AQ_F_0200097_20211118_CMPL_InspRpt

NORTH CAROLINA DIVISION OF Mooresville Regional Office
AIR QUALITY Kincaid Furn. Co.,Inc.,Alexvale Upholstery Div.,
Plant#21
Inspection Report NC Facility ID 0200097
Date: 11/18/2021 County/FIPS:Alexander/003
Facility Data Permit Data
Kincaid Fum. Co.,Inc.,Alexvale Upholstery Div.,Plant#21 Permit 09795/R02
1320 US Hwy 90 East Issued 12/8/2016
Taylorsville,NC 28681 Expires 11/30/2024
Lat: 35d 55.1184m Long: 8ld 9.1452m Class/Status Small
SIC: 2512/Upholstered Household Furniture Permit Status Active
NAICS: 337121 /Upholstered Household Furniture Manufacturing Current Permit Application(s)None
Contact Data Program Applicability
Facility Contact Authorized Contact Technical Contact SIP
Darryl Leonhardt Michael Hyatt Michael Hyatt MACT Part 63: Subpart ZZZZ
Production Manager Vice President of Vice President of
NSPS: Subpart JJJJ
[phone] Operations Operations
[phone] [phone]
Compliance Data
Comments:
Inspection Date 11/18/2021
Inspector's Signature: zjwt e Atiffi ` Inspector's Name Ryan Mills
Operating Status Operating
Date of Signature:November 23, 2021 Compliance Status Compliance-inspection
Action Code FCE
Inspection Result Compliance
Total Actual emissions in TONS/YEAR:
TSP S02 NOX VOC CO PM10 *HAP
2015 0.0300 --- 0.0200 --- --- 0.0000 ---
2010 0.0400 --- 0.0100 --- --- 0.0000 ---
Highest HAP Emitted(in pounds)
Five Year Violation History:None
Date Letter Type Rule Violated Violation Resolution Date
Performed Stack Tests since last FCE:None
Date Test Results Test Method(s) Source(s)Tested

Kincaid Fum. Co.,Inc.,
Alexvale Upholstery Div.,Plant#21
November 18,2021
Page -2
Type X Full Compliance _Partial Compliance _Complaint Investigation Other:
Action: Evaluation Evaluation/Re-inspection
Data Date submitted for initial review: 11/23/2021 _IBEAM WARNING/OB,NOD,NOV,NRE
Tracking: X IBEAM Inspection,list date inspected X IBEAM Document
X IBEAM Inspection, list date draft is submitted IBEAM LAT/LONG, Facility Locked
X IBEAM hasp.,pollutants/programs checked X IBEAM LAT/LONG,Coordinates checked
IBEAM Complaint
X IBEAM Planning,Next Insp. Date: 11/01/2023
Directions: From MRO,travel I-77 north to 1-40 west. Take exit 148 and turn right onto highway 64
west. Travel approximately 10 miles and turn right onto Old Mountain Road. Turn left onto highway 90
west. Travel approximately 3 miles and the facility is located on the right and lower than the road,across
the train tracks,at 1320 East Hwy 90.
Safety Equipment: Safety glasses are required. Safety shoes and ear protection are recommended.
Safety Issues: None noted.
Lat/Long Coordinates: A review of the "Facilities Regulated by Air Quality" on the DAQ web site indicates the
facility's location is accurate and matches the facility's latitude and longitude coordinates listed in IBEAM.No
changes to the latitude and longitude coordinates of this facility are needed in IBEAM. The latitude and longitude
coordinates of this facility are not locked in IBEAM.
Email Contacts: The email contacts were verified. The facility contact changed and with it so did the email
address. This was updated in IBEAM.
COVID-19 Information: I contacted the facility to discuss their current policies concerning COVID. The
facility checks temperatures at the front door and requires face masks. I did a full inside inspection with my mask
on and observed social distancing guidelines.
1. The purpose of this site visit was to conduct a routine air quality inspection. This facility
manufactures upholstered furniture. The facility is currently operating approximately 60 hours per
week with one shift of 115 employees. Mr. Dean Williams,Maintenance Supervisor,Michael
Hyatt,Vice President of Operations, and Darryl Leonhardt,Production Manager,accompanied
me during this inspection.
2. Facility Contact Information:
During the inspection,I verified the facility contact information in IBEAM. The facility contact
was changed to Mr. Darryl Leonhardt in IBEAM.
3. Compliance history file review:
No problems have been noted in the last five years by DAQ,prior to this inspection. The current
compliance status is discussed in the following sections.

Kincaid Furn. Co.,Inc.,
Alexvale Upholstery Div.,Plant#21
November 18,2021
Page -3
4. Observations of permitted air emission sources and control devices:
Emission Source Control System
Description FDescription
ES-1 woodworking operation CD-1 bagfilter(4,820 square feet of filter
area)
Observed: The bag filter system was in operation during this inspection. The woodworking
operations consist primarily of four(4)CNC routers,band sawing, and a"wood hog"that
grinds larger wood waste into particles small enough to be put in the storage bin. The
converted tractor trailer,being used to collect wood waste,is unloaded about every two
weeks. All ductwork appeared to be sound and no wood waste was seen at the trailer loading
area. No visible emissions were observed.
5. Observations of insignificant air emission sources and control devices listed on the current
Permit:
Source Exemption Source of Source of Title
Regulation TAPs? V Pollutants?
I-Fire-diesel fuel-fired emergency fire pump 2Q 0102
engine(150 horsepower) subject to 40 CFR (h)(5) Yes Yes
Part 63, Subpart ZZZZ
F
ed: This diesel fuel-fired emergency fire pump engine was not in operation during
ection. See Condition A.8.below for compliance status.
I-GEN-propane-fired emergency generator(52 2Q 0102
kilowatts) subject to 40 CFR Part 60, Subpart (h)(5) Yes Yes
JJJJ and 40 CFR Part 63, Subpart ZZZZ
Observed: This propane-fired emergency generator was not in operation during this
inspection. See Condition A.8.below for compliance status.
6. Observations of air emission sources and control devices not listed on the current permit:
a. None.
7. Compliance with specific permit conditions and limitations:
a. Condition A.3. 15A NCAC 2D .0512 "Particulates from Wood Products Finishing
Plants". Provide adequate ductwork and properly designed collectors to control
woodworking particulates.
Observed. Wood particulate appeared to be properly controlled. No sawdust waste was
observed at exhaust points around the bag house, and ductwork appears to be sound.
Compliance with this condition is indicated.

Kincaid Furn. Co.,Inc.,
Alexvale Upholstery Div.,Plant#21
November 18,2021
Page -4
b. Condition A.4. 15A NCAC 2D .0521, "Control of Visible Emissions". The facility is
limited to 20 percent opacity.
Observed. No visible emissions were observed at the facility. Compliance with this
condition is indicated.
C. Condition A.5. 15A NCAC 2D .0535. Permittee of a source of excess emissions that last
for more than four hours and that results from a malfunction, a breakdown of process or
control equipment or any other abnormal conditions, shall notify the Director or his
designee of any such occurrence by 9:00 a.m. Eastern time of the Division's next business
day of becoming aware of the occurrence.
Observed. As per a conversation with plant personnel,no excess emissions have
occurred at the facility. Compliance with this condition is indicated.
d. Condition A.6. FUGITIVE DUST CONTROL REQUIREMENT. The Permittee shall
not cause or contribute to substantive complaints or excess visible emissions beyond the
property boundary.
Observed. This office has received no complaints regarding the facility and no fugitive
dust was observed at the time of this inspection. Compliance with this condition is
indicated.
e. Condition A.7. FABRIC FILTER REQUIREMENTS. Conduct an annual internal
inspection of the bag filter system. In addition,conduct periodic inspections and
maintenance as recommended by the equipment manufacturer and list corrections made
and dates of actions in a fabric filter log book.
Observed. The facility conducts weekly external checks of the bag filter system
(including ductwork,as well as inlet and outlet ports) and records the results in a log
book. The last baghouse inspections were conducted on August 18,2017,May 23,2018,
October 9,2018,June 2,2019,May 29,2020 and May 25, 2021. Compliance with this
condition is indicated.
f. Condition A.8. Federal and State Rules Applicable to Sources Exempted from Air
Permitting Requirements -Your facility is subject to the following federal and state rules:
NSPS Subpart JJJJ-Standards of Performancefor Stationary Spark Ignition Internal
Combustion Engines
NESHAPIMACT Subpart ZZZZ--Reciprocating Internal Combustion Engines

Kincaid Furn. Co.,Inc.,
Alexvale Upholstery Div.,Plant#21
November 18,2021
Page - 5
I-GEN-propane-fired emergency generator(52 kilowatts) subject to 40 CFR Part 60,
Subpart JJJJ and 40 CFR Part 63, Subpart ZZZZ
Observed: The emergency generator is a Kohler model no. 50RECGB, serial no.
SGM32G2MP. Output for this generator is 52 kilowatts or 70 horsepower. The
manufactured date on the face plate is February 24,2015. The motor is a Chevrolet 305
that is converted to run on liquid propane gas. The engine does have a non-resettable hour
meter. This generator was installed in February 2016. During the November 2019
inspection the meter was reading 117.7 hours and during this inspection it was reading
173.1 hours. The generator has run 55.4 hours since the last inspection. The EPA
certification for the appropriate emission standard based on model year and size is
maintained on-site. The facility is keeping records of any maintenance performed on the
generator. The last maintenance operations were performed on February 22,2019,
August 19,2020,February 2,2021,July 12,2021 and September 2,2021. (Oil changed,
hoses checked, air cleaner inspected.)
I-Fire-diesel fuel-fired emergency fire pump engine(150 horsepower) subject to 40
CFR Part 63, Subpart ZZZZ
Observed. The fire pump is required to change oil and filter every 500 hours or
annually, inspect the air cleaner every 1000 hours or annually; and inspect all hoses and
belts every 500 hours or annually. The diesel fire pump has a non-resettable hour meter
which was reading 128.7 hours during the 2019 inspection.During this inspection it was
reading 141.1. The generator has run 16 hours since the last inspection. Mr. Williams
provided records of maintenance performed on August 6,2018,August 20,2019,August
19,2020,February 2,2021,July 12,2021, September 2,2021 and the next one is planned
for November 22,2021. Compliance with this condition is indicated.
8. NSPS/NESHAP Review:
The facility was sent a Notification Letter regarding the Subpart 000000 Polyurethane MACT
on November 13,2007. The plant does not conduct any polyurethane foam gluing or fabrication.
The facility has a propane-fired emergency generator which is subject to NSPS Subpart JJJJ and
NESHAP Subpart ZZZZ. The facility has a diesel fuel-fired emergency fire pump engine which
is subject to NESHAP Subpart ZZZZ.
Also,no gasoline storage tanks are located at this facility.
9. Summary of changes needed to the current permit:
None.
10. Compliance assistance offered duringtpection:
None during this visit. During the last inspection it was discussed having the maintenance records
for the generator and fire pump more readily available for future inspections. This was taken into
consideration and records were more readily available.

Kincaid Furn. Co.,Inc.,
Alexvale Upholstery Div.,Plant#21
November 18,2021
Page -6
H. Section 112(r)gpplicabilitX:
This facility does not appear to be subject to the requirements of the Chemical Accident Release
Prevention Program, Section 112(r)of the Clean Air Act
12. Compliance determination:
Based on my observations,this facility appeared to be in compliance with the applicable air
quality regulations at the time of the inspection.
RCM:lms
c: MRO File
https://ncconnect.sharepoint.com/sites/DAQ-MRO/Counties/ALEXANDER/00097/INSPECT 20211118.docx