AQ_F_0400005_20090820_CMPL_InspRpt

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NORTWCARO1,INA DIVISION OF Fayott�villeRegional Office T ,
i AIR QUAIdTY Bonsal Aineriean,
NC facility Ill 640om ;
I- Inspection Report CounryTIRS: Anson/007
Date:; I0/26/2009. _
facility Aata Cmuphauce""Data
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Bonsal American Inspectiow)), " 08/20/2099 "
351 11atl6y s ferry Road Inspector's Name Cindy Orimes "
LilcsviUc NC " 29001 operatin�Stttas Operating
Lat: 34d 57.5360m . "Lung;99d 57.4490m Compliance Code Compliance; mSj)YC06u .
SIC: 3272/Concrete produets,Nec Aelinn Gode , ' "; hC"li "
N"AICS:"32734/Othci;Conactc 1'roducti Manufacturing On-Sift Insliectibn I;esnit "Compliance
Contact Data" Permit Data
Facility Contact - Authorized Contact Tcclnucal Contact, Permit 01759/I,Z19
Issud-;e 10/3/2007
Fjank Ketchum, Frank Ketchun Ken Brown . Fxpues 3/31/2012
Regional PlanrManager" Regional Plant Manager" EllS Director, Cl4ssificatioii Syrflhctia Minor '
(704),848-4141 [phone] (704) $21=1915 Permit Status`Active "
Jaspcclot'S"Signatuic Conuneots: ;
Date of fthatme:
BonsalAmerican is located a0S[ Ilailuy's Ferry Road, outside of Lilcsville,NC, Ansofi County, "
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Directions
From FRO, take Ilwy 401"South to Wagrahi. Tu6i right onto Old Wire Road (Ilwy,144), and go
approximately I I.5 miles to Laurel Hill-Pura right onto US 74(poet and cttutitnte for abbut 25"roles,
3tntil"you enter Anson County,just after crossing the Pce"Dee River. Go app oximatcly 5"more.tnilesto
Pit Roa (S"12 180I);wliere,th"ere are crossroads acid a 14rgc antique cart in a`yard ou the I-ight'Tl)rn left;
go almost.2 mile, and tlicn just Before the railroad tracks,take a leftonto facility's dirt,drive. Ntaiyt
office is on thciight:
Safety Coosideritions:�"Safety shoes,safety y glasses,"ancl hardhat.Elirpiugs tiro optioilaty"
2) General) acuity Description
" W R. Bonsal,Inc,is a mineral mikingaild packaging facility that primarily manuf tctures bagged'
concrete:It also produces play sand, all-purpose sand;;androortar. Thoprocessing plant is on
contiguous property with the W;"1Z. Bonsal'lnitle. This facility is permitted un er Air Permit No.
I" 175*19;effective From 3 etober 2007'until 31 March 2012. Cindy Orirnes"conduc(gd the last
compliance inspection'.on 25 Sep tember200$.
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" a) Current Tlu'onghptit, for 2008 "
Entployecs 21 (ipcluding"drtvers)
Hours: 7AM-4PM,Mon Fri, 40hys/wk;52wks/yr
Material"recei4ed; " Portland Cement 24615,89,01bs (I1,0007.95 tons)
Masonry 3,566,652lbs (1,783.33 tolls)
Fly Ash 3,634;2514b5 (1,81M13 tons),
i nits Produced: ' 1,360,222'13',
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b) Eermitted"Sou rces
;►,mission "mission Source Control . � Cwttrol Sysleni
Source"10 Description System ID i Descriptiop
jDrying Operation,consistingrif:
T S30 'Natw'al gas/No.2 fuel oil-f red(15 BIH A Bagfrltgr(3,825 squ are-feet o1'filter area
irimBty nrax heat input)sand and
,gravel dryer{50 to;Impor hour
xuaximunrcapacity)'
Prodtic6on i,ine I;consisting(if.
Sl?22 . Portlau eernent silo,Line 1 = 1311,2 ,Bagfiltei`(156 square feet of filter area)
Sf23 :Recycled Cement silo,Line 1 BII23 ,Bat3filtei'(,156 square feet of filter area),
Sr24 iFly ash silo,Lino 1 137124 !,'BagMter(156 square foot of filter area) -
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SF25 Noniix camcittsilo, Line 1 61125 ;Bagfilter(I56 square feet of filtor area
L803 =Rock,an<i sand bucketeonveyor BIIIA Bagfilter(3,$2S square feet of,'iiltor aroa) ,,
operation inefudin 'a rock silo and a
sand silo -
�," US()I ,Cement Handling operation(bagging ,- BHO1 II3agfiher(3,840 square feetof litterarea)
wclghing,mixing), Line I
proilaCtion Line 2,consisting of: `
SP4o portlaitd'oomentsilo,Lino 2' BH46 Magfiltor(156 square-foot of fit terarca) -
Sr41 Rock silo, Line 2 Bfic Bagfilter(156 square foot of filter.arc#
S[42, .San6silo split,Line 2 B1142 78agfiltar(I56 square feet of filter'area)
S1r43 rly ash"silo,Lino 2., -- 131443 Bagfifter(156 square feet*frlfei area)
i Sr44 'Type S Cement silo,Line-2 8II44' `B r1 Jilker(156 square feetof liltei u6a)
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SP52 =Recycled cement silo Line 2 B[152 Baghltor(156 square foot of Mier area)
BSIB1Zock soroerrfrom sa d;Line 2 BH13 , , . :73agrlter(I 200 sgriare rector title r uc a) „
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ES02 Ccmcut handtingoperatinn(haggin{, BII02 l3agiilter(1,900 square sect oFlilttr arc)
weighing mixing),Lire 2
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3) .Opelihig Conference .
Oti 20 Aagust 2009,,I, Cindy Ciriines,met with rrarlk Ketchum;new racility Contact anti Plant
j Manager at Bonsai American. We'discussed the following: -
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a) Verified the,FACFiNDE9 inforination.Mr. Ketelium is now ihc-Encility and Authorized Contact, '
replacing Bradflartsell and herb Wiggins, Who were both laid off iiue lo,the'slow.econ6my.
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b}-'There have been no changes in equipment since n new btighouse was installed to rej>lace tile existing -.
one bade in 2007. Mr. Kotehum told-me there have been''-no problems. "
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c) l inspected the logbooks,of which separate ories are kept for each bagfilter.;The lead roam chance -
teelwician usaally performs the inspe6tions,which,includes inspeetions'orthe bags, Mower; duetivni'le,
and observing Tiny visible canissions all,. The results are noted in the logbooks.`Phese.insjlections used to
be done weekly but are now done evcly 3 weeks'. There is also an annuai inspection done on the system,
usually toward the beginning of each year..'
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4) 111,ocess"pescription
Raw materials al delivered on site,processed and hied throe"gh the sand and gravel dryer and stored in
designated"si1gs.They are there"blended and paokagcd/bagged aGcortling to the specified concrete nnx and' "
customer.
'r 5)` 'Inspection Summary,
i Mr. lZetclium"andl walked around the facility, as it was operating at the"tithe. We noticed a Portland cement,
tr uck unloading at C31I-40, asked the driver-what Nis"truck line pressmre nornally was, and ire told us 10-I'5 psi "
I " at"ticinaxinntm."i observed l09/g VE as he wlls nilloading,Uuf when he finished;he"blow excess VI; from his
biickwhen lie opened a relief valve underneath to release pressure.T"hedriver told us his truck is sotto tic
maxiinum"piessure of 15 psi; and when the unloading"is finished,,he releases the truck valve.,ilc said that he
usyally doesn't seedust rhtring this procedure, Mr, Ketchum stated that he has never seen dust during
unloading either:e waited a while for another truck to eome:to u b tdoad,� u n t one arrived. Mr."KeIAntii told "
me that'Bonsal has a procedural;policy for'cernenf and 1Ty asiiilnloa lug for tie company and tonal[ vendors;
and that every vendor_is given acopy of the policy and required to sign it I his particular driver was from
Souther I"Ink, located"hr;llolly'Ilill, S0, they are a"re,gular hauhr of ccmenl for I3onsal." ,
l.observed no other"probtoms during niy inspectioi: I observed no oXccss buildup of materials on any of-the"
silos, whielr Wonld indicate any,comprornises:i also saw nJ excess dust from any tr cks cheering or"leaving '
tieCacility. "
b) "Pei&it$tlpuiations "
E a) "A.3 21) ,0515 P IRIICULATC C6NTR61 REQUIREMCN'F-Particulate matter eaiissioits from sources .
" shall not exceed the allowable rates.
In Cornplianee-Latesupermit review indicates compliance.
" b) A.4 20 :0516,SOLP R DIOXIDE CONTRQL"RT0-11MAIlzNT S02 crliissin s tiorn"the combustion
" sources shall not exceed 2J lbs/nun BTU:
Ter CornlSlimrcc Facilitq is only burning natural gas;
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i c} A.5 2D .0521 ►ISIBLE.TMISSIONS CONTROL RGQUIREMENr—Visible emissions from the
i" emission sourcessthallnot exceed 2q% opacity.
Sir Compliance- hdid see"one slight burst of excess VE when the driver unloading cement opened the
I relief vat"ve when he f nished.Since Boos"al has-their own policy for all vendors to adlig c_by wlicn
unloading products;I"foci c4r9tdent llwt this was an"isolated incident, I asked Mr, Ketchum to inTkc sro�e a(I
of the:v end ors follow di4 ir,,pOIicy by reiterating it,to them.,
�I) A 2D:0540 FUGITIVE CONT 01,REQUII2I;MRN'I`-The Permiltec shall novallow logitive,
non-process dust(emissions to'contribute to substantive complaints:."
In"Compliance I saw no cxCessfugitiuo dust emissions"during lily inspection. The hud roads are
gravcllsand;and Mr;7Cetchum said that he Iias n6trcceived any complaints 13c.evill"use water"front a "
I watering puckif dustb"econres"aproblemduringadryspc "
" o) A.8 2D .0611" BA6)?ILTEIt RTQUIItEMENTS Particulate niattei'emissions shalLbe conn•olled
by the porniittcdequipmciii list;with periodichunival itispoctions perf6rmed and records kept in a "
� 14gbook."" � .. . .
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CourpliAlice—separate logbooks are kept for cach baglitter, and regular"and amwa(inspcction
records kept current: "
7) " Reporting Requiremeirts
'There are no reporting requirements for this facility in their currentpernlit.
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8) , 11212 Status
Based on the facili(y's eufregtlnventofy, it was decidedthat they are not subject l0 1 I2I2 fequircartents.
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9) Cmnarierrts and Compliance Statement "
Even though I did observe' a slight bmstof excess VE during the unloading of cement, 1 believe this was_ .
I an isolated"incident. Pvaill cheep during,noxt year's 1,11spectioi5 to see that Mr. l<etc rum advise011s
vendots.to assure,till's does not reoccur. I saw-no oAhei,problmi ,,v,, any of the em ssronsoiu�ces,
Bonsai Arrterieari appeared to be in compliance on 20 August 2009.
10) 5 YearConipliaince rlistory
a) . 9 Novenil5er 2005—NOV/NRE'efor C36,laiproper Operatiojj and;Maintenance and 2D,Q535,Failuic to
I ReportNlalfunetion, -
b) 30 August 2003 NRE for 2D OS. 21,Excessive Visible Emissions.
NOV/ "
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- cc: DAQ Central Files
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