AQ_F_0400016_20161028_CMPL_InspRpt

NORTH CAROLINA DIVISION OF Fayetteville Regional Office
AIR QUALITY Wade Manufacturing Co-Wadesboro
NC Facility ID 0400016
Inspection Report County/FIPS: Anson/007
Date: 11/07/2016
Facility Data Permit Data
Wade Manufacturing Co-Wadesboro Permit 03577/R18
Highway 74 East Issued 9/11/2015
Wadesboro,NC 28170 Expires 1/31/2019
Lat: 34d 57.8720m Long: 80d 2.6476m Classification Synthetic Minor
SIC: 2261 /Finishing Plants, Cotton Permit Status Active
NAICS: 313311 /Broadwoven Fabric Finishing Mills Current Permit Application(s)None
Contact Data Program Applicability
Facility Contact Authorized Contact Technical Contact SIP
Sherry Wallace Bernard Hodges Sherry Wallace
Cost Manager President Cost Manager
[phone] [phone] [phone]
Compliance Data
Comments:
Inspection Date 10/28/2016
� / Inspector's Name Jeffrey D. Cole
Inspector's Signature: Operating Status Operating
Compliance Code Compliance-inspection
Action Code FCE
Date of Signature: �j/� • On-Site Inspection Result Compliance
Total Actual emissions in TONSIYEAR:
TSP SO2 NOX VOC CO PMIO * HAP
2014 12.39 1.02 5.51 9.77 4.49 12.38 1525.84
2013 11.80 0.0300 5.23 12.30 4.46 11.80 1945.30
* Highest HAP Emitted(inRounds)
Five Year Violation Historv:
Date Letter Type Rule Violated Violation Resolution Date
11/09/2012 NOV 21).0521 Control of Visible Emissions 11/19/2012
Performed Stack Tests since last FCE:None
Date Test Results Test Method(s) Source(s)Tested

DIRECTIONS:
From downtown Fayetteville,take Raeford Road,Hwy 401, south to Wagram,—32 miles. Just west of
Wagram,turn right onto Old Wire Road(SR 144)to Laurel Hill. Turn right on Highway 74,bypass
Rockingham,to Wadesboro,—35 miles. Wade Mfg. is on the north(right) side of the Hwy 74,just after
the `Welcome to Wadesboro' sign.
SAFETY:
Standard DAQ FRO Safety Gear.Main safety concert is slips trips and falls from uneven and slippery
floors, stairs,and forklift traffic.
FACILITY DESCRIPTION/PROCESS DESCRIPTION:
Wade Manufacturing is a Synthetic Minor facility for SOz,mainly from the burning of No. 6 fuel oil.
Wade Manufacturing makes,dyes and prints cotton and polyester/cotton blend fabric. The process
includes bleaching, dying,printing,and finishing of cloth. This facility has fabric-finishing equipment
consisting of natural gas-fired tenter frame ovens and several napping areas. A tenter frame stretches
width under tension and consists of chains fitted with pins or clips to hold the selvages of the fabric,and
travelling on tracks. As the fabric passes through the heated chamber,creases and wrinkles are removed,
the weave is straightened, and the fabric is dried to its final size. The napping process is used to raise a
velvety, soft surface to fabric.The process involves passing the fabric over revolving cylinders covered
with fine wires that lift the short, loose fibers,usually from the weft yarns,to the surface,forming a nap.
The process,which increases warmth, is frequently applied to woolens and worsteds and also to blankets.
The facility does twist some yarn for their Rockingham plant and does weave a specialty product for
McDonalds to clean their grills.All other yarn spinning,twisting,and weaving is now done at the
Rockingham plant.Two natural gas/No. 6 fuel oil-fired boilers are used to provide steam for some of
these processes. The company started business in 1926. Wade Manufacturing currently operates under air
permit no. 03577RI8,has an expiration date of 31 January 2019.
Employees: 117
Hours: 4 or 5 days a week, 7 AM to 3 PM
Through-put:
- ---- - - -
j Year Throughput in Average weight of f Average weight range of
million yards fabric (yd/lb) fabric(yd/lb)
2015 F 6.28 -r 1.49 0.89 - 3.4
2014 6.77 1.51 0.89 - 3.4
2013 6.25 1.55 0.89 - 3.4

PERMITTED EMISSION SOURCES (PLUS CONTROLS):
Emission Emission Source Control Control System
Source ID Description System ID Description
Natural gas/No. 6 fuel oil-fired boiler
B 1 (72 mmBtu/hr maximum heat input) N/A N/A
Not operating
B2 �Natural gas/No. 6 fuel oil-fired boiler
(24.76 mmBtu/hr maximum heat input) N/A N/A
Not operating
Textile roller printer
(3,600 pounds of cloth per hour process
capacity)consisting of:
PR3 a)8 print stations N/A N/A
b) 1 natural gas direct-fired dryer
(2 mmBtu/hr maximum heat input)
Not operating
Textile screen printer
(3,600 pounds of cloth per hour process
capacity)consisting of.
PR4 a) 8 rotary screen printing stations N/A N/A
b) 1 natural gas direct-fired dryer
(4.8 mmBtu/hr maximum heat input)with
four zones
Not operating
Textile screen printer
(3,600 pounds of cloth per hour process
capacity)consisting of:
PR5 a) 12 rotary screen printing stations N/A N/A
b) 1 natural gas direct-fired dryer
(4.8 mmBtu/hr maximum heat input)with
four zones
Not operating
Finishing range
(5,760 pounds of cloth per hour process
capacity)consisting of:
TEN2 a) I pad applied finishing station N/A N/A
b) 1 natural gas direct-fired(12.0 mmBtu/hr
maximum heat input)eight zone tenter frame
oven
Not operating
Finishing range
(4,320 pounds of cloth per hour process
capacity)consisting of:
TEN3 a) 1 pad applied finishing station N/A N/A
b) I natural gas direct-fired(6.0 mmBtu/hr
maximum heat input)two zone tenter frame
oven
Not operating
One 1 bleach range and one 1 natural gas
LBLI and TEN4 direct-fired(8.5 mmBtu/hr maximum heat ! N/A ! N/A
input)three zone tenter frame oven
Neither was operating

Emission Emission Source Control Control System
(, Source ID,_ Description . ,.. system tD 4;;,, Description
CR1 Steam hcated cotton dye range
— -
Not operating N/A N A
Pigment range
(4,800 pounds of cloth per hour process
capacity)consisting of:
PIG 1 a) I natural gas direct-fired dryer(4.0 N/A N/A
mmBtu/hr maximum heat input)predryer
b) 1 pad applied ink dyeing station
c) 1 steam heated dryer
Not operating
Thermasol range
(4,800 pounds of cloth per hour process
capacity)consisting of:
TRl a) 1 pad applied finishing station N/A N/A
b) 1 natural gas direct-fired dryer
(7.0 mmBtu/hr maximum heat input)dryer
Not operating_
Shop lathe
(500 pounds per hour of rubber covered pad Cyclone
SLl rolls) SL-IC ' (15 inch diameter)
Not operating
BF-1 ! Bagfilter
(12 square feet of filter
area)
Starch storage silo
SSl (22.5 tons per hour filling rate) In parallel with In parallel with
Not operating
BF-2 Bagfilter
(12 square feet of filter
area)
OP-iCA Paper Panel Filter
(6.55 square feet of
filter area)
Blendomat
OP 1 (2,600 pounds per hour of cotton fiber) In series with In series with
Not operating
OP-1CB Rotary Drum Filter
(46.5 square feet of
filter area)
Carding and drawing operation Rotary Drum Filter
ACl/CARDI (2100 pounds per hour of cotton fiber) CARDI-IC (545.3squarefeetof
Not operating surface area)
Spinning operationiF Paper Filter
(26
AC2 (2100 pounds per hour of cotton fiber) AC2-1C 6�fa e square area)
of
Not operating )

Emission Emission Source Control Control System
Source ID Description System ID Description
AC3 Three (3) weaving areas i AC3-IC Paper Filter
(1,870 pounds per hour of cotton yarn, (371.2 square feet of
total capacity of AC3,AC4,and AC5) surface area)collecting
C3,AC4,and ACS were not operating from AC-3
AC4 AC4-iC Rotary Drum Filter
(834.9 square feet of
surface area)collecting
AC-4.
AC5 AC54C Rotary Drum Filter
(545.3 square feet of
surface area)collecting
AC-5.
NAP1 Two(2)napping areas NAP1-1C Rotary Drum Filter
(2,370 pounds per hour of cotton cloth,total (483.3 square feet of
capacity of NAP I and NAP2) surface area)collecting
Neither was operating from NAP 1.
NAP2 NAP2-lC Rotary Drum Filter
(142.1 square feet of
surface area)collecting
from NAP 2.
�RP Retention Pond N/A N/A
Operating,no odor present
INSPECTION SUMMARY:
On 28 October 2016,I,Jeffrey Cole of NCDEQ,began the compliance inspection with a check of the
roof stack emissions;I noticed what I initially thought was excess emissions from a stack, but it turned
out to be just large amounts of steam from a condensate exhaust. I then entered the facility to conduct the
compliance inspection. I met with Ms. Shelly Wallace,who has taken over plant Environmental Manager
duties upon the retirement of David Bruton,and began with a FacFinder check and a review of the
required recordkeeping. There were some changes to the Facfinder and these changes have been made to
IBEAM. Ms. Wallace stated that the plant was operating normally and no changes had been made to
sources or operations since the last inspection. Ms. Wallace showed me the data from the required
recordkeeping being accomplished for 2D .1100 and 2Q .501 under their permit.
I then proceeded on an inspection of all the facility's sources,which included(in order):
• Textile roller printer(PR3):Printer hasn't run in a while as foreign competition makes operating
it impractical.
• Textile screen printer(PR4)
• Textile screen printer(PR5)
• Finishing range (TEN2)
• Finishing range (TEN3)
• Bleach range and three zone Tenter Frame Oven(BLI and TEN4)
• Pigment range(PIG 1)

• Thermasol range(TRI)
• Two napping areas (NAP 1 and NAP2): Filter collects particulate and it drops out into building
below filter. Waste material is collected and sold to another company.
• Shop lathe(SLI)
• Carding and drawing operation(ACl/CARDI)
• Spinning operation(AC2)
• Three(3)weaving areas(AC3,AC4, and AC5):AC4 and AC5's power has been cut and do not
operate.
• Starch storage silo(SS1)
• Retention Pond(RP)
• Blendomat(OP 1):Paper filters automatically roll to expose new filter when pressure drop gets
close to 1.25". Blendomat will shut off when a paper filter roll needs to be replaced. Rolls are
checked daily.
• Natural gas/No. 6 fuel oil-fired boiler(B1)
• Natural gas/No. 6 fuel oil-fired boiler(132)
At the inspection's exit summary,I summarized my observations and told Ms. Wallace that I had not seen
any deficiencies during my inspection.
STIPULATION REVIEW:
1. 15A NCAC 2D .0202,"EMISSION INVENTORY REQUIREMENT"—Entire facility subject.
Submit permit renewal application and EI at least 90 days prior to permit expiration.
APPEARED IN COMPLIANCE—This facility was TV prior to last permit action, therefore they
had an annual EI requirement, which they met on 3120115. The facility's next renewal/EI due date is
11102118.
2. 15A NCAC 2D .0503.PARTICULATES FROM FUEL BURNING INDIRECT HEAT
EXCHANGERS—The particulate emissions from boiler ID No. B 1 shall not exceed an emission
rate of 0.33 lbs/mmBtu and boiler ID No. B2 shall not exceed 0.47 lbs/mmBtu.
APPEARS IN COMPLIANCE—The facility burns NG exclusively with oil as a backup during
curtailment. The worst case fuel is No. 6 at 2.1%sulfur(from current fuel certification),which emits
0.15 lbs/mmBtu. The AP-42 emissions factor for natural gas is 0.007 lbs/mmBtu.
3. 15A NCAC 2D .0515, "PARTICULATE CONTROL REOUIREMENT"—Particulate emissions
from miscellaneous sources shall not exceed those limits listed in the permit.
APPEARED IN COMPLIANCE—Compliance was determined during the most recent permit
review based on operating the source as described in the permit conditions. No changes have been
made to their facility since the last permit review.
4. 15A NCAC 2D .0516."SULFUR DIOXIDE EMISSIONS"—Sulfur dioxide emissions shall not
exceed 2.3 lbs/mmBtu heat input.
APPEARED IN COMPLIANCE—The worst-case heel is No. 6 at 1.62%sulfur(current fuel
certification), would emit S02 at rate of 1.71bs/mmBtu. The fuel oil certifications indicated suf<r
content 1.62%the last several times it was purchased. The last purchase ofNo.6 fuel oil was 313114.

5. 15A 2D NCAC .0521,"VISIBLE EMISSIONS CONTROL REQUIREMENT"—Visible
emissions from source ID Nos. PR4, PR5,TEN2,TEN3,TRl, B1,132, BLl,TEN4, OP 1, SLI, and
SS 1, manufactured after July 1, 1971, shall not be more than 20 percent opacity when averaged over a
six-minute period.
APPEARED IN COMPLIANCE—None of these emission sources were operating at the time of the
walk through inspection. The facility contact stated that*she does in her workday observe the
source's stacks when she is outside the facility. She stated that she had not observed any of these
source's stacks exceeding the 20 percent opacity limit.
6. 15A 2D NCAC .0521,"VISIBLE EMISSIONS CONTROL REQUIREMENT"—Visible
emissions from source ID Nos. PIG 1, PR3,AC1/CARDI,AC2,AC3, AC4,AC5,NAP and NAP2,
manufactured before July 1, 1971, shall not be more than 40 percent opacity when averaged over a
six-minute period.
APPEARED IN COMPLIANCE—None of these emission sources were operating at the time of the
walk through inspection. The facility contact stated that she does in her workday observe the
source's stacks when she is outside the facility. She stated that she had not observed any of these
source's stacks exceeding the 40 percent opacity limit.
7. 15A NCAC 2D .0535,"NOTIFICATION REQUIREMENT"—The facility is required to notify
DAQ if excess emissions occur for more than a 4-hour period caused by a breakdown or other
abnormal condition.
APPEARED IN COMPLIANCE—The technical contact, Ms. Wallace, stated that the facility has
had no exceedances, breakdowns, or abnormal conditions requiring notification.
8. 15A NCAC 2D .0540,"FUGITIVE DUST CONTROL REQUIREMENT"—Fugitive dust
emissions shall not cause or contribute to substantive complaints or excess visible emissions beyond
the property boundary.
APPEARED IN COMPLIANCE—There was no dust on the roadways about the facility. The
facility contact stated that they have not received any dust complaints since the last inspection.
9. 15A NCAC 2D .0611,"CYCLONE REQUIREMENTS"—Annual&periodic I&M and
recordkeeping requirements.
APPEARED IN COMPLIANCE—The facility inspects its single cyclone on a monthly basis. Logs
indicate I&M is done by the facility mechanic Steven Burroughs. Last checked on 17 Oct 2016.
Internal inspection was also done on 17 Oct 2016
10. 15A NCAC 2D .0611,"FABRIC FILTER REQUIREMENTS"—Annual&periodic I&M and
recordkeeping requirements.
APPEARED IN COMPLLANCE— The facility inspects rotary drum filters and bagfilters on a
monthly basis. Logs indicate I&M is done by the facility mechanic Steven Burroughs. Last checked
on 17 Oct 2016. Internal inspection was also done on 2 Jul 2016
11. 15A NCAC 2D .0958,WORK PRACTICES FOR SOURCES OF VOC's—Requirements include
closed storage of solvent-laden rags, spill management,minimizing splash,generally reducing
evaporation.
APPEARS IN COMPLIANCE—Did not see any open containers or rags laden with solvents lying
in the open. Everything appeared well maintained and in accordance with the requirements for
minimizing VOC emissions.

12. 15A NCAC 2D .I100,TOXIC AIR POLLUTANT EMISSIONS LIMITATION AND
REPORTING REQUIREMENTS -Pursuant to 15A NCAC 2D .1100 and in accordance with the
approved application for an air toxic compliance demonstration,the permit limit shall not be
exceeded. Record daily;report annually.
APPEARED IN COMPLIANCE -Records showed TAP limits had not been exceeded. Records are
maintained for the maximum hourly rate of ammonia input to each printer(ID Nos. PR3, PR4, and
PR5)for each day of production, and the maximum hourly rate of formaldehyde input to each tenter
frame (ID Nos. TEN2, and TEN3)for each day ofproduction. Usage and emissions reports are
provided to FRO annually. The last annual report containing this data was submitted on 01106116
and appeared to be complete. Ammonia highest emission rate for the last quarter(Jul2016-Sep
2016)for PR5 = 1.701b/hr(limit: <2.86lb/hr). Formaldehyde highest emission rate for the last
quarter for(TEN3) =0.0101b/hr (limit: <0.228 Ib/hr) and for(TEN2) = 0.082 lb/hr(limit: <0.30
lb/hr). Quarterly reporting(under the last Title V permit)was submitted on time and appeared to be
in compliance.
Note: The maximum hourly emissions (listed above) are calculated by dividing the worst case dye
chemicals (i.e., having the highest concentrations of ammonia or formaldehyde, respectively) by the
total hours of operation. This would mean the emissions rates listed above would bias higher than
actual emissions. I asked the facility contact if there was anyway they could record and report more
realistic emission rates of ammonia and formaldehyde. The new facility contact stated that they
would review and modify as appropriate to provide more realistic maximum hourly emission rates
than have been previously reported by the facility annual reports.
13. 15A NCAC 2D .1806,"CONTROL AND PROHIBITION OF ODOROUS EMISSIONS." No
objectionable odors beyond property line.
APPEARED IN COMPLIANCE -No objectionable odors were noted during the inspection; the
facility contact stated that no complaints have been received since the last inspection.
14. 15A NCAC 20 .0315,LIMITATION TO AVOID 15A NCAC 20 .0501—Facility-wide emissions
of PM10, S02,and NOx shall each be less than 100 tons per consecutive 12-month period; sulfur
content of the No. 6 fuel oil<2.1%by weight;combust<601,000 gallons of No. 6 fuel oil during
any consecutive 12-month period. The amount fuel oil combusted shall be totaled monthly and
reported annually. Fuel certifications shall also be kept onsite.
APPEARS IN COMPLIANCE—Since the last inspection the facility has not combusted any fuel
oil. The last annual report containing this data was submitted on 01106116 and appeared to be
complete.
15. 15A NCAC 2D .1111,AVOIDANCE OF BOILER NESHAP(GACT 6J)—Would-be subject
source are boilers B I &B2. Facility avoids applicability of this rule by burning Natural Gas,with
fuel oil only as back-up during emergencies,testing and curtailment. Keep records of fuel oil usage
and reason for usage. Notify DAQ within 30 days of switch to fuel oil outside of emergencies,testing
and curtailment.
APPEARS IN COMPLIANCE—Since the last inspection the facility has not combusted any fuel
Oil.
16. 15A NCAC 2Q. 0317,AVOIDANCE OF PREVENTION OF SIGINIFICANT
DETERIORATION-Discharge into the atmosphere less than 250 tons of PM10 and SOz,
respectively,per consecutive twelve month period.
APPEARED IN COMPLIANCE - The facility has met the requirements of stipulation 15A NCAC
2Q.0315, Limitation to Avoid 15A NCAC 2Q.0501, and therefore has complied with this rule.

NON-COMPLIANCE HISTORY SINCE 2010
20 June 2014 NOD for Visible Emissions for failure to re-establish"normal'VE for emission
sources by 7 March 2014.
10 May 2013 CAI VE Monitoring and Record Keeping
9 Nov 2012 NOV for VE>20%
112R STATUS:
The facility does not store or use any of the listed chemicals above the threshold quantities, and is not
required to maintain a written Risk Management Plan(RMP).
CONCLUSIONS AND RECOMMENDATIONS:
Wade Manufacturing Co.-Wadesboro(0400016)appeared to be IN COMPLIANCE with their current
air permit at the time of inspection.
Pink Sheet Notes:
None