AQ_F_0200014_20190326_CMPL_InspRpt

NORTH CAROLINA DIVISION OF Mooresville Regional Office
AIR QUALITY Craftmaster Furniture,Inc.
NC Facility ID 0200014
Inspection Report County/FIPS:Alexander/003
Date: 03/26/2019
Facility Data Permit Data
Craftmaster Furniture,Inc. Permit 05456/RI 1
221 Craftmaster Road Issued 5/24/2018
Hiddenite,NC 28636 Expires 4/30/2026
Lat: 35d 53.9750m Long: 8 1 d 5.0200m Class/Status Small
SIC: 2512/Upholstered Household Furniture Permit Status Active
NAILS: 337121 /Upholstered Household Furniture Manufacturing Current Permit Application(s)None
Contact Data Program Applicability
Facility Contact Authorized Contact Technical Contact SIP
Beth Propst Kevin Mann Kevin Mann MACT Part 63: Subpart ZZZZ
Director of HR Vice President of Vice President of NSPS: Subpart IIII
[phone] Operations Operations
[phone] [phone]
Compliance Data
Comments:
Inspection Date 03/26/2019
Inspector's Name Ryan Mills
Inspector's Signature, Operating Status Operating
Compliance Code Compliance-inspection
/p (Ll Action Code FCE
Date of Signature: y/ 0 9 On-Site Inspection Result Compliance
Total Actual emissions in TONS/YEAR:
TSP S02 NOX VOC CO PM10 *HAP
2017 --- --- --- 10.72 --- --- 299.43
2012 --- --- 0.0000 4.88 0.0000 --- 397.42
*Highest HAP Emitted inpounds)
Five Year Violation History:None
Date Letter Tyne Rule Violated Violation Resolution Date
Performed Stack Tests since last FCE:None
Date Test Results Test Method(s) Source(s)Tested

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Type Action: X Full Compliance _Partial Compliance _Complaint Other:
Evaluation Evaluation/Reinspection Investigation
Data Date submitted for initial review 4/3/2019 _IBEAM WARNING/OB,NOD,NOV,NRE
Tracking: X IBEAM Document
X IBEAM Inspection, list date inspected X IBEAM LAT/LONG,Facility Locked
X IBEAM Inspection, list date draft is submitted X IBEAM LAT/LONG, Coordinates checked
X IBEAM Inspection,pollutants/programs checked _IBEAM Complaint
X IBEAM Planning,Next Inspection Date 3/1/2021
Directions:
From MRO,travel I-77 north to I-40 west,take exit 148,turn right onto Hwy. 64 West,travel
approximately 8 miles,turn right onto Old Mountain Road. Travel 0.5 miles and turn right onto Hwy 90
in Hiddenite. Travel approximately 0.5 miles and turn left onto Craftmaster Road,and the facility is
located on the left.
Safety Equipment:
Safety glasses are required and steel toe shoes are recommended for an inspection at this facility.
Safety Issues:
None noted.
Lat/Long Coordinates:
The "Maps of DAQ Regulated Facilities" is currently not accessible. However,the last compliance
inspection conducted in 2016 indicated the coordinates were accurate.Also,I used the coordinates in
IBEAM and entered them into the"Google Maps"application and the coordinates appeared to be
accurate.
Email Contacts:
The facility email contacts were checked and no changes were needed.
1. The purpose of this site visit was to conduct a routine air quality inspection. This facility
manufactures upholstered furniture. The facility is currently operating one 8-hour shift per day,
five days per week for 50 weeks per year. Mr.Kevin Mann, Vice President of Operations, as
well as Ms. Beth Propst,Director of HR, accompanied me during this inspection. This facility
currently employs 276 people.
2. Facility Contact Information:
During the inspection I verified the facility contact information in IBEAM. No changes were
needed.
3. Compliance history file review:
No problems have been noted in the last five years by DAQ, prior to this inspection. The current
compliance status is discussed in the following sections.

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4. Observations of permitted air emission sources and control devices:
Emission Emission Source Control
Source ID Description System ID
Four(4) dry-filter type spray booths installed on a
SB-1, SB-2, SB-3, SB-4 N/A
wood furniture finishing operation
Observed: Three of the four spray booths were in operation with no visible emissions observed and no odors
detected outside. All of the filters were in place and in good condition. The filters are cleaned at least once a j
week and replaced at least once a month. The filters currently being used consist of an eight layer slit and
expanded paper baffle. During the last inspection Mr.Bob Caudle attached the filter efficiency document from
the filter provider, "Research Products" in the last inspection report(dated October 10, 2016). The filters are
rated at 99.66%efficiency based on the testing conducted on January 6, 2014.
5. Observations of insignificant air emission sources and control devices listed on the current
ep rmit:
Source Exemption
IF Regulation
IESB-1 -natural gas-fired boiler(1.875 million Btu per hour maximum heat input) rQ .0102
1)(B)
Observed: I did observe this source. The source is located behind the building in a shed.It is referred to as a heat
lexchanger by the facility. It is a PowerFlame Inc. Model C2-GO-15, serial no. 129052832. This boiler only runs
on natural gas.
I-FP-diesel-fired emergency fire pump engine(275 hp) 12Q .0102 (h)(5)
Observed: I did observe the fire pump which is located near the road entering the plant. The fire pump was not in
operation. Please see NSPS/NESHAP discussion below for more information.
6. Observations of air emission sources and control devices not listed on the current permit:
a. None noted.
7. Compliance with specific permit conditions and limitations:
a. Condition A.2.—"Emissions Inventory Requirement". At least 90 days prior to the
expiration date of the permit,the Permittee shall submit the air pollution emission
inventory report. The report shall be submitted to the Regional Supervisor,DAQ.The
report shall document air pollutants emitted for the 2024 calendar year.
Observed: The report is not due at this time.
b. Condition A.3.— 15A NCAC 2D .0512 "Particulates From Wood Products Finishing
Plants". Provide adequate duct work and properly designed collectors to control
woodworking particulates.
Observed: All the operational spray booths appeared to adequately control particulate
from the overspray. No woodworking operations are located at this facility. Compliance
C with this permit condition was indicated.

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C. Condition A.4.— 15A NCAC 2D .0521. "Control of Visible Emissions". The facility is
limited to 20 percent opacity.
Observed: No visible emissions were observed at the facility. Compliance with this
permit condition was indicated.
i
d. Condition A.5.— 15A NCAC 2D .0535 "Notification Requirement". Notify DAQ of
excess emission that last more than four hours that result from a malfunction, a
breakdown of process or control equipment or any other abnormal conditions.
Observed: Mr. Mann stated that there had been no excess emissions to report.
Compliance with this permit condition was indicated.
e. Condition A.6. - 15A NCAC 2D 0540 "Particulates from Fugitive Dust Emission
Sources" requires the facility to develop and submit a fugitive non-process dust control
plan if the facility cause or contribute to substantive dust complaints.
Observed: No complaints have been,received regarding fugitive dust from this facility.
No fugitive dust emissions were observed during the inspection. Compliance with this
permit condition was indicated.
f. Condition A. 7.— 15A NCAC 2D .1806 "Control and Prohibition of Odorous Emissions".
As required by 15A NCAC 2D .1806 "Control and Prohibition of Odorous Emissions"
the Permittee shall not operate the facility without implementing management practices
or installing and operating odor control equipment sufficient to prevent odorous
emissions from the facility from causing or contributing to objectionable odors beyond
the facility's boundary.
Observed: No odors were detected outside the facility or beyond the property boundary.
Compliance with this permit condition is indicated.
g. Condition A. 8. -Federal and State Rules Applicable to Sources Exempted from Air
Permitting Requirements -Your facility is subject to the following federal and state rules:
40 CFR 60-NSPS -- Subpart IIII -- Standards of Performance for Stationary
Compression Ignition Internal Combustion Engines as well as 40 CFR 63 -
NESHAP/MACT-- Subpart ZZZZ--Reciprocating Internal Combustion Engines.
Observed: The facility has one(1) diesel-fired emergency fire pump(ID.No. I-FP)that
is subject to the 4Z MACT and is considered a new engine. The identification plate
indicates that the John Deere engine's Model Number;is 608IAF001, Serial No.
RG6081A187036, and Equipment Model No. is JW6H-UF28 is a 275 HP engine.It was
manufactured by John Deere on 11/21/2008.
The NSPS Subpart IIII applicability requirement for the compression ignition engines is
if the fire pump engine is constructed after 7/11/2005'and manufactured after 7/l/2006.
Since the fire pump was manufactured and installed after these dates,the fire pump is
subject to NSPS Subpart II11 and considered a new engine. Table 3 of 40 CFR 60
Subpart 111I states that 2008 stationary fire pump engines must be certified if>750 HP.
The footnote says that engines between 50 and 600 HP are not required to certify the

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engine until 3 model years following the model year indicated in Table 3. Therefore,the
fire pump does not have to be a certified EPA pump. However, Table 4 of 40 CFR 60
Subpart IIII states that despite not being certified,the 2008 engine that falls in the
category of 175 to 300 HP must meet emissions requirements of NMHC+NOx 10.5
g/KW-hr(7.8 g/HP-hr), 3.5 (2.6)CO and 0.54 (0.40)PM. The engine meets the
emissions requirements of Table 4.
Currently the fire pump is tested routinely for short durations due to discharge piping
constraints. Approximately every two weeks the fire pump is operated for about five
minutes. The non-resettable hour meter showed the engine reading was at 51.5 hours total
and during the last inspection the hour meter was reading 42.5 hours total. (The engine
was only run for 9 hours in the 129 weeks�since the last inspection.This is an average of
10.75 minutes per week).The fire pump is serviced approximately monthly and the last
few service dates were 10/26/2018, 11/26/2018, 1/9/2019 and 2/5/2019.
The fire pump is considered a new engine with regard to NESHAP Subpart 4Z. As a
result,the fire pump complies with NESHAP Subpart 4Z by complying with NSPS
Subpart 41.
8. NSPS/NESHAP Review:
The facility is subject to 40 CFR Part 63 Subpart ZZZZ as well as 40 CFR Part 60 Subpart IIII.
Both of these are discussed above in Condition A.8.
No gasoline storage tanks are located on the property.
9. Summary of changes needed to the current permit:
None.
10. Compliance assistance offered duringthe he inspection:
None.
11. Section 112(r) applicability:
This facility does not appear to be subject to the requirements of the Chemical Accident Release
Prevention Program, Section 112(r) of the Clean Air Act.
12. Compliance determination:
Based on my observations,this facility appeared to be in compliance with the applicable air
quality regulations at the time of the inspection.
RCM:lhe
c: MRO File
https://ncconnect.sharepoint.com/sites/DAQ-MRO/Counties/ALEYANDER/00014/[NSPECT_20190326.docx