WQ0000962_Final O&M Plan_20200326

CULP
CLOSED -LOOP RECYCLE SYSTEM
OPERATION AND MAINTENANCE
PLAN
CULP TICKING
STOKESDALE, NORTH CAROLINA
MARCH 20, 2020
PREPARED BY:
LEONHARDT ENVIRONMENTAL, P.C.
RALEIGH, NORTH CAROLINA
LEO\IlAItDT
F.ttV�rtUYMENTAL� P.C.

1.0 Introduction
Culp Ticking is a textile manufacturing facility located in Stokesdale, Not
Carolina. The facility operates a 20,000 gallon per day (GPD) wastewater
treatment and closed -loop recycle facility. Operation of the facility is in
accordance with permit WQ0000962 issued by the State of North Carolina
Department of Environmental Quality. The provisions of that permit require that
an Operation and Maintenance (O&M) Plan be prepared and implemented for the
for the closed -loop recycle system.
The following document is the O&M Plan for Culp Ticking. This plan was
designed to meet the requirements of the North Carolina Administrative Code
Section: 15 A NCAC 02T .1007.
2.0 Planning and Organization
2.1 Facility Operation and Maintenance Team
Leader: Mark Creech
Title: Plant Manager
Responsibilities: Implementation of the plan; coordinates all stages of
plan development and execution; signature authority
and supervision of Operation and Maintenance
Program Team; makes plan modifications.
Leader: Chris Miles
Title: Safety & Environmental Manager
Responsibilities: Oversees the implementation of the plan; coordinates
employee training program; files all reports.
Team Member: Chad Cusin
Maintenance Manager
Responsibilities: Oversees the implementation of the plan; keeps all
records.
Team Member: Barry Bryant
Daily Wastewater Facility Operations Manager
Responsibilities: Involved in daily system operations of the facility.
Conducts inspections and maintenance as described
in the plan.

3.0 CLRS Process Equipment
Culp Ticking is permitted for the operation of their non -discharge wastewater
recycling facility. Process water from the Culp facility is treated using both
physical and chemical treatment methods. Physical treatment methods used at
the facility include screening, aeration, filtration, and equalization. Chemical
treatment methods used are coagulation/flocculation and neutralization. After
water goes through the treatment process, finished water is then evaporated
through Evapco LSTA Cooling Towers with a surrounding secondary
containment structure. No wastewater is discharged to groundwater or surface
waters at the Culp Ticking Facility. Permitted process equipment includes the
following:
A bar screen; a 3,650-gallon pump tank with high-water alarms and two Gorman
Rupp trash pumps with float level switch for large solids removal; a 20,000 gallon
equalization tank with a 3 horsepower (hp) mixer and pH adjustment; two 6,000
gallon polyethylene treatment tanks with carbon -steel 2-inch air diaphragm
transfer pumps; a Shredmaster high pressure in -line mixing system; a dewatering
roll -off box system; and automatic dry treatment chemistry feed system with
auger lift; fully automated valves for directing flow; dual 10 gallon per minute
(GPM) reverse osmosis systems; dual 100-micron bag filters capable of treating
50 GPM; dual multimedia filters capable of 5 micron removal at 20 GPM; an
8,000 gallon clean water holding tank; a 50,000 gallon finished water storage
tank with an air injection system for aeration; one evaporator with a catch basin;
a concrete secondary containment structure surrounding the evaporator and
associated catch basin; and all associated piping, valves, controls, and
appurtenances.
All equipment is operated and maintained according to manufacturer's
specifications. Culp Ticking has employed Steve Davis, with Shamrock
Environmental Corporation, to be the Operator in Responsible Charge (ORC) of
their system. The ORC visits the system daily to ensure the proper operation of
the system and is available on an on -call basis. The ORC operates the system in
accordance with permit WQ0000962 and documents all operations,
maintenance, and visitations to the system. The ORC will notify the Culp Ticking
Facility Operation and Maintenance Team if any repairs, modifications, or
maintenance is needed to ensure the compliance of the system with permitting
and regulatory requirements. Tyler Miles, with Leonhardt Environmental, P.C.,
has been designated as the Back-up ORC and will ensure the proper operation
of the system if the ORC is unable to be present. Contact information for the
ORC and Back-up ORC can be found in Appendix I.

4.0 System Maintenance Schedule
Culp Ticking has developed a preventative maintenance schedule for their
wastewater system. Chad Cusin and Barry Bryant oversee that the preventative
maintenance and routine inspections are performed.
Routine inspections and maintenance are conducted on a monthly and annual
basis. Monthly maintenance to the system includes the following:
• Grease jockey pump on RO unit, 2 fittings
• Check oil and filter on the air compressor
• Grease A & B auger motors on mixing tanks
• Grease the fan shaft on the evaporator
• Grease the fan motor on the evaporator- do not over grease
• Check the belts on the evaporator fan for proper tension and wear
• Grease the pump on the evaporator -grease heavily, 2 fittings
The reverse osmosis unit is inspected monthly to determine if the filters need to
be changed or if the membrane or tubes need to be cleaned. Maintenance to the
reverse osmosis system is conducted as needed. Metering equipment shall be
tested and calibrated annually. A thorough visual inspection of all tanks will be
conducted annually, and the integrity of each tank will be evaluated. Maintenance
and repairs to all tanks is conducted as needed. See Appendix II for the Monthly
Preventative Maintenance Checklist. Records of all maintenance and inspections
performed will be kept in Appendix III. Residuals from the treatment process will
be removed from the site as needed and will be conducted and recorded as
specified in the permit. All records will be kept on -site for 5 years.
5.0 Site Access and Safety Measures
Culp Ticking makes public and environmental health a priority when operating
their wastewater system by taking safety measures to restrict access to their site
and equipment. Areas at the facility that are fenced, or those that can be locked,
will be locked when not in production or when unattended. Security surveillance
systems have been implemented and are monitored in areas that are not fenced.
Signage, including no trespassing signs and emergency notification contact
information, are posted in appropriate locations at the facility. See Appendix I for
emergency notification contact information.
6.0 Spill Control Provisions
Secondary containment has been provided for some of the tanks and equipment
at the Culp Ticking Wastewater Treatment facility, including the evaporator. See
Appendix IV for a diagram of the facility. If a spill were to occur, the spilled
material would most likely be contained within a concrete secondary containment
structure or would flow into the earthen catch basin located east of the facility.

Culp Ticking personnel go through annual spill prevention training and know who
to call in the event of a spill. Culp Ticking personnel are trained to properly
manage and clean-up minor spills. A spill kit is located within the wastewater
treatment facility.
In the event of a major spill, Culp Ticking has contracted Shamrock
Environmental Corporation as an emergency responder. If a spill occurs, the
O&M Team Leader will immediately determine if Culp personnel have adequate
equipment and training to handle the spill or if outside help is required. If needed,
Shamrock Environmental will be contacted to properly control, contain, and
remediate the spill. The O&M Team Leader is responsible for notifying
emergency responders and regulatory agencies that a spill has occurred. See
Appendix I for contact information for plant personnel, emergency responders,
and regulatory agencies.

APPENDIX I
EMERGENCY NOTIFICATION CONTACT INFORMATION

EMERGENCY NOTIFICATION LIST
FACILITY OPERATION AND MAINTENANCE TEAM
TITLE
NAME
WORK NO.
HOME PHONE
NO.
Plant Manager
Mark Creech
[phone]x2653
[phone]
Safety & Environmental Manager
Chris Miles
[phone]x2635
[phone]
Maintenance Manager
Chad Cusin
[phone]x2514
(336) 4174848
Wastewater Facility Manager
Barry Bryant
[phone]
nuTSInF WASTEWATER OPERATORS
TITLE
NAME
PHONE NO.
Operator in Responsible Charge
Steve Davis- Shamrock
[phone]
ORC
Environmental Corp.
Back-up Operator in Responsible
Tyler Miles- Leonhardt
[phone]
Charge
Environmental, P.C.
CIII P_ INC_ 11PPER MANAGEMENT
TITLE
NAME
PHONE NO.
VP of Human Resources
Teresa Huffman
[phone]
Ol1TSIDE AGENCIES
AGENCY
PHONE NUMBER
North Carolina Department of Environmental
Quality, Division of Water Resources
Mon. -Fri., 8am — 5pm
[phone] (Main Office)
24 hr, 7 days/week
[phone]
Guilford County Emergency Management
(336)
641-2278
City of Stokesdale
(336)
643-4011
Stokesdale Fire Department
911
EPA Region IV
(404)
562-8700
National Response Center
(800)
424-8802
Shamrock Environmental Corporation
(24 hr, emergency responder)
(800)
881 1098

APPENDIX II
MONTHLY PREVENTATIVE MAINTENANCE CHECKLIST
AND REVERSE OSMOSIS SYSTEM MAINTENANCE LOG

Water Plant
Monthly Preventative Maintenance Check List
grease jocky pump on RO unit, 2 fitti
check oil and filter on air compressor
grease A & B auger motors on mixing
grease fan shaft on evaporator
grease fan motor on evaporator, do
check belts on evaporator fan for pro
grease pump on evaporator, grease
Assigned to Date:
Condition Repair Completed Inspection Complete
Repair Required
ngs M
M
tanks M
M
notovergrease M
per tension and wear M
heavily, 2 fittings M
Clean up work area -No grease left on nipples or hanging from bearings
Repairs are to be performed Immediately, if not department manager and Assistant Plant Manager are to be notified when repairs
can be performed.
Notes:
Mechanic
Assistant Plant Manager
Signature Required
Q= Quarterly
M = Monthly
W = Weekly
Clean up work area -No grease left on nipples or hanging from bearings
Repairs are to be performed Immediately, if not department manager and Assistant Plant Manager are to be notified when repairs
can be performed.
Notes:
Mechanic
Assistant Plant Manager
Signature Required
Q= Quarterly
M = Monthly
W = Weekly

REVERSE OSMOSIS UNIT CHECKLIST
FILTER CHANGE CLEAN MEMBRANE CLEAN TUBES

APPENDIX III
RECORDS OF MAINTENANCE AND INSPECTIONS

APPENDIX IV
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