# OAR Box 1413 Prepped by Ollie Stewart



## Document

Number: 

# 60 ) 11-1-6 0 Docket Number: 

# A-94-5 2

Printed 7/9/2008 3:11:23 PM Sheet 60 of 114 P. 1P. 2

,isi<; n o f Ai rQualit y Regiona l Offic e 

## lit y Inspectio n Repor t

AQ-1 6 County : WILSO N C O A 9 4 52
. ERSHIGS IN C 1

1 = 1 '6 0 Permit : 0629 4 R0 3 

# tf

Paae l ERSHIG S IN C 300 LAYTO

N AVENU

E me : WILSO

N me : (919)237-537 1 Region : 5 SIC : 308 9 CoyPrem : WILSO N C O /0016 3

: (Compliance) : MR

. VINCEN T KEEN E Complianc e Status : Facilit y Classification : tion Date : 09/05/9 6 tion Type : 2 7 Las tInspection : 04/28/9 3 Nex tInspection : 06/30/97 Permi tNumber : 06294 R0 3 Issu e Date : 05/10/9 5 Expires : 09/30/9 8 Signature : fcCtW < 1i« ^ Date : Ockj'Wv ^ TM } H-7 w lend a tions : ii. W H

A tf}«A£\c\f.-< Inspector : RP B Coinspector : -acking : 

### • IT

S • AQE

I I I Comp79

5 K [ I-Step s Actio n Number : ilit y Location : RR O tak e U S 6 4 Eas t

t o Zebulo n an dmerg e Eas t ont o U S 26 4 Eas t

t o Wilson
. Follo w cours e o f road , i t wil l b e Raleig h Roadthe n : t o Hine s Street . Fou r

block s after

crossin g Tarbor o Stree t

Lodg e Stree t

wil l b e t o yourJeft
. Tur n lef t ont o Lodg e Stree t

trave l on e o Jone s Stree t

an dturn right
. Th e facilit y wil l b e at

th e en do f

Jone s Stree t

wher e Layto n Avenu e crosses . (Refe r t o attache dmap ) ility Contact : lr
. Vincen t

Keene-Environmental/Safet y Coordinato r ,Oj f O 9 15^ 3 ility Description : '

—— . _ 'acilit y manufacture s assorte dfiberglas s reinforce dtank s b y wrappin g resi n coate df berglass•ifran&fflar-ouTidEEoylindrica l mandrel s an d ig t o dr y exothermically
. Th e fiberglas s pipe s ar e manufacture di n th e sam e way . Al l pipe s an dtanKTare'custom-made't o th e fit th e custome r order
. Th e associate dspigots , valve s an dflange s are prepare di n amol dsho p area . Thes e item s ar e cu t an dgroun dan d >n s ar e controlle dthroug h tw o cyclone/bagfilte r systems . Th e resin s are mixe din 5 5 gallo n drum s an dar e n o longe r mixe di n th e larg e tank
. Al l emission s othe r than thos e controlle dthroug h th e cyclone/bagfilte r ar e vente dthroug h th e roof
. >ectio n conducte dbase do n Ai r Permi t #6294R3 : 1 : Ma y 10 , 199 5 in g on : Septembe r

30 , 199 8 ptembe r 5 , 1996 , Patric k

Butle r me t wit h Mr . Vincen t

Keen e to conduc t

acomplianc e inspection
. Permitte ditem s an dnote s fro mth e io n are a s follows : glas s filament

winde r fo r tank productio n (I D No . TW) , .- ^

. winde r i s locate di n th e tank/pip e winde r sectio n ofth e facility
. I t ca n manufactur e varyin g tank size s u p t o 1 4 feet

in dian£e}e

r an d4 0 g . Tank s ca

n b e mad e large r

tha n this , howeve r

the y hav e t o b e piece dtogethe r at th e sit e o f

th e tank i n sections
. Th e tankFar e mad e ! mandrel s wher e the y ar e slowl y rotated
. A "chop-gun " i s use dt o dispens e resi n int o atray wher e th e fiberglass strafiiRar£aippe dan d y woun du p an ddow n overlappin g a t differen t rate s o f spee dfor th e desire dstrengths/thicknesses
. Th e tank s ar e no t panted g Instea da ; o f resin , wax , an dpigmen t

i s dispense dou t

ofth e sam e chop-gu n tha t th e resi n i s dispense dfromt o mak e acoatin g yfcbich[E}ok s like rh e mixtur e i s als o applie dwit h han droller s o

n th e pipes
. Thi s sourc e wa s observe di n operation , finishin g alarg e tank
. T5 5 styren e i s mos t noticeabl e i n thi s area . i 5 & co
' 0 (2 ) glas s filament

winder s for

pip e productio n (I D Nos . PW 1 an dPW2) , c » pip e winder s ar e at

th e rea r o f th e facility in th e ope n warehous e typ e area . Pipe s ar e manufacture dth e sam e way th e tanks-are
. Th e nder s ca n mak e pipe s fro m6 " t o 78" . Th e windin g i s compute r controlled
. Thi s are aals o ha s on e extr apip e turne r (no t awinder) , otate s th e pip e unti l i t

ha s cure denoug h t o b e remove dfro mth e mandrel
. On e interestin g poin t i s tha t th e tanks/pipe s mus t

continu e unti l the y ar e substantiall y cure do r al l resi n wil l dri p of

f o f th e botto mdu e t o gravity
. Thi s are aals o ha s an additiona l smal l pip e fo r pipe s o f 1.5 " t o 4" , howeve r

thi s wa s no t

i n operation
. I t

ha s no t bee n permitted , bu t

ha s bee n at

th e facility fo

r years . I t i s :ntl y use dan dshoul db e adde dt o th e permi t at nex t renewal/modification
. Again , ther e ar e tw o larg e pip e winder s an don e tiny pip e

ndlay-u p operation s for

manua l applicatio n o f

resi n an dfibrou s glas s (I D No . HLU) ,P. 3

E ; n o f Ai rQualit y Regiona l Offic e 

## lit y Inspectio n Repor t

AQ-1 6 County : WILSO N C O ERSHIG S IN C Permit : 06294 R0 3 Pag e 2 s i s at th e front o f th e buildin g an di s avery labo r intensiv e process . Al l valves , flange s an dspigot s ar e mad e o n mold s in thi s area , r s us e bucket s o f

resi n t o mak e thes e components . Pigment s can b e adde dt o th e resin s fo r differen t colors
. Thi s are awa s observe d svera l worker s bus y makin g differen t components . Thi s i s wher e th e stronges t styren e odor s wer e detected
. v o (2 ) choppe r

gun s fo r spray applicatio n o f

resi n an dfibrous glas s (I D No . CHG- 1 an dCHG-2) , s e tw o choppe r

gun s ar e wher e th e top s an dbottom s o f th e tank s are made
. Neithe r wa s i n operatio n durin g thi s visit
. B y th e anc e o f th e equipmen t

i t looke dlik e the y ar e frequentl y used
. >o l cleanin g operation s utilizin g aphotochemicall y reactiv e solven t (I D No . SOL) , 5 i s atank

in th e valv e an dflang e are awhic h utilize s DiAceton e Alcoho l (DAA) . Thi s i s wher e th e han dlay-u p rollers , knives , et c ar e i
. I t shoul db e note dtha t

sinc e DA A wa s deliste da s aphotochemicall y reactiv e material , tha t th e facilit y currentl y doe s no t

us e an y hemicall y reactiv e solvents
. *Styren e whic h i s photochemicall y reactiv e i s no t use da s asolven t

i n thi s typ e o f

operation , therefore th e a y limi t doe s no t apply*
. Th e vat

i s covere dat

al l time s an dth e DAA i s recycle dthroug h astil l several time s unti l ane w 5 5 gallo n > used
. Accordin g t o Mr . Keene , th e gree n silic aflou r use din th e flang e productio n shorten s th e lif e o f th e DA A greatly
. cyclone/bagfilte r

syste m(2 4 inche s in diamete r cyclon e an d20 8 squar e feet o f filter are abagfilter , in series , I D No . CSI ) installe do n a an dgrindin g operatio n (CGD) , > filtration syste mi s jus t

outsid e th e buildin g in th e flange/valv e productio n area . I t i s aMurph y Roger s syste man dappear s t o b e wel l inedalthoug h ther e i s n o specifi c maintenanc e requiremen t in th e curren t

permit
. Th e cyclon e vent s th e exhaus t t o aplenu mwhic h Du r larg e internall y filtering bagfilters
. Eac h o f th e fou r bagfilter s ven t

t o on e 5 5 gallo n drum
. Th e drum s are emptie dweekl y an dth e carrie dt o th e landfil l for

disposal
. Insid e th e plan t thi s syste mha s 9 potentia l hook-ups , bu t currentl y onl y 6 are bein g used
. N o V E served
. cyclone/bagfilte r

syste m(2 4 inche s i n diamete r cyclon e an d20 8 squar e feet o f filter are abagfilter , i n series , I D No . CS2 ) installe do n a grindin g operatio n (SGD) , ; syste mi s identica l t o th e syste mdescribe dabove
. I t i s locate da t

th e rea r o f th e pip e windin g are ai n th e corner . I t i s bein g use d entl y when spigot s nee dt o b e made
. I t wa s no t in operatio n durin g m

y visit , howeve r

Mr . Keen e demonstrate dthat i t wa s functional b y i t on briefly
. «JERA L FACILIT Y OBSERVATIONS : e i s a n ol dmixin g roo mat

th e facility whic h wa s use dyear s ago , bu t thi s mixin g roo mi s neve r use danymore , a s pe r

Mr . Keene . Al l r e mixe din 5 5 gallo n drum s an dth e catalys t i s applie dat

th e gun s o r

adde dt o smal l batche s a t th e tim e o f

application
. t s of polyurethan e foa

mar e manuall y adde dt o tank s i f th e customer

s o desires
. Thi s proces s ha s n o emission s an ddoe s no t requir e a

ra i woode n mold s ar e mad e fo r custo mparts . The y ar e al l mad e wit h han doperate dtool s whic h d o no t ven t t o an y stac k

o r contro l ent . m ^articula r resin s use da

t th e facility ar e polyester

an dviny l este r

whic h contai n a

n estimate d35-40 % styrene . MEK P (Methy l Ethy l Peroxide ) i s use din cleanin g th e cho p guns . Furthe r examinatio n of

th e produc t

reveale dtha t

onl y 7 % i s actuall y MEK.-pAcetone i s n o lse dt o clean tool s i t

i s onl y use dfo r

Q A tan k durabilit y test s (ver

y smal l quantities)
. Th e compan y als o use s a98iFan d§§ P corrosio n for th e inside s o f

th e tanks
. (PB-'93) . ^^ o thre e tank s are fitte dat

an y on e time
. Thi s i s abottlenec k a t th e facilit y sinc e the y onl y emplo y 3 fitters. Thes e Rggple co t th e hole s i n : s an daddth e spigots , flanges , valves , top s an dbottom s manually
. cr» <•/ > Sheet s wer e spo t

checke dan dnothin g strikin g wa s observed
. Ove r 1 0 TP Y o f

styren e i s emitte dat

thi s facility an dsmgji t

i s redaHA P thi s i s wha t

makes th e facilit

y Titl e V . Styren e i s classifie da s aphotochemicall y reactiv e material , howeve r sita e styren e i s 1 a s asolven t

at thi s facility th e 4 0 lb/da y limitatio n i s no t applicable
. bllowin g are uniqu e specifi c condition s an dlimitations : ITi e facilit y mus t preven t fugitiv e particulat e an dVO C emission s fro mbecomin g airborne
. <In Compliance s

# V PRODUC T ANALYSI S v v KJt.ti.oiiut.Am. 

### (SOLVENTS, PAINTS, FINISHING MATERIALS, ETC.)
, pag e 2 o f 2 AUCTIONS: COMPLET

E ON E SHEE T FO REAC H TYP E O F PRODUCT

. GIV E CHEMICA

L NAMES , NO T BRAN D NAME S O R DEVIATIONS

. FOLLO W THES E PROCEDURE

S I N DETERMININ

G WHETHE

RO RNO T A PRODUC

T O F VARIOU

S 'ENT S I S REACTIV

E (R ) O RNONREACTIV

E (NR) . GROU P TH E CONSTITUENT

S ACCORDIN

G T O WHETHE

RO RNO T THE Y FI T TH E DESCRIPTIO

N I N CLAS S (1 ) (2 ) (3 ) O RNON E O F TH E ABOV E CLASSES. I

F A CONSTITUEN

T COUL D FAL L I N TW O GROUPS

, I T I S PLACE D IN*TH E MOR E LIMITE D GROUP

. DETERMIN

E TH E VOLUM

E PERCEN

T O F AL L LIQUI D CONSTITUENT

S O F TH E PRODUC

T A S APPLIED

. (THI S SHOUL D TOTA L 100%. ) TOTAL" TH

E VOLUM

E PERCEN

T FO REAC H CLAS S (1 , 2, AN

D 3) . I F TH E VOLUM

E PERCEN

T FO RAN Y CLAS S EXCEED S TH E PERCEN

T LIMI T FO RTHA T CLAS S O RI F TH E TOTA L FO RCLASSE

S (1) , (2) , (3 ) EXCEED

S 2 0 PERCENT

, THE N TH E PRODUC

T I S REACTIVE

. I F NON E O F THES E LIMIT S AR E EXCEEDED

, TH E PRODUC

T I S NONREACTIVE

. duc tNam e Polyeste rResi n Produc tNo . Thi

s Produc ti s Classifie d as : (x ) Reactiv

e (R ) ( ) Nonreactiv

e (NR )

IGANI C .AS S PRODUC T COMPOSITIO N 

### DESCRIPTIO

N O F ORGANI

C CLAS S NAM

E O F CONSTITUENT

S % B

Y VOLUM E O F TH E TOTA L VOLATILE S ACTUA L % LIMI T 

### A COMBINATIO

N O F HYDROCARBONS

, ALCOHOLS

, ALDEHYDES

, ESTERS, O

R (1 ) KETONE

S HAVIN G A N OLEFINI

C O R CYCLOOLEFINICTYP

E O F UNSATURA

TIO N EXCEP T PERCHLOROETHYLEN E

- 5 PERCEN

T A COMBINATIO

N O F AROMATI

C HYDROCARBON

S WIT H EIGH T O R (2 ) MOR

E CARBO N ATOM S T O TH E MOLECUL

E EXCEP T ETHYLBENZEN

E

- 8 PERCEN

T

. A COMBINATIO

N O F ETHYLBENZENE

, KETONE S HAVIN G BRANCHE

D (3 ) HYDROCARBO N STRUCTURE

, TRICHLOROETHYLENE

, O R TOLUEN E -20PERGEN T AL L SOLVENT

S NO T LISTE D ABOV E
49.8 5 Produc tUag e (gal/hr

) . Produc tWeigh t(lb/gal) . Weigh tof volatile s i n produc t(lb/gal) 3. 6 SUB-TOTA L = 

### 5 %

Styren e 

### 100 %

SUB-TOTA

L =

SUB-TOTAL

« 

### 20 %

8.1 8 TOTAL * 100 % 100 % Tota l % volatile

s b y volum e i n produc t44. 0 .% 

### I F TH E TOTA L REACTIV

E PRODUC

T EMISSION

S EXCEE D 4 0 POUNDS/DA

Y FRO M YOU RFACILITY

, DESCRIB

E TH ! CONTROL-METHOD

S EMPLOYE

D FO RMEETIN

G COMPLIANC

E WIT H DE M REGULATIO

N 1 5 NCA C 2D .0518 : Accordin g t o th e DE M Regulatio n 2D.0518 , paragrap h (f) , an y sourc e t o whic h Regulatio n 2D . •0518 , paragrap h (d ) applie s shal l b e exempte d o f th e 4 0 lb./da y photoreactiv e emissio n ca p i f th e facilit y i s operate d i n suc h a manne rtha ti tmeet s th e requirement s v 

### o f ..Bes t Availabl e Contro l Technolog y (BACT) . Ershigs , Inc . believe s th e curren tra w material - an d technolog y use d constitute s BACT . 0£ £ j>$ 199 4 

# 3 CWS&L . w&

# c

r

### HYDROCARBO N EMISSIO N SOURCE S

- , pag e 1 o f 2 i : Fo remissio n source s o f volatil e organi c compound s includin g spra y booths , painting , finishing , printin g an d solven tusage . S E TYP E O RPRINT . fiTTACH

T O TH E GENERA L INFORMATION FOR M "A" . I F APPLICABLE , ATTAC H AI RPOLLUTION ROL DEVIC E FOR

M "C" . iissio n Sourc e an d I

D NO . (FROM GENERA L INFORMATION FOR M "A" , ITE

M 6) Tan k winde r(TW) 

### . pi p e 

### . winder s , PW2) ; Han

d Lay-u p (HLU) ; Too l Cleanin g Solvent s (SOL) ; Choppe rGun s ( CHG1. CHG2

) •ces s Descriptio

n (INDICAT

E NO. O F IDENTICA

L PROCESSE

S - BOOTHS

, FINISHIN

G LINES , ETC.) ; Glas s strand s e dippe d throug h a resi n bat h and wound ont o mol d (TW . PWl . PW?) : n rchoppe d an d raye d o n mol d (CHG1 , CHG2) ; o rapplie d manuall y wit h han d tool s (HLU) . mi tApplicatio

n i s mad e fo r(CHEC KON E ONLY) : Ne w Sourc e ( ) Existin

g Sourc e (x ) Modificatio

n - Las tPermi tNo . ^ mmenc e Constructio

n Dat e Jul 

### V '. , 1 9 87

_Operatio n Dat e Jul v ..19-82 - P. 5



### ximu m Sourc e Operation : J i Hours/Da y 

### .Days/Wee k -1 2 Weeks/Year tal l VOLATIL E ORGANI C COMPOUND S a s used : USE NEX T PAG E (PRODUC T ANALYSI S WORKSHEET ) T O DETERMIN E PRODUC T I S REACTIV

E (R ) O RNONREACTIVE (NR ) A S DEFINE D B Y 1 5 NCA C 2 D .0518 . TOTA L PRODUC T USAG E (gal/day ) 259. 6 UC T NAM E /este rresin-T W R x N R -PW l -PW 2 -HLU -CHG 1 -CHG 2 cleaning solven t X X X X X X 

### PRODUC T

WEIGH T 

### (lb/gal ) 8.1 8 8.1 8 8.1 8 VOLATILE B Y WEIGH

T X (lb/gal ) * 3. 6 x .07 5 VO C EMISSION RATE S 

### (lb/day ) (ton/yr ) 7Q.1* A 1Q-Q4 

### 129. 7 y 3. 6 x .07 5 = 35.0* A 5:4 6 8.1 8 129. 7 y 3. 6 x .07 5 = 35.0* A 

### 5.4 6

196. 8 

# xhL .07 5 = 53.1* A 8.2 8 

### 8.1 8 40. 9 8.1 8 40. 9 * 3. 6 x



## xh±JL 1 1 = 16.2* A 2.5 3



### 1 1 - 16.2* A 2.5 3 

### 7.81 8 19. 2 Y 

### 7.81 8 1.2* B '1 Ethy l Keton e 8. 0 

### tWfcATE SHEET(S

) I F NEEDE D 10-5 6 yQ.1 6 1.69* C 0.15 6 0.2 6 TOTA L = 228.4 9 35.6 2 crib e th e storag e an d handlin g method s use d i n employin

g th e organi c product s liste d above . Includ e th e ultimat e disposa l method : h e collecte d wast e an d wastewater

. Resi n store d i n 55-gal . drums . Too l cleanin g solven tstore d i 55-gal . drums . Hardene d waste/resi n dispose d i n soli d wast e landfill . Too l cleanin g ilven trecycle d onsite . Hardene d distillatio n residu e dispose d i n soli d wast e landfill . fac e Coatin g Operations : crib e Article s Bein g Coated : Fibe rreinforce d plasti c product s (CHG ) •ho d o f Spray : Airles s ( ) Ai r Atomiz

e 

### ( ) Electrostati c ( ) Other . Stac k Flo w Rate (CFM ) >aus t(x ) Non e itrol : ( ) Waterwas

h ( ) Othe r ( ) Dr y Filte r

( ) Baffle s ( ) Adsorptio n

( ) Incineratio n Contro l Efficienc y Particulat e % Hydrocarbo n % o f Bake Oven s Metho d o f

Heating : ( ) Stea m ( ) Direc tFired

( ) Electri c ( ) Othe r Fuel Type . Usage 'entDegreasin g Operations : crib e Article s Bein g Degreased : Tool s ar e cleane d i n close d to p vats . 

### reise rType : Open To p Vapo r (x ) Col d Qeanin g ( . ) Conveyorize d ( ) Other . k Capacit y Ions) 2- 8 

### Makeu

p Rat e (gallons/day ) 19.2 5 Exhaus tControl : ( ) Non e ( ) Adsorptio n ( ) Othe r ( ) Surfac e Condensers

( ) Close d Loo p : . K: -Se e emission s calculations-Attachmen t A J : Se e emission s calculations-Attachmen t B 2: Se e emission s calculatigns r Attachmen t C 

# H