AQ_F_0900081_20140909_CMPL_InspRpt

NORTH CAROLINA DIVISION OF Fayetteville Regional Office
AIR QUALITY Gildan Yarns,LLC Plant 71
NC Facility ID 0900081
Inspection Report County/FIPS:Bladen/017
Date: 09/12/2014
Facility Data Permit Data
Gildan Yarns,LLC Plant 71 Permit 09529/G03
820 West Highway 211 Issued 2/11/2014
Clarkton,NC 28433 Expires 2/28/2015
Lat: 34d 29.6060m Long: 78d 40.1260m Classification Small
SIC: 2281/Yarn Mills,Except Wool Permit Status Active
NAILS: 313111/Yarn Spinning Mills Current Permit Application(s)None
Contact Data Program Applicability
Facility Contact Authorized Contact Technical Contact SIP
Ron Daniel Randall Ferguson Randall Ferguson
Plant Manager Director of Engineering Director of Engineering
[phone] [phone] [phone]
Compliance Data
Comments:
Inspection Date 09/09/2014
Inspector's Name Neil Joyner
Inspector's Signature: Operating Status Operating
Compliance Code Compliance-inspection
q Action Code FCE
Date of Signature: l — 12 �� �I 1 On-Site Inspection Result Compliance
Total Actual emissions in TONS/YEAR: V l
TSP S02 NOX VOC CO PM10 *HAP
- 2008 0.2100 --- 0.0900 ---
*Highest HAP Emitted npounds)
Five Year Violation History:None
Date Letter Tvue Rule Violated Violation Resolution Date
Performed Stack Tests since last FCE:None
Date Test Results Test Method(s) Source(s)Tested

GACT/MACT Considerations:
The facility has a 135 brake horsepower fuel oil fired fire pump generator made in CY1989 with non-
resettable hour meter(150 hours total)that is exercised 30 minutes each week and is subject to the
requirements of GACT 4Z. The generator is a Clarke GM Diesel model MD6T 1334, serial number
2266 97252. The facility appeared to already be following the 4Z rule by documenting on-time oil
and oil filter changes, and air cleaner,belt, and hose inspections. On 12 September 2014,the facility
was emailed a copy of the GACT 4Z requirements regarding this engine. The facility has no boiler or
hot water heater.
Directions:
From FRO take Highway 87 about 34 miles to Elizabethtown(stay on Bypass);turn right onto Hwy
701 South;travel about 10 miles into Clarkton;turn right onto Highway 211. The facility is about %z
mile on the right. Park in the first lot and use the door by the flags.
Safety Equipment: All standard DAQ FRO safety gear is required. Be aware that machinery is
possibly operating during the inspection. The principal hazards to the unwary inspector are noise and
pinches and scratches because of the air pressure-driven doors.
Facility Description:
Gildan Yarns is a cotton and cotton-blend spinning mill. It is necessary for the plant process to
maintain the air temperature and relative humidity in the plant,respectively at 75 to 78 degrees F and
63 percent. The facility has two sections of cotton thread machines: Side A with 18 machines and
Side B with 28 machines.
Bales of ginned cotton are processed using several cleaner blender-mats to remove the cotton waste
from the usable fibers. The fibers go through multi-mixer CVT guars(machines and are drawn to
frames machines where the fibers are spun into continuous loose strands that are barely held together
in thick appearing rope type strands. These spun fiber strands are accumulated through a special
computerized process, into large barrels that are fed to the open-end spinner machines where it is
spun into 8-count thread realms. The facility produces a 50/50 polyester/cotton blend thread and a
100%cotton thread. The cotton waste is again recycled through the process,and the final wasted
matter is received outback by a dump truck that transports it off site for agricultural use.
Air Filtration Systems:
There are 4 fabric filter house units and 3 air wash scrubber units with associated fabric filter lined
rotating drums,which all remove particle matter. The fabric filters are used to remove larger particle
matter before the air is drawn through a series of water wash scrubber type spray nozzles. This wash
removes smaller particle matter and aids in the needed control of the facility temperature and
humidity levels. The large amount of water used for the scrubber system is filtered through a special
screen and reused for the wet scrubber control device. Winter months require less water use,whereas
the summer months require a greater usage of water. From the air wash units,the air is put through a
fabric filter lined rotating drum and then exhausted back into the plant. Exhausts from these control
devices are not released into the atmosphere but re-enter back into the plant.
The facility has a 135 brake horsepower fire pump generator made in CY1989 with non-resettable
hour meter that is exercised 30 minutes each week.
Number of Employees: 115
Hours of Operations: 24 hours per day; 7 days per week; closed Christmas week
Thread produced in CY2013: 101,563,654 pounds

Emission Sources and Operating Status:
The facility has a general permit for yarn spinning that covers the following:
(1)Emission sources associated with the air filtration system(s)utilized in the yarn spinning process.
-Operating at--4700 pounds of thread per hour;^-0%opacity.
(2)Combustion equipment firing No. 2 fuel oil/natural gas with a combined total maximum heat input
not to exceed 45 million Btu per hour.
-This facility does not have combustion equipment on-site except for the 135hrake horsepower no.
2 fuel oil fired fire pump generator that was not operating at the time.
Inspection Summarv.
On 9 September 2014,I,Neil Joyner,DAQ FRO,met with Mr. Ron Daniel;Plant Manager, and Mr.
Steve Bedsole,Plant Engineer,to conduct a compliance inspection. I was at the facility by
appointment to also offer help with upcoming permit renewal including CY2013 emissions inventory.
Mr. Bedsole stated that Mr.Randall Ferguson,Technical Contact,would be completing the renewal
probably utilizing Mills Engineering out of Gastonia,NC. I went online at the AERO web site with
Mr. Bedsole while at the facility. I also gave him a copy of the permit renewal letter that had already
been sent to Mr. Ferguson. He stated that he would call Mr. Ferguson about the progress so far.
Mr. Bedsole stated that there was no new process or equipment at the facility related to air quality and
none were planned during upcoming permit renewal. He reviewed the FACFINDER and no
corrections were needed. He stated that he had received no complaints from anyone regarding air
quality. He stated that no exhausts from the air filtration systems are released into the atmosphere but
re-enter back into the plant. I checked the only record keeping requirement—filter system I&M.
Mr. Bedsole led me around the facility and explained the process. He took me to the air filtration
systems located in separate areas around the outside rooms of the facility.Mr. Bedsole advised
against photography because of the potentially explosive nature of the organic dust,and camera
flashes that could set off the fire extinguishing system. I toured the entire site that day including
walking around the outside perimeter of the building. The air filtrations systems did not appear to be
exhausting to the atmosphere and I noticed negative air pressure at the filtration system louvers
located on the side of the building.
Regulatory Review:
A.3 2D.0503 "Particulates from Fuel Burning Indirect Heat Exchangers"—Particulate matter
emissions from the fuel burning indirect heat exchangers shall not exceed the allowable emission
rates.
Appeared to be in Compliance-The facility has no fuel burning indirect heat exchangers on site.
A.4 2D .0515"Particulates from Miscellaneous Industrial Processes"—Particulate matter
emissions from the emission sources shall not exceed allowable emission rates.
Appeared to be in Compliance-Compliance was determined by the permit writer, based on
operating these sources as in the permit application. There have been no changes to these sources.
A.5 2D .0516 "Sulfur Dioxide Emissions from Combustion Sources"—Sulfur dioxide emissions
from the emission sources shall not exceed 2.3 pounds per million Btu heat input.
Appeared to be in Compliance-The only combustion equipment at the site is a 135 brake
horsepower no. 2 fuel oil fired fire pump generator that is exercised for 30 minutes each week.

A.6 2D.0521 "Control of Visible Emissions"—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.
Appeared to be in Compliance—No visible emissions were observed at the time of this inspection.
A.7 2D .0521 "Control of Visible Emissions"—Visible emissions from the emission sources,
manufactured prior to July 1, 1971, shall not be more than 40 percent opacity when averaged over a
_ six-minute period.
Appeared to be in Compliance—Facility does not have equipment manufactured prior to 1 July
- 1971.
A.9 2D.0540 "Particulates from Fugitive Dust Emission Sources," -The Permittee shall not cause
or allow fugitive dust emissions to cause or contribute to substantive complaints or excess visible
emissions beyond the property boundary.
Appeared to be in Compliance—No fugitive dust emissions were observed. Facility grounds are
paved. The cotton waste receiving dump truck was not operating at the time.
A.10 NCGS 143-215.107(a) (4) "Reporting Requirements" -The Permittee,within 30 days after
the end of each calendar year, shall report in writing the pounds of cotton processed each month for
the previous 12-month period.
Appeared to be in Compliance-The annual report for the pounds of cotton processed for CY2013
was received 30 January 2014.
A.11 2Q.0310"Permitting of Numerous Similar Facilities"-The facility shall qualify for this
permit provided the following conditions are complied with:
a) The facility does not operate any emission sources other than emission sources as listed
specifically in this permit.
b) The facility is not subject to any other 2D or 2Q regulation not addressed in Specific
Condition No. 1.
c) The facility shall not process more than 490,000,000 pounds of ginned cotton per consecutive
twelve month period.
d) To comply with the provisions of this permit and ensure that optimum control efficiency of
air filtration system is maintained,the Permittee shall establish an inspection and
maintenance schedule/checklist based on manufacturer's recommendations.This inspection
and maintenance schedule shall be followed throughout the yarn spinning time period. The
results of these inspections and any maintenance performed on the air pollution control
equipment shall be recorded in a log book. The log book shall be made available upon
request.
e) The facility's storage tanks(if applicable)are used solely to store fuel oils,kerosene, diesel,
crude oil,used motor oil,natural gas, gasoline or liquefied petroleum gas and are exempted
from permitting under 2Q.0102(c)(1)(1)).
Appeared to be in Compliance-
a) The facility does not operate any significant emission sources other than those listed
specifically on the permit.

b) The facility is not subject to any other 2D or 2Q regulation except 2D .1111 "National
Emission Standards for Hazardous Air Pollutants"- Reference the fire pump generator,"The
Permittee shall comply with all applicable provisions,including the maintenance and
recordkeeping requirements contained in 2D .1111, as promulgated in 40 CFR 63, Subpart
ZZZZ."
c) The facility processed 101,563,654 pounds of ginned cotton during CY2013.
d) The facility was currently documenting inspections of all of the air filtration devices,
including internal inspections of the fabric filter houses,once each week. hispection and
maintenance logbooks were available at the locations of each filtration device station. The
fabric filter house no. 6 logbook indicated that on 27 August 2014, an internal inspection was
done and belts and a hose were changed out. The fabric filter house no. 1 logbook indicated
that on 18 August 2014, an internal inspection was done and hoses were replaced. All fabric
filters are changed out at least once per year.
e) The facility has a no.2 diesel fuel storage tank on the site for the 135 brake horsepower fire
pump generator,that based on small size appeared exempted from permitting under 2Q
.0102(c)(1)(D).
A.12 20 0310(d) "A Permittee shall be subiect to enforcement action for operating without a
permit if the facility is determined not to qualify under the terms and conditions of the general
ep rmit."
Appeared to be in Compliance—Based on the results of this inspection,the facility appears to
qualify for its current general air permit.
112r Applicability:
Through observations and discussions with facility personnel,this facility does not require a written
risk management plan;reference 40 CFR Part 68,Accidental Release Prevention.
Five-Year Compliance History:"
No violations or other compliance issues over the past 5 years.
Recommendations and Compliance Statement:
Based on review of records and visual observations, this facility appeared to be operating in
compliance with their air quality standards and regulations at the time of this inspection.
Notes to Pink Sheet: The facility has a 135 brake horsepower no.2 fuel oil fired fire pump generator
made in CY1989 that is subject to GACT 4Z. Also, exhausts from the air filtration systems are not
released into the atmosphere but re-enter back into the plant.
/caj