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HomeMy WebLinkAboutAQ_F_1800419_20220422_CMPL_InspRpt NORTH CAROLINA DIVISION OF Mooresville Regional Office AIR QUALITY Prysmian Cables and Systems USA,LLC NC Facility ID 1800419 Inspection Report County/FIPS: Catawba/035 Date: 04/22/2022 Facility Data Permit Data Prysmian Cables and Systems USA,LLC Permit 07334/T29 2512 Penny Road Issued 12/16/2019 Claremont,NC 28610 Expires 11/30/2024 Lat: 35d 42.1680m Long: 8ld 9.2538m Class/Status Title V SIC: 3229/Pressed And Blown Glass,Nec Permit Status Active NAICS: 327212/Other Pressed and Blown Glass and Glassware Manufacturing Current Permit Application(s)TV-Sign-501(b)(2) Part I Contact Data Program Applicability Facility Contact Authorized Contact Technical Contact Jeff Roseberry Glenn Peterson Jeff Roseberry SIP/Title V Environmental Safety Fiber Plant Director Environmental Safety MACT Part 63: Subpart DDDDD, Subpart ZZZZ Manager (828)459-9787 Manager (828)459-8668 (828)459-8668 Compliance Data Comments: Inspection Date 04/22/2022 Inspector's Name Karyn Kurek Inspector's Signature: KG I'IJi vA, K.Lcr h Operating Status Operating Compliance Status Compliance-inspection Action Code FCE Date of Signature:May 4,2022 Inspection Result Compliance Total Actual emissions in TONS/YEAR: TSP S02 NOX VOC CO PM10 *HAP 2020 10.97 0.7400 272.04 31.62 3.00 10.88 23652.00 2019 10.25 0.6700 237.48 35.22 2.94 10.16 21474.84 2018 8.73 0.6500 242.81 32.43 2.61 8.73 23652.00 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 Prysmian Cable and Systems USA,LLC April 22,2022 Page 2 Type Action: X Full Compliance _Partial Compliance _Complaint Other: Evaluation Evaluation/Reinspection Investigation Data Date submitted for initial review 04/26/2022 _IBEAM WARNING/OB,NOD,NOV,NRE Tracking: X IBEAM Document X IBEAM Inspection,list date inspected X IBEAM LAT/LONG,Facility Locked X IBEAM Inspection,list date draft is submitted X IBEAM LAT/LONG,Coordinates checked X IBEAM Inspection,pollutants/programs checked IBEAM Complaint X IBEAM Planning,Next Inspection Date 04/01/2023 Directions: Take I-77 to 1-40 West. Take exit 135 and turn right/south into Claremont on North Oxford Street. Turn right on Main Street/US 70 and after about 'V2 mile turn left onto Penny Drive. Turn on Frazier Dr. Take first right onto Frazier; go to the back of the facility for entrance. The entrance is not where the visitor parking is located, from the visitor parking area you must walk down a hill to the lower section of the building. There are secure turn styles and you will need to call your contact upon arrival for access to the facility. PRYSMIAN FIBER 2512 Penny Rd Claremont,NC 28610 Dan—828-578-3128 Directions to Prysmian's Claremont Fiber Plant(we have multiple facilities onsite)Will meet at ENTRANCE Safety Equipment: Safety glasses and safety shoes are required. A lab coat is required in some areas and will be provided by the facility. A hard hat may be required if entering construction areas. Safety Issues: None noted. Prysmian Cable and Systems USA,LLC April 22,2022 Page 3 Lat/Long Coordinates: A review of the facility's coordinates on DAQ's"Facilities Regulated by Air Quality"website indicates the facility latitude and longitude coordinates are not listed;however,the location appears to be accurate.No changes to the latitude and longitude coordinates of this facility in IBEAM are needed. The coordinates are locked in IBeam. Email Contacts: The facility contact information was reviewed and no changes are needed at this time. 1. General Information. The purpose of this site visit was to conduct a full compliance evaluation. This facility manufactures glass fibers and fiber optic cable. This facility operates the fiber optic cable plant with four shifts, 24 hours per day, seven days per week, 51 weeks per year,and employs about 520 people. 2. On Friday,April 22,2022, I arrived at the facility and met with Mr. Jeff Roseberry who accompanied me during the inspection. 3. File Review. A. Contacts: The facility contact information was reviewed with no changes needed. B. Files: The following files were reviewed prior to the inspection: previous inspection reports; correspondence since the last inspection; semiannual, and annual reports; complaints; stack test results, annual emissions inventories, etc. C. Compliance History: A Notice of Deficiency was issued on September 10,2015 for late submission of a stack test report. A stack test was conducted on April 15,2015 and the report was to be submitted 30 days after the stack test. However,the report was not received until September 8,2015. D. Operating Conditions established by Stack Testing: The permittee was required to conduct an annual stack test for the over-cladding unit(ID No. ES- 9, IDS)per Section 2.2.C.l.c.iii of the previous air permit 07334T27 to determine NOx emissions. The permittee conducted a stack test(Tracking No. 2018-131 ST)on April 3, 2018. The stack test report was received on April 27,2018 and approved on July 25, 2018. The permittee was required to conduct an annual stack test for the over-cladding unit(ID No. ES- 9a, 2DS)per Section 2.2.C.1.c.iii of the previous air permit 07334T27 to determine NOx emissions. The permittee conducted a stack test(Tracking No. 2018-012ST)on February 6, 2018. The stack test report was received on April 27,2018 and approved on July 25, 2018. The most recent stack testing occurred for sources ES-9 and ES-9a on March 22 &23,2022 (2022- 058ST)with results still pending. The permittee was required to conduct a one-time PM test on the chemical vapor deposition units (ES-1)and the SiCL4 storage room(ES-18)venting to the scrubber system(3WS)within 180 days of commencement of operations in Section 2.1.A.I.a.i.A under permit 07334T27. The facility conducted this required test on February 17,2016,the test results were reviewed and approved by SSCB on November 10,2016. In addition,the permittee was required to conduct a one-time HCI, Cl,HF stack test on the chemical vapor deposition units(ES-1), gas cabinets(ES-4), collapse furnaces (ES14), chemical room(ES-I 1)and the SiCL4 storage room(ES-I8)venting to the scrubber system(3WS)within Prysmian Cable and Systems USA,LLC April 22,2022 Page 4 180 days of commencement of operations. The scrubber(3WS) started operation on August 23, 2015 and the required stack tests(ES-1,ES-11,ES-14,ES-18,ES-4-3WS)were completed on February 17,2016(within 180 days). The stack test(ID No. 2016-029ST)report was reviewed and approved by the SSCB on November 10,2016. Again, stack testing(ID No. 2017-045ST) was conducted on February 14,2017 and results approved on November 30,2017. E. Records Required by Title V: During this inspection,all records required by the Title V permit were reviewed. F. NSPS/NESHAP Review: A letter was mailed by DAQ to the facility regarding MACT Subpart 6S for Glass Manufacturing. In a letter received June 10,2008,the Permittee stated the facility is not subject to NESHAP Subpart 6S since they do not have continuous furnace operations for glass manufacturing. The facility is not subject to NESHAP Subpart 5H—Miscellaneous Coating Operation because the facility is an area source for HAPs. NESHAP Subpart 5H only applies to major HAP sources. The facility is not subject to NESHAP Subpart 6H—Paint Stripping and Miscellaneous Surface Coating Operations at Area Sources because the facility does not coat any metal or plastic parts with paint or inks containing the targeted HAPs. The facility is not subject to NESHAP Subpart 6J—for Boilers at Area Sources because the facility's boilers only combust natural gas. They are subject to NESHAP Subpart 5D. The facility is subject to NESHAP Subpart 4Z. The facility has a diesel fire pump (ID No. I-FP). The facility is not subject to NESHAP 6C since the facility has no gasoline storage tanks. 4. Part I-AIR QUALITY TITLE V OPERATION PERMIT. The following permitted emission sources and/or control devices listed in Section 2 Paragraph 2.1-Emission Source(s) and Control Devices(s) Specific Limitations and Conditions were observed during this inspection: Prysmian Cable and Systems USA,LLC April 22,2022 Page 5 A. Emission Emission Source Description Control Control Device Source Device Description ID No. ID No. ES-1, Chemical vapor deposition units 3WS Wet scrubber(13,000 -Cells 5, 6,and 7 acfin)consisting of a variable throat venturi scrubber(10 to 15 inches water pressure drop)with greater than 90 gallons per ES-4-3WS Gas cabinets—Cells 5,6, and 7 minute caustic solution injection(pH 8 or higher ES-14 Collapse furnaces -Cells 5, 6, as determined from source and 7 Or testing) ES-11 Chemical Room 2WS Wet scrubber(a.k.a. ES-18 SiC14 Storage Room Xerxes; 11,000 acfm) consisting of a packed bed countercurrent scrubber (greater than 120 gal/min caustic solution injection pH 8 or higher)installed on a venturi scrubber (greater than 70 gal/min caustic solution injection pH 8 or higher) Observed. The chemical vapor deposition units(ES-1)controlled by a wet scrubber (3WS)were started on August 23,2015. The chemical vapor deposition units(ES-1)use an electromagnetic field to heat plasma around a glass tube as various chemicals are added to the inner diameter of the glass tube. One unit is located in cell 5 and the second unit is located in ce116. The permittee stores bulk SiC14 in the building(ES-18)and emissions are controlled by the wet scrubber(3WS). Note that the chemical, SiC14,is piped from the SiC14 storage room to the chemical vapor deposition units (ES-1). As a result,any emissions being vented directly from the SiC14 storage room to the scrubber(3WS)are the result of any malfunctions or leaks in the storage room and minor amounts during tank changes. No issues were observed at the time of inspection. Prysmian Cable and Systems USA,LLC April 22,2022 Page 6 Emission Emission Source Description Control Control Device Source Device Description ID No. ID No. ES-9 Over-cladding Units—Cell 4 IDS Fabric filter with hydrated CAM and four Cell 5 units lime injection(30 dry pounds per hour lime Or injection or higher as determined by testing; 9,800 square feet of filter area or greater) ISCR Ammonia injected catalytic NO,reduction system(ID No. 1 SCR space velocity 11,214 hr-1) with natural gas-fired flue gas re-heater(10 million Btu per hour heat input) and natural gas-fired ammonia injector dilution air heater(one million Btu per hour heat input) installed on IDS Observed. Overcladding unit(ES-9)was observed in operation with no visible emissions noted at the time of inspection. The emissions are controlled by the hydrated lime injection dry scrubber fabric filter system(IDS). The overcladding process consists of silica glass being added to the outside of a glass rod to increase the diameter on a lathe. An air plasma plume is used to provide heat to the process. Hydrogen fluoride is produced in the overcladding process and the emissions are controlled by the hydrated lime injection dry scrubber fabric filter system(IDS). To control HF, lime is fed from supersacks that are located in the lime feed building and injected into the dry scrubber fabric filter system. The lime collected at the fabric filter is drained into empty supersacks. Silica particulate from the process is so fine that without the lime the bags would clog. Selective catalytic NOx reduction system(1 SCR)has never operated,and the facility has no plans to use it but were advised to keep it on the permit. Prysmian Cable and Systems USA,LLC April 22,2022 Page 7 Emission Emission Source Description Control Control Device Source Device Description ID No. ID No. ES-9a Over-cladding Units-Cell 6, 7, 2DS Fabric filter with hydrated CAM and remaining Cell 5 units lime injection(ID No. 2DS; 30 dry pounds per Or hour lime injection or higher as determined by testing; 9,800 square feet of filter area or greater) Ammonia injected 2SCR catalytic NO,reduction system(ID No. 2SCR; space velocity 11,214 hr-1) with natural gas-fired flue gas re-heater(10 million Btu per hour heat input) and natural gas-fired ammonia injector dilution air heater(one million Btu per hour heat input) installed on 2DS Observed. Overcladding unit(ES-9a)was observed in operation with no visible emissions noted at the time of inspection. The emissions are controlled by the hydrated lime injection dry scrubber fabric filter system(2DS). The overcladding process consists of silica glass being added to the outside of a glass rod to increase the diameter on a lathe. An air plasma plume is used to provide heat to the process. Hydrogen fluoride is produced in the overcladding process and the emissions are controlled by the hydrated lime injection dry scrubber fabric filter system(2DS). To control HF, lime is fed from supersacks that are located in the lime feed building and injected into the dry scrubber fabric filter system. The lime collected at the fabric filter is drained into empty supersacks. Silica particulate from the process is so fine that without the lime the bags would clog. Selective catalytic NOx reduction system(2SCR)has never operated,and the facility has no plans to use it but were advised to keep it on the permit. Prysmian Cable and Systems USA,LLC April 22,2022 Page 8 1. 15A NCAC 2D .0515: Particulates from Miscellaneous Industrial Processes a. Emission Emission Source Control Control Device Source Description Device Description ID No. ID No. ES-1, Chemical vapor 3WS Wet scrubber(13,000 deposition units- acfin)consisting of a Cells 5, 6,and 7 variable throat venturi scrubber(10 to 15 inches ES-18 water pressure drop)with SiC14 Storage Room greater than 90 gallons per minute caustic solution injection(pH 8 or higher as determined from source Or testing) 2WS Wet scrubber(a.k.a. Xerxes; 11,000 acfm) consisting of a packed bed countercurrent scrubber (greater than 120 gal/min caustic solution injection pH 8 or higher)installed on a venturi scrubber (greater than 70 gal/min caustic solution injection pH 8 or higher) Emissions of particulate matter from this source(ID No.ES-1)shall not exceed an allowable emission rate as calculated by the following equation: E=4.10XpO.67 Where: E=allowable emission rate in pounds per hour,and P=process weight in tons per hour Liquid and gaseous fuels and combustion air are not considered as part of the process weight. Observed.This was determined in compliance during the most recent permit review process for T29,Dec. 16,2019. Compliance is indicated. Testing If emissions testing is required,the testing shall be perforined in accordance with General Condition JJ. Monitoring Particulate matter emissions from the chemical vapor deposition units(ID No.ES-1) shall be controlled by the wet scrubber system(ID No. 3WS or 2WS). The Permittee shall establish an inspection and maintenance schedule/checklist based on manufacturer's recommendations.The Prysmian Cable and Systems USA,LLC April 22,2022 Page 9 permittee shall conduct internal inspections of the wet scrubber systems (3WS and 2WS) at least quarterly. The inspection shall include inspection of the: - Spray nozzles - Packing material - Chemical feed system - Cleaning and calibration of all associated instrumentation For wet scrubber ID No. 3WS,the permittee shall monitor the following parameters each shift: - Recycle liquid flow rates(>90 gpm), - Liquid make-up flow rates(> 1 gpm), - pH of recirculation tank scrubbing solution(pH of 8 or higher as determined from source testing)and, - pressure drop across scrubber(10 to 15 inches of H20), For wet scrubber ID No. 2WS,the permittee shall monitor the following parameters each shift: - Recycle liquid flow rates(> 120 gpm for the packed bed scrubber portion AND>70 gpm for the venturi scrubber portion), - Liquid make-up flow rates(4- 14 gpm each scrubber portion), - pH of recirculation tank scrubbing solution(pH of 8 or higher)and, - pressure drop across scrubber(0.5—4.0 inches of H2O for the packed bed scrubber portion and 8- 14 inches of water for the venturi scrubber portion), The results of the monitoring shall be maintained in a logbook. The permittee shall submit a summary report of the monitoring activities semi-annually. Observed. Scrubber 2WS is not functional and not in use. The scrubber(3WS) started operating on August 23, 2015. During the inspection the following parameters were observed for 3WS. o recycle liquid— 103.2 gpm o liquid make-up—4.0 gpm o pH—8.7 o AP— 11.7 "water The logbook was reviewed,and all observations were made.No deviations were noted. The SiC14 storage room(ES-18)is used to store SiC14 in bulk but the room is currently under construction and is not operational. Currently, SiCL4 is being stored in smaller quantities (canisters) in the chemical room(ES-11). The permittee performs quarterly internal inspections of the scrubber. The most recent internal inspection was conducted on April 14,2022. The required semi-annual summary reports were received on January 30,2022,and July 28,2021. Compliance with this stipulation is indicated. b. Overcladding Units(ES-9 and ES-9a) Testing If emissions testing is required,the testing shall be performed in accordance with General Condition JJ. Monitoring,Recordkeeping, and Reporting: The Permittee shall ensure the proper performance of the lime injection/fabric filter system(ID Nos. IDS and 2DS)by monitoring and recording the following operating parameters at least once per shift: (A)Lime injection rate(minimum 30 dry pounds per hour)and (B) Pressure drop across the fabric filter(0.1 to 9 inches of water). Prysmian Cable and Systems USA,LLC April 22,2022 Page 10 The above records shall be maintained in a logbook. The Permittee shall perform, at a minimum, monthly visual inspections of the ductwork and material collection unit for leaks; and an annual(for each 12-month period following the initial inspection)internal inspection of the bagfilter's structural integrity.The results of inspection and maintenance shall be maintained in a logbook The permittee shall submit a summary report of the monitoring and recordkeeping activities semi-annually. Observed. Overcladding unit(ES-9)was observed operating during the inspection. The unit was started,and source tested on April 3,2018. The permit requires monthly visual inspections,however,the facility conducts weekly visible inspections for leaks in the ductwork and collection units. Weekly visual inspection records were reviewed,and no issues were noted. Logs were reviewed and once per shift the bagfilter delta P and lime injected rate are recorded(the most recent entry was for April 22,2022,the day of this inspection). The annual internal inspections were conducted within the required time frame. The required semi-annual summary reports were received on January 30,2022,and July 28, 2021. Compliance with this stipulation is indicated. The overcladding unit(ES-9a)was observed operating during this inspection. The permit requires monthly visual inspections,however,the facility conducts weekly visible inspections for leaks in the ductwork and collection units. Weekly visual inspection records were reviewed,and no issues were noted. Logs were reviewed and once per shift the bagfilter delta P and lime injected rate are recorded(the most recent entry was for April 22,2022,the day of this inspection). The annual internal inspections were conducted within the required time frame. The required semi-annual summary reports were received on January 30,2022, and July 28,2021. Compliance with this stipulation is indicated. 2. 15A NCAC 2D .0521: Control of Visible Emissions a. Chemical Vapor Deposition Units(ID No.ES-1) and Over-cladding Units(ID No.ES-9& ES 9a) Visible emissions shall not be more than 20 percent opacity when averaged over a six-minute period. Testing If emissions testing is required,the testing shall be performed in accordance with General Condition JJ. Monitoring The Permittee shall observe the emissions points to reestablish normal within 30 days of the operation of each additional CVD lathe. To assure compliance,once a week(each week of the calendar year period)the permittee shall observe the emission points for the sources listed below for any visible emissions above normal. The results of the monitoring shall be maintained in a logbook(written or electronic format)on-site and made available to an authorized representative upon request. The permittee shall submit a summary report of the monitoring and recordkeeping activities semi- annually. Prysmian Cable and Systems USA,LLC April 22,2022 Page 11 Observed. The chemical vapor deposition units(ES-1)and the overcladding units(ES-9a and ES-9)were in operation during the inspection with no visible emissions. The permittee conducts daily visible emission observations for these sources and records the findings. No deviations were noted. The required semi-annual summary reports were received on January 30,2022, and July 28,2021. Compliance with this stipulation is indicated. B. Emission Emission Source Control Control Device Description Source Description Device ID No. ID No. ES-9 Over-cladding 113S Fabric filter with hydrated lime injection(30 CAM Units—Cell 4 and dry pounds per hour lime injection or higher four Cell 5 units as determined by testing; 9,800 square feet of filter area or greater) Or Ammonia injected catalytic NO,,reduction 1 SCR system(ID No. 1 SCR space velocity 11,214 hr 1)with natural gas-fired flue gas re-heater (10 million Btu per hour heat input) and natural gas-fired ammonia injector dilution air heater(one million Btu per hour heat in ut)installed on 1DS ES-9a Over-cladding 2DS Fabric filter with hydrated lime injection CAM Units -Cell 6, 7, (ID No. 2DS; 30 dry pounds per hour lime and remaining injection or higher as determined by testing; Cell 5 units Or 9,800 square feet of filter area or greater) Ammonia injected catalytic NO,reduction 2SCR system(ID No. 2SCR; space velocity 11,214 hr 1)with natural gas-fired flue gas re-heater (10 million Btu per hour heat input) and natural gas-fired ammonia injector dilution air heater(one million Btu per hour heat input)installed on 2DS 1. 15A NCAC 2D .0516: Sulfur Dioxide Emissions from Combustion Sources. Emissions of sulfur dioxide from these source groups shall not exceed 2.3 lbs/mmBtu heat input. There are no monitoring or reporting requirements. Observed. Compliance with this stipulation was determined during the permit renewal process. Compliance with this stipulation is indicated. Prysmian Cable and Systems USA,LLC April 22,2022 Page 12 C. Emission Emission Source Control Control Device Description Source Description Device ID No. ID No. ES-Etch Etching 4WS Wet scrubber(3,254 acfin)consisting of a Operations packed scrubber(2.5 to 5.0 inches water pressure drop)with greater than 264 gallons per minute of alkaline solution injection (pH 10.5) Observed.This operation was observed not working,the control device 4Ws has not operated since June 2019. The following table provides a summary of limits and standards for the emission source(s)described above: Regulated Limits/Standards Applicable Pollutant Regulation Toxic Air C12,HCl,HF,NH3 15A NCAC 02D Pollutants See Section 2.2 C. Multiple Emissions Sources .1100 Observed.The facility is tracking TAPS on a monthly basis and a 12-month rolling basis to ensure compliance. The table below illustrates TAPS data through March 2022. Compliance with this stipulation is indicated. Pollutant Previous Current Inspection Inspection 12-month 12-month Rolling(tpy) Rolling(tpy) Chlorine 1.21 1.507 HCI 0.081 0.1 Hydrogen Fluoride 0.128 0.141 Acrylic Acid 0.003 0.003 Methanol 0.003 0.003 Glycol Ether Acrylate 0.000 0.001 Toluene 0.004 0.004 D. Emission Emission Source Control Control Device Description Source Description Device ID No. ID No. ES-boilerl One natural gas- N/A N/A MACT fired boiler(8.0 DDDDD million Btu per hour) Observed. This unit was observed operating with no issues noted at the time of inspection. Prysmian Cable and Systems USA,LLC April 22,2022 Page 13 Emission Emission Source Control Control Device Description Source Description Device ID No. ID No. ES-boiler2 One natural gas- N/A N/A MACT fired boiler(8.0 DDDDD million Btu per hour) Observed. This unit was not in o eration at the time of inspection. ES-boiler3 One natural gas- N/A N/A MACT fired boiler(8.76 DDDDD million Btu per hour) Observed. This unit is located in the basement and was not in operation at the time of inspection. ES-boiler4 One natural gas- N/A N/A MACT fired boiler(8.76 DDDDD million Btu per hour) Observed. This unit is located in the basement and was observed operating with no issues noted at the time of inspection. 1. 15A NCAC 02D.0503: PARTICULATES FROM FUEL BURNING INDIRECT EXCHANGERS Emissions of particulate matter from the combustion of natural gas discharged from these sources(ID Nos.ES-boilerl through ES-boiler4)into the atmosphere shall not exceed 0.40 pounds per million Btu heat input. Testing If emissions testing is required,the testing shall be performed in accordance with General Conditions JJ. Monitoring,Recordkeeping,and Reporting Requirements No monitoring,recordkeeping,or reporting is required. Observed.Compliance was determined during the permit renewal process.Compliance with this stipulation is indicated. 2. 15A NCAC 02D.0516: SULFUR DIOXIDE EMISSIONS FROM COMBUSTION SOURCES Emissions of sulfur dioxide from these boilers(ID Nos. ES-boilerl through ES-boiler4) shall not exceed 2.3 pounds per million Btu heat input. Sulfur dioxide formed by the combustion of sulfur in fuels,wastes,ores,and other substances shall be included when determining compliance with this standard. Testing If emissions testing is required,the testing shall be performed in accordance with General Condition JJ. Monitoring,Recordkeeping,and Reporting Requirements No monitoring,recordkeeping,or reporting is required for sulfur dioxide emissions from the firing of natural gas in these sources(ID Nos.ES-boilerl through ES-boiler4). Prysmian Cable and Systems USA,LLC April 22,2022 Page 14 Observed.Compliance was determined during the permit renewal process. Compliance with this stipulation is indicated. 3. 15A NCAC 02D.0521: CONTROL OF VISIBLE EMISSIONS Visible emissions from these boilers(ID Nos. ES-boilerl through ES-boiler4)shall not be more than 20 percent opacity when averaged over a six-minute period. However, six-minute averaging periods may exceed 20 percent not more than once in any hour and not more than four times in any 24-hour period. In no event shall the six-minute average exceed 87 percent opacity. Testing If emissions testing is required,the testing shall be performed in accordance with General Condition JJ. Monitoring,Recordkeeping,and Reporting No monitoring,recordkeeping,or reporting is required for visible emissions from the firing of natural gas in these sources(ID Nos. ES-boilerl through ES-boiler4). Observed.Compliance was determined during the permit renewal process.No visible emissions were observed at the time of inspection.Compliance with this stipulation is indicated. 4. 15A NCAC 02D.1111: MAXIMUM ACHIEVABLE CONTROL TECHNOLOGY For these sources (ID Nos. ES-boilerl through ES-boiler4) (existing sources(s) designed to burn gas I fuels with a heat input capacity greater than or equal to 5 million Btu per hour and less than 10 million Btu per hour),the Permittee shall comply with all applicable provisions,including the monitoring,recordkeeping, and reporting contained in Environmental Management Commission Standard 15A NCAC 02D .I I I I "Maximum Achievable Control Technology" (MALT)as promulgated in 40 CFR 63, Subpart DDDDD"National Emission Standards for Hazardous Air Pollutants for Major Sources: Industrial, Commercial, and Institutional Boilers and Process Heaters"and Subpart A"General Provisions."The Permittee shall comply with the requirements of 40 CFR 63 Subpart A General Provisions according to the applicability of Subpart A to such sources as identified in Table 10 to 40 CFR Part 63, Subpart DDDDD. The Permittee shall complete the initial tune up and the one-time energy assessment no later than March 18,2022. (i.e, March 18, 2019 plus three years) The Permittee shall submit a Notification of Compliance Status to the DAQ.The notification must be signed by a responsible official and submitted by May 17,2022. Work Practice Standards The Permittee shall conduct a tune-up every two years while burning the type of fuel(or fuels in case of units that routinely burn a mixture)that provided the majority of the heat input to the boiler or process heater over the 12 months prior to the tune-up, as specified below. • As applicable,inspect the burner, and clean or replace any components of the burner as necessary(the Permittee may perform the burn inspection any time prior to the tune-up or delay the burner inspection until the next scheduled unit shutdown. • 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; Prysmian Cable and Systems USA,LLC April 22,2022 Page 15 • 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); • Optimize total emissions of carbon monoxide. This optimization should be consistent with the manufacturer's specifications,if available, and with any NOx requirement to which the unit is subject; and • Measure the concentrations in the effluent stream of carbon monoxide 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. Each biennial tune-up shall be conducted no more than 25 months after the previous tune-up. If the unit is not operating on the required date for a tune-up,the tune-up must be conducted within 30 calendar days of startup. Energy Assessment Requirements The Permittee shall have a one-time energy assessment performed by a qualified energy assessor. Recordkeeping Requirements The Permittee shall keep a copy of each notification and report submitted to comply with this subpart,including all documentation supporting any Initial Notification or Notification of Compliance Status,or compliance report that has been submitted. Maintain on-site and submit, if requested by the Administrator, an annual report containing the information in paragraphs(A)through(C)below: (A)the concentrations of carbon monoxide 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 source; (B) a description of any corrective actions taken as a part of the tune-up; and (C) the type and amount of fuel used over the 12 months prior to the annual adjustment,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. Reporting Requirements The Permittee shall submit compliance reports to the DAQ on a 2-year basis. The first report shall cover the period beginning on the March 18,2022 and ending on December 31,2023. Subsequent 2-year reports shall cover the periods from January 1 to December 31. The Permittee shall submit the compliance reports postmarked on or before January 30 for the preceding reporting period. The compliance report must also be submitted electronically via the Compliance and Emissions Data Reporting Interface(CEDRI). CEDRI can be accessed through the EPA's Central Data Exchange(CDX) (https:Hcdx.epa.gov/).) Observed.These sources were moved from the insignificant list to the permitted source list with the issuance of T29. The first energy assessments are due March 18,2022. The Notification of Compliance Status is due May 17,2022. Tune-ups are due every 2 years. Tune ups were performed for Boilers 1,2,3 &4 on October 5—7,2021 (previously on Nov. 5,2020). The one- time energy assessment was conducted January 10,2020 by Wilson Engineering Services. The Notification of Compliance report for the one-time energy assessment is not due until May 17, 2022. Annual reporting begins January 30, 2024. Compliance with this stipulation is indicated. Prysmian Cable and Systems USA,LLC April 22,2022 Page 16 E. Emission Emission Source Control Control Device Description Source Description Device ID No. ID No. ES-WB-3 One hot water N/A N/A MALT boiler(8.0 million DDDDD Btu per hour) Observed. This unit was not in operation at the time of inspection. 1. 15A NCAC 02D.0503: PARTICULATES FROM FUEL BURNING INDIRECT EXCHANGERS Emissions of particulate matter from the combustion of natural gas discharged from this source(ID No.ES-WB-3)into the atmosphere shall not exceed 0.40 pounds per million Btu heat input. Testing If emissions testing is required,the testing shall be performed in accordance with General Conditions JJ. Monitoring,Recordkeeping,and Reporting Requirements No monitoring,recordkeeping,or reporting is required for particulate emissions from the firing of natural gas in this source(ID No. ES-WB-3). Observed.Compliance was determined during the permit renewal process. Compliance with this stipulation is indicated. 2. 15A NCAC 02D.0516: SULFUR DIOXIDE EMISSIONS FROM COMBUSTION SOURCES Emissions of sulfur dioxide from boiler(ID No.ES-WB-3) shall not exceed 2.3 pounds per million Btu heat input. Sulfur dioxide formed by the combustion of sulfur in fuels,wastes,ores,and other substances shall be included when determining compliance with this standard. Testing If emissions testing is required,the testing shall be performed in accordance with General Condition JJ. Monitoring,Recordkeeping, and Reporting Requirements No monitoring,recordkeeping, or reporting is required for sulfur dioxide emissions from the firing of natural gas in this source(ID No.ES-WB-3). Observed.Compliance was determined during the permit renewal process. Compliance with this stipulation is indicated. 3. 15A NCAC 02D.0521: CONTROL OF VISIBLE EMISSIONS Visible emissions from this boiler(ID No.ES-WB-3) shall not be more than 20 percent opacity when averaged over a six-minute period. However,six-minute averaging periods may exceed 20 percent not more than once in any hour and not more than four times in any 24-hour period. In no event shall the six-minute average exceed 87 percent opacity. Testing If emissions testing is required,the testing shall be performed in accordance with General Condition JJ. Prysmian Cable and Systems USA,LLC April 22,2022 Page 17 Monitoring,Recordkeeping,and Reporting No monitoring,recordkeeping,or reporting is required for visible emissions from the firing of natural gas in this source(ID Nos.ES-WB-3). Observed.Compliance was determined during the permit renewal process.No visible emissions were observed at the time of inspection.Compliance with this stipulation is indicated. 4. 15A NCAC 02D.1111: MAXIMUM ACHIEVABLE CONTROL TECHNOLOGY For this source(ID Nos. ES-WB-3) (i.e., new source, units designed to burn gas 1 fuels with a heat input capacity equal to or greater than 5MMBtu/hr and less than 10 MMBtu/hr, with no autotrim),the Permittee shall comply with all applicable provisions,including the monitoring, recordkeeping, and reporting contained in Environmental Management Commission Standard 15A NCAC 02D .1111 "Maximum Achievable Control Technology" (MALT)as promulgated in 40 CFR 63, Subpart DDDDD"National Emission Standards for Hazardous Air Pollutants for Major Sources: Industrial, Commercial, and Institutional Boilers and Process Heaters"and Subpart A "General Provisions." Compliance Date The Permittee shall comply with the applicable requirements upon startup of this source. Notifications The Permittee shall submit an Initial Notification to the DAQ not later than 15 days after the actual date of startup of the affected source. The Permittee shall submit a Notification of Compliance Status to the DAQ within 60 days of startup and signed by a responsible official. Work Practice Standards The Permittee shall conduct a tune-up every 2 years while burning the type of fuel(or fuels in case of units that routinely burn a mixture)that provided the majority of the heat input to the boiler or process heater over the 12 months prior to the tune-up, as specified below: • as applicable,inspect the burner, and clean or replace any components of the burner as necessary. The Permittee may perform the burner inspection any time prior to the tune-up or delay the burner inspection until the next scheduled unit shutdown. • 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; • inspect the system controlling the air-to-fuel ratio, as applicable, and ensure that it is correctly calibrated and functioning properly(the Permittee may delay the inspection until the next scheduled unit shutdown). • optimize total emissions of CO. This optimization should be consistent with the manufacturer's specifications, if available, and with any NOX requirement to which the unit is subject. • 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. Each 2-year tune-up shall be conducted no more than 25 months after the previous tune-up. The initial tune-up shall be conducted no later than 25 months after the initial startup of the source. If the unit is not operating on the required date for a tune-up,the tune-up must be conducted within 30 calendar days of startup. Prysmian Cable and Systems USA,LLC April 22,2022 Page 18 Recordkeeping Requirements The Permittee shall keep a copy of each notification and report submitted to comply with this subpart,including all documentation supporting any Initial Notification or Notification of Compliance Status or compliance report that has been submitted,maintain on-site and submit, if requested by the Administrator, a report containing the information in paragraphs below: • 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 or process heater; • a description of any corrective actions taken as a part of the tune-up; and • the type and amount of fuel used over the 12 months prior to the tune-up,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. Reporting Requirements The Permittee shall submit compliance reports to the DAQ on a 2-year basis. The first report shall cover the period beginning on the compliance date specified in Section 2.1 E.4.d(i.e., start-up) of the permit and ending on the earliest December 3 1"less than two years from the compliance date. Subsequent 2-year reports shall cover the periods from January 1 to December 31. The Permittee shall submit the compliance reports postmarked on or before January 30. The compliance report must also be submitted electronically via the Compliance and Emissions Data Reporting Interface(CEDRI). CEDRI can be accessed through the EPA's Central Data Exchange (CDX) (https:Hcdx.epa.gov/).) Observed.This source is an existing source that was moved from the insignificant list to the permitted source list with the issuance of T29. Tune-ups are due every 2 years. A tune up was performed on October 5-7,2021 (previously Nov. 4,2020). Compliance with this stipulation is indicated. F. Emission Emission Source Control Control Device Description Source Description Device ID No. ID No. ES-SB One steam boiler N/A N/A MALT (2.1 million Btu DDDDD per hour) Observed. This unit was not in operation at the time of inspection. 1. 15A NCAC 02D.0503: PARTICULATES FROM FUEL BURNING INDIRECT EXCHANGERS Emissions of particulate matter from the combustion of natural gas discharged from this source(ID No. ES-SB)into the atmosphere shall not exceed 0.40 pounds per million Btu heat input. Testing If emissions testing is required,the testing shall be performed in accordance with General Conditions JJ. Monitoring,Recordkeeping,and Reporting Requirements No monitoring,recordkeeping,or reporting is required for particulate emissions from the firing of natural gas in this source(ID No.ES- SB). Observed.Compliance was determined during the permit renewal process.Compliance with this stipulation is indicated. Prysmian Cable and Systems USA,LLC April 22,2022 Page 19 2. 15A NCAC 02D.0516: SULFUR DIOXIDE EMISSIONS FROM COMBUSTION SOURCES Emissions of sulfur dioxide from boiler(ID No. ES-SB)shall not exceed 2.3 pounds per million Btu heat input. Sulfur dioxide formed by the combustion of sulfur in fuels,wastes,ores,and other substances shall be included when determining compliance with this standard. Testing If emissions testing is required,the testing shall be performed in accordance with General Condition JJ. Monitoring,Recordkeeping,and Reporting Requirements No monitoring,recordkeeping,or reporting is required for sulfur dioxide emissions from the firing of natural gas in this source(ID No. ES-SB). Observed.Compliance was determined during the permit renewal process. Compliance with this stipulation is indicated. 3. 15A NCAC 02D.0521: CONTROL OF VISIBLE EMISSIONS Visible emissions from this boiler(ID No. ES-SB)shall not be more than 20 percent opacity when averaged over a six-minute period. However,six-minute averaging periods may exceed 20 percent not more than once in any hour and not more than four times in any 24-hour period. In no event shall the six-minute average exceed 87 percent opacity. Testing If emissions testing is required,the testing shall be performed in accordance with General Condition JJ. Monitoring,Recordkeeping,and Reporting No monitoring,recordkeeping,or reporting is required for visible emissions from the firing of natural gas in this source(ID Nos. ES-SB). Observed.Compliance was determined during the permit renewal process.No visible emissions were observed at the time of inspection. Compliance with this stipulation is indicated. 4. 15A NCAC 02D.1111: MAXIMUM ACHIEVABLE CONTROL TECHNOLOGY For this steam boiler(ID Nos. ES-SB) (i.e., new source, units designed to burn gas I fuels with a heat input capacity less than SMMBtu/hr, with no autotrim),the Permittee shall comply with all applicable provisions,including the monitoring,recordkeeping, and reporting contained in Environmental Management Commission Standard 15A NCAC 02D .I I I I "Maximum Achievable Control Technology" (MACT)as promulgated in 40 CFR 63, Subpart DDDDD"National Emission Standards for Hazardous Air Pollutants for Major Sources: Industrial, Commercial, and Institutional Boilers and Process Heaters"and Subpart A"General Provisions." The Permittee shall submit an Initial Notification to the DAQ not later than 15 days after the actual date of startup of the affected source. The Permittee shall submit an initial Notification of Compliance Status to the DAQ within 60 days of startup and signed by a responsible official. Work Practice Standards The Permittee shall conduct a tune-up every 5 years while burning the type of fuel(or fuels in case of units that routinely burn a mixture)that provided the majority of the heat input to the boiler or process heater over the 12 months prior to the tune-up, as specified below: Prysmian Cable and Systems USA,LLC April 22,2022 Page 20 • as applicable,inspect the burner, and clean or replace any components of the burner as necessary. The Permittee may perform the burner inspection any time prior to the tune-up or delay the burner inspection until the next scheduled or unscheduled shutdown but the burner must be inspected at least once every 72 months. • 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; • 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). • optimize total emissions of CO. This optimization should be consistent with the manufacturer's specifications, if available,and with any NOX requirement to which the unit is subject. • 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. Each 5-year tune-up shall be conducted no more than 61 months after the previous tune-up. The initial tune-up shall be conducted no later than 61 months after the initial startup of the source. If the unit is not operating on the required date for a tune-up,the tune-up must be conducted within 30 calendar days of startup. Recordkeeyin2 Requirements The Permittee shall keep a copy of each notification and report submitted to comply with this subpart,including all documentation supporting any Initial Notification or Notification of Compliance Status or compliance report that has been submitted, maintain on-site and submit, if requested by the Administrator,a report containing the information in paragraphs below: • 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 or process heater; • a description of any corrective actions taken as a part of the tune-up; and • the type and amount of fuel used over the 12 months prior to the tune-up,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. Reporting The Permittee shall submit compliance reports to the DAQ on a 5-year basis. The first report shall cover the period beginning on the compliance date specified in Section 2.1 FAA(i.e., start-up) and ending on the earliest December 31"within five years from the compliance date. Subsequent 5-year reports shall cover the periods from January 1 to December 31. The Permittee shall submit the compliance reports postmarked on or before January 30. The compliance report must also be submitted electronically via the Compliance and Emissions Data Reporting Interface (CEDRI). CEDRI can be accessed through the EPA's Central Data Exchange(CDX) (https://cdx.epa.gov�.) Observed.This source is an existing source that was moved from the insignificant list to the permitted source list with the issuance of T29. Tune-ups are due every 5 years,the most recent tune up was performed October 5-7,2021. Compliance with this stipulation is indicated. Prysmian Cable and Systems USA,LLC April 22,2022 Page 21 5. Part I-AIR QUALITY TITLE V OPERATION PERMIT. The following permitted emission sources and/or control devices listed in Section 2 Paragraph 2.2-Multiple Emission Source(s) Specific Limitations and Conditions were observed during this inspection: A. Over-cladding Units (ID No.ES-9, excluding cell 5 units). Insignificant Sources Two natural gas-fired hot water boilers (ID Nos.I-WB-1 and I-WB-2); One waste water sludge dryer(ID No.I-SD-1); One diesel-fired fire pump (ID No.I-FP); One parts washer(ID No.I-PW); and Multiple roof top air handling units (ID No.I-AHU) 1. 15A NCAC 2Q .0317: AVOIDANCE CONDITIONS for 15A NCAC 02D. 0530: PREVENTION OF SIGNIFICANT DETERIORATION Total emissions of nitrogen oxides from equipment in Cells 1,2, 3, and 4 and two boilers shall be less than 250 tons per consecutive 12-month period. To ensure compliance with the above emissions limits, nitrogen oxides from Over-cladding Units contained in Cells 4(ID No. ES-9,excluding cell 5 units)shall be controlled by: i. A fabric filter with hydrated lime injection(ID No. IDS),or ii. A fabric filter with hydrated lime injection(ID No. IDS) in series with a selective catalytic NOx reduction system(ID No. 1 SCR). Testing Requirements Over-cladding Units i. Uncontrolled NOx emissions from individual small and large torch Over-cladding Units (Cells 4; ID No.ES-9)shall be tested to determine emission rates in pounds of NOx per unit-hour to be used in demonstrating compliance with the PSD avoidance condition. ii. Uncontrolled over-cladding emission rates must be revalidated annually by May 30 of each calendar year. The Permittee shall be deemed in noncompliance with 15A NCAC 02D .0530 if uncontrolled NOx emissions from these sources are not tested and validated as provided above. Dry Scrubber System(Lime Injection and Fabric Filter) i. NOx emissions from Over-cladding Units(Cells 4; ID No. ES-9) shall be tested prior to the dry scrubber control (ID No. IDS) to determine the dry scrubber uncontrolled NOx rate used in demonstrating compliance with the PSD avoidance condition. The Permittee shall be deemed in noncompliance with 15A NCAC 02D.0530 if NOx emissions from these sources are not tested and validated as provided above. SCR System i. NOx emissions from Over-cladding Units(Cells 4;ID No.ES-9)shall be tested prior to and after the SCR control (ID No. 1 SCR) to validate the data generated by the continuous NO and NO2 emission analyzers. The control efficiency calculated from the test and the analyzers at the time of the test shall be within 5%to validate the analyzers. ii. Initial validation test results for SCR control efficiency must be submitted to the Regional Supervisor,DAQ,within 120 days(or alternate date approved by DAQ)of SCR(ID No. 1 SCR) startup. Prysmian Cable and Systems USA,LLC April 22,2022 Page 22 The Permittee shall be deemed in noncompliance with 15A NCAC 02D.0530 if NOx emissions from these sources are not tested as provided above. General Emissions testing is required. The testing shall be performed in accordance with General Condition JJ found in Section 3. Monitoring and Recordkeeping Requirements Continuous NO and NO2 emission analyzers shall be installed upstream and downstream of the SCR(D)No. 1 SCR)to monitor emissions from the Over-cladding Units(TO No. ES-9)venting to and from the selective catalytic NOx reduction system(TO No. 1 SCR). i. Analyzers shall be calibrated daily. ii. Measurements of NO and NO2 shall be recorded after calibration at the inlet and outlet monitors. iii. NO and NO2 concentrations at the inlet shall be summed and NO and NO2 concentrations at the outlet shall be summed for the determination of a daily control efficiency. The Permittee shall be deemed in noncompliance with 15A NCAC 02D . 0530 if NOx emissions are not monitored as provided above. Calculation of monthly NOx emissions shall be made at the end of each month.Facility-wide NOx emissions shall be determined by adding emissions from the insignificant sources using AP-42 emission factors,and the Over-cladding Units in Cells 4(ID No.ES 9)including dry scrubber NOx emission rate, and the SCR control efficiency for periods when the SCR system was used. Calculation of NOx emissions using test data from(D)No. ES 9) shall be performed as follows: i. NOx emissions from Over-cladding Units in Cells 4(D)No. ES-9) shall be determined by multiplying operating hours for each over-cladding unit group type by the pounds of NOx per unit-hour determined from source testing.The number of operating hours for small and large torch groups shall be a separate record. Emissions of NOx shall be calculated using the uncontrolled emission rate demonstrated in the most recent stack test, as provided in Section 2.2 A. lc. ii. Inclusion of SCR Emissions Reductions Calculation of NOx emissions may include SCR emissions reductions during SCR operating periods. The daily control efficiency determined in accordance with 2.2A.Le.shall be used to reduce the amount of uncontrolled emissions calculated per 2.2.A. 1 .c.ii on a daily basis. 1. If a daily measurement is not available during a period that the SCR is operational, the last available measurement shall be used in place of the missing data provided that the missing data does not exceed more than 25%of the data for any one-month period. 2. If a daily measurement is not available during a period that the SCR is operational, and the missing data exceeds more than 25% of the data for any one-month period,no control efficiency shall be assumed for that day. 3. Inspection and Maintenance Requirements-To comply with the provisions of this permit and ensure that emissions do not exceed the regulatory limits, the Permittee shall establish an inspection and maintenance (I&M) schedule/checklist for the SCR based on manufacturer's recommendations.As a minimum,the I&M program will include an annual inspection of the burners, catalyst, the catalyst housing, and associated ducting to ensure structural integrity. Prysmian Cable and Systems USA,LLC April 22,2022 Page 23 Operating hours for the SCR, Over-cladding Units, SCR control efficiency calculations, NOx emission calculations, inspection/calibration/maintenance of the NOx analyzers, inspection and maintenance of the SCR, and the total monthly amount of NOx emissions must be recorded in an emissions log. The Permittee shall make the log available to officials of the DAQ upon request. The emissions log must be kept on file for a minimum of five years. Reporting Requirements Submit a semiannual summary report, acceptable to the Regional Air Quality Supervisor, of monitoring and recordkeeping activities postmarked on or before January 30 of each calendar year for the preceding six-month period between July and December, and July 30 of each calendar year for the preceding six-month period between January and June. The report shall contain the following: i. Monthly NOx emissions for each of the previous 17 calendar months; and, ii. 12-month rolling NOx emissions for each consecutive 12-month period ending in the previous six months. Observed.Per previous inspections,the selective catalytic NOx reduction systems(1 SCR and 2SCR)have never operated, and the facility has no plans to use them. The facility's permit lists it as an alternate control to the fabric filter(IDS);the fabric filter is used to control these sources. The testing requirements are outlined below. The facility is tracking the required ES-9 data, through the end of March 2022,the hours of operation were 4,537 hours,total NOx 6.51 tons for March 2022 and the 12-month rolling NOx was 84.34 tons. The required semi-annual summary reports were received on January 30, 2022, and July 28,2021. Compliance with this stipulation is indicated. Source Test Requirement Date of test Cells 4 &ES9 Uncontrolled over-cladding emission Most recent test performed March rates validation(by Mar 30 of each 6,2020 approved by SSCB year) October 20,2020 and March 23, 2021 with SSCB approval still outstanding. IDS Control efficiency annually AND each The previous stack test was Dry Scrubber time filter material changed performed March 6,2020 (lime injection approved by SSCB October 20, and fabric filter) 2020 and the most recent one was performed March 23,2021 with SSCB approval still outstanding. 1SCR Initial validation test for SCR control Per the facility,the SCR control SCR control efficiency within 120 days of startup system has never operated,and is system for ES-9 (one-time test) not physically connected. Previous testing was conducted for uncontrolled NOx emissions, initially the intent was believed to be to determine if the dry scrubber had NOx control efficiency;however, data was inconsistent with showing a NOx control, so the facility uses the uncontrolled NOx testing value in their reporting. IBEAM documents shows the test Prysmian Cable and Systems USA,LLC April 22,2022 Page 24 Source Test Requirement A Date of test protocol went to SSCB 12/22/17, the test protocol approved by SSCB on Feb. 2,2018,test conducted Apr. 3,2018,test results approved by SSCB July 25,2018. B. Cells 5, 6, and 7 Equipment consisting of- Over-cladding Units (ID No.ES-9a and cell 5 units in ES-9). Two 8.0 million Btu per hour heat input natural gas-fired boilers; Two 10.0 million Btu per hour SCR flue gas re-heaters; and, Two 1.0 million Btu per hour SCR ammonia injector dilution air heaters. 1. 15A NCAC 2Q .0317: Avoidance of 2D.0530 Prevention of Significant Deterioration. The nitrogen oxides emissions increase due to equipment operation shall be less than 250 tons per consecutive 12-month period. To ensure compliance with the above emissions limits, nitrogen oxides from Over-cladding Units contained in Cells 5, 6,and 7 shall be controlled by: i. A fabric filter with hydrated lime injection(ID No. 2DS),or ii. A fabric filter with hydrated lime injection(ID No. 2DS)in series with a selective catalytic NOx reduction system(ID No.2SCR). Testing Requirements New Technology Over-cladding Units NOx uncontrolled emissions from individual new technology torch Over-cladding Units (Cells 5, 6, and 7,ES-9a)shall be tested and results submitted within 120 days from startup to determine emission rates in pounds of NOx per unit-hour to be used in demonstrating compliance with the PSD avoidance condition.Uncontrolled over-cladding emission rates must be revalidated annually. Dry Scrubber System(Lime Injection and Fabric Filter) NOx emissions from Over-cladding Units (Cells 5, 6, 7; ID No. ES-9a) prior to and after the dry scrubber control(ID Nos. 2DS) shall be tested and results submitted within 120 days from startup to determine dry scrubber control efficiency to be used in demonstrating compliance with the PSD avoidance condition. Control efficiency of the dry scrubber system(lime injection and fabric filter) must be revalidated annually and each time the type of filter material is changed unless the Permittee assumes no fabric filter control for the purposes of compliance demonstration until further DAQ approved testing is conducted. SCR S, s e NOx emissions from Over-cladding Units (Cells 5, 6, 7; ID No. ES-9a) shall be tested prior to and after the SCR controls(ID Nos.2SCR)to validate the data generated by the continuous NO and NO2 emission analyzers. The control efficiency calculated from the test and the analyzers at the time of the test shall be within 5%to validate the analyzers. Initial validation test results for SCR control efficiency must be submitted to the Regional Supervisor,within 120 days(or alternate date approved by DAQ)of SCR(ID Nos. 2SCR)startup. Prysmian Cable and Systems USA,LLC April 22,2022 Page 25 General Emissions testing is required. The testing shall be performed in accordance with General Condition JJ found in Section 3 of the permit. Monitoring and Recordkeeping Requirements Continuous NO and NO2 emission analyzers shall be installed upstream and downstream of each SCR(ID Nos. 2SCR)to monitor emissions from the Over-cladding Units(ID No. ES-9a)venting to and from each selective catalytic NOx reduction system(ID Nos. 2SCR). i. Analyzers shall be calibrated daily. ii. Measurements of NO and NO2 shall be recorded after calibration at the inlet and outlet monitors. iii. NO and NO2 concentrations at the inlet shall be summed and NO and NO2 concentrations at the outlet shall be summed for the determination of a daily control efficiency. Calculation of monthly NOx emissions shall be made at the end of each month. Calculation of NOx emissions may include SCR emissions reductions during SCR operating periods. To comply with the provisions of this permit and ensure that emissions do not exceed the regulatory limits,the Permittee shall establish an inspection and maintenance(I&M) schedule/checklist for the SCRs based on manufacturer's recommendations. As a minimum,the I&M program will include an annual inspection of the burners, catalyst, the catalyst housing, and associated ducting to ensure structural integrity. Operating hours for the SCR, Over-cladding Units, SCR control efficiency calculations, NOx emission calculations, inspection/calibration/maintenance of the NOx analyzers, inspection and maintenance of the SCRs, and the total monthly amount of NOx emissions must be recorded in an emissions log. Reporting Requirements Submit a semiannual summary report, acceptable to the Regional Air Quality Supervisor, of monitoring and recordkeeping activities postmarked on or before January 30 of each calendar year for the preceding six-month period between July and December, and July 30 of each calendar year for the preceding six-month period between January and June. The report shall contain the following: i. Monthly NOx emissions for each of the previous 17 calendar months; and, ii. 12-month rolling NOx emissions for each consecutive 12-month period ending in the previous six months. Observed.Per previous inspections the selective catalytic NOx reduction systems (I SCR and 2SCR)have never operated and the facility does not plan to use them. The facility's permit lists it as an alternate control to the fabric filter(1DS);the fabric filter is used to control these sources. The facility is tracking the required data,through the end of March 2022,the hours of operation were 13,448 hours,total NOx 17.01 tons and the 12-month rolling NOx was 199.55 tons. The testing requirements are outlined below. The required semi-annual summary reports were received on January 30,2022, and July 28,2021. Compliance with this stipulation is indicated. ource Test Requirement Date of test Cells 5,6,and NOx uncontrolled emissions shall be tested Testing protocol was 7,ES-9a with and results submitted within 120 days from approved by SSCB on Dec. dry scrubber startup to determine emission rates in 3,2007,testing was control(ID Nos. pounds of NOx per unit-hour to be used in performed Dec. 20,2007 and 2DS) demonstrating compliance with the PSD again June 2,2008,the June Prysmian Cable and Systems USA,LLC April 22,2022 Page 26 Source Test Requirement Date of test avoidance condition and to determine dry 2, 2008 testing was reviewed scrubber control efficiency. (one-time test) and approved by SSCB on Jan. 21,2009 Cells 5,6,and NOx uncontrolled over-cladding emission Most recent test performed 7,ES-9a with rates and dry scrubber control efficiency March 22 &23,2022 with dry scrubber must be revalidated annually. results still pending(this test control(ID Nos. was conducted on both ES-9 2DS) and ES-9a) C. Chemical Vapor Deposition Units (ID No. ES-1), Gas Cabinets (ID No.ES-4), and Collapse Furnaces (ID No. ES-14) consisting of: Cells 5, 6, and 7 with Wet Scrubber(ID No.3WS); and, Over-cladding Units(ID No.ES-9) consisting of: Cells 4, and some cell 5 units venting to Hydrated Lime Injection Dry Scrubber Fabric Filter System (ID No. IDS) that vents to a Selective Catalytic NOx Reduction System (ID No. 1SCR). Over-cladding Units (ID No.ES-9a) consisting of: Cells 6,7,and remaining cell 5 units venting to Hydrated Lime Injection Dry Scrubber Fabric Filter System (ID No. 2DS) that vents to a Selective Catalytic NOx Reduction System(ID No.2SCR); and, Chemical Room (ID No.ES-11)with Wet Scrubber System (ID No.3WS); and, SiC14 Storage Room(ID No. 18)with Wet Scrubber System(ID No.3WS). Etching Operations(ID No.ES-Etch)equipped with a Wet Scrubber System(ID No.4WS) The following provides a sunitnary of limits and/or standards for the emission sources described above. Regulated Pollutant Limits/Standards Applicable Regulation STATE-ONLY REQUIREMENT Emissions of HCI, C12,HF,and NH3 must be emitted at or below the emission rates tabulated in the next table in order to comply with the following acceptable ambient levels. Toxic Air Pollutants HCl: 0.7 milligrams/cubic meter- lhr 15A NCAC 02D.1100 C12: 0.9 milligrams/cubic meter- 1 hr and 0.0375 milligrams/cubic meter-24 hr HF: 0.25 milligrams/cubic meter- lhr 0.03 milligrams/cubic meter-24 hr NH3: 2.7 milligrams/cubic meter- lhr 1. STATE-ONLY REQUIREMENT 15A NCAC 2D .1100: Toxic Air Pollutant Emissions. The permittee shall comply with the following toxic emission limits: Prysmian Cable and Systems USA,LLC April 22,2022 Page 27 Affected Sources Pollutant Emission Limit EP-11: Wet Scrubber#1 (ID No.3WS) Envirocare#1 Hydrogen Chloride 9.063 lb/hr Includes emission from: Cells 5, 6,and 7 CVD (ID Nos.ES-1) Chlorine 5.582 lb/hr; and, 133.97 lb/day Cells 5, 6,and 7 GC (ID No.ES-4), Cells 5, 6 and 7 CF(ID No.ES-14) Chemical Room(ID No.ES-11) SiC14 Storage Room(ID No.ES-18) EP-21 combined stack for SCRs Ammonia 1.584 lb/hr per SCR EP-11: Wet Scrubber#1 (ID No.3WS) Envirocare#1 Includes emission from: Cells 5, 6,and 7 CVD (ID Nos.ES-1) Cells 5, 6,and 7 GC (ID No.ES-4), Cells 5, 6 and 7 CF(ID No.ES-14) Chemical Room(ID No.ES-11) SiC14 Storage Room(ID No.ES-18) EP-18: dry scrubber(ID No. IDS) or EP-21: SCR(ID No. 1SCR) Cells 4, and some cell 5 OC units(ID No. Hydrogen Fluoride 2.67 lb/hr; and,41.03 lb/day ES-9 EP-19: dry scrubber#1 (ID No.2DS) or EP-21: SCR(ID No.2SCR) Cells 6, 7, and remaining cell 5 OC units (ID No.ES-9a) EP-4WS:Wet Scrubber(ID No.4WS) Includes emission from: Etching operations(ID No.ES-Etch) The Permittee has submitted a toxic air pollutant dispersion modeling analysis (March 21, 2018) for the facility's toxic air pollutant emissions as listed in the above table. The modeling was reviewed and approved by the AQAB on(April 10,2018). Placement of the emission sources, configuration of the emission points, and operation of the sources shall be in accordance with the submitted dispersion modeling analysis and should reflect any changes from the original analysis submittal as outlined in the AQAB review memo. Emissions from the CVD processes will be controlled by the scrubber(ID No. 3WS or 2WS). Emissions from the Over-cladding Units (ID Nos. ES-9 and ES-9a) shall be controlled by two fabric filters each with hydrated lime injection(ID Nos. IDS and 2DS). Prysmian Cable and Systems USA,LLC April 22,2022 Page 28 General If emissions testing is required,the testing shall be performed in accordance with General Condition JJ of the permit. Monitoring,Recordkeeping and Reporting Monitoring, recordkeeping, and reporting pertain to inspection and maintenance of control devices and parametric monitoring to ensure control efficiencies. Continuous emission analyzers for ammonia emissions from the selective catalytic NOx reduction systems (ID Nos. 1SCR and 2SCR) shall be inspected and maintained in accordance with the manufacturer's recommendations. As a minimum, the instruments shall be calibrated daily. Records of calibrations,inspections,and maintenance shall be kept in a logbook and maintained on site. Records shall be made available to the DAQ personnel upon request. All required records on file for a minimum of two years. Observed. Overcladding units(ES-9a and ES-9)were in operation and the emissions were being controlled by the fabric filter with hydrated lime injection(2DS & IDS). Per previous inspections the selective catalytic NOx reduction systems(1SCR and 2SCR)have never operated and the facility does not plan to use them. The facility's permit lists it as an alternate control to the fabric filter(IDS); the fabric filter is used to control these sources. The chemical vapor deposition units(ES-1), gas cabinets(ES-4), collapse furnaces (ES-14) and the chemical room(ES-11)were in operation and venting emissions to the wet scrubber(3WS). The remaining sources were not in operation. The permittee provided electronic records of production and amounts of HCI, Cl and HF emitted. Ammonia is not being emitted by the facility as the selective catalytic reduction systems which uses ammonia have not been operated nor are anticipated to be operated. The scrubber(ID No. 3WS) started operation on August 23, 2015 and the required stack tests(ES-1,ES-11,ES-14,ES-18,ES-4- 3WS)were completed on February 17, 2016(within 180 days). The stack test(ID No. 2016-029ST) report was reviewed and approved by the SSCB on November 10,2016.Again, stack testing(ID No. 2017-045ST)was conducted on February 14, 2017 and results approved on November 30,2017. Compliance with this stipulation is indicated. 6. Part I-AIR QUALITY TITLE V OPERATION PERMIT. 2.3- Compliance Assurance Monitoring (CAM; 40 CFR Part 64) A. One Fabric Filter with Hydrated Lime Injection(ID No. IDS) 1. 15A NCAC 02D .0614: Continuous Assurance Monitoring for fabric filter with hydrated lime injection(ID No. IDS) The Permittee shall ensure that PM emitted from the Over-cladding Units(ID No. ES-9)is controlled by a fabric filter(ID No. 1DS)by monitoring the Pressure drop across the fabric filter,and the Lime injection rate. No testing is required. The key elements of the monitoring approach are Pressure drop across the scrubber and water flow rate. An excursion is defined as an hourly average differential pressure (DP) less than 0.1 inches of water pressure drop or more than 9 inches of water pressure drop. An excursion is defined as an injection rate reading less than 30 pounds per hour. The permittee must maintain monthly records of the above operating parameters and submit a semi-annual report. Observed. Records reviewed indicated that all monitoring is being conducted with no issues noted at the time of inspection. Annual maintenance on fabric filter (IDS) was conducted on December 29, 2021 (previously Dec. 4, 2020, Jan. 16, 2019, and January 22, 2018). The required semi-annual summary reports were received on January 30, 2022, and July 28, 2021. Compliance with this stipulation is indicated. Prysmian Cable and Systems USA,LLC April 22,2022 Page 29 B. One Fabric Filter With Hydrated Lime Injection (ID No.2DS) 1. 15A NCAC 02D .0614: Continuous Assurance Monitoring for fabric filter with hydrated lime injection(ID No.2DS) The Permittee shall ensure that PM emitted from the Over-cladding Units (ID No. ES-9a) is controlled by a fabric filter (ID No. 2DS) by monitoring the pressure drop across the fabric filter, and the lime injection rate. No testing is required. The key elements of the monitoring approach are Pressure drop across the scrubber and water flow rate.An excursion is defined as an hourly average differential pressure (DP) less than 0.1 inches of water pressure drop or more than 9 inches of water pressure drop. An excursion is defined as an injection rate reading less than 30 pounds per hour.The Permittee must maintain all measurements of operating parameters on a monthly basis. The Permittee shall submit a summary report of all monitoring activities postmarked on or before January 30 of each calendar year for the preceding six-month period between July and December and July 30 of each calendar year for the preceding six-month period between January and June. Observed. Records reviewed indicated that all monitoring is being conducted with no issues noted at the time of inspection. Annual internal maintenance on fabric filter(2DS)was conducted on December 29, 2021 (previously Dec. 4, 2020, Sept. 13, 2019, and Sept. 27, 2018.) The required semi-annual summary reports were received on January 30, 2022, and July 28, 2021. Compliance with this stipulation is indicated. 7. Part I-AIR QUALITY TITLE V OPERATION PERMIT. Section 3 -GENERAL CONDITIONS A. Permit. Maintain a copy of the permit and application at the facility. Observed. The permit and application are at the facility. Permit 07334T29 was issued December 16, 2019 with an effective date of December 16,2019 and an expiration date of November 30,2024. Compliance with this stipulation is indicated. B. Submissions. Except as otherwise specified,two copies of all documents,reports,test data, monitoring data are required to be submitted to MRO. Observed. The permittee submits two copies. Compliance with this stipulation is indicated. C. Circumvention. Operate and maintain the facility at all times in a manner that will affect an overall reduction in air pollution. Observed. The facility modifies control operations to meet permit requirements. Compliance with this stipulation is indicated. D. Excess Emissions. Report excess emissions and permit deviations as required. Observed. No deviations have been reported since last inspection. Compliance with this stipulation is indicated. G. Retention of Records. The Permittee shall retain records of all required monitoring data and supporting information for a period of at least five years from the date of the monitoring sample, measurement,report, or application. Observed. Records are being maintained. Compliance with this stipulation is indicated. Prysmian Cable and Systems USA,LLC April 22,2022 Page 30 H. Compliance Certification. By March 1 submit a compliance certification(for the preceding calendar year). Observed. Received on March 1,2022. Compliance with this stipulation is indicated. I. Emissions Inventory. Submit an emissions inventory by June 30 of each year. Observed. The 2020 emission inventory was received June 29,2021. The 2021 emission inventory report is not due until June 30, 2022. Compliance with this stipulation is indicated. J. Refrigerant Requirements(Stratospheric Ozone and Climate Protection). The facility must dispose of refrigerants properly. Observed. The facility has standard air conditioners with R123. Trane representatives service the refrigerant. Compliance with this stipulation is indicated. K. Section 112(r). Observed. 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. Quantities of hydrogen are kept below 10,000 pounds. Compliance with this stipulation is indicated. 8. The Following Non-permitted/Insignificant Air Emission Sources and Control Devices were Observed as Follows: Emission Source ID Emission Source Description No. I-AHU Multiple roof top air handling units Observed.These units were not observed during the inspection. I-ES-15 Collapse process hoods Observed.The collapse process hoods are used on a few of the older sources and there are also units known as collapse process lathes which uses a plasma process with the same emissions. These units were not observed during the inspection. I-ES-5 Prep hoods Observed. Glass rods are leveled and handles are placed on the rods. A single natural gas-fired flame is used to heat the rods and add the handles. There are six prep hoods. These units were not observed during the inspection. I-ES-13, I-ES-13a, Three central vacuum systems ES-13b Observed.There are only two central vacuum systems and they are used to clean grain from the over cladding cabinets and fiber strands around the draw towers. These units were not observed during the inspection. I-ES-10 Glass saw hoods Observed.The saw cuts glass rods to meet specific product requirements. These units were not observed during the inspection. I-SD-1 Waste water sludge dryer Observed.This unit were not observed during the inspection. The dryer is natural gas fired and has a maximum heat input rating of 0.41 mmBtu/hr. Prysmian Cable and Systems USA,LLC April 22,2022 Page 31 Emission Source ID Emission Source Description No. I-ES-7 Draw towers Observed. Glass rods are placed in the draw tower and heated to produce fiber strands. The fiber strands go through a series of quality control checks on the draw tower and is also coated/painted as it goes through the draw tower. The facility has numerous draw towers in different business units. These units were not observed during the inspection. I-Clean Machine cleaning stations with 10 eight-gallon capacity acetone baths Observed.The cleaning stations are used to clean the dies that manage and paint the fiber strands in the draw tower. This operation uses charcoal filter traps to retain the volatile acetone. This activity was not observed. I-BEL Sixteen Buffering extruder lines Observed.The glass fibers are twisted and then a plastic coating is applied. The twisting allows the fibers to bend without breaking. The plastic is extruded onto the fibers then cooled in chilled water. These units were not observed during the inspection. I-JEL Eleven Jacketing extruder lines Observed.After the fibers have been processed through the buffering extruder lines,the jacketing extruder lines place additional layers of protection around the fibers after coating the fiber with a plastic coating. The plastic is extruded onto the fibers then cooled in chilled water. These units were not observed during the inspection. I-JM Jacket Melters Observed.Bulk compound is melted(jacket melters)at each jacket line and then the melted compound goes through the extruders(jacketing extruders—ID No. I-JEL). These units were not observed during the inspection. I-FH Eight flame heaters for the jacket extruder lines(0.044 million Btu per hour each) Observed.A flame is used to heat the plastic coating around the glass fibers then a product code is applied with ink to the coating. These units were not observed during the inspection. I-PL Sixteen printing lines Observed. Ink is applied to the outer finish of the fiber cable. The process uses a non-VOC ink that is dried with UV light. The activity was not observed. I-RL Six ribbon lines Observed. Glass fibers strands are glued together, flattened and product code information is applied in ink to the coating. There are five ribbon lines in operation. This operation has been removed from the facility and has been added to the yellowsheet. I-FBW Fluidized bed washer Observed.Parts are placed in a cylinder where sand and water are heated(electric) and injected to clean the metal parts. A small cyclone is used to capture any particulates. This was not observed. I-PW Parts washer Observed.The parts washers are small washers located near the ribbon line. These units were not observed during the inspection. I-Draw Clean Cleaning stations Observed.These units were not observed during the inspection. Prysmian Cable and Systems USA,LLC April 22,2022 Page 32 Emission Source ID Emission Source Description No. 1. M: I-WB-1,I-WB-2 Two hot water boilers (0.75 million Btu per hour each) Observed.These Fulton hot water boilers are labelled as 750 M Btu/hr each. They are seasonally used for comfort heat. These units were not observed during the inspection. I-WH-1 and I-WH-2 Two domestic water heaters (0.75 million Btu per hour each) Observed.These large domestic style hot water heaters were not observed. They are rated at 75,100 Btu/hr. I-ANNEAL Annealing Furnace Observed.The furnace is used to clean the irradiator tubes used on the draw towers. The annealing furnace is electric and was not observed during this inspection. I-CORRAL One natural gas-fired corral lathe(0.10 million Btu per hour) Observed. Glass rods are leveled on the corral lathe. Multiple natural gas fired flames are used to heat the rods while it is rotated. The facility no longer uses this equipment. I-M-1 and I-M-2 Two natural gas-fired munters(2.4 million Btu per hour each) Observed.These units were not observed during the inspection. I-ES-FP Diesel-fired fire pump 105 HP MACT ZZZZ Observed.The fire pump is subject to NESHAP Subpart 4Z as an existing engine. The engine's serial number is 4474811. The permittee conducts annual maintenance on the engine since the fire pump has never operated more than 500 hours per year. The hour meter reading during the inspection was 611.0(previously 605.3 hours). Annual maintenance was conducted on January 21, 2022 (previously May 20,2021,and Dec. 7,2020). I-CT-601 Fiber Plant 2 cell Cooling Tower I-CT-701 Fiber Plant 3 cell Cooling Tower I-CT-702 Fiber Plant 3 cell Cooling Tower I-CT-801 Fiber Plant 3 cell Cooling Tower I-CT-1 Cable Plant Cooling Tower Observed.This units were observed with no issues noted. 9. Other Compliance Requirements and Issues: None noted. 10. Compliance Assistance: None. 11. Summary of Changes Needed to the Current Permit: None. Prysmian Cable and Systems USA,LLC April 22,2022 Page 33 12. Findings. Based on my observations during this inspection, this facility appeared to be in compliance with the applicable air quality regulations. KAK:lms cc: MRO Files https://ncconnect.sharepoint.com/sites/DAQ-MRO/Counties/CATAWBA/00419/INSPECT 20220422.docx