AQ_F_0800109_20160330_CMPL_CompRpt

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Perdue Farms Incorporated
P.O.Box 460
Lewiston Woodville, NC 27849
www.perdue.com®
Office [phone]
March 30, 2016 Keep on File-Submit Upon Request
Attn: Betsy Huddleston
North Carolina Division of Air Quality
Washington Regional Office
943 Washington Square Mall
Washington, NC 27889
RE: Biennial Tune-up and
Compliance Certification—
Air Permit# 102651102
Perdue Foods, LLC—Lewiston, NC
Bertie County
Dear Ms. Huddleston,
This document is to fulfill recordkeeping requirements in Air Permit#102651102 issued to
Perdue Foods, LLC located in Lewiston, NC. Please find enclosed biennial tune-up records for a
tune-up/inspection of boilers ES-4 and ES-5 conducted on November 16, 2015.
I certify that my facility has complied with the requirements in §63.11223 to conduct a biennial
tune-up, as applicable, of each boiler. By my signature, 1 am certifying that my facility has
complied with all relevant standards and other requirements of 40 CFR part 63 subpart JJJJJJ and
certifying the truth, accuracy and completeness of this document.
Respectfully submitted,
//'�'�� /✓%
Timothy Mizelle
Environmental Manager
Perdue Foods, LLC
A Family commitment to Quality Since 19200

i
Huddleston, Betsy
From: Weller, Ashton <[e-mail]>
Sent: Wednesday, March 30, 2016 4:40 PM
To: Huddleston, Betsy
Cc: Mizelle, Timothy
Subject: Lewiston Biennial
Attachments: 201603301630.pdf
Hi Betsy,
C& C Boilers had on file the attached records for the tune-up/inspection performed November 16, 2015 that we had
discussed.They were familiar with the biennial tune-up required under the NESHAP 6.1 and had completed this record
when the tune-up was performed in November. Please let us know if this is sufficient for the biennial tune-up that is
required. If so, we will file this one and schedule the next biennial for 2017 when the annual boiler tune-up/inspection is
performed.
Thank you,
Ashton Weller
Environmental Technician
Perdue Foods, LLC
Lewiston, NC
[phone]
This communication, including attachments, may contain confidential, privileged, copyrighted or other legally protected
information. If you are not the intended recipient, you are hereby notified that any use, disclosure, dissemination,
distribution, or copying of this communication, or any of its contents, is strictly prohibited. If you have received this
communication in error, please immediately re-send this communication to the sender and delete the original message
and any copy of it, including all attachments, from your computer system.
1

i
Huddleston, Betsy
From: Huddleston, Betsy
Sent: Thursday, March 31, 2016 10:49 AM
To: '[e-mail]'
Cc: Baggett, Joey [e-mail])
Subject: Lewiston Bienniel
Hi Ashton (and Joey),
This is great! These documents satisfy the CO test requirement. I also read through the recordkeeping requirements in
the regulation and noted it says, "Records must identify each boiler, the date of tune-up, the procedures followed for
tune-up, and the manufacturer's specifications to which the boiler was tuned." This C&C's 6J area source form, along
with the records we saw in John's office (his spec document for the tuneup and the more detailed tuneup forms that C&C
provides after completing the work) are more than sufficient to meet this recordkeeping requirement.
There was one other thing we did not talk about for the 61 boiler GACT during the inspection. Permit condition 10.c.3.
states,
Biennial Compliance Report must be prepared by March 1 of every other year starting March 1, 2015 and submitted
upon request. If the source experiences any deviations from the applicable requirements, then a report must be
submitted by March 15. The report must meet the requirements of 40 CFR 63.11225(b)(1-4).
For your boilers, the regulation (63.11225) states the report content include the following:
(1)Company name and address.
(2)Statement by a responsible official, with the official's name, title, phone number, email address, and signature,
certifying the truth, accuracy and completeness of the notification and a statement of whether the source has complied
with all the relevant standards and other requirements of this subpart. Your notification must include the following
certification(s)of compliance, as applicable, and signed by a responsible official:
(i) "This facility complies with the requirements in §63.11223 to conduct a biennial or 5-year tune-up, as applicable, of
each boiler."
(ii)For units that do not qualify for a statutory exemption as provided in section 129(g)(1)of the Clean Air Act: "No
secondary materials that are solid waste were combusted in any affected unit."
(iii) "This facility complies with the requirement in§§63.11214(d)and 63.11223(g) to minimize the boiler's time spent
during startup and shutdown and to conduct startups and shutdowns according to the manufacturer's recommended
procedures or procedures specified for a boiler of similar design if manufacturer's recommended procedures are not
available."
This is just more paper pushing, but has to be done to satisfy the federal rule. If you do not have something that
satisfies the elements above on file, please go ahead and create one now. You might have met this with your 5/08/2014
Notice of Compliance Status report. If so,then you'll need to create another report this May. If not, then you need to
create a report now to cover March 1, 2015 to current, and since the first report was due March 1, 2015, the next one
needs to be filed away by March 1, 2017.
Switching back to the topic of tuneup requirements...........For our future reference, I've copied and pasted the exact
regulatory language from the CFR below for GACT 61 boiler tuneups. Note the highlights about the CO testing. I read
1
I

the rule to require a brief CO and oxygen measurement from the stack at normal or high fire before starting the'tune-up,
and then again at the same firing rate once tune-up is completed.
§63.11223 How do I demonstrate continuous compliance with the work practice and management practice standards?
(b)Except as specified in paragraphs (c) through (f)of this section, you must conduct a tune-up of the boiler biennially to
demonstrate continuous compliance as specified in paragraphs (b)(1) through (7)of this section. Each biennial tune-up
must be conducted no more than 25 months after the previous tune-up. For a new or reconstructed boiler, the first
biennial tune-up must be no later than 25 months after the initial startup of the new or reconstructed boiler.
(1)As applicable, inspect the burner, and clean or replace any components of the burner as necessary(you may delay the
burner inspection until the next scheduled unit shutdown, not to exceed 36 months from the previous inspection). Units
that produce electricity for sale may delay the burner inspection until the first outage, not to exceed 36 months from the
previous inspection.
(2) Inspect the flame pattern, as applicable, and adjust the burner as necessary to optimize the flame pattern. The
adjustment should be consistent with the manufacturer's specifications, if available.
(3) Inspect the system controlling the air-to-fuel ratio, as applicable, and ensure that it is correctly calibrated and
functioning properly(you may delay the inspection until the next scheduled unit shutdown, not to exceed 36 months from
the previous inspection). Units that produce electricity for sale may delay the inspection until the first outage, not to
exceed 36 months from the previous inspection.
(4) Optimize total emissions of CO. This optimization should be consistent with the manufacturer's specifications, if
available, and with any nitrogen oxide requirement to which the unit is subject.
(5)Measure the concentrations in the effluent stream of CO in parts per million, by volume, and oxygen in volume
percent, before and after the adjustments are made(measurements may be either on a dry or wet basis, as long as it is
the same basis before and after the adjustments are made). Measurements may be taken using a portable CO analyzer.
(6)Maintain on-site and submit, if requested by the Administrator, a report containing the information in paragraphs
(b)(6)(i) through (iii)of this section.
(i) The concentrations of CO in the effluent stream in parts per million, by volume, and oxygen in volume percent,
measured at high fire or typical operating load, before and after the tune-up of the boiler.
(ii)A description of any corrective actions taken as a part of the tune-up of the boiler.
(iii) The type and amount of fuel used over the 12 months prior to the tune-up of the boiler, but only if the unit was
physically and legally capable of using more than one type of fuel during that period. Units sharing a fuel meter may
estimate the fuel use by each unit.
Please call me if you have questions. My inspection report will reflect that your facility is in compliance with the
conditions of the permit. Would you like a copy of the DAQ inspection report for your files?
Betsy Huddleston
Division of Air Quality
North Carolina Department of Environmental Quality
252 948 3836 office
252 975 3716 fax
[e-mail]
z

Charlotte(704)597-0003
�( Greensboro(336)275-1631 ,
Greer(864)968-3363
BOBER
Sates&Service,Inc. Columbia(603)808-3366
Date: 11/16/2015 AREA SOURCE TUNING REQUIREMENTS
Customer: Perdue
Serial N L-60657
Model N CB400-500-150ST
Tune-Up Conducted By: Michael Bristow
•Check the box as completed.
TUNE UP PROCEDURES: elf procedure does not apply-note"NA"
.F:+1��� � ,.�=u.'+,.r ,: :mod;• •v.a--ac k,y xvx, s �ur, .AN,'s'.n.�. r' e. y7 � •1 � �'`
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y`='�`�"t-,3�ziy..-_ �.^ �^�.• _l 1 � �.<�.1.7.4..r r«
Inspect the burner Clean or replace any components of the burner as necessary. COMPLETE
Adjust the burner as necessary to optimize the flame pattern. The
Inspect the flame pattern adjustment should be consistant with the manufacturer's COMPLETE
specifications,if applicatable.
Ensure system is calibrated and fuctioning properly,if such a system
Inspect the air/fuel ratio system COMPLETE
is installed on the boiler.
Optimize emissions consistent with the manufacturer's spec,if
Optimize emission of carbon monoxide(co) COMPLETE
available.
Parameter Before After
Measure CO and 02 levels in exhaust,before and Basis(wet/dry) DRY DRY
COMPLETE
after tune-up CO(ppmv) 67 3
02(%by volume) 3.3 4.8

Charlotte(7Q1)597-0003
�4 Greensboro(336)275-1631
Greer(864)968-3363
BMM
Safes&Service,Inc. Columbia(803)808-3366
Date: 11/16/2015 AREA SOURCE TUNING REQUIREMENTS
Customer: Perdue
Serial# L-60658
Model#f CB 400-500-1505T
Tune-Up Conducted By: Michael Bristow
*Check the box as completed.
TUNE UP PROCEDURES: -if procedure does not apply-note"NA"
.:--_� ..,+rn. .-. ,W.^a ,, p.a•;�„ f -1;�r ,r, r. ._✓. .x,.Fc r�•o'; y „�5 m. zr,.e:e �t Y ti i�Jfe l,f W �
i .t:..��-:�. �_:�.�;��".i. . :'�_
inspect the burner Clean or replace any components of the burner as necessary. COMPLETE
Adjust the burner as necessary to optimize the flame pattern. The
Inspect the flame pattern adjustment should be consistant with the manufacturer's COMPLETE
specifications,if applicatable.
Ensure system is calibrated and fuctioning properly,if such a system COMPLETE
Inspect the air/fuel ratio system is installed on the boiler.
Optimize emissions consistent with the manufacturer's spec,if COMPLETE
Optimize emission of carbon monoxide(co) available.
Parameter Before After
Measure CO and 02 levels in exhaust,before and Basis(wet/dry) DRY DRY
COMPLETE
after tune-up Co(ppmv) 43 16
02(%by volume) 5.4 4.2

C&C Boiler Sales&Service, Inc.
3401 Rotary Dr
Charlotte,NC 28269
Sales& Service, Inc. Ph: 704.597.0003
Fx: 704.598.2242
GAS COMBUSTION TEST
CUSTOMER: Perdue BOILER MODEL# CB 400-500-150ST
CITY: Lewiston,NC BOILER SERIAL# L-60657
CONTACT: John Hathaway NCDOL/SCLLR# NC135033
DATE: 11/16/2015 NB# 36352
TECHNICIAN Michael Bristow BOILER ID: #2
MEASURES UNITS MIN 10% 20% 30% 40% 50% 60% 70% 80% 90% 1009/
AIR ACTUATOR POSITION % 21.5 26.6 30.5 35 40.1 46 53.1 59 66.1 73 80.1
GAS ACTUATOR POSITION % 1.2 3.1 4.9 6.8 9 11.7 14 16 21.1 22.5 24.2
VSD AMPS 6.4 6.7 7 7.3 7.5 7.9 8.3 8.8 9.2 9.9 10.7
VSD HZ HZ 41.3 41.9 42.8 43.3 43.9 44.5 45.4 46.8 47.9 49.4 51.8
STEAM PRESSURE PSIG 75 77 79 82 85 89 92 94 96 98 102
FEEDWATER TEMP °F 230 230 230 230 230 230 230 230 230 230 230
FEEDWATER PRESSURE PSI 225 225 225 225 225 225 225 225 225 225 225
GAS PRESSURE BEFORE REGULATOR PSI 12 12 12 12 12 11.8 11.8 11.7 11.6 11.5 11.5
GAS PRESSURE AFTER REGULATOR WC" 42 42 43 43 44 44 44 45 46 47 48
STACK DRAFT WC" N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A
AMBIENT AIR TEMP(T.Air) 7 76 76 77 77 78 78 78 79 81 81 82
STACK TEMP/ECON IN(T.Gas) °F 341 340 342 344 348 351 358 364 365 373 378
OXYGEN 02 % 8.3 7.7 7 6.1 5.5 4.9 4.8 4.6 4.4 4.7 4.7
CO PPM 20 9 3 0 0 0 0 0 0 1 9
NOx PPM 63 67 68 72 79 82 86 88 93 93 91
CO2 % 7.1 7.4 7.8 8.3 8.6 9 9 9.1 9.2 9.1 9.1
COMBUSTION EFFICIENCY % 81.1 81.5 81.9 82.3 82.4 82.6 82.4 82.4 82.5 82.2 82.1

C&C Boiler Sales&Service, Inc.
C i 3401 Rotary Dr
(M Charlotte,NC 28269
Sales& Service, Inc. Ph: 704.597.0003
Fx: 704.598.2242
GAS COMBUSTION TEST
CUSTOMER: Perdue BOILER MODEL# CB 400-500-150ST
CITY: Lewiston,NC BOILER SERIAL# L-60658
CONTACT: John Hathaway NCDOL/SCLLR# NC135032
DATE: 11/16/2015 NB# 36373
TECHNICIAN Michael Bristow BOILER ID: #1
MEASURES UNITS MIN 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%
AIR ACTUATOR POSITION % 16.1 20 25.1 30 37.1 43 52 62 70 75 83.1
GAS ACTUATOR POSITION % 2.4 3.7 5.7 8 11 13.5 19.3 22.5 24.8 29.5 31.3
VSD AMPS 5.6 6.3 6.7 7 7.4 8 8.2 8.8 9 9.3 9.6
VSD HZ HZ 40.7 42 44 45.8 46.3 47.2 48.6 49.4 50 51 51.8
STEAM PRESSURE PSIG 71 73 76 79 82 84 86 89 92 95 100
FEEDWATER TEMP °F 230 230 230 230 230 230 230 230 230 230 230
FEEDWATER PRESSURE PSI 225 225 225 225 225 225 225 225 225 225 225
GAS PRESSURE BEFORE REGULATOR PSI 12 12 12 12 12 11.8 11.8 11.7 11.6 11.5 11.5
GAS PRESSURE AFTER REGULATOR WC" 43 43 44 44 44 45 45 46 46 47 47
STACK DRAFT WC" N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A
AMBIENT AIR TEMP(T.Air) °F 89 89 89 88 88 88 88 88 87 88 87
STACK TEMP/ECON IN(T.Gas) °F 322 321 323 325 330 335 342 352 362 381 387
OXYGEN 02 % 7.4 7.3 6.4 6.2 5.3 4.8 4.7 4.7 4.5 4.2 4.2
CO PPM 7 5 2 1 0 0 1 4 7 15 16
NOx PPM 80 82 81 80 79 79 79 83 84 89 92
CO2 % 7.6 7.6 8.1 8.2 8.7 9 9.1 9.1 9.2 9.4 9.4
COMBUSTION EFFICIENCY % 82.7 82.8 83.1 83.1 83.3 83.3 83.2 82.9 82.7 82.3 82.1
r.

Munich RE
P.O.Box 61509 • King of Prussia,Pennsylvania 19406-0909
Tel:[phone] • Fax[phone]
www.hsb.com
Loss Prevention Report
The Hartford Steam Boiler Inspection and Insurance Company
Insured: Client Company:
Perdue Farms Incorporated AIG- DIV 93- Philadelphia
Location: Policy No.:
Perdue Farms Incorporated 084144017
3539 Governors Rd
Lewiston, NC 27849 HSB ID No.:
AT-2269054
Conferred With:
Tim Mizelle HSB Location No.:
00057
Service Date:
November 14, 2015 HSB Representative:
James 011ison
Inspection Summary
The purpose of this visit to your facility was to perform required jurisdictional inspections on the Fire tube boiler
NC135033 and NC135032. These inspections are required to renew the N.C. Certificate of Inspection for each
pressure vessel. The fire tube boilers were internally and externally inspected. The waterside surfaces were
carefully examined and no appreciable amount of scale or sludge was observed. The firesides surfaces of the
boiler were examined and found to be in satisfactory condition. The external examination of this boiler disclosed
no unusual conditions. The boiler logs were checked and appear to be in good order.
Inspected Equipment
Object Description: Jurisdiction or Type of Inspection: Specific Location:
Designating Number:
Firetube Boiler NC135033 Internal(certificate) BLR 2
Firetube Scotch Marine Boiler NC135032 Internal(certificate) PROCESS PLT
Deaerating Tank NC337182 Certificate Inspection BLRM
This report does not purport to set forth all hazards nor to indicate that other hazards do not exist.By issuing this report,neither the Company
makes an warranty,a ress or implied,concerning the contents of this report.Furthermore neither the Company nor
nor any of its employees y express p b P . P Y
I
any of its employees shall be liable in any manner(other than liability that may be expressed in any policy of insurance that may be issued by
i$86 the Company)for personal injury or property damage or loss of any kind arising from or connected with this inspection or failure to inspect.
Hartford Steam Boller 0 Copyright HSB

Munich RE
P.O.Box 61509 • King of Prussia,Pennsylvania 19406-0909
Tel:[phone] • Fax[phone]
www.hsb.com
Perdue Farms Incorporated
November 14, 2015
Page 2
HSB not only provides equipment breakdown insurance and loss prevention services, but is also committed to
helping its customers save money and resources by identifying equipment energy efficiency opportunities. To
learn how you can potentially save money and resources with your boiler, electrical, mechanical, and HVAC
equipment, please visit www.hsb.com/calc/ENG and use our online tools and calculators developed by our
engineering staff. In addition, you may find useful information specific to equipment care, operating logs and
maintenance fact sheets on our web site.
JO:tc
This report does not purport to set forth all hazards nor to indicate that other hazards do not exist.By issuing this report,neither the Company
nor any of its employees makes any warranty,express or implied,concerning the contents of this report.Furthermore,neither the Company nor
_ any of its employees shall be liable in any manner(other than liability that may be expressed in any policy of insurance that may be issued by
the Company)for personal injury or property damage or loss of any kind arising from or connected with this inspection or failure to inspect.
11artford Stearn Boiler 0 Copyright HSB

Munich RE
P.O.Box 61509 • King of Prussia.Pennsylvania 19406-0909
Tel:[phone] • Fax[phone]
www.hsb.com
POL — 2269054 LOC — 00057
THIS REPORT HAS BEEN DISTRIBUTED TO:
DON MCENTAFFER FRANK CRUICE
PERDUE FARMS INCORPORATED PERDUE FARMS INCORPORATED
ELECTRONIC COPY ELECTRONIC COPY
[e-mail] [e-mail]
COPIES = 00 COPIES = 00
CARL JOHNSON MARK GARTH
PERDUE FARMS INCORPORATED PERDUE FARMS INCORPORATED
ELECTRONIC COPY ELECTRONIC COPY
[e-mail] [e-mail]
COPIES = 00 COPIES = 00
LESTER GRAY SHARON BROOKS
PERDUE FARMS INCORPORATED PERDUE FARMS INCORPORATED
ELECTRONIC COPY ELECTRONIC COPY
[e-mail] [e-mail]
COPIES = 00 COPIES = 00
ROD FLAGG JEFF STALLS
PERDUE FARMS INCORPORATED PERDUE FARMS INCORPORATED
ELECTRONIC COPY ELECTRONIC COPY
[e-mail] [e-mail]
COPIES = 00 COPIES = 00
KEN JANEK TIM MIZELLE
PERDUE FARMS INCORPORATED PERDUE FARMS INCORPORATED
ELECTRONIC COPY 3539 GOVERNORS RD
[e-mail] LEWISTON, NC 27849
COPIES = 00 COPIES = 01
This report does not purport to set forth all hazards nor to indicate that other hazards do not exist.By issuing this report,neither the Company
nor any of its employees makes any warranty,express or implied,concerning the contents of this report.Furthermore,neither the Company nor
any of its employees shall be liable in any manner(other than liability that may be expressed in any policy of insurance that may be issued by
1 � the Company)for personal injury or property damage or loss of any kind arising from or connected with this inspection or failure to inspect.
Ifariford Steam Boller 0 Copyright HSB
L

Factony Auti._.__ed Service
BOILLK CleaverBroolm
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Sales tt Service, Inc.
All Models • 24 Hr. Service e New & Used Boilers
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All Models • 24 Hr. Service • New & Used Boilers
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SIGNATURE: -- -- ---- — - - - -
Revised 3/10 TECHNICIAN'S REPORT
CC-100