WQ0000962_Final Permit_20190822

ROY COOPER
Govemor
MICHAEL S. REGAN
Secretary
LINDA CULPEPPER
Director
MARK CREECH — PLANT MANAGER
CULP, INC.
POST OFFICE BOX 488
STOKESDALE, NORTH CAROLINA 27357
Dear Mr. Creech:
NORTH CAROLINA
Environmental Quality
August 22, 2019
Subject: Permit No. WQ0000962
Culp Ticking CLRS
Closed -Loop Recycle System
Guilford County
In accordance with your permit minor modification request received June 4, 2019, we are
forwarding herewith Permit No. WQ0000962 dated August 22, 2019, to Culp, Inc. for the continued
operation of the subject wastewater treatment and closed -loop recycle facilities.
The following modifications to the subject permit are as follows: A secondary containment
structure surrounding the evaporator will be installed; the permitted flowrate is decreased from 130,000
gallons per day (GPD) to 20,000 GPD per the Permittee's request; the water storage tank has been changed
to 50,000 gallons in the facility description for accuracy; the equalization tank has been changed to 20,000
gallons in the facility description for accuracy; the automatic dry treatment chemistry feed has been changed
from a vacuum lift to an auger lift in the permit description for accuracy; an air injection system has been
added to the finished water tank serving the evaporator; and MW-1 will be permanently abandoned since it
is damaged and represents similar information to MW-3R, another up gradient well.
This permit shall be effective from the date of issuance through November 30, 2021, shall void
Permit No. WQ0000962 issued August 15, 2017, and shall be subject to the conditions and limitations
therein. The Permittee shall submit a renewal application no later than June 3, 2021.
Please pay attention to the monitoring requirements listed in Section IV and Attachment C for they
may differ from the previous permit issuance. Failure to establish an adequate system for collecting and
maintaining the required operational information shall result in future compliance problems.
The Division has removed the following permit condition since the last permit issuance dated
August 15, 2017:
➢ Old Condition VI.2. — This permit is not voidable.
The following permit conditions are new since the last permit issuance dated August 15, 2017:
➢ Condition I.1. — Requires the Permittee to submit an engineering certification from a North
Carolina licensed Professional Engineer upon completion and prior to operation of the
permitted modifications.
.,_ North Carolina Department of Environmental Quality I Division of Water Resources
512 North Salisbury Street 1 1617 Mail Service Center I Raleigh, North Carolina 27699-1617
rvoarncaaouru
au �"� 919.707.9000

W. Mark Creech
August 22, 2019
Page 2 of 2
➢ Condition I.2. — This condition requires that the Permittee notify the Winston-Salem Regional
Office at least two business days in advance of initial operation of the constructed facilities so
that the Division can conduct a startup inspection.
➢ Condition I.3. — Requires MW-1 to be permanently abandoned within 60 days of the effective
date of this permit. Within 30 days of abandonment, a Well Abandonment Record (Form GW-
30) shall be completed for each well abandoned.
➢ Condition 1.4. — Requires a Final Operation and Maintenance Plan to be submitted for review
prior to operation of the permitted modifications.
➢ Condition III.7. — Requires a protective vegetative cover to be established and maintained on
all berms, pipe runs, erosion control areas, surface water diversions, and earthen embankments.
➢ Condition 111.8. — Requires metering equipment to be tested and calibrated annually.
➢ Condition IV.5. — Requires a maintenance log to be kept at this facility.
➢ Condition VI.10. — States this permit shall not be renewed if the Permittee or any affiliation
has not paid the required annual fee.
If any parts, requirements, or limitations contained in this permit are unacceptable, the Permittee
has the right to request an adjudicatory hearing upon written request within 30 days following receipt of
this permit. This request shall be in the form 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, NC 27699-6714. Otherwise, this permit shall be final and binding.
If you need additional information concerning this permit, please contact Ashley Kabat at (919)
707-3658 or ashley.kabaCaincderingov.
Sincerely,
?mda Culpepper, Director
• Division of Water Resources
cc: Guilford County Health Department (Electronic Copy)
Winston-Salem Regional Office, Water Quality Regional Operations Section (Electronic Copy)
Laserfiche File (Electronic Copy)
Digital Permit Archive (Electronic Copy)
Central Files

NORTH CAROLINA
ENVIRONMENTAL MANAGEMENT COMMISSION
DEPARTMENT OF ENVIRONMENTAL QUALITY
RALEIGH
CLOSED -LOOP 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
PERMISSION IS HEREBY GRANTED TO
Culp, Inc.
Guilford County
FOR THE
operation of a 20,000 gallon per day (GPD) wastewater treatment and closed -loop recycle facility consisting
of the:
construction and operation of: an air injection system for aeration in the 50,000 gallon finished water storage
tank; an evaporator to replace the second evaporator that has been taken out of service; a concrete secondary
containment structure surrounding the evaporator and associated catch basin; and all associated piping,
valves, controls, and appurtenances; and the
continued operation of. 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; an 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; and all associated piping, valves, controls, and
appurtenances
to serve the Culp Ticking CLRS, with no discharge of wastes to surface waters, pursuant to the application
received June 4, 2019, and in conformity with the Division -approved plans and specifications considered a
part of this permit.
This permit shall be effective from the date of issuance through November 30, 2021, shall void Permit No.
WQ0000962 issued August 15, 2017, and shall be subject to the following conditions and limitations:
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I. SCHEDULES
Upon completion of construction and prior to operation of the permitted modifications, the Permittee
shall submit an engineering certification from a North Carolina licensed Professional Engineer
certifying that the permitted facility has been constructed in accordance with G.S. 143-215.1,
Administrative Code Title 15A Subchapter 02T, this permit, and the Division -approved plans and
specifications. For phased and partially certified facilities, the Permittee shall retain the responsibility
to track further construction approved under this permit, and shall provide a final engineering
certification upon project completion. Mail the Engineering Certification to the Division of Water
Resources, Non -Discharge Branch, 1617 Mail Service Center, Raleigh, NC 27699-1617, or Non-
Dischar e.Re orts(a-).ncdenr. ov. [15A NCAC 02T .0116(a)]
The Permittee shall notify the Winston-Salem Regional Office, telephone number [phone], at
least two business days in advance of initial operation of the constructed facilities so that the Division
can conduct a startup inspection. [15A NCAC 02T .0108(b)(1)(B)]
3. Within 60 days of the effective date of this permit, monitoring well MW-1 shall be permanently
abandoned. Within 30 days of abandonment, a Well Abandonment Record (Form GW-30) shall be
completed for each well abandoned, and mailed to the Division of Water Resources, Non -Discharge
Branch, 1617 Mail Service Center, Raleigh, NC 27699-1617, or Non-Discharge.Reports�ncdenr.gov.
A North Carolina Certified Well Contractor shall abandon the monitoring wells according to the North
Carolina Well Construction Standards (15A NCAC 02C .0113) and local county rules. [15A NCAC
02C .0113, 02T .0 1 08(b)(1)(B)]
4. Prior to operation of the modified facilities, a Final Operation and Maintenance Plan shall be submitted
for review. The plan shall be sent to the Division of Water Resources, Non -Discharge Branch, 1617
Mail Service Center, Raleigh, NC 27699-1617 orNon-Disch=[e-mail]. [15A NCAC
02T .0108(b)(1)(B), 02U .0801(a)]
5. The Permittee shall request renewal of this permit on Division -approved forms no later than June 3,
2021. [15A NCAC 02T .0105(b), 02T .0109]
II. PERFORMANCE STANDARDS
The Permittee shall maintain and operate the subject non -discharge facilities so there is no discharge to
surface waters, nor any contravention of groundwater or surface water standards. In the event the
facilities fail to perform satisfactorily, including the creation of nuisance conditions due to improper
operation and maintenance, the Permittee shall take immediate corrective actions, including Division
required actions, such as the construction of additional or replacement wastewater treatment or recycle
facilities. [15A NCAC 02T .0108(b)(1)(A)]
2. This permit shall not relieve the Permittee of their responsibility for damages to groundwater or surface
water resulting from the operation of this facility. [15A NCAC 02T .0108(b)(1)(A)]
3. Groundwater monitoring wells shall be constructed in accordance with 15A NCAC 02C .0108
(Standards of Construction for Wells Other than Water Supply), and any other jurisdictional laws and
regulations pertaining to well construction. [ 15A NCAC 02C .0108]
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4. The facilities herein were permitted per the following setbacks:
a. The storage and treatment units were modified May 8, 1998. The setbacks for storage and treatment
units originally permitted or modified from February 1, 1993 to September 1, 2006 are as follows
(all distances in feet):
i. Each private or public water supply source: 100
ii. Surface waters: 50
iii. Each well with exception of monitoring wells: 100
iv. Each property line: 501
v. Nitrification field: 20
1 Setbacks to property lines are not applicable when the Permittee, or the entity from which the
Permittee is leasing, owns both parcels separated by the property line.
[15A NCAC 02H .02190)(5)]
III. OPERATION AND MAINTENANCE REOUIREMENTS
1. The Permittee shall operate and maintain the subject facilities as a non -discharge system. [15A NCAC
02U .0101]
2. The Permittee shall maintain an Operation and Maintenance Plan, which shall include operational
functions, maintenance schedules, safety measures, and a spill response plan. [15A NCAC 02U
.0801(a)]
3. Upon the Water Pollution Control System Operators Certification Commission's (WPCSOCC)
classification of the subject non -discharge facilities, the Permittee shall designate and employ a certified
operator in responsible charge (ORC), and one or more certified operators as back-up ORCs. The ORC
or their back-up shall operate and visit the facilities as required by the WPCSOCC. [15A NCAC 02T
.0117]
4. The Permittee shall prohibit public access to the wastewater treatment, storage, and closed -loop recycle
facilities. [15A NCAC 02U .0404(b)(1)]
5. The Permittee shall dispose or utilize generated residuals in a Division -approved manner. [15A NCAC
02U .0802, 02T .1100].
6. The Permittee shall not divert or bypass untreated or partially treated wastewater from the subject
facilities. [15ANCACO2T.0108(b)(1)(A)]
7. A protective vegetative cover shall be established and maintained on all berms, pipe runs, erosion
control areas, surface water diversions, and earthen embankments (i.e., outside toe of embankment to
maximum allowable temporary storage elevation on the inside of the embankment). Trees, shrubs, and
other woody vegetation shall not be allowed to grow on the. earthen dikes or embankments. Earthen
embankments shall be kept mowed or otherwise controlled and accessible. [15A NCAC 02U .0801(g)]
8. Metering equipment shall be tested and calibrated annually. [15A NCAC 02U .0801(d)]
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IV. MONITORING AND REPORTING REQUIREMENTS
1. The Permittee shall conduct and report any Division required monitoring necessary to evaluate this
facility's impact on groundwater and surface water. [ 15A NCAC 02T .0108(c)]
2. A Division -certified laboratory shall conduct all analyses for the required effluent, groundwater, and
surface water parameters. [15A NCAC 02H .0800]
The Permittee shall maintain a record of all residuals removed from this facility. This record shall be
maintained for five years, and shall be made available to the Division upon request. This record shall
include:
a. Name of the residuals hauler;
b. Non -Discharge permit number authorizing the residuals disposal, or a letter from a municipality
agreeing to accept the residuals;
c. Date the residuals were hauled; and
d. Volume of residuals removed.
[15A NCAC 02U .0802(b)]
4. The Permittee shall monitor the post -treatment wastewater recycling stream at the subject facilities at
the frequencies and locations for the parameters specified in Attachment A. Monitoring records shall
be recorded on the attached NDMR report form and shall be available at the facility for examination
by authorized Division personnel. [15 A NCAC 02T .0108(c)]
5. A maintenance log shall be kept at this facility. ,This log shall be maintained for five years, and shall
be made available to the Division upon request. This log shall include:
a. Visual observations of the plant and plant site; and
b. Record of preventative maintenance (e.g., changing of equipment, adjustments, testing, inspections
and cleanings, etc.).
[15A NCAC 02U .0801(h)]
6. Monitoring wells MW-2, MW-3R, MW-4, MW-5, and MW-6 shall be sampled at the frequencies and
for the parameters specified in Attachment C. All in in well construction forms well abandonment
forms and monitoring data shall refer to the permit number and the well nomenclature as provided in
Attachment C and Figure 1. [15A NCAC 02T .0105(m)]
7. Two copies of the monitoring well sampling and analysis results shall be submitted on a Compliance
Monitoring Form (GW-59), along with attached copies of laboratory analyses, on or before the last
working day of the month following the sampling month. The Compliance Monitoring Form (GW-59)
shall include this permit number, the appropriate well identification number, and one GW-59a
certification form shall be submitted with each set of sampling results. All information shall be
submitted to the following address:
Division of Water Resources
Information Processing Unit
1617 Mail Service Center
Raleigh, North Carolina 27699-1617
[15A NCAC 02T .0I05(m)]
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8. Noncompliance Notification:
The Permittee shall report to the Winston-Salem Regional Office, telephone number [phone]
within 24 hours of first knowledge of the following:
a. Treatment of wastes abnormal in quantity or characteristic, including the known passage of a
hazardous substance.
b. Any process unit failure (e.g., mechanical, electrical, etc.) rendering the facility incapable of
adequate wastewater treatment.
c. Any facility failure resulting in a discharge to surface waters.
d. Any time self -monitoring indicates the facility has gone out of compliance with its permit
limitations.
Emergencies requiring reporting outside normal business hours shall call the Division's Emergency
Response personnel at telephone number [phone], [phone], or [phone]. All
noncompliance notifications shall file a written report to the Winston-Salem Regional Office within
five days of first knowledge of the occurrence, and this report shall outline the actions proposed or
taken to ensure the problem does not recur. [15A NCAC 02T .0108(b)(1)(A)]
V. INSPECTIONS
1. The Permittee shall perform inspections and maintenance to ensure proper operation of the wastewater
treatment and recycle facilities. [15A NCAC 02U .0801(i)]
2. The Permittee shall inspect the wastewater treatment and recycle facilities to prevent malfunctions,
facility deterioration, and operator errors that may result in discharges of wastes to the environment,
threats to human health, or public nuisances. The Permittee shall maintain an inspection log that
includes the date and time of inspection, observations made, and maintenance, repairs, or corrective
actions taken. The Permittee shall maintain this inspection log for a period of five years from the date
of the inspection, and this log shall be made available to the Division upon request. [15A NCAC 02U
.0801(h), 02U .0801(i)]
3. Division authorized representatives may, upon presentation of credentials, enter and inspect any
property, premises, or place related to the wastewater treatment and recycle facilities permitted herein
at any reasonable time for determining compliance with this permit. Division authorized
representatives may inspect or copy records maintained under the terms and conditions of this permit,
and may collect groundwater, surface water, or leachate samples. [G.S. 143-215.3(a)(2)]
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V1. GENERAL CONDITIONS
1. Failure to comply with the conditions and limitations contained herein may subject the Permittee to a
Division enforcement action. [G.S. 143-215.6A, 143-215.613, 143-215.6C]
2. This permit is effective only with respect to the nature and volume of wastes described in the permit
application, and Division -approved plans and specifications. [G.S. 143-215.1(d)]
3. Unless specifically requested and approved in this permit, there are no variances to administrative codes
or general statutes governing the construction or operation of the facilities permitted herein. [15A
NCAC 02T .0105(n)]
4. The issuance of this permit does not exempt the Permittee from complying with all statutes, rules,
regulations, or ordinances that other jurisdictional government agencies (e.g., local, state, and federal)
may require. [15A NCAC 02T .0105(c)(6)]
5. If the permitted facilities change ownership, or the Permittee changes their name, the Permittee shall
submit a permit modification request on Division -approved forms. The Permittee shall comply with
all terms and conditions of this permit until the permit is transferred to the successor -owner. [G.S. 143-
215.1(d3)]
6. The Permittee shall retain a set of Division -approved plans and specifications for the life of the facilities
permitted herein. [15A NCAC 02T .0105(o)]
7. The Permittee shall maintain this permit until the proper closure of all facilities permitted herein, or
until the facilities permitted herein are permitted by another authority. [15A NCAC 02T .01050)]
8. This permit is subject to revocation or modification upon 60-day notice from the Division Director, in
whole or part for:
a. violation of any terms or conditions of this permit or Administrative Code Title 15A Subchapter
02T;
b. obtaining a permit by misrepresentation or failure to disclose all relevant facts;
c. the Permittee's refusal to allow authorized Department employees upon presentation of credentials:
i. to enter the Permittee's premises where a system is located or where any records are required
to be kept;
ii. to have access to any permit required documents and records;
iii. to inspect any monitoring equipment or method as required in this permit; or
iv. to sample any pollutants;
d. the Permittee's failure to pay the annual fee for administering and compliance monitoring; or
e. a Division determination that the conditions of this permit are in conflict with North Carolina
Administrative Code or General Statutes.
[I 5A NCAC 02T .0110]
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9. Unless the Division Director grants a variance, expansion of the facilities permitted herein shall not
occur if any of the following apply:
a. The Permittee or any parent, subsidiary, or other affiliate of the Permittee has been convicted of
environmental crimes under G.S. 143-215.6B, or under Federal law that would otherwise be
prosecuted under G.S. 143-215.613, and all appeals of this conviction have been abandoned or
exhausted.
b. The Permittee or any parent, subsidiary, or other affiliate of the Permittee has previously abandoned
a wastewater treatment facility without properly closing the facility.
c. The Permittee or any parent, subsidiary, or other affiliate of the Permittee has not paid a civil
penalty, and all appeals of this penalty have been abandoned or exhausted.
d. The Permittee or any parent, subsidiary, or other affiliate of the Permittee is currently not compliant
with any compliance schedule in a permit, settlement agreement, or order.
e. The Permittee or any parent, subsidiary, or other affiliate of the Permittee has not paid an annual
fee.
[15A NCAC 02T .0120(b), 02T .0120(d)]
10. This permit shall not be renewed if the Permittee or any affiliation has not paid the required annual fee.
[15A NCAC 02T .0120(c)]
Permit issued this the 22°a day of August 2019
NORTH CAROLINA ENVIRONMENTAL MANAGEMENT COMMISSION
inda Culpepper, Director
Division of Water Resources
By Authority of the Environmental Manage ent Commission
Permit Number WQ0000962
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Permit No. WQ0000962
Culp, Inc.
Culp Ticking CLRS
ENGINEERING CERTIFICATION
❑ Partial ❑ Final
Closed -Loop Recycle System
August 22, 2019
Guilford County
I, , as a duly licensed North Carolina Professional
Engineer, having ❑ periodically / ❑ fully observed the construction of the permitted facilities, do hereby
state to the best of my abilities that the facility was constructed in compliance with G.S. 143-215.1,
Administrative Code Title 15A Subchapter 02U, this permit, and the Division -approved plans and
specifications.
Documentation of any variation to this permit, and the Division -approved plans and specifications, is in the
attached as -built drawings.
Description of variations:
Professional Engineer's Name
Firm Name i Firm No.
Address
City I State I Zip Code
Telephone
Email
Seal, Signature, and Date
THE COMPLETED ENGINEERING CERTIFICATION, INCLUDING ALL SUPPORTING
DOCUMENTATION, SHALL BE SENT TO THE FOLLOWING ADDRESS:
NORTH CAROLINA DEPARTMENT OF ENVIRONMENTAL QUALITY
DIVISION OF WATER RESOURCES
NON -DISCHARGE BRANCH
By U.S. Postal Service By Courier/Special Delivery
1617 MAIL SERVICE CENTER 512 N. SALISBURY ST.
RALEIGH, NORTH CAROLINA 27699-1617 RALEIGH, NORTH CAROLINA 27604
WQ0000962 Version 3.2 Shell Version 180901
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