WQ0000962_Final Permit_20071218

�O� WAT�cgQ Michael F. Easiey, Governor
�� 6 William G. Ross Jr., Secretary
cq 7 North Carolina Department of Environment and Natural Resources
Coleen H. Sullins, Director
Division of Water Quality
December 18, 2007
MR. BILL CALLAHAN, PLANT MANAGER
CULP TICKING (A DIVISION OF CULP, INC.)
POST OFFICE BOx 488
STOKESDALE, NORTH CAROLINA 27357
Subject: Permit No. WQ0000962
Culp, Inc.
Culp Ticking Facility
Wastewater Recycle System
Guilford County
Dear Mr. Callahan:
In accordance with your perinit renewal application package received on January 21, 2004 as well
as the additional information received on May 21, 2004, we are forwarding herewith a renewed Permit
No. WQ0000962, dated December 18, 2007, to Culp, Inc. for the continued operation of the subject
wastewater recycle system;.
This permit shall be effective from the date of issuance until November 30, 2012; shall void
Permit No. WQ0000962, issued on May 7, 1999; and shall be subject to the conditions and limitations as
specified therein. Make note of this permit's expiration date and the fact that a permit renewal application
is due to the Division of Water Quality (Division) no later than six months prior to that date (i.e., see
Condition 21), as the Division does not send reminders to apply for permit renewal.
This permit approves the continued operation of the wastewater recycle program for another five-
year cycle. As always, remember to take the time to review this permit thoroughly, as some of the
conditions contained therein may have been added, changed, or deleted since the last issuance. 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, and/or limitations contained in this permit are unacceptable, you have
the right to request an adjudicatory hearing upon written request within 30 days following receipt of this
permit. This request shall be in the from of a written petition, conforming to Chapter 150B of the North
Carolina General Statutes and filed with the Office of Administrative Hearings at 6714 Mail Service
Center, Raleigh, North Carolina 27699-6714. Unless such demands are made, this permit shall be final
and binding.
Wa
no
rtliCarolina
Nawally
Aquifer Protection Section 1636 Mail Service Center Raleigh, NC 27699-1636 Phone [phone] Customer Service
lnterneL www.ncwaterquality.org 2728 Capital Boulevard Raleigh, NC 27604 Fax [phone]
Fax [phone]
An Equal Opportunity/Affirmative Acton Employer— 50% Recycled/1 0% Post Consumer Paper

If you need any additional information concerning this matter, please contact Mr. Duane Leith by
telephone at [phone], or via e-mail at [e-mail].
Sincerel ,
for Coleen H. Sullins
cc: Guilford County Health Department
Winston-Salem Regional Office-APS
Technical Assistance and Certification Unit
APS Central Files
LAU Files

NORTH CAROLINA
ENVIRONMENTAL MANAGEMENT COMMISSION
DEPARTMENT OF ENVIRONMENT AND NATURAL RESOURCES
RALEIGH
CLOSED -LOOP RECYCLE OF WASTEWATER 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
PERMISSION IS HEREBY GRANTED TO
Culp Inc. (Culp Ticking Facility)
Guilford County
FOR THE
continued operation of a 130,000-GPD wastewater recycle system for the Culp, Inc. Culp Ticking Facility,
consisting of a bar screen, a 3,650-gallon pump tank with high water alarms and large solids removal (two
Gorman -Rupp trash pumps with a float level switch), a 27,700-gallon equalization tank with a three -HP
mixer, wastewater equalization and pH adjustment (a 100,000-gallon equalization tank, floating downdraft
mixer, acid metering pump, pH analyzer/controller, pH recirculation pump, and appurtenances), dissolved
air flotation system (a 400-GPM stainless steel DAF unit, a mixing pipe flocculator with chemical
injection, recirculation pump, stainless steel sparge tank and distribution manifold, stainless steel sludge
scraper, transfer pump, automatic DAF blowdown valve, magnetic flow meter, and appurtenances),
polymer containment mixing and metering (caustic pump, pH analyzer/controller, coagulant metering gear
pump, flocculant mix tank, flocculant tank mixer, flocculant metering gear pump), a 200-GPM pre -
assembled ClaRite 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, a 8,000-gallon sludge storage tank, a
0.5-meter belt filter press, a 100,000-gallon finished water storage tank, an automatic control system, and
all the necessary pipes, valves, and appurtenances required for the proper operation of the system, with no
discharge of wastes to surface waters, pursuant to the permit renewal application package received on
January 21, 2004 as well as the additional information received on May 21, 2004 and in conformity with
the project plan, specifications, and other supporting data subsequently filed and approved by the
Department of Environment and Natural Resources and considered a part of this permit.
This permit shall be effective from the date of issuance until November 30, 2012; shall void
Permit No. WQ0000962, issued on May 7, 1999; 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 and 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.

The facilities shall be properly maintained and operated at all times.
4. The following buffers shall be maintained:
a) 100 feet between treatment/storage units and any wells,
b) 50 feet between treatment/storage units and surface waters, and
c) 50 feet between treatment/storage units and property lines.
5. 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
Water Quality (Division) 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.
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 actions that may be
required by this Division, such as the construction of additional or replacement treatment or disposal
facilities.
7. The residuals generated from these treatment facilities must be disposed in accordance with General
Statute 143-215.1 and in a manner approved by the Division.
The issuance of this permit shall not relieve the Pennittee of the responsibility for damages to
surface or groundwaters resulting from the operation of this facility.
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.
10. Diversion or bypassing of untreated wastewater from the treatment facilities is prohibited.
11. Any monitoring deemed necessary by the Division to insure surface and ground water protection
will be established and an acceptable sampling reporting schedule shall be followed.
12. Adequate inspection, maintenance, and cleaning shall be provided by the Permittee to insure proper
operation of the subject facilities.
13. 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 wasters to
the environment, a threat to human health, or a nuisance. The Permittee shall maintain 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 to the Division or other permitting authority, upon request.
14. Any duly authorized officer, employee, or representative of the Division 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 maintained under the terms and conditions of this permit, and may
obtain samples of groundwater, surface water, or leachate.
2

15, 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 15A NCAC 2T .0105(e).
16. Failure to abide by the conditions and limitations contained in this permit may subject the Permittee
to an enforcement action by the Division in accordance with North Carolina General Statute 143-
215.6A to 143-215.6C.
17. The issuance of this permit does not exempt the Pernttee 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, including but not limited to applicable river buffer rules in 15A
NCAC 2B.0200, erosion and sedimentation control requirements in 15A NCAC Chapter 4 and under
the Division's General Permit NCG010000, and any requirements pertaining to wetlands under 15A
NCAC 2B .0200 and 2H .0500.
18. A set of approved plans and specifications for the subject project must be retained by the Permittee
for the life of this project.
19. Noncompliance 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 renders 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; or
d. Any time that self -monitoring information indicates that the facility is not in compliance with its
permit limitations.
Occurrences outside normal business hours may also be reported to the Division's Emergency
Management personnel at telephone number [phone], or [phone]. Persons reporting
such occurrences by telephone shall also file a written report in letter form within five (5) 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.
3

20. Upon classification of the wastewater treatment and spray irrigation facilities by the Water Pollution
Control System Operators Certification Commission (WPCSOCC), the Permittee shall designate and
employ a certified operator to be in responsible charge (ORC) and one or more certified operator(s)
to be back-up ORC(s) of the facilities in accordance with 15A NCAC 8G .0201. The ORC shall
visit the facilities in accordance with 15A NCAC SG ,0204 or as specified in this permit and shall
comply with all other conditions specified in these rules.
21. The Permittec, 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.
22. Groundwater Sampling Criteria:
a. Monitor wells MW-1, MW-2, MW-3, MW-4, MW-5 and MW-6 shall be sampled every March,
July and November for the parameters listed below. Prior to sampling the parameters, the
measurement of water levels must be taken. The depth to 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 relative to a common datum.
Water Level pH
Iron Total Dissolved Solids (TDS)
Manganese Total Organic Carbon (TOC)
Nitrate Chloride
Volatile Organic Compounds (VOC) — In November only
b. The treated wastewater recycle stream shall be sampled, after treatment and prior to recycle use,
every November for the parameters listed below.
Volatile Organic Compounds
Total Organic Carbon (TOC)
Dissolved Organic Carbon (0.45 um filter followed by TOC analysis)
Residual Chlorine
c. For Total Organic Carbon (TOC), if concentrations greater than 10 mg/1 are detected in any
down -gradient 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 down -gradient wells shall be subject to the additional
sampling and analysis as described above.
d. For Volatile Organic Compounds (VOCs) use only one of the following methods:
1) Standard method 6230D, Practical Quantitation Limit (PQL) at 0.5 ug/L or less
2) Standard Method 6210, PQL at 0.5 ug/L or less
3) EPA Method 8021, Low concentration, PQL at 0.5 ug/L or less
4) EPA Method 8260, Low concentration, PQL at 0.5 ug/L or less
5) Another method with prior approval by the Groundwater Section Chief.
e. Any of the referenced methods used for VOCs must at a minimum, include all the constituents
listed in Table VIII of Standard Method 6230D. Any method used must provide a PQL of 0.5
ug/L or less, which must be supported by laboratory proficiency studies as required by the DWQ
Laboratory Certification Unit. Any constituents detected above the Method Detection Limit
(MDL) but below the PQL of 0.5 ug/L must be qualified (estimated) and reported.
4

Any laboratory selected to analyze parameters must be Division of Water Quality (DWQ)
certified for those parameters required.
23. Groundwater Reporting / Documentation:
a. All reports and documentation (GW-59) shall be mailed to the following address:
Division of Water Quality
Information Processing Unit
1617 Mail Service Center
Raleigh, NC 27699-1617
Updated blank fonns (GW-59) may be downloaded from the Aquifer Protection Section's
website at http://h2o.enr.state.nc.us/aps/ind.ex,htna or requested from the address mentioned
above.
b. The results of the sampling and analysis must be received on Form GW-59 (Groundwater
Quality Monitoring: Compliance Report Form) by the Information Processing Unit (address
listed in the Reporting / Documentation: section of the Groundwater Requirements), on or before
the last working day of the month following the sampling month. The data of all groundwater
sampling analyses required by the permit conditions must be reported using the most recent
GW-59 form along with attached copies of the laboratory analyses.
Permit issued this the 18th day of December, 2007
NORTH C OLINA ENVIRONMENTAL MANAGEMENT COMMISSION
oleen H. Sullins, Director
Division of Water Quality
By Authority of the Environmental Management Commission
Permit Number WQ0000962
5

Culp Ticking (A Division of Culp, Inc.)
Layout of Monitoring Wells
by tec from 98 dogq in 8/04
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FIGURE 1
CULP TICKING
WASTEWATER RECYCLE SYSTEM
GUILFORD COUNTY
WQ0000962/GW99017
SITE LOCATION•MAP