OAR Box 1413 

Prepped by Ollie Stewart 

Document Number: 

60) 11-1-60 

Docket Number: 

A-94-52 

Printed 7/9/2008 3:11:23 PM Sheet 60 of 114 

P.1 
P.2 

,isi<;n of Air Quality 

Regional Office 

lity Inspection Report AQ-16 

County: WILSON CO A 9 4 52 . 

ERSHIGS INC 11 = 1 '6 0 

Permit: 06294 R03 

tf 

Paael 

ERSHIGS INC 

300 LAYTON AVENUE 

me: WILSON 

me: (919)237-5371 

Region: 5 

SIC: 3089 

CoyPrem: WILSON CO /00163 

: (Compliance): MR. VINCENT KEENE Compliance Status: Facility Classification: 

tion Date: 09/05/96 

tion Type: 27 

Last Inspection: 04/28/93 

Next Inspection: 06/30/97 

Permit Number: 06294 R 03 

Issue Date: 05/10/95 

Expires: 09/30/98 

Signature: fcCtW < 1i« ^ 

Date :

 Ockj'Wv^ TM} H-7 w 

lenda tions: 

ii. W HA tf}«A£\c\f.-< Inspector: RPB 

Coinspector: 

-acking: • ITS • AQEI I I Comp795 K[ I-Steps Action Number: 

ility Location: 

RRO take US 64 East to Zebulon and merge East onto US 264 East to Wilson. Follow course of road, it will be Raleigh Road then 

: to Hines Street. Four blocks after crossing Tarboro Street Lodge Street will be to yourJeft. Turn left onto Lodge Street travel one 

o Jones Street and turn right. The facility will be at the end of Jones Street where Layton Avenue crosses. (Refer to attached map) 

ility Contact: 

lr. Vincent Keene-Environmental/Safety Coordinator ,Ojf O 9 15^3 

ility Description: '— —. _ 

'acility manufactures assorted fiberglass reinforced tanks by wrapping resin coated f berglass•ifran&fflar-ouTidEEoylindrical mandrels and 

ig to dry exothermically. The fiberglass pipes are manufactured in the same way. All pipes and tanKTare'custom-made'to the fit the 

customer order. The associated spigots, valves and flanges are prepared in a mold shop area. These items are cut and ground and 

>ns are controlled through two cyclone/bagfilter systems. The resins are mixed in 55 gallon drums and are no longer mixed in the large 

tank. All emissions other than those controlled through the cyclone/bagfilter are vented through the roof. 

>ection conducted based on Air Permit #6294R3: 

1: May 10, 1995 

ing on: September 30, 1998 

ptember 5, 1996, Patrick Butler met with Mr. Vincent Keene to conduct a compliance inspection. Permitted items and notes from the 

ion are as follows: 

glass filament winder for tank production (ID No. TW), .-^ 

. winder is located in the tank/pipe winder section ofthe facility. It can manufacture varying tank sizes up to 14 feet in dian£e}er and 40 

g. Tanks can be made larger than this, however they have to be pieced together at the site of the tank in sections. The tankFare made 

! mandrels where they are slowly rotated. A "chop-gun" is used to dispense resin into a tray where the fiberglass strafiiR ar£aipped and 

y wound up and down overlapping at different rates of speed for the desired strengths/thicknesses. The tanks are not pantedg Instead a 

; of resin, wax, and pigment is dispensed out ofthe same chop-gun that the resin is dispensed from to make a coating yfcbich[E}oks like 

rhe mixture is also applied with hand rollers on the pipes. This source was observed in operation, finishing a large tank. T55 styrene 

is most noticeable in this area. i 5 & 

co 

'0 (2) glass filament winders for pipe production (ID Nos. PW1 and PW2), c» 

pipe winders are at the rear of the facility in the open warehouse type area. Pipes are manufactured the same way the tanks-are. The 

nders can make pipes from 6" to 78". The winding is computer controlled. This area also has one extra pipe turner (not a winder), 

otates the pipe until it has cured enough to be removed from the mandrel. One interesting point is that the tanks/pipes must continue 

until they are substantially cured or all resin will drip off of the bottom due to gravity. This area also has an additional small pipe 

for pipes of 1.5" to 4", however this was not in operation. It has not been permitted, but has been at the facility for years. It is 

:ntly used and should be added to the permit at next renewal/modification. Again, there are two large pipe winders and one tiny pipe 

nd lay-up operations for manual application of resin and fibrous glass (ID No. HLU), 
P.3 

E; n of Air Quality 

Regional Office 

lity Inspection Report AQ-16 

County: WILSON CO 

ERSHIGS INC 

Permit: 06294 R03 

Page 2 

s is at the front of the building and is a very labor intensive process. All valves, flanges and spigots are made on molds in this area, 

rs use buckets of resin to make these components. Pigments can be added to the resins for different colors. This area was observed 

sveral workers busy making different components. This is where the strongest styrene odors were detected. 

vo (2) chopper guns for spray application of resin and fibrous glass (ID No. CHG-1 and CHG-2), 

se two chopper guns are where the tops and bottoms of the tanks are made. Neither was in operation during this visit. By the 

ance of the equipment it looked like they are frequently used. 

>ol cleaning operations utilizing a photochemically reactive solvent (ID No. SOL), 

5 is a tank in the valve and flange area which utilizes DiAcetone Alcohol (DAA). This is where the hand lay-up rollers, knives, etc are 

i. It should be noted that since DAA was delisted as a photochemically reactive material, that the facility currently does not use any 

hemically reactive solvents. *Styrene which is photochemically reactive is not used as a solvent in this type of operation, therefore the 

ay limit does not apply*. The vat is covered at all times and the DAA is recycled through a still several times until a new 55 gallon 

> used. According to Mr. Keene, the green silica flour used in the flange production shortens the life of the DAA greatly. 

cyclone/bagfilter system (24 inches in diameter cyclone and 208 square feet of filter area bagfilter, in series, ID No. CSI) installed on a 

and grinding operation (CGD), 

> filtration system is just outside the building in the flange/valve production area. It is a Murphy Rogers system and appears to be well 

ined although there is no specific maintenance requirement in the current permit. The cyclone vents the exhaust to a plenum which 

Dur large internally filtering bagfilters. Each of the four bagfilters vent to one 55 gallon drum. The drums are emptied weekly and the 

carried to the landfill for disposal. Inside the plant this system has 9 potential hook-ups, but currently only 6 are being used. No VE 

served. 

cyclone/bagfilter system (24 inches in diameter cyclone and 208 square feet of filter area bagfilter, in series, ID No. CS2) installed on a 

grinding operation (SGD), 

; system is identical to the system described above. It is located at the rear of the pipe winding area in the corner. It is being used 

ently when spigots need to be made. It was not in operation during my visit, however Mr. Keene demonstrated that it was functional by 

it on briefly. 

«JERAL FACILITY OBSERVATIONS: 

e is an old mixing room at the facility which was used years ago, but this mixing room is never used anymore, as per Mr. Keene. All 

re mixed in 55 gallon drums and the catalyst is applied at the guns or added to small batches at the time of application. 

ts of polyurethane foam are manually added to tanks if the customer so desires. This process has no emissions and does not require a 

rai wooden molds are made for custom parts. They are all made with hand operated tools which do not vent to any stack or control 

ent. 

m 

^articular resins used at the facility are polyester and vinyl ester which contain an estimated 35-40% styrene. MEKP (Methyl Ethyl 

Peroxide) is used in cleaning the chop guns. Further examination of the product revealed that only 7% is actually MEK.-pAcetone is no 

lsed to clean tools it is only used for QA tank durability tests (very small quantities). The company also uses a 98iFand §§P corrosion 

for the insides of the tanks. (PB-'93). ^ ^ 

o 

three tanks are fitted at any one time. This is a bottleneck at the facility since they only employ 3 fitters. These Rggple cot the holes in 

:s and add the spigots, flanges, valves, tops and bottoms manually. cr» <•/> 

Sheets were spot checked and nothing striking was observed. Over 10 TPY of styrene is emitted at this facility and smgjit is 

red a HAP this is what makes the facility Title V. Styrene is classified as a photochemically reactive material, however sitae styrene is 

1 as a solvent at this facility the 40 lb/day limitation is not applicable. 

bllowing are unique specific conditions and limitations: 

ITie facility must prevent fugitive particulate and VOC emissions from becoming airborne. <In Compliances 
V PRODUCT ANALYSIS vv KJt.ti.oiiut.Am. 

(SOLVENTS, PAINTS, FINISHING MATERIALS, ETC.) 

, page 2 of 2 

AUCTIONS: COMPLETE ONE SHEET FOR EACH TYPE OF PRODUCT. GIVE CHEMICAL NAMES, NOT BRAND NAMES OR 

DEVIATIONS. FOLLOW THESE PROCEDURES IN DETERMINING WHETHER OR NOT A PRODUCT OF VARIOUS 

'ENTS IS REACTIVE (R) OR NONREACTIVE (NR). 

GROUP THE CONSTITUENTS ACCORDING TO WHETHER OR NOT THEY FIT THE DESCRIPTION IN CLASS (1) (2) 

(3) OR NONE OF THE ABOVE CLASSES. IF A CONSTITUENT COULD FALL IN TWO GROUPS, IT IS PLACED IN*THE 

MORE LIMITED GROUP. 

DETERMINE THE VOLUME PERCENT OF ALL LIQUID CONSTITUENTS OF THE PRODUCT AS APPLIED. (THIS SHOULD 

TOTAL 100%.) 

TOTAL" THE VOLUME PERCENT FOR EACH CLASS (1, 2, AND 3). IF THE VOLUME PERCENT FOR ANY CLASS 

EXCEEDS THE PERCENT LIMIT FOR THAT CLASS OR IF THE TOTAL FOR CLASSES (1), (2), (3) EXCEEDS 20 PERCENT, 

THEN THE PRODUCT IS REACTIVE. IF NONE OF THESE LIMITS ARE EXCEEDED, THE PRODUCT IS NONREACTIVE. 

duct Name 

Polyester Resin 

Product No. This Product is Classified as: 

(x) Reactive (R) ( ) Nonreactive (NR) 

IGANIC 

.ASS 

PRODUCT COMPOSITION 

DESCRIPTION OF ORGANIC CLASS NAME OF CONSTITUENTS 

% BY VOLUME OF THE 

TOTAL VOLATILES 

ACTUAL % LIMIT 

A COMBINATION OF HYDROCARBONS, 

ALCOHOLS, ALDEHYDES, ESTERS, OR 

(1) KETONES HAVING AN OLEFINIC OR 

CYCLOOLEFINICTYPE OF UNSATURATION EXCEPT PERCHLOROETHYLENE 

- 5 PERCENT 

A COMBINATION OF AROMATIC 

HYDROCARBONS WITH EIGHT OR 

(2) MORE CARBON ATOMS TO THE 

MOLECULE EXCEPT ETHYLBENZENE 

- 8 PERCENT 

. A COMBINATION OF ETHYLBENZENE, 

KETONES HAVING BRANCHED 

(3) HYDROCARBON STRUCTURE, 

TRICHLOROETHYLENE, OR 

TOLUENE 

-20PERGENT 

ALL SOLVENTS NOT LISTED ABOVE 

Produc 49.85 t Uage (gal/hr) . 

Product Weight (lb/gal). 

Weight of volatiles in product (lb/gal) 3.6 

SUB-TOTAL = 

5% 

Styrene 100% 

SUB-TOTAL = 

SUB-TOTAL« 

20% 

8.18 TOTAL* 100% 

100% 

Total % volatiles by volume in product 44.0 .% 

IF THE TOTAL REACTIVE PRODUCT EMISSIONS EXCEED 40 POUNDS/DAY FROM YOUR FACILITY, DESCRIBE TH! 

CONTROL-METHODS EMPLOYED FOR MEETING COMPLIANCE WITH DEM REGULATION 15 NCAC 2D .0518: 

According to the DEM Regulation 2D.0518, paragraph (f) , any source to which Regulation 2D. 

•0518, paragraph (d) applie s shall be exempted of the 40 lb./day photoreactive emission 

cap if the facilit y is operated in such a manner that i t meets the requirements

 vof ..Best 

Available Control Technology (BACT). Ershigs, Inc. believe s the current raw material- and 

technology used constitute s BACT. 0££ j>$ 1994 

3 

CWS&L. w& 
c r

 HYDROCARBON EMISSION SOURCES 

-, page 1 of 2 

i: For emission sources of volatile organic compounds including spray booths, painting, finishing, printing and solvent usage. 

SE TYPE OR PRINT. fiTTACH TO THE GENERAL INFORMATION FORM "A". IF APPLICABLE, ATTACH AIR POLLUTION 

ROL DEVICE FORM "C". 

iission Source and ID NO. (FROM GENERAL INFORMATION FORM "A", ITEM 6) Tan k winde r (TW) . pi p e . winders 

, PW2); Hand Lay-up (HLU); Tool Cleaning Solvents (SOL); Chopper Guns (CHG1. CHG2) 

•cess Description (INDICATE NO. OF IDENTICAL PROCESSES - BOOTHS, FINISHING LINES, ETC.); Glass strands 

e dipped through a resin bath and wound onto mold (TW. PWl. PW?): nr chopped and 

rayed on mold (CHG1, CHG2); or applied manually with hand tools (HLU). 

mit Application is made for (CHECK ONE ONLY): 

New Source ( ) Existing Source (x) Modification - Last Permit No. ^ 

mmence Construction Date

 Jul V '. , 19 87_ Operation Date Julv ..19-82-

P.5 

ximum Source Operation: J i Hours/Day .Days/Week -12 Weeks/Year 

t all VOLATILE ORGANIC COMPOUNDS as used: USE NEXT PAGE (PRODUCT ANALYSIS WORKSHEET) TO DETERMINE 

PRODUCT IS REACTIVE (R) OR NONREACTIVE (NR) AS DEFINED BY 15 NCAC 2D .0518. 

TOTAL 

PRODUCT 

USAGE 

(gal/day) 

259. 6 

UCT NAME 

/este r resin-TW 

R 

x 

NR 

-PWl 

-PW2 

-HLU 

-CHG1 

-CHG2 

cleaning solvent 

X 

X 

X 

X 

X 

X 

PRODUCT 

WEIGHT 

(lb/gal) 

8.1 8 

8.1 8 

8.1 8 

VOLATILE 

BY WEIGHT 

X (lb/gal) 

* 3. 6 x .075 

VOC 

EMISSION 

RATES 

(lb/day) (ton/yr) 

7Q.1*A 1Q-Q4 

129. 7 y 3. 6 x .075 = 35.0*A 5:46 

8.1 8 

129. 7 y 3. 6 x .075 = 35.0*A 5.46 

196.8 xhL .075 = 53.1*A 8.28 

8.18 40.9 

8.18 40.9 

* 3.6 x 

xh±JL 

11 = 16.2*A 2.53 

11 - 16.2*A 2.53 

7.818 19. 2 Y 7.81 8 1.2*B 

'1 Ethyl Ketone 8.0 

tWfcATE SHEET(S) IF NEEDED 

10-56 yQ.16 1.69*C 

0.156 

0.26 

TOTAL = 228.49 35.62 

cribe the storage and handling methods used in employing the organic products listed above. Include the ultimate disposal method: 

he collected waste and wastewater. Resin stored in 55-gal. drums. Tool cleaning solvent stored 

i 55-gal. drums. Hardened waste/resin disposed in solid waste landfill . Tool cleaning 

ilvent recycled onsite . Hardened distillatio n residue disposed in solid waste landfill . 

face Coating Operations: 

cribe Articles Being Coated: Fiber reinforced plasti c products (CHG) 

•hod of Spray: 

Airless ( ) Air Atomize ( ) Electrostatic ( ) Other. 

Stack Flow 

Rate (CFM) 

>aust (x) None 

itrol: ( ) Waterwash 

( ) Other 

( ) Dry Filter 

( ) Baffles 

( ) Adsorption 

( ) Incineration 

Control Efficiency 

Particulate % 

Hydrocarbon % 

of Bake Ovens Method of 

Heating: 

( ) Steam ( ) Direct Fired 

( ) Electric ( ) Other 

Fuel Type. 

Usage 

'ent Degreasing Operations: 

cribe Articles Being Degreased: Tools are cleaned in closed top vats. 

reiser Type: 

Open Top Vapor (x) Cold Qeaning ( .) Conveyorized ( ) Other. 

k Capacity 

Ions) 

2-8 

Makeup Rate 

(gallons/day) 

19.2 5 

Exhaust Control: ( ) None 

( ) Adsorption 

( ) Other 

( ) Surface Condensers 

( ) Closed Loop :. 

K: -See emissions calculations-Attachment A 

J: See emissions calculations-Attachment B 

2: See emissions calculatignsrAttachment C H