p. 1 

# OAR Box 

# 1490 Prepped by Charmelle Mathews



### Document

Number: 

# 9 ) IV-B- 9 Docket Number: 

# A-94-5 2

Printed 8/4/200811:51:46

AM Sheet 9of 273P. 2

MEMORANDU M NONCONFIDENTIA L VERSIO N BASE D O N PLAN T COMMENT S TO : Keith Barnett

U.S . EPA/ESD/MIS G FROM : Kenneth R . Meardo n

Pacifi c Environmenta l Services , Inc . (PES ) DATE : Marc h 18 , 2002 , Revise d Septembe r 17 , 200 2 SUBJECT : Tri p Repor t fo r Januar y 17 , 2002 , Visi t

t o Profor[ n LOCATION : Proform , Wes t Memphis , A R ATTENDEES : cr-- > o 7 */ r i i UJ L • (• '•• J EP A AI R DOCKE T

Mr . Crai g Peterso n Mr . Roderic k

Anni s Mr . Joh n Schweitze r Mr . Ro b Haberiei n Mr . Lyndo n Pool e Mr . Bil l Swafford Mr . Nic k Nixo n Mr . Keith Barnett Dr . Kenneth Meardo n Mr . Fran k

Meadow s Ms . Susa n Cassid y Profor m(952 ) 887-180 7 Profor m(870 ) 735-535 3 Composite s Fabricator s Associatio n (734 ) 662-016 2 Engineerin g Environmenta l Consultin g Service s (410 ) 268-736 7 Arkansa s DE Q (501 ) 682-074 7 Arkansa s DE Q (501 ) 682-074 6 Arkansa s DE Q (870 ) 935-722 1 EPA/MIC G (919 ) 541-560 5 PE S (919 ) 941-033 3 PE S (919 ) 541-033 3 PE S (919 ) 541-033 3 PURPOS E Th e purpos e o f

thi s tri p wa s t o observ e an d discus s plan t operation s t o evaluat e th e feasibility o f

permanen t

tota l enclosure s o r

th e us e o f

buildin g enclosure s t o captur e emission s i n respons e t o publi c comment s mad e o n th e propose d NESHA P fo r reinforce d plastic s composites . INTRODUCTIO N Th e facility , whic h i s locate d o n 2 7 acres , starte d buildin g part s i n 1997 . Th e facility produce s barg e cover s fo r acompan y i n Indian aan d undergroun d storag e tank s (UST ) fo r nationa l distribution . Th e barg e cove r productio n are ai s approximatel y 47,70 0 squar e feet an d th e US T productio n are ai s approximatel y 15,80 0 squar e feet . A Phas e II I expansio n i s bein g considered , whic h woul d ad d anothe r 52,00 0 cf

mo f ai r flo w t o th e facility .P. 3

Keit h Barnet t March 18 , 200 2 Pag e 2 The barg e cover s ar

e used o n grai n barges . Steel barg e cover s ma y flak e an d dro p stee l flake s int o th e grain ; th e RF

P cover s d

o not do this . The US T are use d primaril y fo r storag e o f gasoline , water , an

d chemicals . Th e US T are warrante d fo r 3 0 year s an

d mus t b e goo d i n an

y ground condition s in which the y are installed . Th e US T underg o stringent structura l testing , including vacuuman

d pressurize d tests . Directe d air

flo w system s (push-pull ) are use d withi n th e facility . Th e ai r flo w system was designe d b y Frees , who ha s returne d o n severa l occasion s t

o increas e th e air

flows in order t o reduc e employe e exposure . Th e facilit y ha s conducte d employe e exposur e testin g an

d foun d exposure s t

o b e belo w 5 0 ppm . However , worker s stil l hav e to b e rotate d to avoi d exceedin g thi s limit . It

wa s noted an

d observe d that , a

t laminat e statio n 2 , som

e worker s are o n th e downwin d side o f the mold . There ar

e heater s an

d chiller s locate d in th e genera l ventilatio n syste mt o th e productio n area . Th e facilit y ha s conducte d test s to determin e styren e concentration s in th e stacks . Mr . Haberiei n indicate d tha

t the y ha d trie d t o qualif y th e buildin g a s aMetho d 20 4 complian t enclosure , but

tha t th e buildin g ha

d failed . It

was note d tha

t th e firs t sourc e tes t

inspector (Mr . Ke n Fell s o f ADEQ ) requeste d ademonstratio n o f Metho d 204 . H e wa s show n tha t th e buildin g di d no t

mee t Metho d 20 4 usin g smok

e and , rather

tha n cal l of f th e sourc e test , ADE Q waived th e criteri aan

d note d tha

t th e tes t was conducte d wit

h "capture a s bes t

a s possible. " Barg e Cove

r Production . The descriptio n o f

th e barg e cove

r productio n proces s ha s been claime d t o b e confidentia

l busines s information . US T Productio n The constructio n o

f US T occur s a

t wor k station s an

d no t i n acontinuou s lin e fashion an d begin s wit h buildin g tw o halve s i n rotatin g molds . Worker s stand o n platform s insid e th e mold s an d us e FI T technology to appl y th e resi n (no ge

l coa t i s used ) to th e rotatin g mold , which rotate s a t 24 revolution s pe r

minute . The mol d i s ventilate d wit h ai r flow s rangin g fro

m5 0 to 10 0 fee t per minut e a t th e entranc e to the mold . Currently , tw o mold s are 8-foo t diamete r an d th e othe r tw o are 10-foo

t diameter . Constructio n ofth e US T follow s aproprietar y schedule , which i s ver

y complex , i n order

t o develo p asaf e product . I t

was note d tha

t there i s aver

y high potentia

l liabilit y wit h a n in-groun d failur

e o f a n UST . The rotatio n o

f th e mold keep s th e resi n agains t the inside o

f th e mol d a s i t cures . Th e concentratio n i n th e mol d decrease s significantl y whe n th e sprayin g stop s an d a s th e cure progresses . Thus , the averag e concentratio n in th e ai r flo w fro mth e US T mol d ma

y b e hig h whil e spraying , bu

t i t drop s afte

r rollin g an

d durin g curing . Ther

e wil l b e alon g perio d o

f time whe n th e concentratio n wil l b e low . The ai r ventilatio n systemi s turne d of f whe n the US T i sP. 4

Keit h Barnet t March 18 , 200 2 Pag e 3 pulle d fro mth e mold . The halve s are removed fro mth e mold s an

d then joine d usin g manua

l applicatio n techniques . I n addition , manways , collars , an d fitting s ar

e attache d to th e US T a

s needed usin g manua l applicatio n techniques . A resi n putty , comprise d o f resi n used in th e constructio n o f th e US T an d filler , i s applied to eve

n ou t righ t angle s an d appl y fitings. Miscellaneou s 1 . Utilit y cost s fo r electricit y hav e been constan

t sinc e th e facilit

y bega n operation . 2 . The increas e in gas usag e i n 200 1 versu s previou s year s i s likely explaine d by increas e i n operatin g hour s (numbe r o f shifts ) an d aver y col d winter . 3 . Door s coul d b e considere d natura l draf t openings , although i

t was questioned as t

o wh y anyone woul d wan

t t o do s o in tryin g t

o qualif y abuildin g enclosur

e a s aMetho d 20 4 enclosure . Actio n Item s EP A requeste d tha

t Profor mprovide informatio n on resi n an d ge l coa t usag e an d HAP contents .