activity and be
specified in Part II, Section A, Paragraph
discharges from the operation of the
The perntittee must comply with all conditions of this individual permit. Any permit noncompliance
constitutes a violation of the Clean Water Act -and is grounds for enforcement action; for permit
termination, revocation and rei11
ssuance, orr modification; or denial of a permit upon renewal application.
a. The penninee shall comply.with standards or prohibitions established under section 307(a) of the
Clean Water Actt for toxic,pollutants within the time provided in the regulations that establish
these standards or prohibitions, even if the permit has not yet been modified to incorporate the
requirement.
b. The Clean Water Act provides that any person who violates a permit condition is subject to a civil
penalty not to exceed $25,000 per day for each violation. Any person who negligently violates
any permit condition is subject to criminal penalties of $2,500 to 25,000 per day of violation, or
imprisonment for not more than 1 year, or both. Any person who knowingly violates permit
conditions is subject to criminal penalties of 55,000 to $50,000 per day of violation, or
imprisonment for not more than 3 years, or both. Also, any person who violates a permit
condition may be assessed an administrative penalty not to exceed $10,000 per violation with the
maximum amount not to exceed $125,000. [Ref: Section 309 of the Federal Act 33 USC 1319 and
40 CFR 122.41(a).]
Under state law, a daily civil penalty of not more than ten thousand dollars ($10,000) per violation
may be assessed against any person who violates or tails to act in accordance with the terms,
conditions, or requirements of a permit. [Ref: NC General Statutes 143-215.6A].
d. Any person may be assessed an administrative penalty by the Director for violating section 301,
302, 306, 307, 308, 318 or 405 of the Act, or any permit condition or limitation implementing any
of such sections in a permit issued under section 402 of the Act. Administrative penalties for Class
I violations are not to exceed $10,000 per violation, with the maximum amount of any Class I
penalty assessed not to exceed $25,000. Penalties for Class II violations are not to exceed
Part III Page 1 of 8

Permit No. NCS000040
$ I0,000 per day for each day during which the violation continues, with the maximum amount of
any Class 11 penalty not to exceed $125,000.
3. Duty to Mitigate
4.
:a
a
Q
The permittee shall take all reasonable steps to minimize or prevent any discharge in violation of this
individual permit which has a reasonable likelihood of adversely affecting human health or the
environment.
Civil and Criminal Liability
Except as provided in Part 111, Section C of this permit regarding bypassing of stormwater control facilities,
nothing in this individual permit shall be construed to relieve the permittee from any responsibilities,
liabilities, or penalties for noncompliance pursuant to NCGS 143-215.3, 143-215.6A, 143-215.6B, 143-
215.6C or Section 309 of the Federal Act, 33 USC 1319. Furthermore, the permittee is responsible for
consequential damages, such as fish kills, even though tesp he ronsibilliity for effective compliance may be
temporarily suspended. /( ��\ \
Oil and Hazardous Substance Liability
Nothing in this individual permit shall be
the permittee from any responsibilities, li,
to under NCGS 143-215.75 et seq. or Sect
Property Rights C
The issuance of this individual pe\dot
property, or any exclusive privileges,nor
personal rights, nor any infr�ingemen�t�I, F
Severability
ued-to preclude the institution of any legal action or relieve
s %penalties/to which the permittee is or may be subject
1 of the,Federal Act, 33 USC 1321.
convey any property rights in either real or personal
it authorize any injury to private property or any invasion of
I, State or local laws or regulations.
The provisions of this individual permit are severable, and if any provision of this individual permit, or the
application of any provision of this individual permit to any circumstances, is held invalid, the application
of such provision to other circumstances, and the remainder of this individual permit, shall not be affected
thereby.
Duty to Provide Information
The permittee shall furnish to the Director, within a reasonable time, any information which the Director
may request to determine whether cause exists for modifying, revoking and reissuing, or terminating the
permit issued pursuant to this individual permit or to determine compliance with this individual permit.
The permittee shall also furnish to the Director upon request, copies of records required to be kept by this
individual permit.
Penalties for Tampering
The Clean Water Act provides that any person who falsifies, tampers with, or knowingly renders
inaccurate, any monitoring device or method required to be maintained under this individual permit shall,
upon conviction, be punished by a fine of not more than $10,000 per violation, or by imprisonment for not
more than two years per violation, or by both. If a conviction of a person is for a violation committed after
a first conviction of such person under this paragraph, punishment is a fine of not more that $20,000 per
day of violation, or by imprisonment of not more than 4 years, or both.
Part I I I Page 2 of 8

Permit No. NCS000040
10. Penalties for Falsification of Reports
The Clean Water Act provides that any person who knowingly makes any false statement, representation,
or certification in any record or other document submitted or required to be maintained under this
individual permit, including monitoring reports or reports of compliance or noncompliance shall, upon
conviction, be punished by a fine of not more than $10,000 per violation, or by imprisonment for not more
than two years per violation, or by both.
SECTION li: GENERAL CONDITIONS
Individual Permit Expiration
The permittee is not authorized to discharge after the
authorization to discharge beyond the expiration date,
required by the agency authorized to issue permits no
pernittee that has not requested renewal at least 180 d
have a permit after the expiration and has not requeste
be subjected to enforcement procedures as provided.it
2. Transfers
This permit is not transferable to any
Director may require modification or
incorporate such other require nen[s,�
It
required to notify the Division'"t A
3. minatory Requirements
'date.' In order to receive automatic
ttee�shall submit forms and fees as are
111
80 dys.pnor to the expiration date. Any
to expiration, or any permittee that does not
I at least 180 days prior to expiration, will
1'43-2153.6 and 33 USC 1251 ct. seq.
t after notice to and approval by the Director. The
td reissuance of the permit to change the name and
essary under the Clean Water Act. The Permittee is
event the permitted facility is sold or closed.
All applications, reports,loror i� ation submitted to the Director shall be signed and certified.
a. All applications to be covered under this individual permit shall be signed as follows:
(1) In the case of a corporation: by a principal executive officer of at least the level of vice-
president, or his duly authorized representative, if such representative is responsible for
the overall operation of the facility from which the discharge described in the permit
application form originates;
(2) In the case of a partnership or limited partnership: by a general partner;
(3) In the case of a sole proprietorship: by the proprietor;
(4) In the case ol'a municipal, state, or other public entity: by a principal executive officer,
ranking elected official, or other duly authorized employee.
b. All reports required by the individual permit and other information requested by the Director shall
be signed by a person described above or by a duly authorized representative of that person. A
person is a duly authorized representative only if:
(1) The authorization is made in writing by a person described above;
(2) The authorization specified either an individual or a position having responsibility for the
overall operation of the regulated facility or activity, such as the position of plant
Part III Page 3 of 8

Permit No. NCS000040
4.
manager, operator of a well or well field, superintendent, a position of equivalent
responsibility, or an individual or position having overall responsibility for
environmental matters for the company. (A duly authorized representative may thus be
either a named individual or any individual occupying a named position.); and
(3) The written authorization is submitted to the Director
C. Any person signing a document under paragraphs a. or b. of this section shall make the following
certification:
"I certify, under penalty of law, that this document and all attachments were prepared under my
direction or supervision in accordance with a system designed to assure that qualified personnel
properly gather and evaluate the information submitted. Based on my inquiry of the person or
persons who manage the system, or those persons directly responsible for gathering the
information, the information submitted is, to the best of my knowledge and belief, true, accurate,
and complete. I am aware that there are significant penalties for submitting false information,
including the possibility of fines and imprisonmen[,for knowing.yiolations."
The issuance of this individual permit does not prohibit the Director from reopening and modifying the
individual permit, revoking and reissuing the individ�uabp�rmlt, or terminating the individual permit as
allowed by the laws, rules, and regulations contained in/Title 40, Code of Federal Regulations, Parts 122
and 123; Title 15A of the North Carolina Administrative Code, Subchapter 21-1 .0100; and North Carolina
General Statute 143-215.1 >revo
�\��
Permit Actions The permit may be modifiedked'and reissued, or terminated for cause. The notification of planned
changes or anticipated noncompliance/does not stay any individual permit condition.
SECTION C: OPERATION AND MAINTENANCE OF POLLUTION CONTROLS
Proper Operation and Maintenance
The permittee shall at all times properly operate and maintain all facilities and systems of treatment and
control (and related appurtenances) which are installed or used by the permittee to achieve compliance with
the conditions of this individual permit. Proper operation and maintenance also includes adequate
laboratory controls and appropriate quality assurance procedures. This provision requires the operation of
back-up or auxiliary facilities or similar systems which are installed by a permittee only when the operation
is necessary to achieve compliance with the conditions of this individual permit.
2. Need to Halt or Reduce Not a Defense
It shall not be a defense for a permittee in an enforcement action that it would have been necessary to halt
or reduce the permitted activity in order to maintain compliance with the condition of this individual
permit.
3. Bypassing of Stormwater Control Facilities
Bypass is prohibited and the Director may take enforcement action against a permittee for bypass unless:
a. Bypass was unavoidable to prevent loss of life, personal injury or severe property damage; and
Part III Page 4 of 8

Permit No. NCS000040
b. There were no feasible alternatives to the bypass, such as the use of auxiliary control facilities,
retention of stormwater or maintenance during normal periods of equipment downtime or dry
weather. This condition is not satisfied if adequate backup controls should have been installed in
the exercise of reasonable engineering judgment to prevent a bypass which occurred during
normal periods of equipment downtime or preventive maintenance; and
C. The permittee submitted notices as required under, Part 111, Section E of this permit.
If the Director determines that it will meet the three conditions listed above, the Director may approve an
anticipated bypass after considering its adverse effects.
SECTION D: MONITORING AND RECORDS
2.
3.
4.
Representative Sampling
Samples collected and measurements taken, as requ
nature of the permitted discharge. Analytical sampl
event. Samples shall be taken on a day and time tht
be taken before the discharge joins or is diluted by
Monitoring points as specified in this permit shall n
the Director. /-JJ/
Recording Results
For each measurement, sai
requirements of this indivi
of the volume and
aformed during a representative storm
slit of the discharge. All samples shall
e stream, body of water, or substance.
without notification to and approval of
nance activity performed or collected pursuant to the
shall record the following information:
a. The date, exact plzce, and lime of sampling, measurements, inspection or maintenance activity;
b. The individual( )'who paned the sampling, measurements, inspection or maintenance activity;
C. The date(s) analyses were performed;
d. The individual(s) who performed the analyses;
e. The analytical techniques or methods used; and
f. The results of such analyses.
Flow Measurements
Where required, appropriate flow measurement devices and methods consistent with accepted scientific
practices shall be selected and used to ensure the accuracy and reliability of measurements of the volume of
monitored discharges.
Test Procedures
Test procedures for the analysis of pollutants shall conform to the EMC regulations published pursuant to
NCGS 143-215.63 et. seq, the Water and Air Quality Reporting Acts, and to regulations published pursuant
to Section 304(g), 33 USC 1314, of the Federal Water Pollution Control Act, as Amended, and Regulation
40 CFR 136.
Part II I Page 5 of 8

Permit No. NCS000040
To meet the intent of the monitoring required by this individual permit, all test procedures must produce
minimum detection and reporting levels and all data generated must be reported down to the minimum
detection or lower reporting level of the procedure.
5. Representative Outfall
If a facility has multiple discharge locations with substantially identical stormwater discharges that are
required to be sampled, the permittee may petition the Director for representative outfall status. If it is
established that the stormwater discharges are substantially identical and the permittee is granted
representative outfall status, then sampling requirements may be performed at a reduced number of
outfalls.
6. Records Retention
Visual monitoring shall be documented and records n
Pollution Prevention Plan. Copies of analytical mom
permittee shall retain records of all monitoring inforn
records and all original strip chart recordings for cont
reports required by this individual permit for a period
measurement, report or application. This period may -
Inspection and Entry
facility along with the Stormwater
ill alsosbe maintained on -site. The
and maintenance
lion, and copies of all
5 years from the date of the sample,
id.by request of the Director at any time.
The permittee shall allow the Director, or an authdrized'representative (including an authorized contractor
acting as a representative of the Director) or intthe,case of a facility which discharges through a municipal
separate storm sewer system, an authorized representative of a municipal operator or the separate storm
sewer system receiving the discharge, upon,the presentation of credentials and other documents as may be
required by law, to;
a. Enter upon the permittec's piamises where a regulated facility or activity is located or conducted,
or where records must -be kept under the conditions of this individual permit;
b. Have access to and copy, at reasonable times, any records that must be kept under the conditions
of this individual permit;
C. Inspect at reasonable times any Facilities, equipment (including monitoring and control
equipment), practices, or operations regulated or required under this individual permit; and
d. Sample or monitor at reasonable times, for the purposes of assuring individual permit compliance
or as otherwise authorized by the Clean Water Act, any substances or parameters at any location.
SECTION E: REPORTING REQUIREMENTS
Discharge Monitoring Reports
Samples analyzed in accordance with the terms of this permit shall be submitted to the Division on
Discharge Monitoring Report (DMR) forms provided by the Director. Submittals shall be delivered to the
Division no later than 30 days from the date the facility receives the sampling results from the laboratory.
When no discharge has occurred from the facility during the report period, the permittee is required to
submit a discharge monitoring report within 30 days of the end of the six-month sampling period, giving
all required information and indicating "NO FLOW" as per NCAC T 15A 0213 .0506.
Part I I I Page 6 of 8

Permit No. NCS000040
The permittee shall record the required qualitative monitoring observations on the SDO Qualitative
Monitoring Report (QMR) form provided by the Division, and shall retain the completed forms on site.
Qualitative monitoring results should not be submitted to the Division, except upon DWQ's specific
requirement to do so.
2. Submitting Reports
Duplicate signed copies of all reports required herein, shall be submitted to the following address:
Division of Water Quality
Surface Water Protection Section
ATTENTION: Central Files
1617 Mail Service Center
Raleigh, North Carolina 27699-16�
3. Availability of Reports //n
Except for data determined to be confidential under NCGS 1.43 21�5.3(a)(2)or Section 308 of the Federal
Act, 33 USC 1318, all reports prepared in accordance A th the terms shall be available for public
inspection at the offices of the Division of Water Qualit"s'required by the Act, analytical data shall not
be considered confidential. Knowingly making any false statement on any such report may result in the
imposition of criminal penalties as provided for idNCGS�143' 215.6B or in Section 309 of the Federal Act.
4.
5.
G'1
Non-Stormwater Discharges
If the storm event monitored
discharge, the permittee shall
discharge permit and provide
Planned Chances
lhis'individual permit coincides with a non-stormtwater
all parameters as required under the non-stormwater
th the Stormwater discharge monitoring report.
The permittee shall give hotibe4o'ifie Director as soon as possible of any planned changes at the permitted
facility which could significantly alter the nature or quantity of pollutants discharged. This notification
requirement includes pollutants which are not specifically listed in the individual permit or subject to
notification requirements under 40 CFR Part 122.42 (a).
Anticipated Noncompliance
The permittee shall give notice to the Director as soon as possible of any planned changes at the permitted
facility which may result in noncompliance with the individual permit requirements.
Bypass
Anticipated bypass. If the permittee knows in advance of the need for a bypass, it shall submit
prior notice, if possible at least ten days before the date of the bypass; including an evaluation of
the anticipated quality and affect of the bypass.
It. Unanticipated bypass. The pennittee shall submit notice within 24 hours of becoming aware of an
unanticipated bypass.
8. Twenty-four I lour Reporting
The permittee shall report to the central office or the appropriate regional office any noncompliance which
may endanger health or the environment. Any information shall be provided orally within 24 hours from
PartIII Page 7 of 8

Permit No. NCS000040
9.
on
the time the permittee became aware of the circumstances. A written submission shall also be provided
within 5 days of the time the permittee becomes aware of the circumstances.
The written submission shall contain a description of the noncompliance, and its causes; the period of
noncompliance, including exact dates and times, and if the noncompliance has not been corrected, the
anticipated time compliance is expected to continue; and steps taken or planned to reduce, eliminate, and
prevent reoccurrence of the noncompliance.
The Director may waive the written report on a case -by -case basis if the oral report has been received
within 24 hours.
Other Noncompliance
The permittee shall report all instances of noncompliance not
monitoring reports are submitted.
Other Information
Where the penmittee becomes aware that it failed to
individual permit or in any report to the Director, it
24 hour reporting at the time
want facts in an application for an
submit such facts or information.
PartIll Page 8 of 8

NCS000040
PART IV LIMITATIONS REOPENER
This individual permit shall be modified or alternatively, revoked and reissued, to comply with any applicable
effluent guideline or water quality standard issued or approved under Sections 302(b) (2) (c), and (d), 304(b) (2)
and 307(a) of the Clean Water Act, if the effluent guideline or water quality standard so issued or approved:
a. Contains different conditions or is otherwise more stringent than any effluent limitation in the individual
permit; or
b. Controls any pollutant not limited in the individual permit.
The individual permit as modified or reissued under this paragraph
Act then applicable.
PART V ADMINISTERING A
REQUI
The permittee must pay the administering and
by the Division. Failure to pay the fce,in.time
this Division to initiate action to revoke the•ln
Act
See Clean Water Act.
2. Arithmetic Mean
other requirements in the
MONITORING FEE
fee within 30 (thirty) days after being billed
with 15A NCAC 2H .0105(b)(4) may cause
PAI2TWI DEFINITIONS
The arithmetic mean of any set of values is the summation of the individual values divided by the number
of individual values.
Allowable Non-Storntwater Discharges
This permit regulates stormwater discharges. Non-stormwater discharges which shall be allowed in the
stormwaler conveyance system are:
(a) All other discharges that are authorized by a non-stormwater NPDES permit.
(b) Uncontaminated groundwater, foundation drains, air -conditioner condensate without added
chemicals, springs, discharges of uncontaminated potable water, waterline and fire hydrant
flushings, water from footing drains, flows from riparian habitats and wetlands.
(c) Discharges resulting from fire -fighting or fire -fighting training.
Best Management Practices (BMPs)
Measures or practices used to reduce the amount of pollution entering surface waters. BMPs may take the
form of a process, activity, or physical structure.
Parts IV, V and VI Page I of 5

Permit No. NCS000040
Bypass
A bypass is the known diversion of stormwater from any portion of a stormwater control facility including
the collection system, which is not a designed or established operating mode for the facility.
6. Bulk Storaec of Liquid Products
Liquid raw materials, manufactured products, waste materials or by-products with a single above ground
storage container having a capacity of greater than 660 gallons or with multiple above ground storage
containers located in close proximity to each other having a total combined storage capacity of greater than
1,320 gallons.
7. Clean Water Act
The Federal Water pollution Control Act, also known
USC 1251, et. seq.
8. Division or DWQ
The Division of Water Quality, Department
9. Director
The Director of the Division
10. EMC
The North Carolina
1 I. Grab Sample
(CWA), as amended, 33
Resources.
issuing authority.
Commission.
An individual sample collected instantaneously. Grab samples that will be directly analyzed or
qualitatively monitored must be taken within the first 30 minutes of discharge.
12. Hazardous Substance
Any substance designated under 40 CFR Part t 16 pursuant to Section 311 of the Clean Water Act.
13. Landfill
A disposal facility or part of a disposal facility where waste is placed in or on land and which is not a land
treatment facility, a surface impoundment, an injection well, a hazardous waste long-term storage facility
or a surface storage facility.
14. Municipal Separate Storm Sewer System
A stortwater collection system within an incorporated area of local self-government such as a city or
town.
15. No Exposure
A condition of no exposure means that all industrial materials and activities are protected by a storm
resistant shelter or acceptable storage containers to prevent exposure to rain, snow, snowmelt, or runoff.
Part VI Page 2 of 5 Pages

Permit No. NCS000040
NO
17
19
]'
20.
F1
22.
23
Industrial materials or activities include, but are not limited to, material handling equipment or activities,
industrial machinery, raw materials, intermediate products, by-products, final products, or waste products.
DWQ may grant a No Exposure Exclusion from NPDES Stormwater Permitting requirements only if a
facility complies with the terms and conditions described in 40 CFR §122.26(g).
Overburden
Any material of any nature, consolidated or unconsolidated, that overlies a mineral deposit, excluding
topsoil or similar naturally -occurring surface materials that are not disturbed by mining operations.
Perntittec
The owner or operator issued a permit pursuant to this individual permit.
Point Source Discharge of Stormwater
Any discernible, confined and discrete conveyance incldding4liuf not specifically limited to, any pipe,
ditch, channel, tunnel, conduit, well, or discrete fissure; from which stormwater is or may be discharged to
waters of the state. %
Representative Storm Event
A storm event that measures greater than 0.1"ihche"s of rainfall and that is preceded by at least 72 hours in which no
storm event measuring greater than 0.1 inches has occurred. A single storm event may contain up to 10 consecutive
hours of no precipitation. For exampl , if it rains,for�2 hours without producing any collectable discharge, and then
stops, a sample may be collected if a.raih,pr`odu ing a discharge begins again within the next 10 hours.
Representative Outfall Sr<t��
When it is established that the discharge of stormwater runoff from a single outfall is representative of the
discharges at multiple out falls; the DWQ may grant representative outfall status. Representative outfall
status allows the permittee to perform analytical monitoring at a reduced number of outfalls.
Rinse Water Discharge
The discharge of rinse water from equipment cleaning areas associated with industrial activity. Rinse
waters from vehicle and equipment cleaning areas are process wastewaters and do not include washwaters
utilizing any type of detergent or cleaning agent.
Secondary Containment
Spill containment for the contents of the single largest tank within the containment structure plus sufficient
freeboard to allow for the 25-year, 24-hour storm event.
Section 313 Water Priority Chemical
A chemical or chemical category which:
a. Is listed in 40 CFR 372.65 pursuant to Section 313 of Title III of the Superfund Amendments and
Reauthorization Act (SARA) of 1986, also titled the Emergency Planning and Community Right -
to -Know Act of 1986;
b. Is present at or above threshold levels at a facility subject to SARA Title III, Section 313 reporting
requirements; and
Part VI Page 3 of 5 Pages

Permit No. NCS000040
24.
25
26.
27
28.
29.
30.
That meets at least one of the following criteria:
(1) Is listed in Appendix D of 40 CFR part 122 on Table II (organic priority pollutants),
Table III (certain metals, cyanides, and phenols), or Table IV (certain toxic pollutants
and hazardous substances);
(2) Is listed as a hazardous substance pursuant to section 31 1(b)(2)(A) of the CWA at 40
CFR 1 16.4; or
(3) Is a pollutant for which EPA has published acute or chronic water quality criteria.
Severe Property Damage
Means substantial physical damage to property, damage to the control facilities which causes them to
become inoperable, or substantial and permanent loss of natural resources which can reasonably be
expected to occur in the absence of a bypass. Severe pro perty4damage �not mean economic loss
�% caused by delays in production. 8 \
Significant Materials
Includes, but is not limited to: raw materials; fuels; materials sudh as solvents, detergents, and plastic
.
pellets; finished materials such as metallic prodii J� ter
ucts ,raw materials used in food processing or production;
hazardous substances designated under section 101(14) of CERCLA; any chemical the facility is required
to report pursuant to section 313 of Title `D of SARA;�fertilizers; pesticides; and waste products such as
ashes, slag and sludge that have the po{ent, ial to(be.released with stormwater discharges.
Significant Spills ��
Includes, but is not limited'to: ref///r///eleas\\\eiiisr f otl or hazardous substances in excess of reportable quantities
under section 311 of the Clean Wateo/Act (Ref: 40 CFR 110.10 and CFR 117.21) or section 102 of
CERCLA (Ref: 40 CFR 302�4)--/
Stormwater Runoff
The (low of water which results from precipitation and which occurs immediately following rainfall or as a
result of snowmelt.
Stonnwater Associated with Industrial Activity
The discharge from any point source which is used for collecting and conveying stormwater and which is
directly related to manufacturing, processing or raw material storage areas at an industrial site. Facilities
considered to be engaged in "industrial activities" include those activities defined in 40 CFR 122.26(b)(14).
The term does not include discharges from facilities or activities excluded from the NPDES program.
Stonnwater Pollution Prevention Plan
A comprehensive site -specific plan which details measures and practices to reduce stormwater pollution
and is based on an evaluation of the pollution potential of the site.
Ten Year Design Storm
The maximum 24 hour precipitation event expected to be equaled or exceeded on the average once in ten
years. Design storm information can be found in the State of North Carolina Erosion and Sediment
Control Planning and Design Manual.
Part VI Page 4 of 5 Pages

Permit No. NCS000040
31.
32.
Total Flow
The flow corresponding to the time period over which the entire storm event occurs. Total flow shall be
either; (a) measured continuously, (b) calculated based on the amount of area draining to the outfall, the
amount of built -upon (impervious) area, and the total amount of rainfall, or (c) estimated by the
measurement of flow at 20 minute intervals during the rainfall event.
Total Maximum Daily Load (TMDL)
A TMDL is a calculation of the maximum amount of a pollutant that a waterbody can receive and still meet
water quality standards, and an allocation of that amount to the pollutant's sources. A TMDL is a detailed
water quality assessment that provides the scientific foundation for amimplementation plan. The
implementation plan outlines the steps necessary to reduce pollutant loads in a certain body of water to
restore and maintain water quality standards in all seasons Tlie Clean Walcr.Act, Section 303, establishes
the water quality standards and TMDL programs. %� ���
33. Toxic Pollutant
34.
35.
36.
37
Any pollutant listed as toxic under Section
Upset
Means an exceptional incider
technology based permit efllt
permitlee. An upset does not
designed treatment or control
maintenance, or careless orr
Water Act.
Intentional and temporary noncompliance with
to of factors beyond the reasonable control of the
cc to the extent caused by operational error, improperly
treatment or control facilities, lack of preventive
Vehicle rehabilitation, mechanical repairs, painting, fueling, lubrication, vehicle cleaning operations, or
airport deicing operations.
Visible Sedimentation
Solid particulate matter, both mineral and organic, that has been or is being transported by water, air,
gravity, or ice from its site of origin which can be seen with the unaided eye.
25-year, 24 hour storm event
The maximum 24-hour precipitation event expected to be equaled or exceeded, on the average, once in 25
years.
Part VI Page 5 of Pages

NPDES yr/nno/day Inspection Type
NCS000040 I11 12I 06/04/05 1
17 18ICI
(ccnt.)
Section D: Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary)
GENERAL:
The Charlotte Pipe & Foundry Company (CP&F) facility is located at 1335 South Clarkson Street in
Charlotte, North Carolina. The facility is located on approximately 35 acres of property and has numerous
building structures that span several blocks just west of downtown Charlotte. Total impervious (parking lots,
buildings, roadways, etc.) area of the site is estimated at 95 percent of the total site area.
The facility has been operating as a pipe foundry since 1926 at this location and currently has 475
employees. Plant operations typically occur 24 hours a day, 5 days a week. The facility is engaged in the
manufacture of cast iron piping and fittings. The facility's Standard Industrial Classification (SIC) Code is
reportedly 3321 — Gray and Ductile Iron Foundries. The facility stores and distributes the following major
raw materials: cast iron scrap, coke, coal, limestone, quartz, sand, silicon, bentonite, petroleum -asphalt,
gasoline and diesel fuel.
The Mecklenburg County Water Quality Program (MCWQP) has historically conducted NPDES
inspections of the Charlotte Pipe & Foundry Company (CP&F).
PERMIT:
CP&F holds an individual NPDES Stormwater Permit, NCS000040. The permit became effective on
January 1, 2000 and expired on December 31, 2004. CP&F has documentation that the Permit Coverage
Renewal Application Form was completed and signed on June 20, 2004 (prior to the permit renewal
deadline) and has phone logs documenting that the renewal application was received by the North Carolina
Department of Environment and Natural Resources. CP&F continues to operate under the conditions of the
expired permit. The permit authorizes the permittee to discharge stormwater associated with industrial
activities, to the surface waters of the State or to the Municipal Separate Storm Sewer System, providing
that the permittee treats, controls, limits and monitors the discharge as specified in the permit.
RECORDS/REPORTS:
CP&F provided the following documents to MCWQP for review: Stormwater Pollution Prevention Plan
(SPPP), Spill Prevention, Control and Countermeasure Plan, facility drainage map, hazardous material
inventory report, facility inspection records, and storm water analytical records. Compliance with the
recordkeeping requirements of the permit and the SPPP is discussed under the Stormwater / Pollution
Prevention section of the report.
FACILITY SITE REVIEW:
The facility is located in the Irwin Creek Watershed. Irwin Creek is a Class-C water in the Catawba River
Basin.
FACILITY SITE REVIEW (cont.).
The outdoor operations observed during the inspection included the loading and unloading of bulk solid
materials from rail -cars and trucks, storage of raw materials, storage of products and intermediate products,
Page At 2

Permit: NCS000040
Inspection Date: 04/05/2006
Owner -Facility: Charlotte Pipe & Foundry Company
Inspection Type: Compliance Evaluation
bulk above ground storage tanks, truck fueling station, wastewater treatment operations, and general facility
grounds.
The following describes each of the stormwater outfalls listed in the SPPP for the facility:
SWO01: This outfall drains approximately 7.2 acres of the southwestern portion of the facility that
contains the wastewater treatment plant, fitting storage area, scrap iron storage area and the cupola bag
houses. This outfall also drains several off -site properties up gradient of the CP&F facility. This drainage
area is approximately 95 percent impervious. There was no discharge from this outfall at the time of the
inspection.
SWO02: This outfall drains approximately 3.1 acres of the central portion of the facility, which contains
the main raw material unloading area, machine shop, shell cure building, and cupola furnace building. This
drainage area is approximately 95 percent impervious. There was no discharge from this outfall at the time
of the inspection.
SWO03: This outfall is located up gradient of the facility and was historically used to sample off -site
water that flowed onto the property for purposes of comparing influent stormwater samples (at SWO03) to
effluent stormwater samples (SWO04) from the same storm drain system. However, CP&F determined that
SWO03 was not collecting the major portion of the influent stormwater and thus is no longer used for
sampling.
SWO04: This outfall drains approximately 11.1 acres of the western portion of the facility which contains
the fueling station, fuel storage tanks, maintenance shop, bulk spent material storage area, pipe production
building, pipe coating building, the hot dip coating area, and serves as the permitted discharge pipe for
non -contact cooling water. This outfall also drains several off -site properties up gradient of the CP&F
facility. This drainage area is approximately 95 percent impervious. There was discharge from this outfall
at the time of the inspection (most likely discharge of non -contact cooling water).
SWO05: This outfall drains approximately 2.5 acres of the northwestern portion of the site, which
contains the hot dip collectors and the fittings tar pit building. In addition, stormwater from SWO04 flows into
SWO05 at Clarkson Street. This drainage area is approximately 95 percent impervious. There was
discharge from this outfall at the time of the inspection (most likely discharge of non -contact cooling water
from SWO04).
From review of the outdoor operations during the facility inspection, the following items were noted:
1. Process water from metal slag pile discharging to the storm drain system: Wet process metal slag is
conveyed outdoors to a storage pile. During the inspection, water from the slag pile was flowing into the
storm drain system. This discharge of non-stormwater is not currently permitted under a separate NPDES
permit and is not allowed by the Stormwater NPDES permit.
FACILITY SITE REVIEW (cont.):
2. Compressor condensate discharging to the ground surface: A compressor located at one of the parcels
along West Palmer Street (Tax Parcel ID 07325216) owned by CP&F that adjoins the manufacturing plant
contains a condensate discharge line that discharges to the ground surface. This discharge of
non-stormwater is not currently permitted under a separate NPDES permit and is not allowed by the .
Stormwater NPDES permit.
3. Particulate matter from process operations on the ground surface: The facility handles large amounts
of raw materials (such as sand, oxidized metal, limestone, etc) that create dust / particulate matter on the
ground surface throughout the facility. In addition, some of the dust collecting equipment (baghouses, etc.)
is located near storm drains and some of the collected material is discharging to the ground surface. During
Page # 3

Permit: NCS000040 Owner - Facility: Charlotte Pipe & Foundry Company
Inspection Date: 04/05/2006 Inspection Type: Compliance Evaluation
rain events, this particulate matter is transported into the storm drain system and then into Irwin Creek.
Facility personnel have recognized this potential issue and have instituted a street sweeper that runs 8 hrs /
day during plant operation as a Best Management Practice (BMP) throughout the accessible areas of the
plant. However, many outside areas of the plant are not accessible by the street sweeper. Some
stormwater that collects in concrete lined foundations underneath process equipment is collected and
treated in the wastewater pretreatment plant prior to discharge to the sanitary sewer system. Facility
personnel have proposed to collect and treat additional stormwater from these areas in their wastewater
pretreatment plant, but have been unable to gain the support of the pretreatment permitting agency,
Charlotte -Mecklenburg Utility Department.
EFFLUENT/RECEIVING WATERS
This inspection was conducted during clear, dry weather conditions. The SPPP identified five (5)
stormwater discharge outfalls (SW001 through SWO05) from the manufacturing facility. A minor discharge
was observed at SWO05 during the inspection. The permittee identified the source of this discharge as
non -contact cooling water being discharged under NPDES Permit No. NCG500117. The permittee
indicated that this storm drainpipe also collects stormwater from industrial properties southeast of the
property. The discharge was clear and the flow was estimated to be less than five (5) gallons per minute.
MCWQP had noted and sampled this discharge during a stream walk on March 1, 2006. The laboratory
results showed an unusually
high concentration (18 mg/L) of fluoride. MCWQP inquired about the use of fluoride or
fluorine -containing products at CP&F. During the inspection, CP&F health and safety staff reviewed the
database of Material Safety Data Sheets (MSDSs) for all products in use that contain fluoride of fluorine and
CP&F identified one product (a metal brazing flux) that contains potassium fluoride at 10 to 50 percent
concentration. This material is reportedly used infrequently in small quantities in the maintenance shop for
machine repair. CP&F personnel did note that the storm drain pipe drains other off -site areas that could be
contributing to the flow.
Stormwater runoff from the main manufacturing plant property discharges via three stormwater outfalls
(SW001, SW002, and SWO05) across 1-77, and ultimately to Irwin Creek, which is a Class-C water in the
Catawba River Basin. Please note that CP&F have identified two additional intermediate outfalls (SW003
and SW004) on their Site Plan for sampling purposes. EFFLUENT/RECEIVING WATERS (cont.):
CP&F personnel have mapped the storm drain system from the main manufacturing plant and have labeled
storm drains, piping and outfalls; however, the storm drain system on the adjoining parcels (along West
Palmer Street, Post Street, and Summit Avenue) has not been mapped. These adjoining parcels appear to
have significant materials exposed to stormwater (old core storage, material transfer areas, etc.) and should
be evaluated and included as part of the SPPP and sampling regime.
MCWQP collected grab samples from stormwater ouffalls SWO05 and SWO02 at the point of discharge into
Irwin Creek on April 26, 2006. The sample temperature was recorded and the samples transported under
ice to the Charlotte -Mecklenburg Utilities Laboratory at approximately 3:30 pm. Analytical results from the
sampling will be sent under separate cover.
SELF -MONITORING PROGRAM:
The facility's permit (Part II Section C) requires that qualitative monitoring of stormwater outfalls be
conducted twice per year. From review of records (July 2004 to March 2006), CP&F conducts monthly
Page # 4

Permit: NCS000040 Owner- Facility: Charlotte Pipe & Foundry Company
Inspection Date: 04/05/2006 Inspection Type: Compliance Evaluation
inspections of significant materials storage areas and stormwater outfalls.
Quantitative monitoring of each stormwater outfall is required (under Part II Section 8 of the permit) for
various discharge characteristics annually during the first 3 years of the permit and quarterly the fourth year
(2003). From review of the quantitative records, sampling was not conducted at all during the fourth year
(2003) of the permit. CP&F personnel confirmed that sampling was not performed in 2003 due to lack of
rainfall events. Quantitative sampling was performed in June 2004; however, the data was missing required
information such as total rainfall, event duration, and estimated flow. No quantitative sampling was
performed in 2005.
Quantitative monitoring of each stormwater discharge outfall that discharges stormwater runoff from vehicle
maintenance areas that use more than 55 gallons of new motor oil per month is required under Part II
Section D of the permit. CP&F personnel indicated that more than 55 gallons of new motor oil per month is
used at the facility, but no records of quantities have been kept. CP&F has not sampled any outfalls from
their vehicle maintenance area.
RATING: Unsatisfactory
OPERATIONS & MAINTENANCE:
The overall operation and maintenance strategy for this type of facility appears to be adequate with the
exception of the accumulated particulate matter on the impervious areas throughout the grounds. During
the inspection, liquid containers (tanks, drums, etc.) appeared to be in good condition with no sign of leaks,
stains or corrosion. Large tanks were provided with secondary containment structures and the fuel island
was covered with a canopy and surrounded by a blind trench drain to contain any small spills during
material transfer.
STORMWATER/POLLUTION PREVENTION:
The permit requires the permittee to develop a Stormwater Pollution Prevention Plan, as detailed in Part II,
Section A. Stormwater Pollution Prevention Plan. The permittee has developed a plan; however portions
were either absent or inadequate, as detailed below.
1. Part II, Section A. 1. Site Plan. (a) — Discharge Point(s) Location.
The permit requires accurate latitude and longitude coordinates for the point(s) of discharge. There were no
specific coordinates for each outfall provided in the plan.
2. Part II, Section A. 1. Site Plan. (c) — Site Map.
The permit requires the site map to be drawn to scale and show locations of all drainage structures. The
site map provided was not to scale. Also, the storm drain system for the adjoining parcels (owned by
CP&F) had not been mapped on the plan.
3. Part II, Section A. 1. Site Plan. (e) — Non-Stormwater Discharge Certification.
The permit requires that certification of non-stormwater discharges be made and signed by the responsible
party. A non -discharge certification form was in the plan, but had not been completed or signed.
4. Part II, Section A. 2. (b) — Secondary Containment Schedule.
The SPCC plan identified numerous above ground petroleum storage tanks that meet the permit criteria for
required secondary containment, however, secondary containment for bulk storage (single container greater
Page # 5

Permit: NCS000040 Owner- Facility: Charlotte Pipe & Foundry Company
Inspection Date: 04/05/2006 Inspection Type: Compliance Evaluation
than 660 gallons in capacity or multiple containers the same location exceeding 1,320 gallons in capacity
total) had not been evaluated for appropriate secondary containment. Secondary containment capacity
should be provided to contain the largest single storage container in storage
area plus enough freeboard to contain a 25-yr, 24-hr storm event. Additionally, there was no record of
release of accumulated storm water from diked areas. The permittee indicated that accumulated
stormwater is allowed to evaporate and has never been released.
5'. Part II, Section A. 5. Employee Training
The permit requires the permittee to provide annual training and document the training for employees that
have the potential to contaminate stormwater runoff. The permittee does not have training record
Page # 6

tj
_ �Aq®sq
HCDE R
North Carolina Department of Environment and Natural Resources
Division of Water Quality
Beverly Eaves Perdue Coleen H. Sullins Dee Freeman
Governor Director Secretary
March 26, 2009
Individual NPDES Stormwater Permit Renewal Transmittal Cover Page
To: Mooresville Regional Office Jomrr�& IV""D
Subject: NPDES Stormwater Permit No. NCSO 0040 REU
Charlotte, NC =WQtS (6 t1V* ��x c�
( y) 7 MAR 3 0 2009
Attachment Description
® Staff Report
® Draft Permit
® Renewal Application
LCIYK irv'v{it5.!
DWID-Surface Water Pro,eeflon
Please provide comments on the draft permit and sign staff report if acceptable.
rp
Return to Brian Lowther at the Central Office by April 26, 2009.
Brian Lowther
Division of Water Quality
Stormwater Permitting Unit
1617 Mail Service Center
Raleigh, NC 27699-1617
Wetlands and Stormwater Branch
1617 Mail Service Center, Raleigh, North Carolina 27699-1617
Loudon: 512 N. Salisbury St. Raleigh, North Carolina 27604
Phone'. 919-807-63001 FAX: [phone] Customer Service: 1-877-623-6748
Internet: www.ncwaterquality.org
An Equal Opportunity 1 Allirmad,e Action Employer
NorthCarolina
Naturally

STORK WAT 1-R POLLUTION PREVENTION PLAN
LDEVELOPMENT AND IMPLEMENTATION
CERTIFICATION
N. C. Division of Water Quality Stori,nivater and Gaienal-pe
Facility Name: CHARLOTTE PIPE & FOUNDRY C
Permit Number:
NCS000040
Location Address:
T ,
1335 SOUTH CLARKSON STRE
CHARLOTTE, NC 28208 LIU!
County: I JUL 26 7, '
MECKLENBURG 1 , 0
rp 0 '1 iNi Ti
� � d � D I
2004
777�
"I certify, under penalty of law, that the Stormw
at 4
were developed and implementeder Pollution Prevention Plan (SPPP)-docum­";�
(hat qualified Personnel properly gather and eVaft ent anIJ all attachments
under my direction or supervision in accordance with a system designed to assure
evaluate the information required by the SPPP. Based On my inquiry of
the person or persons who manage the system, or those Persons directly responsible for gathering the information,
the information gathered is, to the best of my knowledge and belief, true, accurate, and complete"
"I certify that the SPPP has been developed signed and retained at the facility location and the SPPP has been fully
implemented at the named facility location '
permit." in accordance with the terms and conditions of the stormware, general
am aware that there are significant penalties for falsifying information, including the Possibility of fines and
imprisonment for knowing violations"
Sign (according to Permit signatory requirements) and return this Certification. DO NOT SEND THE
STORMWATER POLLUTION PREVENTION PLAN WITH THE CERTIFICATION.
-------------
C —
Signature ,,e -,-5,
Print or type name of pei-soff'ilgrim.- above
Date6 - 0C., —e,
Title
7d-/ 3 3,z-,2&
SPPf'Cenification 2/99

MONTHLY STORMWATER INSPECTION REPORT
CHARLOTTE PIPE AND FOUNDRY C015IPANy
j CHARLOTTE, NORTH CAROLINA
Page 1 of 5
Date:
Inspector:
Weather Conditions (indicate any recent precipitation and current conditions, conduct inspection under dry weather condit:
DIRECTIONS:
Check areas below for the implementation ofBMPs as listed in Table 5-1. If the condition of an area is not acceptable,
note why and list corrective actions to be taken.
1 -
L Outdoor Liquid Storage Areas (check for
condition of containers, secondary
containment, evidence of spills,
implementation of BMPs etc )
a. Unleaded Gasoline Storage Tank; G
b. Diesel Storage Tank; H
C. Water -based Coating Tank; L
d. Kerosene Storage Tank; M
e. Raw Wastewater Storage Tanks; S, T
f. Waste Oil Storage Tank, U
g. Outside Drum Storage Area; V, W
h. Wastewater Treatment Tanks; AL
i. Fitting Coating Vat; -
AP---). 5-ft Pipe Coating Vat; AO
%- 03 I A[ f Vr'Y 4
QD 15203-4

MONTHLY
STORtMWATER INSPECTION REPORT
CHARLOTTE PIPE AND FOUNDRY COMPANY
CHARLOTTE, NORTH CAROLINA
Page 2 of 5
Area Is
2. Outside Materials Storage Areas (Check
housekeeping, sumps, catch -basins, presence of
drums/containers, covers, signs of existing or
Potential stormwater contamination, completion of
BMPs)
a. Spent Materials Storage Area; A
b. Pig Iron Storage Area; D
c. Scrap Iron Storage Area; E
d. Scrap Iron Storage Area; F
e. Coke Storage Hoppers; AA and Z
f. Limestone Storage Hopper; Y
g. Ferrosilicon Storage Hopper; X
h. Coke Hopper Pit; AD
is '
j. Slag Storage Area; AC
k. Foundry Sand Storage Bins and Silo;
B and C
1. Cement Silo; R
b
QD 1 i203-4

MONTHLY
STORMWATER INSPECTION REPORT
CHARLOTTE PIPE AND FOUNDRY COMPANY
CHARLOTTE, NORTH CAROLINA
Page 3 of 5
Area
3. Finished Materials Storage Area (Check
for coating spillage on
paved area or into catch -basins,
corrosion, and presence of empty drums or other
authorized materials)
a. Fitting Storage Area; AR (garage)
b. Fitting Storage Area; AS (rolocast) .
C. Pipe Storage Area; AT
d. Pipe Storage Area; AU
e. Fittiq
Storage Area; AV
4. Foraintenance Area; AM
5. Avaty of spill response and clean up
equit
a. OiStorage Area
b. FoMaintenance Building
c. Futation6. Obsoquip en torage, AW (Checkintegflow ersion s[metures and tarps,corroeaks n other signs potentialstormco tamina 'on)
6'—vq
6--6y
y -oy
Required t'o,Cor
rs
rg
s
iJ LL f
QD 1520.3-4

MONTHLY
STORMWATER INSPECTION REPORT
CHARLOTTE PIPE AND FOUNDRY COMPANY
CHARLOTTE, NORTH CAROLINA
Page 4 of 5
Area ' IS
7. Bag Houses (Check for accumulation of
Particulates on ground around structure,
integrity of duct form rotary valve, etc.)
a. Bag House; O (rolocast)
b. Bag House; P (new foundry)
e. Cupola Baghouse
d. Bag House; Q (rattleroom)
S. Finished Materials Con or Systems
(Check for stained soil Mialt dripping to
ground and integrity of a and cover.)
a. fitting Conveyor System; AJ
b. 5-Ft Pipe Conveyor System; AK
9. Empty Drum Storage Areas including and BC
(Check to see that drums are capped, stored
horizontally on wooden pallets.)
10. Slurry Spills (Check for spills of"whitish"
colored liquid throughout site.)
11. Obsolete Steel M d Vore Storage; BJ
(Verify material is s red in bins and does not
accumulate more en ecessary.)
QD 15=C3-4

MONTHLY
STORMWATER INSPECTION REPORT
CHARLOTTE PIPE AND FOUNDRY COMPANY
CHARLOTTE, NORTH CAROLINA
Page 5 of 5
Area
-------------
y. Yes'
Stormwater System (Check for accumulation of ~
debris, visible sheen, color, foam, outfall staining, dry
weather flow, soil erosion, signs of pollutant
dischar e.
a. Outfall 001 (pipe yard)
b. DUtfIII 002 (10- tarring)
9
13.
a. Compressor condensate (various) w
b. Pattern Shop welder cooling water
c. Hydro[est water
d. Hose Stations
Fueling Station (1) (Check for signs of leaks,
staining on concrete, flow diversion structure,
Fc Mr; a mop
- -r .-F.....0 rcqutrea for any conditions found not acceptable.
2• Description of potential pollutants and pollution prevention measures and control i
Plan (S WP3) to be revised in accordance with inspections. in Stormwater Pollution
CERTIFICATION:
"I certify under penalty of law that this document and all attachments were prepared under my direction or supervision in accordance with a
system designed to assure that qualified personnel properly gathered and evaluated the information submitted. Based on m in ui
person or persons who manage the system, or those persons directly responsible for gathering the information, the information submitted is,
Y 9 ry of the
to the best of my knowledge and belief, true, accurate, and complete. I am aware that there are significant penalties for submitting false
information, including the possibility of fine and imprisonment for knowing violations."
Signature
Date
QD 1520S-4

TABLE 3 -1
SELECTED BEST MANAGEMENT PRACTICES
Charlotte Pipe & Foundry
Charlotte, NC
Page i of 9
POTENTIAL STORMWATER777777777
POLLUTANT SOURCES „ BMPs
1. Spent Materials Storage Area, A Minimize run-on fromdjacent areas with diversion
dikes, berms, etc.; ✓/
Provide curb around spent sand and baghouse dust
storage area; ✓
Maintain covers on sludge roll -off boxes;
Establish regular disposal schedule to minimize
quantities stored on -site; and Vol
Monthly housekeeping inspections. /
2. a) Foundry Sand Storage Bins, B;
b) Foundry Wood Chip Cyclone Silo,
Sweep sand from areas exposed to stormwater runoff
daily;
C
and
Monthly housekeeping inspections.
3. a) Pig Iron Storage Area, D;
b) Scrap Iron Storage Area, E;
Minimize run=on from adjacent areas with diversion
c) Scrap Iron Storage Area, F
structures such as curbing, berms, containment
trenches, elevated
d) Miscellaneous Raw Steel Storage,
concrete pads or other equivalent
measures;
Including, AZ o bia t k
e) Metal Parts and Grates Storage
Evaluate alternatives for minimizing oil and grease in
Area; BD
these areas; and
Inspect the storage areas monthly for good
housekeeping.
4. a) Unleaded Gasoline Storage Tank, Install a lock on the containment drain valve to�
G' prevent release of contaminated stormwater;
b) Diesel Storage Tank, H
Inspect storage tanks, containment structures, and
Piping systems (pipes, pumps, flanges, couplings,
hoses, and valves) monthly for failures or leaks and
perform preventive maintenance as required; t/
Train affected employees on spill response and
cleanup, proper filling and transfer procedures, and to
avoid "topping off' of tanks; and
Inspect rainwater in secondary containment, remove
any oil, and document release of contaminated water
to the storm sewers. 41 w: y s le f e v tOCla !�
31
FINAL 8/95

TABLE3-1
SELECTED BEST MANAGEMENT PRACTICES
Charlotte Pipe & Foundry
Charlotte, NC
Page 2 of 9
POTENTIAL STORMWATER
POLLUTANT SOURCES BMPs
5. Four -Pump Fueling Station, I Provide dry adsorbents to clean up fuel spills; ✓
Facility personnel to direct trucks while positioning to
unload fuel; ✓
Provide drip pads to catch spills; /
Minimize/eliminate run-on onto the fueling area by
curbing the adjacent area; j3 , I t li Ca,1cP y F
F1Cw d,�'rsiy.9�et,
Inspect fueling area monthly to detect problems,
before they occur and to verify good housekeeping
and cleanup of spills; and I,/,, —
Train employees on spill response and cleanup, ✓
proper fueling techniques, and to avoid "topping off,
of tanks;
6. a) Asphalt Stge Tank, J; Install a lock on the containment d71eaks
b) Mineral S it Storage Tank, K prevent release of contaminated std
(] S� /� Inspect storage tanks, containment d
u Sfac k- yw; piping systems (pipes, pumps, flans,
hoses, and valves) monthly for failud
perform preventive maintenance.
7. Water -Based Coating Storage Tank, L Provide secondary containment structure for the
1-4 4- 'o� ✓
; _5.�storage tank;
,-o �u s h
` /{� Install a lock oncontainment drain valve to
Tc.� /� 5 L L / f prevent release ntaminated stormwater, and
t /4-k!- Fran cvnfz'Aole.t f ja 1��,`1j1N.f
Inspect storage tanks, containment structures, and
piping systems (pipes, pumps, flanges, couplings, ✓ ��eafi„rn
hoses, and valves) monthly for failures or leaks and P lu f
perform preventive maintenance.
32
FINAL 8/95

TABLE3-1
SELECTED BEST
MANAGEMENT PRACTICES
Charlotte Pipe & Foundry
Charlotte, NC
Page 3 of 9
POTENTIAL STORMWATER
B,s
POLLUTANTSOURCES
8. Kerosene Storage Tank, M
Eliminate the tank or complete the following:
Provide secondary containment for the storage tank;
Install lock on the containment drain valve to prevent
release of contaminated stormwater; and
Inspect monthly for signs of leaks, corrosion, etc. and
perform preventative maintenance.
9. Kerosene Stage Tank, N
Eliminate the tank or complete the following:
G b- ce le, PC
Provide posts to prevent collisions with the tank;
Install lock on the containment drain valve to prevent
release of contaminated stormwater; and
Inspect monthly for signs of leaks, corrosion, etc. and
erform preventative maintenance.
10.. a) Bag House, O (Z) /Z , /> s /
Sweep under structure weekly to prevent particulate
b) Bag House, P r l e ma
accumulation; and s/
c) Bag House, Q cict ec,1 } a .M
L�11 p�r F4�u ton le,�sq � ,n3 tk"+t. ee kly
d) Bag House, BF poia 13.y
Insoblemsaandoto m
NoLi�.PF�m, s.
Hli
v rift' ood house ee
P fyg PgP
practices
arebein followed.
s R
Sweep azea to remove materials exposed tostormwater
runoff; andI
Ga Flcu:Ins
P12.Raw
ectareamonthl .
Water Storage Tanks, S and T
Plug the drain lines in the secondary containment
structures to prevent contaminated stormwater from
being discharged to the stormwater sewer; and L/
Install a sump and pump any accumulated
stormwater into the -tams for treatment; and
Inspect storage tanks, containment structures, and
piping systems (pipes, pumps, flanges, couplings,
hoses, and valves) monthly for failures or leaks and
perform preventive maintenance. l enlucdd F/unc. s
33
"I 7hp of �n�5
FINAL 8/95

TABLE3-1
SELECTED BEST MANAGEMENT PRACTICES
Charlotte Pipe & Foundry
Charlotte, NC
Page 4 of 9
POTENTIAL STORMWATER; . .,.
BMPs ., ..
POLLUTANT SOURCES
13. Waste Oil Storage Tank, U
Install lock on the containment drain valve to prevent
release of
contaminated stormwater; and ✓
Inspect storage tanks, containment structures, and
piping systems (pipes, pumps, flanges, couplings,
hoses, and valves) monthly for failures or leaks and
perform preventive maintenance. ;,/
14. Drums Containing Material
Cover all drum storage areas or store drums inside;
a) Outside Drum Storage Area, V
L* 9 5`7o c1 �•��
b)-Quu " "' Gas«•+ ahs. tC sere drums in vertical position, and install hand
c) Facility -wide Drum Storage
pumps to dispense chemicals; f
Provide secondary containment or berms for all
drums and containers; ✓
Utilize effective inventory control to reduce the
volume of chemicals stored on -site; ✓
Dispose of all obsolete or unused oils and chemicals;
M-o 4—A 1 y ? ,',, k N1.1
Prepare and train employees in dealing with spills
and leaks properly, and use dry clean-up methods
when possible; and
Inspect all drums and containment structures monthly
for leaks, spill, corrosion, dama e, etc. ✓
Drums
Collect and dispose of all emptydrumsandOutside
ty asphalt drum
containers promptly;
rage are r6' al&ie_Facility
:Empty
wide empty drum storage
[16.
Store empty drums capped and in horizontal position
on wooden pallets; and
Inspectmonthl .
a) Coke Storage Hopper, X
Discontinue drainage to the storm sewer, obtain
b) Coke Storage Hopper, Y
permit and permanently tie-in each sump to the
c) Limestone Storage Hopper, Z
sanitary sewer; — F_4 � n s,.,,, p +, e.E „) +r
d) Ferrosilicon Storage Hopper, AA
°` ' -�' f eai• ,¢,, } pJ�,rf
e) Coke Hopper Pit, AD
Prevent or divert run-on from adjacent areas with
7s.teFe
curbs; /
g) Materials Handling Conveyors
Maintain good housekeeping; and
34
FINAL 8/95

TABLE3-1
SELECTED BEST MANAGEMENT PRACTICES
Charlotte Pipe & Foundry
Charlotte, NC
Page 4 of 9
POTENTIAL STORM4VATER BMPs
POLLUTANT SOURCES r
Inspect equipment monthly for spill or leakage of
fluids, oils, etc.
35
FINAL 8/95
0

TABLE3-1
SELECTED BEST MANAGEMENT PRACTICES
Charlotte Pipe & Foundry
Charlotte, NC
Page 5 of 9
POTENTIAL STORMWATER BMPs 3:
POLLUTANTSOURCES
17 �`� r ti c` s r tswales,
t coke from precipitation by covering if feasible:
c7 h s� ie�
t or divert run-on from adjacent areas with
dikes or curbs; and
Inspect area monthly for signs of stormwater run-on,
integrity of tarps, etc.
18. Slag Storage Area, AC Evaluate alternative storage locatio s/p)ptions; and ✓
p:cKS Iw �' c, /0cc CA¢,fy
Inspect area monthly to verify good housekeeping
and integrity of curbing and drains. ✓
19.
06 50/e_k
20. Wastewater Treatment Tanks (Inside
Building), AL
Prevent oil spray d of AK from becoming wind
blown and from faliing onto the ground; and Ch s. k {e
Inspect area monor signs of stormwater
contamination froM bil and dripping.
Inspect tanks, pumps, and piping systems monthly to
signs of leaks and perform preventative maintenance.
36
FINAL 8/95

TABLE 3 -1
SELECTED BEST MANAGEMENT PRACTICES
Charlotte Pipe & Foundry
Charlotte, NC
Page 6 of 9
POTENTIAL STORMWATER
POLLUTANTeSOURCES
BMPs
21. Forklift Maintenance Shop, AM, Q
y rags, oil filters, air filters, batI
Ei
d degreasers properly;the
recycling of waste material
lvents, batteries); ✓
Drainoil filters before disposing or recycling;
-�''"�nlEMrnfGc:i ,j 5 wh�c�h
Sitc ct a Fu r :
Promptly transfer used fluids to the proper container;
do not leave full drip pans or other open containers
around the shop. Empty and clean drip pans and
S o r
containers;
•n C'
Provide spill response equipment and adsorbent
IA
materials at a convenient location; ✓
S la �� w,-�i • G2
Inspect the maintenance area monthly for proper
implementation of control measures; and
In h a• h all d e ar fit'` e,,I s
Train employees on spill response and cleanup
methods and proper waste control
a
and disposal
procedures.
Continue to store all liquid chemicals/oils inside.
22'
b) Pipe Coating Operation, AO
Install curbing aroun l0-ft Pipe Coating vat to
c) Fitting Coating Operation, AP
prevent overflow ont and outside the building;
Clean up stained soil and asphalt spills around
building;
Install drip pans or pads under the conveyors to
collect drippings; and Sa n cf be. ,n s
Inspect the coating operations quarterly for signs of
leaks, spills, or potential stormwater contamination.
37
FINAL 8/95

TABLE3-1
SELECTED BEST MANAGEMENT PRACTICES
Charlotte Pipe & Foundry
Charlotte, NC
Page 7 of 9
POTENTIAL STORMWATER
BMPs
POLLUTAIV I SOURCES
; fi
23.
Vehicle Washing Area, AQ
Use phosphate -free biodegradable detergents if
`1
Du, lL�;nei, a e'l c./v 5ed
feasible; ✓
'"'65 !, be. y Fir p/�,,/%;ie/,, cle;.
Verify drain connection to sanitary sewer; and
Inspect the vehicle wash area monthly for good
housekeeping.
24.
Equipment Stored Outside, AY, and
Where possible, dispose of unused equipment
various locations
properly, or move indoors; /
Minimize runoff coming into contact with old
equipment with curbs;
Inspect area monthly for leaks, corrosion, or signs of
stormwater contamination. ✓
25.
Finished pipe and fitting storage Not a significant source, therefore no additional
areas AR, AS, AT, AU, AV BMps. /
26.
Obsolete equent stored outside, Where possible, di se of unused equipment
AW and locations
properly, or move,' oors;
/vari
f f ��r. Pr I y Minimize runoff co inwith to contact old
equipment by const p'ng curbs, .
Inspect area monthlyintegrity of tarps, leaks,
corrosion, or siXOrmwater contamination.
91
FINAL 8/95

TABLE3-1
SELECTED BEST MANAGEMENT PRACTICES
Charlotte Pipe & Foundry
Charlotte, NC
Page 8 of 9
POTENTIAL STORMWATER
BMPs
POLLUTANT SOUR
27. Improper connection of floor, sink, or
Inspect and test all floor, sink, and process wastewater
process wastewater drains
drains from proper connection to process sewer or
sanitary sewer and remove any improper connections
to stormwater sewer or ditches; ✓
Seal the tops of stormwater catch -basins located inside
buildings so that chemicals may not be poured into
the stormwater sewer; and ,/
Stencil all stormwater inlets, catch basins and
manholes to promote awareness: (i.e. "Stormwater
only, discharges to Irwin Creek'). /
28. Compressor condensate discharges
Install tote -bins to collect compressor condensate
streams for transport to the oil removal process at
wastewater treatment; and ;✓
Inspect all condensate discharges at the facility
monthly to verify that none of these streams are ✓
discharged onto the ground or into catch -basins.
29. Pattern shop welder cooling water
Permit and connect to sanitary sewer. /
discharge
30. Hydrotest water
Permit and connect to � or obtain a
direct discharge permit. wu is l-rca t �- plea 11
31. Hose stations
Permit and connect to sanitary sewer;
a) Outside Wastewater Treatment
b) Outside Cafeteria (BE)
Post signs "Do not rinse outside"; and
Train employees about outdoor rinse ban.
32. Ob�i��
�uspcfiP
39
FINAL 8/95

TABLE 3 -1
SELECTED BEST MANAGEMENT PRACTICES
Charlotte Pipe & Foundry
Charlotte, NC
Page 9 of 9
POTENTIAL STORMWATER ,
BMPs
POLLUTANT SOURCES
33.
Obsolete steel mol)core storage, BJ
Not a significant source; continue to store off the
ground in wooden bins to minimize corrosion and
0 b; � 1B4-e
prevent run-on.
34.
Slurry spills
Improve containment system of slurry on trucks; and
06e C/o s,A 4Lje 4-QdAC-5 4hau
Train slurry truck drivers about spill prevention and
response.
35.
Hydraulic unit line burst, BL and
Preventative maintenance of equipment; and
other potential areas
1, ns l,! lacQ -,lrc n k r Afl t
Train operators about spill prevention and response.
36.
Small pil f outdoor sand storage,
Construct berm to eliminate run-on.
covered; obSJl P_
37.
Wood storage (for bin construction);
Not a significant source, no additional BMPs required.
BA
40
FINAL 8/95

TABLE 1. STORM WATER SAMPLING RESULTS - CHARLOTTE PIPE AND FOUNDRY COMPANY, INC.
CHARLOTTE, NORTH CAROLINA
Analytical Method:
EPA 200.7 (ug/L)
EPA 351.2
(mg/L)
EPA 420.1
(ug/L)
HACH 8000
(mg/L)
SM2540D
(mg/L)
n
32
Storm
E
U
Z
N
Y
i4 c
a
c
Drainage
6 o
76
Z
r
y
a
Datea
L
'
U O a
iOutfall
w
SW-001
6232004
100
79
550
33
800
1.9
290
210
210
SW-002
6232004
150
120
810
56
1200
1.6
170
220
250
SW-002A
623/2004
1200
450
3200
320
4700
1.5
90
900
850
SW-004
6/232004
270
420
1300
180
2500
8.5
13000
1700
6,400
SW-005
6232004
61
70
120
16
200
<1.0
1400
400
500
ug/L = micrograms per liter
mg/L = milligrams per liter

A�

�' n F 1r
- `it`
North Carolina Department of Environment and Natural I t
Division of Water Quality
i I
Beverly Eaves, Perdue Coleen H. Sullins d� . -, `: Dee Preeman
Governor Director Secretary
MAY, 2 6 2009•
May 20, 2009
Mr. David Waggoner
Charlotte Pipe & Foundry Company
PO Box35430
Charlotte, NC 28208
Subject: Draft NPDES Storm water Permit
Permit No. NCS000040
Charlotte Pipe & Foundry Company
Mecklenburg County
Dear Mr. Waggoner:
Enclosed with this letter is a copy of the draft Stormwater permit for your facility. Please review the draft
very carefully to ensure thorough understanding of the conditions and requirements it contains.
The draft permit contains the following significant changes from this facility's current permit:
Analytical monitoringchanges:
hanges
1. Analytical monitoring parameters, COD, TSS, Total KjeldahlNitrogen,.Phenols, Total Copper, Total
Recoverable Lead, Total Nickel, Total Zinc and Total Chromium, have been maintained. in the permit. Oil
& Grease and pH has been added to the permit based on the parameter being potential pollutants at the
site.
2. All analytical monitoring has been set to semi-annually during a representative. storm event as defined in
Part I1 Section B. The permittee must also document the total precipitation for each event. If no discharge
occurs during the sampling period, the permittee must submit a monitoring report indicating "No Flow"
within 30 days of the end of the six-month sampling period. -Additionally, samples must be taken a
minimum of 60 days apart, as specified in Table 2.
3. Benchmarks for analytical monitoring have been added to this draft permit: Exceedances of benchmark
values require the permittee to increase monitoring, increase management actions, increase record.
keeping, and/or install stormwater Best Management Practices (BMPs) in a tiered program. If the
sampling results are above a benchmark value, or outside of the benchmark range, for ainy.paranneter at
any outfall then the facilityshall follow the Tier 1 guidelines which require a facility inspection within
two weeks and implementation of a mitigation plan within two months. If during the term of this permit,
the sampling results are above the benchmark values, or outside of the benchmark range, for any specific
parameter at a specific discharge outfall two times in a row (consecutive), then the facility shall follow the
Tier 2 guidelines which require a repetition of the steps listed for `Fier 1 and also immediately institute
monthly monitoring for all parameters at every outfall, where a sampling result exceeded the benchmark
'value for two consecutive samples.
4. You are required to collect all of the analytical and qualitative monitoring.samplesduring representative
storm events as defined in Part II Section B. Qualitative monitoring is required regardless of
representative outfall status.
5. You are responsible for all monitoring until the renewal permit is issued. See Footnote 1 of Tables 1, 4,
and 5.
.
Wetlands and Stormwater Branch. One
1617 Mail Service Center, Raleigh, North Carolina 27699-1617 Nori.hCarohna
Location: 512 N. Salisbury St. Raleigh, North Carolina 27604
Phone: [phone] FAX: [phone] Customer Sewioe:1-877-623-6748
lmemetw .ncwaterquality.org
An Equal Opportunity l Affirmative Action Employer -

Mr. illavid Waggoner
Charlotte Pipe & Foundry Company
Permit No. NCS000040
6. The flow reporting requirement has been removed per DWQ revised strategy. (The total rainfall
parameter is in this permit, however.)
7. Vehicle maintenance monitoring has been revised to.semi-annually in order to coincide with analytical
and qualitative monitoring. This requirement appears in all Individual Stormwater permits, however it
only applies to facilities that do vehicle maintenance. If the facility begins vehicle maintenance during the
permitted timeframe then the requirements shall apply.
Other permit charges .
1. Additional guidance is provided about the Site Plan requirements. The site map must now identify if the
receiving stream is impaired and if it has a TMDL established. It must also describe potential pollutants
in each outfall. The map requirements are stated more explicitly. And, the site.plan must contain a list of
significant spills that have occurred in.the past three years and also must certify that the outfalls have
been inspected to ensure that they do not contain non-stormwaler.discharges. Additional information is
provided in Part II Section A.
2. Additional requirements for the Stormwater Management Plan have been specified in Part II Section A.
More details regarding secondary containment are provided.
3. Additional requirements for the Stormwater Pollution Prevention Plan have been specified in Part II
Section -A. The plan must also be updated annually to include a list of significant spills and to certify that
the outfalls do not contain non-stormwater discharges.
4. The facility must now implement a semi-annual Facility Inspection Program of the site's stormwater
management controls as specified in Part II Section A.
5. Information regarding the No Exposure Exclusion has been added to this draft permit. If industrial ,
materials and activities are not exposed.to precipitation. or runoff as described in 40 CPR §122.26(g), the
facility may qualify for a No Exposure Exclusion from.NPDES stormwater discharge permit
requirements. Additional information is provided in Part I Section A.
6, Per the requirements of the Catawba Riparian Buffer Rule, all stormwater drainage from portions of .
this site that have been constructed after June 30: 2001 must be discharged tl-rough a correctly
designed level spreader or another device that meets diffuse flow requirements per 15A NCAC 2B
.0243. Diffuse flow requirements are described in Chapter 8 of the North Carolina Stormwater BMP
Manual, available at: http://l12o.enr:state.nc.us/su/bmp- forms.lihn
Please submit any comments to me no later than thirty (30) days following your receipt of the draft.
Comments should be sent to the address listed at the. bottom of this page. If no adverse comments are
received from the public or from you, this permit will likely be issued in -about two months.
If you have any questions or comments concerning this draft permit, contact nne at [phone] or
[e-mail]
Sincerely,
Brian Lowther
Enviroinmental Engineer
Stormwater Permitting Unit
cc: 'Mooresville Regional Office
Stormwater Permitting Unit
Attachments: Draft Permit
2

'
NC®ENR
North Carolina Department of Environment and u eFtsources"
Division of Water Quality R `, r• yI
Beverly Eaves Perdue Coleen H. Sullins Dee Free Do
Governor Director Secretary
Nr,fl 1 2 2009
March 10, 2009
Mr. David Waggoner
Charlotte Pipe &Foundry Company
PO Box 35430
Charlotte, NC 28208
DWQ-Stet fuV- 10r P;o,i t tlon
Subject: NPDES Permit Renewal Application
Charlotte Pipe & Foundry Company
Permit Number NCS000040
Individual Stormwater Permit
Mecklenburg County
Dear Mr.- Waggoner:
The Division of Water Quality's Stormwater Permitting Unit (SPU) acknowledges receipt of
your renewal application for coverage under NPDES Permit Number NCS000040 on July 7, 2004. We
apologize for the lengthy delay in responding to your submittal and are now making every effort to
review your permit renewal as expeditiously as possible. Our Unit anticipates making significant
progress on individual permits over the next six months to reduce our backlog.
We are currently beginning our review of your renewal application. Please continue to comply
with all conditions and monitoring requirements in your expired NPDES stormwater permit. As
long as you have submitted a complete renewal request package and maintain compliance with those
permit conditions, stormwater discharges from this facility are authorized by that permit until the
Division issues a renewal permit or notifies you of an alternative action.
No additional information is required at this time, but we may contact you in the future. Please
notify us if any significant changes have taken place at this facility since you submitted the renewal
package. If you have any questions about this matter, please contact me at [phone],
[e-mail].
cc: Moo sville-Regional-Office
StormwaterPennittingnnUnit iles
Central Files
Wetlands and Stormwater Branch
1617 Mail Service Center, Raleigh, North Carolina 27699-1617
Location: 512 N. Salisbury St. Raleigh, North Carolina 27604
Phone: [phone] FAX: [phone] Customer Service: 1-877-623-6748
Internet:w .ncwaterqualityrorg
An Equal Opportunity 1 Affirmative Action Employer
Sincerely,
-t
Brian Lowther
Environmental Engineer
Stormwater Permitting Unit
One
Not-thCarolina
Naturally