AQ_F_0400047_20110420_CMPL_InspRpt

NORTH CAROLINA DIVISION OF Fayetteville Regional Office
AIR QUALITY B.V. Hedrick Gravel and Sand Company
NC Facility 1D 0400047
Inspection Report County/FIPS: Anson/007
Date: 04/25/2011
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Facility Data Compliance Data
B.V. Hedrick Gravel and Sand Company Inspection Date 04/20/2011
B.V. Hedrick Gravel Plant Rd. &Hwy 74 E Inspecto's Name Cindy Grimes
Lilesville,NC 28091 Operating Status Operating
Lat: 34d 56.7302m Long: 79d 55.8806m Compliance Code Compliance- inspection
SIC: 1442/Construction Sand And Gravel Action Code FCE
NAICS: 212321 /Construction Sand and Gravel Mining On-Site bnspection Result Compliance
I
Contact Data Permit Data
Facility Contact Authorized Contact Technical Contact Permit 09572/R03
Timothy Jones Jeffrey Goodman Jason Conner Issued 10/12/2010
Superintendent President Environmental Director Expires 9/30/2015
[phone] [phone] [phone] Classification Synthetic Minor
Permit Status Active
Inspector's Sig 4turF: _I Comments:
Date of Signature: S l0 �VV� — �1
MACUGACT Applicability: This facility,considered an area source,is subject to MACT Subpart ZZZZ
for four diesel generators (Cl ICE< 50011P) on site.Units T-G10 and XQ60 are "existing" units under this
regulation (before 12 June 2006) and will be required to comply as of May 3,2013. Units C50-G4 and Aztec
G-1 are"new" units (on/after 12 June 2006),will be required to comply as of May 3,2013, and also will be
required to comply with the requirements of NSPS Subpart HII now.
1) Location
B.V. Hedrick Gravel and Sand is located at 403 B.V. Hedrick Gravel Plant Road, off Hwy 74 East near
Lilesville,NC, in Anson County.
Directions
From FRO, take Hwy 401 South to Wagram. Turn right at Old Wire Road (Hwy144) and go— 11 '/2 miles to
Laurel Hill. Turn right at Hwy 74 and go west 30 miles toward Lilesville;you'll pass Rockingham and then
the Pee Dee River. Look for Gravel Plant Road on the left about 5 %z miles after crossing the river.There will
be a B.V. Hedrick Gravel and Sand Company sign at entrance of road. Turn left,follow drive, and after
crossing the railroad tracks,you'll see the scale house to the right at entrance to plant. Check in at scale house.
Safety considerations: Standard DAQ safety equipment,as well as safety vest.Watch for trains at the railroad tracks
just before entering property and large trucks and loaders while on site.
2) Facility and General Description
B.V. Hedrick Gravel and Sand Company is a mining facility that primarily produces sand for commercial use
and is permitted for crushing gravel. This facility is permitted under Air Permit No. 09572R03, effective
from 12 October 2010 until 30 September 2015. Cindy Grimes conducted the last inspection on 26 May 2010.
This facility is a quarry which extracts mainly granite from the earth. The granite and crushed stone products
are loosened by drilling and blasting, and then are loaded by power shovel or front-end loader into large haul
bucks that transport the material to the processing operations.Primary operations include ajaw, which is used
for initial crusher reduction,and a series of conveyors.This crusher product is next fed through a grizzly feeder
for undersize material, and then is discharged onto a conveyor,where it goes through more screening
processes, until it is conveyed to a surge pile for temporary storage or sold as coarse aggregate.The finest
product is sold to customers, who then bag and sell the "sand", which is used mainly in small aquariums.

At the present time(April 2011),this facility is operating the Telesmith 38SBS Portable Crushing Plant,which
consists of orie cone crusher unit, one horizontal screen, one feed conveyor, one closed conveyor, one
underscreen fines conveyor and two discharge conveyors.The generators currently being used with this
operation are the T-G10 and the XQ-60.
a) Permitted Sources
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Quarry71-
Equipment
Crushers(NSPS) Crushing and Feeding Operations WS Wet suppression water
spray system
Screens (NSPS) Screening Operations WS Wet suppression water
spray system
Conveyors(NSPS) Convey ng Operations WS Wet suppression water
spray system
P_oiver Generati6n Uutts-'
Aztec G-I (NESHAP),
C50 64 (NESHAP), Diesel-Fired Generators N/A N/A
T-G10 (NSPS,NESHAP),
XQ60 (NSPS,NESHAP)
b) Throughput for 2010
Tons Generator Hours NOx Emissions
Production of Jan, Oct-Dec 27,501 436 .53 tons
crushed stone: (2009) (22,450) (162) (.31 tons)
Employees: 3 (same in 2009)
Hours: variable(between 7AM and 6PM) (same in 2009)
3) Inspection Conference
On 20 April 2011, I(Cindy Grimes)arrived at this facility. Tim Jones, Superintendent and Facility Contact
here,was on vacation and not available. I met with the office manager,who supplied me with the DAQ
binder-logbook, and I learned the following:
a) Verified the FACFINDER information as being correct; there have been no changes.
b) They initiated production in November 2009,after performing two blasts, but then only ran for—2 %,
months, due to the poor economy.They started backup in September 2010 and have run on and off since.
c) They have received a new permit since the last compliance inspection.I told the office manager that I
would call Mr. Jones in the next couple of weeks to discuss if he had any questions regarding the permit.
d) I went through the logbook and noted the following within it:
i) The required fugitive dust control plan and log was submitted to and approved by DAQ in October
2009.The log has daily entries of mechanical water suppression for fugitive dust,as well as elates it
had rained (when suppression was not needed).The log was up to date.
ii) Daily tons of crushed stone, as well as monthly total (including 0 tons for all the inactive(lays).
iii) Daily number of unit homy each permitted generator ran, as well as the total monthly NOx
emissions for each. The log contains a separate section for each individual generator, noting the
hours ran,tons of stone crushed while operating, and any maintenance performed on the unit.
iv) The plot plan showing the boundary distance(the shortest distance between any non-road source
and the property boundary here) is 441 feet.
v) The equipment list and scheme,which contains ID numbers, size/capacity, manufacturing(late,and
any performance test dates.The Aztec G-1,T-G10,and XQ 60 are the generators currently running;
the C50 G4 is not being used at this time.

e) This facility has been using ultra low sulfur diesel fuel (< .0015% S)since 1 October 2010, when it was
required by NSPS to do so.I verified this by observing the fuel bills of lading.
f) A stack test was performed on 4 November 2010 and reviewed and approved by DAQ on 17 Dec 2010.
4) Inspection Summary(facility was operating during inspection)
a) Screens and Conveyors (Screen T-PS2 and Conveyors T-F3,T-PCI,2,3, and 4): I observed all
screen and conveyors on site, as well as the water spray points on each conveyor.All were at or below
5%VE; the wet suppression here is good.
b) 125IV Diesel Generator(Astec G-1): This engine was manufactured in 2008,on site, and still had a
meter showing 177 hours of operation, from when it ran from 18 November 2009 through 13 January
2010.It has not run since.
c) 350 HP Diesel Generator(C50 G4): This engine was manufactured in 2009, on site, but has not
operated yet.
(1) 365IIP Diesel Engine(T-G10): This engine was manufactured in 2002,on site and operating; it has run
— 148 hours since operations began.
e) 100IIP CAT Generator (XQ 60): This engine was manufactured in 2001, on site and operating; it has
run—505 hours since operations began.
f) Roads: All roads on site were damp from the water truck, which was continually spraying oil site during
my inspection. I observed no fugitive dust problems.
5) Permit Stipulations:
a) A.4 2D .0501(c) PRODUCTIONRATE LIMITATION—Production shall not exceed the Maximum
Allowable Production Rate of 12,000 tons/day and 4,250,000 tons/year,with a boundary distance b/t 300
and 450 feet;records shall be kept indicating so (indicating daily and monthly quantity).
In Compliance—I viewed the logbooks,and the highest production of crushed stone to date was 675 tons
per day and 17,250 tons per month(in Dec 2009).The facility ran for 2 '/2 months in 2009 and didn't run
again until 14 September 2010; therefore, it has yet to have a 12-month rolling production rate. With
indications of the monthly totals so far,the annual production will be far below the production maxionim
capacity.
b) A.5 2D .0501(c) EQUIPMENT REPORTING—An equipment list shall be kept on site, showing
compliance with all permitted requirements.The Permittee must notify FRO if equipment changes are
made.
In Compliance—A diagram of the permitted equipment list is kept on site in a DAQ binder,as well as the
permitted equipment yet to be brought in, showing the rated capacities,ID numbers, size, and dates. I
viewed this list, and it meets all requirements of this facility's permit.
c) A.6 2D .0510 PARTICULATE CONTROL REQUIREMENT—As required by"Particulates from
Sand, Gravel,or Crushed Stone Operations", this operation shall take measures to reduce particulate
matter from becoming airborne so as to prevent exceeding the ambient air quality standards beyond the
property line for PM; emissions from all operating equipment shall be controlled.
In Compliance—The crushers, screens, and conveyors are all controlled by a wet suppression water
spray system.I saw no particulate matter/dust beyond the property boundaries, and there have been no
complaints regarding dust.
d) A.7 2D .0521 VISIBLE EMISSIONS CONTROL REQUIREMENT-Visible emissions from sources
post 1 July 1971 shall not be more than 20% opacity.
In Compliance—All visible emissions I observed were<20% opacity.

e) A.8 2D .0524 NEW SOURCE PERFORMANCE STANDARDS(for the processing equipment) -
The Permittee shall comply with all NSPS reporting,testing, and recordkeeping requirements as
promulgated in 40 CFR 60, Subpart 000.
In Compliance—DAQ FRO received notification of initial start up of its equipment on 3 December 2009
(start up date was 18 November 2009, but facility did not achieve maximum production rate until
September 2010);facility keeps logbook on site showing inspections of the wet suppression system;NSPS
Performance Testing(with the pollutant being visible emissions)was achieved on 4 November 2010
(within 180 days of September 2010)with a Method 9 test being performed;this stack test was approved
by DAQ on 17 December 2010.
f) A.9 2D .0524 NEW SOURCE PERFORMANCE STANDARDS, Subpart 1111(for the Compression
Ignition Internal Combustion Engines Generators[Astec G-1 and C50-G4])—The Permittee shall
comply with all NSPS reporting,testing, and requirements as promulgated in 40 CFR 60 Subpart IIII;
applicable sources are the generators constructed after 1 April 2006; compliance includes: (1) purchase
of a 2007 model or later CI ICE and ensuring that it is emissions-compliant and keeping records of al I
manufacturing data(indicating compliance); (2)diesel fuel used shall be < .05% S through 1 October
201-0 and<.0015%S thereafter; (3)installation of a non-resettable hour meter;(4)record hours of engine
operation; (5) submit a semi-annual report that includes monthly and 12-month operation homy.
In Compliance—(1)Manufacture date of Aztec G-1 is 2008 and of C50-G4 is 2009,of which
manufacturer's information indicates compliance of EPA emission standards; (2)the fuel delivery bills of
lading showed that the diesel fuel purchased was < .05% S thru Sept'10 and< .0015% S diesel fuel since
then; (3)The sources all have non-resettable hour meters; (4) I reviewed the logbook that had entries for
the hours of operation for the Aztec G-1 (C50-G4 has not operated yet); (5)facility's latest semiannual
report due 30 January of this year was submitted on time and compliant.
g) A.11 2D.0540(e)(1) FUGITIVE DUST CONTROL PLAN—The Permittee shall have a DAQ approved
written fugitive dust control plan to minimize dust emissions from fugitive sources.
In Compliance—Facility submitted a fugitive dust control plan that was approved by DAQ on 16 October
2009. 1 observed it on site, and I saw no excess dust emissions during my inspection. The facility appears to
be following the plan.
h) A.12 2D .0540 FUGITIVE DUST CONTROL REQUIREMENT—The Permittee shall not cause or
allow fugitive dust emissions to contribute to complaints or excess visible emissions beyond the property.
I» Compliance—I saw no excess fugitive dust emissions during my inspection.
i) A.13 2D .11 11,40 CFR 63, Subpart ZZZZ NATIONAL EMISSIONSTANDARDS FOR HAZARDOUS
AIR POLLUTANTS FOR STA TIONAR Y RECIPROCA TING INTERNAL COMBUSTION ENGINES
—Applicable to new sources (if commenced construction on or after 12 June 2006); installed generators
must have manufacturing data showing emissions compliance,and facility must keep records of
maintenance and operating hours; the Permittee shall comply with all notification, testing, and monitoring
requirements; compliance date would be upon start-up.
In Compliance—All four of the current diesel engines on site are applicable to this regulation. Units
T-G10 and XQ 60 are"existing"units(manufactured on or prior to 12 June 2006), and they will be
required to comply with Subpart ZZZZ as of 3 May 2013. Units C50 G4 and Aztec G-1 are"new" units,
required to comply with Subpart ZZZZ as of 3 May 2013 (as well as NSPS Subpart III1 now).
j) A.14 2Q .0315 LIMITATION TO AVOID 15A NCAC 2Q.0501 FOR SYNTHETIC MINOR
FACILITIES—Facility-wide NOx emissions shall be less than 100 tons per each 12 month period, and
facility shall keep records indicating so.
In Compliance—Facility has not operated for a continousl2 month period yet; it keeps a logbook with
monthlyNOx emission entries for all generators operating. With indications of the monthly emissions so
far,an annual total will be far below 100 tons(operating 4 months in 2010,NOx emissions were.53 tons).

6) Reporting Requirements
Semiannual report is due 30 January and 30 July of each year showing compliance of 2D .0524 NSPS,40 CFR
60 Subpart II11, for the CI ICE.
7) 112R Status
This facility neither uses nor stores chemical compounds that require a written risk management plan under the
Clean Air Act, Section 112R.
8) DAQ Compliance History
There have been no prior DAQ violations in this facility's permitted history.
9) Comments and Compliance Statement
Upon the startup at B.V.Hedrick Gravel&Sand,this facility appears to be complying with all DAQ
stipulations so far. The superintendent,Tim Jones, seems to be keeping the proper documents and is aware of
the compliance for air quality.The Authorized Contact,Jason Conner,appears to be providing DAQ FRO with
the proper notifications per permit stipulations.
B.V. Hedrick Gravel & Sand Company appeared to be in compliance on 20 April 2011.
Below is the current equipment which is operating at this facility, as of 20 April 2011:
T-PCr3: 38SBS Cone
T-PS2: 6x20 Horizontal Screen
T-F3: 30"Feed Conveyor
T-PC L 30"Closed-circuit Conveyor
T-PC2: 42"Underscreen Fines Conveyor
T-PC3: 30"Discharge Conveyor
T-PC4: 30"Discharge Conveyor
T-G10: 3651-IP CAT Diesel Engine
XQ-60: 100HP CAT generator
/clg
cc: DAQ Central Files