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Home My WebLink AboutAQ_F_0400005_20170413_CMPL_InspRpt J NORTH CAROLINA DIVISION OF Fayetteville Regional Office AIR QUALITY Adams an Old Castle Company-Lilesville NC Facility ID 0400005 Partial Inspection Report County/FIPS:Anson/007 Date: 04/19/2017 Facility Data Permit Data Adams an Old Castle Company-Lilesville Permit 01759/R22 351 Hailey's Ferry Road Issued 3/8/2017 Lilesville,NC 28091 Expires 2/28/2025 Lat: 34d 57.5360m Long: 79d 57.4490m Classification Synthetic Minor SIC: 3272/Concrete Products,Nee Permit Status Active NAICS: 32739/Other Concrete Product Manufacturing Current Permit Application(s)None Contact Data Program Applicability Facility Contact Authorized Contact Technical Contact SIP Kevin Tucker Colin Clampett Doug Fouts Plant Manager President EH&S Manager (704)848-4144 (336)275-9114 (336)275-9114 Compliance Data Comments: Inspection Date 04/13/2017 Inspector's Name Jeffrey D.Cole Inspector's Signature: Operating Status Operating Compliance Code Compliance-inspection Action Code PCE Date of Signature: ��// I 7 On-Site Inspection Result Violation Total Actual emissions in TONS/YEAR: t� TSP S02 NOX VOC CO PM10 * HAP 2015 3.07 --- 0.7900 0.0400 0.6600 0.9800 28.30 2010 0.4400 0.0100 0.8800 0.0500 0.7400 0.2300 31.49 *Highest HAP Emitted inpounds) Five Year Violation History:None Date Letter Type Rule Violated Violation Resolution Date Performed Stack Tests since last FCE: None Date Test Results Test Method(s) Source(s)Tested I. DIRECTIONS: From Wadesboro,take US 74 West until just after crossing the Pee Dee River. Go—5 more miles to Hailey's Ferry Road(crossroads SR 1801),where there is a large antique cart in a yard on the right and a sign for Welika Fish Camp on the left.Turn left, go almost 0.2 miles,and then just before the railroad tracks,take a left onto facility's dirt drive. Proceed around the truck loading area to the parking lot. Main office is directly in front of the parking lot and there is visitor parking to the right of the entrance. II. SAFETY CONSIDERATIONS: Standard DAQ safety equipment, including vest. Watch for forklifts and truck traffic throughout the whole facility during inspection. Stairs and ladders are slippery because of cement dust M. FACILITY AND PROCESS DESCRIPTION: Adams an Old Castle Company—Lilesville is a mineral mixing and packaging facility that primarily manufactures bagged concrete. It also produces play sand, all-purpose sand, and mortar. Raw materials are delivered on site,processed and dried through the sand and gravel dryer and stored in designated silos. They are then blended and packaged/bagged according to the specified concrete mix and customer. IV. INSPECTION SUMMARY: On 13 April 2017, I, Jeffrey Cole of the NC Division of Air Quality,Fayetteville Regional Office, was proceeding to a separate facility to conduct their annual compliance inspection. At approximately 9:00, I was driving down Hailey's Ferry Road, south of US 74 West,when I passed the Adams an Old Castle Company facility and noticed that the facility was emitting excess dust. I decided at that time to continue to the other facility I planned on inspecting. While on the roof of that other facility, at around 1:00,I noted that the excess dust emissions from the Adams an Old Castle Company facility were continuing as they were still visible above the tree line. After completing my compliance inspection at the other facility,I proceeded north on Hailey's Ferry Road and again observed the excess dust emissions and decided to conduct a Method 9 visible emissions(VE) observation. I chose an observation position conforming to Method 9 requirements which was located along a haul road at the southeast of the facility, Once in position to observe the emissions,I noted excess dust emitting from 2 sources. The first source of emissions was a small house-like structure atop what I later identified as their rock silo and sand silo,containing the shaker screen(Source ID No.ES03;—112 feet of the ground)and a second source of emissions was a near ground level exhaust stack from Bagfilter(later identified as ID No. BH1A;—10 feet of the ground). I proceeded to conduct a 19-minute visible emissions evaluation (VEE)on both emission points concurrently. While conducting the VEE,I was approached by Mr. Jeff Scully,Maintenance Manager of the facility. I told Mr. Scully that I would talk with him after the VEE was completed. After the VEE was complete,I advised Mr. Scully that the visible emissions that he had observed appeared to exceed the opacity standard in their permit. Mr. Scully and I then entered the facilities offices and met with Mr. Kevin Tucker,Plant Manager. Mr. Tucker provided me with the status of operations at the facility during my inspection. The facility was operating as follows: i Production: g —40,000 bags of concrete per day Overall material processing rate: —2.8 million lbs per day 8 Consisting of: —504,000lbs of cement —1,400,000 lbs of sand —896,000 lbs of rock Mr. Scully and Mr.Tucker then provided records that showed that inspection and maintenance was being performed on the bagfilter. The most recent internal inspection of the bagfilter(ID No. BH1A) was conducted on 4/2/17. Mr. Tucker stated that during that inspection all bags and internal components appeared to be in good shape and working properly. Mr.Tucker stated that all 140 bags in the bagfilter had been changed on 10/22/16. Finally, Mr. Tucker stated that the ID fan following the bagfilter had failed on 2/3/17. The company was able to procure an identical replacement ID fan that same day and had it installed on the same date as the failure. Mr. Scully told me that amongst the maintenance work they were performing onsite that week,which included refurbishing and reinstalling several silos,was to replace the seals on the small house-like structure atop the rock silo and a sand silo containing the shaker screen from where I had observed the excessive dust emissions. Finally, upon my request they also produced a copy of the facility's current air quality permit. I showed Mr. Scully and Mr.Tucker the applicable permit stipulation(A.5) and noted that the visible emissions that he had observed appeared to exceed the opacity standard in their permit. I also stated that the facility would be contacted by mail about what action would be taken by DEQ. V. REGULATORY REVIEW: The facility's current permit stipulation A.5 (15A NCAC 2D .0521) states, "... visible emissions from the emission sources, manufactured after July 1, 1971, shall not be more than 20 percent opacity when averaged over a six-minute period, except that six-minute periods averaging not more than 87 percent opacity may occur not more than once in any hour nor more than four times in any 24-hour period." After returning to the FRO,I ran a calculation of 6-minute averages from the instantaneous readings every 15 seconds that I had recorded during the inspection. The three highest 6 minute averages from the small structure atop the rock silo and a sand silo containing the shaker screen were 26%,23%and 11%opacity, respectively. Allowing for one of the two 6-minute opacity averages per hour being above 20%opacity,as stated in the permit,the second 6-minute opacity average above 20%opacity, on this source in the same hour, is a single violation of 15A NCAC 2D .0521. The three highest 6-minute averages from the bagfilter exhaust stack,were 27%,29% and 32%opacity, respectively. Allowing for one of the three 6-minute opacity averages per hour being above 20% opacity, as stated in the permit,the second and third 6-minute opacity averages both being above 20%opacity, on this source in the same hour, constitutes two violations of 15A NCAC 2D .0521. VI. CONCLUSION: I recommend sending a NOV/NRE letter to Adams an Old Castle Company—Lilesville for two violations of 15A NCAC 2D .0521. ENCL: VEE evaluation(readings,calculation of 6-minute averages,map, 2 photo pages) /jdc VISIBLE EMISSION OBSERVATION FORM Company Name�Ayftf �/ 06G GASlt B C/1ff3aH%LICtS Observation Date Time Zone Start Time End Time q h31n Facility Name s4N GLpC45TCF GO, -L1Zj4SV14Ze1096AA Street Address 31Y j4WCsy15',E/eky 47,0. Seconds econds p Min. 00 15 30 45 Min. 00 15 30 45 l City(/ SU 44d State � zip Z�09/ Key Contact/Phone Source ID DSO l is 31 21) 2 / 7t/ckBllL BAIQ 2 2 32 �d 3 33 2 Process Equipment Unit# Operating Mode -a 34 cs03 c!"S3G A�9Wt- 5 3s Control Equipment Operating Mode 6 36 �osGi�T 6N1 Q NoRM4L 7 z 37 8 38 39 Describe Emission Point(S).91W& �y� ,eJff S IgtalW7PIAC 10 9 40 Jb Cr9,10 ApDSMpo sAOcWPX/wNiW SA("w$, Al rx4.�s'r /asQ 11 / / at -V Height Above Ground bevel Height Relative to Observer /VXr( 12 / yf, 3t 42 z Start Endl11///o Start /tL' Q ' End 1(z/ 13 ' Zd /$ / d 43 3 Distance From Observer Direction From Observer 14 / 6 44 Z� Start 7 End 7$ Start End 15 / 45 O 16 G o 46 G Describe Emission ' 17 o 47 35 Start _. End y e- 18 48 35 O Emissions Color Water Droplet Plume 19 49 O Start M467 End h/l(fC Attached o Detached a None 20 50 Point In the Plume At Which Opacity Was Determined 21 51 Start End 22 52 Describe Plume Backgrounds ._, 23 53 Start ova r'� � �° End SiQM7E 24 Background Color Sky Conditions 54 Start gc C End&ee Start ctiG.1? End CGS 25 55 Wind Speed Wind Direction _ 26 56 Start Z-E En� s Start 1,)e End WE 27 57 Ambient Temp. Wet Bulb Temp RH Percent 28 58 Start 77 End 77 29 59 30 60 Source Layout Sketch Draw North Arrow ylb5 ❑TN OMN Observer's Name(print) JtACR&Y C046 V 8� Observer's Signature Date ObservaXon Point ��// GC / C10 Q //1 I�EET Certified By e7A Date y3 3770 FEET Observer's Position sidew.w Form Number Page / of / 140o StackCE_ Continued on VEO Form Number - - - - - - _ --_- -_ plume Su Locatlont a Sun Wind longitude LatXude Declinatlon —-79.957y 97 I3y.9S87o6' Additional Information: Adams an Old Castle Company - Lilesville 0400005 13-Apr-08 Rock and sand bucket conveyor Source E03 operation including a rock silo VEE Calculation Form and a sand silo Actual Minute Minute VE% 6-min avg Count 12:30 1 25 20 25 25 12:31 2 30 25 25 30 12:32 3 25 25 20 20 12:33 4 30 30 25 20 12:34 5 30 30 30 25 12:35 6 25 25 30 23 30 26.0 24 12:36 7 25 26.0 24 25 26.3 24 30 26.5 24 30 26.7 24 12:37 8 30 26.7 24 30 26.9 24 30 27.1 24 30 27.1 24 12:38 9 25 27.1 24 30 27.3 24 25 27.5 24 25 27.7 24 12:39 10 30 27.7 24 25 27.5 24 20 27.3 24 25 27.5 24 12:40 11 15 26.9 24 10 26.0 24 10 25.2 24 10 24.6 24 12:41 12 15 24.2 24 15 23.8 24 25 23.5 24 25 23.3 24 12:42 13 20 23.1 24 15 22.7 24 15 22.1 24 20 21.7 24 12:43 14 15 21.0 24 10 20.2 24 10 19.4 24 15 18.8 24 12:44 15 15 18.3 24 10 17.5 24 15 17.1 24 10 16.5 24 12:45 16 10 15.6 24 10 15.0 24 10 14.6 24 10 14.0 24 12:46 17 10 13.8 24 5 13.5 24 5 13.3 24 5 13.1 24 12:47 18 10 12.9 24 10 12.7 24 5 11.9 24 10 11.3 24 12:48 19 5 10.6 24 10 10.4 24 5 10.0 24 5 9.4 24 Adams an Old Castle Company - Lilesville 0400005 13-Apr-08 Natural gas/No. 2 fuel oil-fired (15 mmBtu/hr max heat input) Source E030 sand and gravel dryer (50 tons per hour maximum VEE Calculation Form capacity) Actual Minute Minute VE% 6-min avg Count 12:30 1 30 20 30 25 12:31 2 25 25 20 20 12:32 3 25 25 25 30 12:33 4 25 30 30 30 12:34 5 30 30 30 25 12:35 6 30 30 30 23 30 27.1 24 12:36 7 30 27.1 24 30 27.5 24 35 27.7 24 30 27.9 24 12:37 8 30 28.1 24 30 28.3 24 30 28.8 24 30 29.2 24 12:38 9 30 29.4 24 30 29.6 24 25 29.6 24 25 29.4 24 12:39 10 30 29.6 24 35 29.8 24 25 29.6 24 30 29.6 24 12:40 11 30 29.6 24 25 29.4 24 25 29.2 24 30 29.4 24 12:41 12 25 29.2 24 30 29.2 24 30 29.2 24 35 29.4 24 12:42 13 35 29.6 24 30 29.6 24 35 29.6 24 30 29.6 24 12:43 14 25 29.4 24 30 29.4 24 30 29.4 24 30 29.4 24 12:44 15 30 29.4 24 30 29.4 24 35 29.8 24 30 30.0 24 12:45 16 30 30.0 24 30 29.8 24 25 29.8 24 35 30.0 24 12:46 17 35 30.2 24 40 30.8 24 35 31.3 24 30 31.3 24 12:47 18 35 31.7 24 30 31.7 24 35 31.9 24 30 31.7 24 12:48 19 30 31.5 24 30 31.5 24 35 31.5 24 35 31.7 24 SunCalc - sun position, sunlight phases, sunrise, sunset, dusk and dawn times calculator Page l of 1 V.4 �► � � , ' • it \ 4 —i ,', .RAJ +' v � �C• 71 1 fI n\ UGCJ/ilGGGJ� /✓G /13 G/�R -7� 017 /2.3o /07,2 Map data=176o le lmageq .' Globe,USDA F: _ http://suncale.net/ 4/18/2017 Adams an Old Castle Company -Lilesville,Anson PHOTOS TAKEN BY J. Cole, 13 April 2017 Excessive V.E. from door and baghouse. Excessive V.E. from door. � d F ri I9I •'.. i t A Y{! t Excessive V.E. from ID fan. Impact of excessive V.E. from plant.