WQ0000962_Final Permit_19930930

State of North Carolina
Department of Environment,
Health and Natural Resources
Division of Environmental Management
James B. Hunt, Jr., Governor
Jonathan B. Howes, Secretary
A. Preston Howard, Jr., P.E., Director
AS 0
[DEHNF1
September 30, 1993
Mike Messer, Plant Manager
Culp Ticking
Post Office Box 488
Stokesdale, North Carolina 27357
Subject: Permit No. WQ0000962
Culp Ticking
Wastewater Recycle System
Guilford County
Dear Mr. Messer:
In accordance with your modification request received April 23, 1993, we are forwarding herewith
Permit No. WQ0000962 as amended, dated September 30, 1993, to Culp Titling for the construction and
operation of the subject wastewater recycle system.
This permit shall be effective from the date of issuance until May 1, 1994, shall void Permit No.
WQ0000962 issued May 31, 1989 and shall be subject to the conditions and limitations as specified
therein. Please pay particular attention to the monitoring requirements in this permit. Failure to establish an
adequate system for collecting and maintaining the required operational information will result in future
compliance problems.
If any parts, requirements, or limitations contained in this permit are unacceptable to you, you have
the right to request an adjudicatory hearing upon written request within 30 days following receipt of this
permit. This request must be in the form of a written petition, conforming to Chapter 150B of North
Carolina General Statutes, and filed with the Office of Administrative Hearings, P.O. Drawer 27447,
Raleigh, NC 27611-7447. Unless such demands are made this permit shall be final and binding.
One set of approved plans and specifications is being forwarded to you. If you need additional
information concerning this matter, please contact Mr. Michael D. Allen at [phone].
Sincerely,
A. Pres Howard, Jr., P.E.
cc: Guilford County Health Department
Winston-Salem Regional Office, Water Quality
Winston-Salem Regional Office, Groundwater
Jack Floyd, Central Office, Groundwater
Leonhardt Environmental
Facilities Assessment Unit
Training and Certification Unit
P.Q. Box 29535, Raleigh, North Carolina 27626-0535 Telephone [phone] FAX [phone]
An Equal Opportunity Affirmative Action Employer 50% recycled/ 10% post -consumer paper

NORTH CAROLINA
ENVIRONMENTAL MANAGEMENT COMMISSION
DEPARTMENT OF ENVIRONMENT, HEALTH AND NATURAL RESOURCES
RALEIGH
RECYCLE SYSTEM PERMIT
In accordance with the provisions of Article 21 of Chapter 143, General Statutes of North Carolina as
amended, and other applicable Laws, Rules, and Regulations
Culp Ticking
Guilford County
FOR THE
operation of a 130,000 GPD wastewater recycle system consisting of an existing barscreen, an existing
3,650 gallon pump station with high water alarms, a 70 GPM pump and a 140 GPM pump, the renovation
of an existing clarifier to a 27,700 gallon equalization basin with a 3 HP mixer, the construction and
operation a new 3,500 GPD chemical coagulant mixing tank and feed system, an existing 12,000 gallon
dissolved air flotation (DAF) unit, the construction and operation of a 200 GPM pre -assembled C1aRite
Diatomaceous Earth Pressure Filter Unit with a 5,000 gallon filter feed pump station with 140 GPM
duplex pumps and a 45 SCFM pneumatic system, an existing 8,000 gallon sludge storage tank, an
existing 0.5 meter belt filter press, an existing 100,000 gallon finish water storage tank and all associated
valves, piping and appurtenances and the proper abandonment and closure of an existing 0.271 million
gallon lagoon and a 1.35 million gallon lagoon serve Culp Ticking with no discharge of wastes to the
surface waters, pursuant to the modification request received April 23, 1993, and in conformity with the
project plan, specifications, and other supporting data subsequently filed and approved by the Department
of Environment, Health and Natural Resources and considered a part of this permit.
This permit shall be effective from the date of issuance until May 1, 1994, shall void Permit No.
WQ0000962 issued May 31, 1989 and shall be subject to the following specified conditions and
limitations:
1. This permit shall become voidable unless the facilities are constructed in accordance with
the conditions of this permit, the approved plans, specifications, and other supporting data.
2. This permit is effective only with respect to the nature and volume of wastes described in
the application and other supporting data.
3. The facilities shall be properly maintained and operated at all times.

4. This permit is not transferable. In the event there is a desire for the facilities to change
ownership, or there is a name change of the Permittee, a formal permit request must be
submitted to the Division of Environmental Management accompanied by an application
fee, documentation from the parties involved, and other supporting materials as may be
appropriate. The approval of the request will be considered on its merits and may or may
not be approved.
5. Upon completion of construction and prior to operation of this permitted facility, a
certification must be received from a professional engineer certifying that the permitted
facility has been installed in accordance with this permit, the approved plans and
specifications. Mail the Certification to the Permits and Engineering Unit, P.O. Box
29535, Raleigh, NC 27626-0535.
6. In the event that the facilities fail to perform satisfactorily, including the creation of
nuisance conditions, the Permittee shall take immediate corrective action, including those as
may be required by this Division, such as the construction of additional or replacement
wastewater treatment or disposal facilities.
7. The Winston-Salem Regional Office, telephone number [phone], shall be notified
at least forty-eight (48) hours in advance of operation of the installed facilities so that an in -
place inspection can be made. Such notification to the regional supervisor shall be made
during the normal office hours from 8:00 a.m. until 5:00 p.m. on Monday through Friday,
excluding State Holidays.
8. The sludge generated from these treatment facilities must be disposed of in accordance with
General Statute 143-215.1 and in a manner approved by the North Carolina Division of
Environmental Management.
9. The issuance of this permit shall not relieve the Permittee of the responsibility for damages
to surface or groundwaters resulting from the operation of this facility.
10. The facilities shall be effectively maintained and operated as a non -discharge system to
prevent the discharge of any wastewater resulting from the operation of this facility.
11. Diversion or bypassing of untreated wastewater from the treatment facilities is prohibited.
12. Any monitoring deemed necessary by the Division of Environmental Management to insure
surface and ground water protection will be established and an acceptable sampling
reporting schedule shall be followed.
13. Adequate inspection, maintenance, and cleaning shall be provided by the Permittee to
insure proper operation of the subject facilities.
14. The Permittee or his designee shall inspect the wastewater recycle facilities to prevent
malfunctions and deterioration, operator errors and discharges which may cause or lead to
the release of wastes to the environment, a threat to human health, or a nuisance. The
Permittee shall keep an inspection log or summary including at least the date and time of
inspection, observations made, and any maintenance, repairs, or corrective actions taken
by the Permittee. This log of inspections shall be maintained by the Permittee for a period
of three years from the date of the inspection and shall be made available upon request to
the Division of Environmental Management or other permitting authority.
15. Any duly authorized officer, employee, or representative of the Division of Environmental
Management may, upon presentation of credentials, enter and inspect any property,
premises or place on or related to the recycle system at any reasonable time for the purpose
of determining compliance with this permit; may inspect or copy any records that must be
kept under the terms and conditions of this permit; or may obtain samples of groundwater,
surface water, or leachate.
2

16. The annual administering and compliance fee must be paid by the Permittee within thirty
(30) days after being billed by the Division. Failure to pay the fee accordingly may cause
the Division to initiate action to revoke this permit as specified by 15 NCAC 2H .0205
(c)(4)..
17. Failure to abide by the conditions and limitations contained in this permit may subject the
Permittee to an enforcement action by the Division of Environmental Management in
accordance with North Carolina General Statute 143-215.6A to 143-215.6C.
18. The issuance of this permit does not preclude the Permittee from complying with any and
all statutes, rules, regulations, or ordinances which may be imposed by other government
agencies (local, state, and federal) which have jurisdiction.
19. A set of approved plans and specifications for the subject project must be retained by the
Peirnittee for the life of this project.
20. NoncompIiance Notification:
The Permittee shall report by telephone to the Winston-Salem Regional Office, telephone
number [phone], as soon as possible, but in no case more than 24 hours or on the
next working day following the occurrence or first knowledge of the occurrence of any of
the following:
a. Any occurrence at the wastewater treatment facility which results in the treatment of
significant amounts of wastes which are abnormal in quantity or characteristic, such
as the dumping of the contents of a basin or tank; the known passage of a slug of
hazardous substance through the facility; or any other unusual circumstances.
b. Any process unit failure, due to known or unknown reasons, that render the facility
incapable of adequate wastewater treatment such as mechanical or electrical failures
of pumps, aerators, compressors, etc.
c. Any failure of a pumping station, sewer line, or treatment facility resulting in a by-
pass directly to receiving waters without treatment of all or any portion of the
influent to such station or facility.
d. Any time that self -monitoring information indicates that the facility is not in
compliance with its permit limitations.
Persons reporting such occurrences by telephone shall also file a written report in letter
form within 15 days following first knowledge of the occurrence. This report must outline
the actions taken or proposed to be taken to ensure that the problem does not recur.
21. Upon classification of the facility by the Certification Commission, the Permittee shall
employ a certified wastewater treatment plant operator to be in responsible charge (ORC) of
the wastewater treatment facilities. The operator must hold a certificate of the type and
grade at least equivalent to or greater than the classification assigned to the wastewater
treatment facilities by the Certification Commission. The Permittee must also employ a
certified back-up operator of the appropriate type and grade to comply with the conditions
of Title 15A, Chapter 8A, .0202. The ORC of the facility must visit each Class I facility at
Ieast weekly and each Class II, III, and IV facility at least daily, excluding weekends and
holidays, and must properly manage and document daily operation and maintenance of the
facility and must comply with all other conditions of Title 15A, Chapter 8A, .0202.
22. The Permittee, at least six (6) months prior to the expiration of this permit, shall request its
extension. Upon receipt of the request, the Commission will review the adequacy of the
facilities described therein, and if warranted, will extend the permit for such period of time
and under such conditions and limitations as it may deem appropriate.
3

23. Proper records shall be maintained by the Permittee tracking all disposal activities. These
records shall include, but are not necessarily limited to the following information:
a) description of materials removed,
b) quantity of materials removed in gallons of liquid or pounds of solids,
c) name of the Company removing material,
d) location of disposal
An annual report shall be furnished to the Winston-Salem Regional Office by January 31st
of each calendar year, summarizing the disposal of materials for the previous year through
December 31 st.
24. The three (3) existing monitoring wells, W-101, W-102, and W-103, shall be sampled
every March, July and November for the following parameters:
NO3 Chromium
TDS TOC
pH Water Level
Chloride Manganese
Cadmium Iron
Volatile Organic Compounds - In November only (by Method 1 or Method 2 below).
Method 1: Method 6230D (Capillary - Column), "Standard Methods For The
Examination of Water and Wastewater", 17th ed., 1989.
Method 2: Method 502.2 "Methods For The Determination of Organic Compounds
in Drinking Water", U.S. EPA - 600/4-88/039.
The measurement of water level must be made prior to sampling for the remaining
parameters. The depth of water in each well shall be measured from the surveyed point on
the top of the casing.
The measuring points (top of well casing) of all monitoring wells shall be surveyed to
provide relative elevations of the measuring point for each monitoring well.
If TOC concentrations greater than 10 mg/I are detected in any downgradient monitoring
well, additional sampling and analysis must be conducted to identify the individual
constituents comprising this TOC concentration. If the TOC concentration as measured in
the background monitor well exceeds 10 mg/l, this concentration will be taken to represent
the naturally occurring TOC concentration. Any exceedances of this naturally occurring
TOC concentration in the downgradient wells shall be subject to the additional sampling
and analysis as described above.
If any volatile organic compounds are detected by method 6230D, or the equivalent method
502.2, then EPA methods 604 and 611 must also be run to detect other organic compounds
which may be present. The results of alI analyses specified in the monitoring requirements,
including 604 and 611 if required, must be submitted simultaneously.
The results of the sampling and analysis shall be sent to the N.C. Division of
Environmental Management on Form GW-59 (Compliance Monitoring Report Form) every
April, August and December.
4

25. The Compliance Boundary for the disposal system is specified by regulations in 15 NCAC
2L, Groundwater Classifications and Standards. The Compliance Boundary is established
at either (1) 250 feet from the waste disposal area, or (2) 50 feet within the property
boundary, whichever is closet to the waste disposal area. An exceedance of Groundwater
Quality Standards at or beyond the Compliance Boundary is subject to immediate
remediation action on addition to the penalty provisions applicable under General Statute
143-215.6(a)(1).
Also in accordance with 15A NCAC 2L, a REVIEW BOUNDARY is established around
the disposal systems midway between the Compliance Boundary and the perimeter of the
waste disposal area. Any exceedance of standards at the Review Boundary shall require
rezmediation action on the part of the permittee.
26. For disposal system permitted or repermitted after January 1, 1993, a permittee shall not
transfer land within an established compliance boundary unless :
1. the land transferred is served by a community water system as defined in 15A
NCAC 18C, the source of which is located outside the compliance boundary; and
2. the deed transferring the property:
a. contains notice of the permit number, a description of the type of permit, and
the name, address and telephone number of the permitting agency; and
b. contains a restrictive covenant running with the land and in favor of the
permittee and the State, as a third party beneficiary, which prohibits the
construction and operation of water supply wells within the compliance
boundary; and
c. contains a restrictive covenant running with the land and in favor of the
permittee and the State, as a third party beneficiary, which grants the right to the
permittee and the State to enter on such property within the compliance
boundary for groundwater monitoring and remediation purposes.
Permit issued this the 30th day of September, 1993
NORTH CAROLINA ENVIRONMENTAL MANAGEMENT COMMISSION
kn.q-y�' �G[A&.00 'A.
C
A. Preston oward, Jr., P.E , Director
Division of -Environmental anagement
By Authority of the Environmental Management Commission
Permit No. WQ0000962
5

Permit No. WQ0000962
September 30, 1993
Engineer's Certification
I, , as a duly registered Professional Engineer in the State of North
Carolina, having been authorized to observe (periodically, weekly, full time) the construction of the
project,
Project Name
Location
for the
Perri ttee hereby state that, to the best of my abilities, due care and diligence was used in the observation
of the construction such that the construction was observed to be built within substantial compliance and
intent of the approved plans and specifications.
Signature
Date
T
Registration No.

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ITEM POINTS (5) SECONDARY TREATMENT UNITS
(a) Carbonaceous Stage
(1) industrial Pretreatment Units and/or
(i)Aeration - Nigh Purity Oxygen Systern .. , . .
Industrial Pretreatment Program
Diffused Air System ... - - ..... .
(see definition No. 33) 4
Mechanical Air System (fixed,
(2) DFS1Q FLOW OF PLANT IN GPD
floating or rotor) .. . .. . ....... .
x (not applicable to non-conlaminated cooling waters, sludge
Separate Sludge Reaeration . - . - .
handling facilities for water purification plants, totally
(ii) Trickling Filler
closed cycle syslerns (def. No. 11), and facilities
High Rate . ......... . . . ..... .
consisting only of Item (4) (d) or Items (4) (d) and -(11) (d))
Standard Rate - ....... .
0 20,000................ ........ 1
20,001 50,000 .......................... 2
Packed Tower ...............
(iii) Biological Aeraled Filler or Aerated
50,001 -- 100.000 .............
100,001 -• 250,000 .... ,-!-���� ..........
250 001 50
Biological Filter .. - .................. .
(iv) Aeraled Lagoons ...... .
500,001 --1,000,000 ......... . . . .......... . ...
8
1.000,001 -- 2,000,000 ................... . ....
10
2,000,001 (and up) - rate 1 point additional for each
200,000 gpd capacity up to a
maximum of 30
Design Flow (gpd) r' 3[ 5; cr Lj o
(3) PRELIMINARY UNITS (see definilion no. 32)
(a) Bar Screens ..... . . ........ . . . ..............
r
(b) Mechanical Screens, Static Screens or
Comminuting Devices . . . .... . ... .............
2
(c) Grit Removal ...............................
1
or
(d) Mechanical or Aerated Grit Removal . - ... • • ....
2
(e) Flow Measuring Device ..... . . ...... . .... . .. . .
1
or
(f) Instrumented Flow Measurement .... . . . .......
(g) Preaeration ............... . .............. . .
(h) fnfluent Ffow•Equaliza0on ........... . . . .... .
(i) Grease or Oil Separators - Gravity ... - ..... -
Mechanical .... - .... . �
Dissolved Air Flotation- (8�
{j) Prechlorinalion ... . ...................... . ...
PRIMARY TREATMENT UNITS
(a) Seplic Tank (see definition no. 43) .. . .... . .. . ... 2
(b) Imhoff Tank.... ........................ 5
(c) Primary Clarifiers .. . ... . ........ . . . .......... 5
(d) Settling Ponds or Settling Tanks for Inorganic
Non -toxic Materials (sludge handling faci€flies
for water purification plants, sand, gravel,
stone, and other mining operations except
recrealionai activities such as germ or gold %]
mining) ...................................... 2 1 f
(v) Rotating Biological Conlaclors ......... .
(vi) Sand Filters-
inlermittenl biological .. - .
recirculating biological .. .
(vii) Stabilization Lagoons ............. - .. - - .
(viii)Cfarifier ................ . .. . ......... .
(ix) Single stage system for combined
carbonaceous removal of BOD and
nitrogenous removal by nilrilication
(see def. No. 12) (Poinls for this item
have to be in addition to items (5) (a)
(i) through (5) (a) (viii) .......... . . .... .
(x) Nutrient additions to enhance BOD
removal ...............................
(xi) Biological Culture ("Super Bugs`) addition
to enhance organic compound removal .... .
(b) Nitrogenous Stage
(i) Aeration - High Purity Oxygen System . .
Diffused Air System . - ........ .
Mechanical Air System (fixed,
floating, or rotor) . , .... .. - .. .
Separate Sludge Reaeralion .... .
(ii) Trickling Filter -
High Rate ..............
Standard Rate ...... _ - .
Packed Tower ._........-.
(iii) Biological Aeraled Filter or Aerated
Biological Filler .......... . ..... . .. . .. . . .
(iv) Rotating Biolog-ical Conlaclors ....... - . - . .
(v) Sand Filler -
intermittent biological . - , - . . , .
recirculating biological , - . - , . .
(v i) Clarifier .. . ....... . ..... .
20
10
8.
3
10
20
10
10
10

r OR ADVANCED TREATMENT UNIT (10) CHEMICAL ADDITION SYSTEM (S) (See definition No. 9)
rivaled Carbons Beds - (not applicable io chemical additions rated as item
without carbon regeneration .................. 5 (3) (j), (5) (a) (xi), (6) (a), (6) (b), (7) (b), (7) (e),
with carbon regeneration .................... is (9) (a), 9) (b), or (9) (c) 5 points each'' Ust: /
(b) Powdered or Granular Activated Carbon Feed - QD y M P, C S � 0o
without carbon regeneration ................. 5
with carbon regeneration ................... 1 5
(c) Air Stripping ....................... ....... 5 1
(d) Denitrification Process (separate process) . .. 1 0
(e) E[ectrodialysis ...:.......... I ..... I ......... . 5 (11) MISCELLANEOUS UNITS
(f) Foam Separation ............................. 5 (a) Holding Ponds, Holding Tanks or Settling Ponds
(g) Ion Gxchange................................ 5 for Organic or Toxic Materials including wastes
(h) Land Application of Treated Effluent from mining operations containing nitrogen and/or
(see delinilion no. 22b) (not applicable for phosphorous compounds in amounts significantly
sand, gravel, stone 'and other similar mining greater than is common for domestic wastewater ..........
operations) (b) Effluent Flow Equalization (not applicable to storage
(i) on agricoliuraily managed sites (See def. basins which are inherent in [and application systems).
No- 4)................................ . ... 10 (c) Stage Discharge {not applicable 10 storage basins
(i i) by high rate infiltration on non -agriculturally inherent in land application systems ....................................... r
managed sites (includes rotary dislribuiors (d) Pumps ....................
and similar fixed nozzle systems) ....... - .. , 4 (e) Stand -By Power Supply ..................................
(iii) by subsurface disposal (includes low pressure (f) Thermal Pollution Control Device ................... e
pipe systems and gravity systems except at
plants consisting of septic lank and nitrifica-
tion lines only) ............. ............. 4 gil TOTAL POINTS
(i) Microscreens .................... . ............. 5
(j) Phosphorus Remoaal by Biological Processes CLASSIFICATION
(See det- No. 26) 20
(k) Polishing Ponds - without aeration . 2 Class I .................... - 25 Points
with aeration .......... 5 Class 11........................................................ 26- 50 Points
(1) Post Aeration . cascade .............. 0 Class III......................................... 51- 65 Points
diffused or mechanical ... 5 Class IV ........................................................ 66- Up Points
(m) Reverse Osmosis ............................... 5
(n) Sand or Mixed -Media Fitters - tow rate .......... Facilities having a rating of one through four points, inclusive,
high rate .......... do not require a certified operator. Classification of all other
(o) Treatment processes for removal of metal or facilities requires a comparable grade operator in responsible
cyanide .................................... 1 5 charge.
tip) Treatment processes for removal of toxic
materials other than meta[ or cyanide ......... 1,� ` Facilities having an activated sludge process will be assigned
a minimum classification of Class If.
SLut�,E TREATMENT a �i 1�
Facilities having treatment processes for the removal of metal
(a) Sludge Digestion Tank - Heated ............... 1 0 or cyanide will be assigned a minimum classification of Class 11,
Aerobic ............... 5
Unheated ...... ....... 3 Facilities having treatment processes for the biological removal
(b) Sludge Stabilization (chemical or thermal) ... . . .. 5 of phosphorus will be assigned a minimum classification of Class
(c) Sludge Drying Beds - Gravity ......... _ ....... 2 III.
Vacuum Assisted ....... 5
(d) Sludge l IW6alion ... . ......................... 5 In -plant processes and related control equipment which are an
(e) Sludge Conditioner (chemical or thermal) ........ 5 integral part of industrial production shall not be considered waste
(f) Sludge Thickener (gravity) ............... . ...... 5 treatment. Likewise, discharges of wastewater from residences
(g) Dissolved Air Flotation Unit having a design flow of 1.000 gpd or less, shall not be subject to
(not applicable to a unit rates as (3) (i) ......... 6 rating.
(h) Sludge Gas Uliliza6on (including gas storage) . . . . 2
(i) Sludge Holding Tank - Aerated ................ 5 ADDITIONAL COMMENT$;
Non -aerated ........ - - .. 2
{j) Sludge Incinerator - (not including activated d_re) S�-�t/1
carbon regeneration1 ..... 1 0
(k) Vacuum Filter, Centrifuge or Filter Press✓or other
similar dewatering devices ............ I ....... 1 0
(8) SLUDGE DISPOSAL (including incinerated ash) � � -7
(a) Lagoons ........................................ 2 Qt
(b) Land Application (surface and subsurface) a If
(see definition 22a) 3-�'-rLl
-where the facility holds the land app. permit 10 1 -7r-
-by contracting to a land application operator who
holds the land application permit ................ 2 ~� r
-land application of sludge by a contractor who does
not hold the permit for the wastewaler treatment
facility where the sludge is generated ..... .... 1 0
(c) Landfilled (burial) ............................ 5
(9) DISINFECTION
(a) Chlorination ........................ ..... 5
(b) Dechlorinalion ........................ 5
(c) Ozone .............................. 5 �
(d) Radialion ............ • ............ 5