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Home My WebLink AboutAQ_F_1600128_20200805_CMPL_InspRpt r NORTH CAROLINA DIVISION OF Wilmington Regional Office AIR QUALITY Bally Refrigerated Boxes,Inc. NC Facility ID 1600128 Inspection Report County/FIPS:Carteret/031 Date: 08/05/2020 Facility Data Permit Data Bally Refrigerated Boxes,Inc. Permit n/a 135 Little Nine Drive Issued n/a Morehead City,NC 28557 Expires n/a Lat: 34d 44.2690m Long: 76d 48.8720m Class/Status Registered SIC: 5078/Refrigeration Equip&Supplies Permit Status Inactive NAICS: 42374/Refrigeration Equipment and Supplies Merchant Wholesalers Current Permit Application(s)None Contact Data Program Applicability Facility Contact Authorized Contact Technical Contact SIP Ted Jennings Mike Coyle Mike Coyle MACT Part 63: Subpart 6X,Subpart ZZZZ Maintenance Manager President President (252)240-2829 (252)240-2829 (252)240-2829 r Asa Comments: Compliance Data Inspection Date 07/31/2020 Inspector's Name Tony Sabetti Inspector's Signature: / Operating Status Operating Compliance Code Compliance-inspection �y f Action Code FCE Date of Signature: a /�/Z pf On-Site Inspection Result Compliance Z& o Total Actual emissions in TONS/YEAR: TSP S02 NOX VOC CO PM10 •HAP 2014 0.0100 -- 7.21 --- 0.0100 3333.00 2009 0.0000 --- -- 7.48 0.0000 407.80 s( *Highest HAP Emitted inpounds) Five Year Violation History:None ' Date Letter Type Rule Violated - '� Violation Resolution Date Performed Stack Tests since last FCE:None Date Test Results Test Methods) Source(s)Tested Compliance History Bally has a history of operating in compliance with DAQ Rules. This assessment is based on a review of !t the office file documents and I-beam module. The review revealed that no NOV's have been issued during the past 5 years(time period reviewed). Compliance Inspection Contact for the inspection was with Ted Jennings, Facility Manager. Facility was operating. 3 General Information This plant manufactures insulated panels and doors for the construction of walk-in freezers, refrigerated warehouses, and environmental chambers. MDI (Methylisocyanate)is used in the manufacturing process. -V Registration ! Bally Refrigerated Boxes, Inc. is hereby authorized to construct and operate the air emissions sources and/or air cleaning devices and appurtenances described below: In accordance with the provisions of Article 2 1 B of Chapter 143, General Statutes of North Carolina(NCGS)as amended, and other applicable . Laws, Rules and Regulations. i4 Emission Emission Source Control Control System j� Source ID Description System ID Description ;one paint spray booth CD-1 1,370 square feet of dry ' equipped with one airless panel filters spray gun ES-2 one coating operation !� consisting of two(auto) conveyor fed spray coating N/A N/A lines with two electric heat lamps ES-MDI two storage tanks for MDI CD-2 one portable carbon bed adsorber �S-4 miscellaneous production activities including gluing N/A N/A and clean-up ES-5 (NESHAP) one welding operation N/A r N/A ES-6 (NESHAP) one abrasive blasting N/A I N/A operation Insignificant Sources List l Source Exemption Source of Source of Title V Regulation TAPs? Pollutants? IES-HW I -Natural gas fired hot water heater 2Q .0102 (222'000 Btu/hr.heat input) I(aX2xBxii) Yes No IES-Gen-I -one emergency back-up diesel fuel-fired 2 0102 generator(30 kw rating, 1981 model year,ZZZZ (Q 2)(Bxv)(III) No No SHAP) IES-Gen-2-one emergency back-up diesel fuel-fired _[2Q 0102 1gaeneraattorr(I I kw rating,2003 model year,ZZZZ F(ESP) c)(2)(B)(v)(III) No No �. i a Registration Criteria: Pursuant to 15A NCAC 2D .0202 'Registration of Air Pollution Sources," and 15A NCAC 2Q .0102(e), the facility-wide actual total aggregate emissions of particulate matter 10, sulfur dioxide, nitrogen oxides, volatile organic compounds, carbon monoxide, hazardous air pollutants, and toxic air pollutants shall be less than 25 tons per year. Bally Refrigerated Boxes,Inc. was issued a registration permit on January 9, 2017. Actual emission at the time were evaluated to be approximately 7 tons/year VOC and .01 tons/year PM. ' Record Keening: (15A NCAC 2D .0202)- Bally Refrigerated Boxes, Inc. is maintaining records on site to establish that facility-wide annual air pollutant emissions remain below the 25 ton per year threshold level listed above. Records of paint and wielding wire usage are kept onsite and were reviewed by DAQ during the compliance assurance inspection. ,> Notification Requirements: (15A NCAC 2D 00202) -Bally Refrigerated Boxes, Inc. shall notify DAQ as soon as possible of the following occurrences: r Process Modifications: No modifications of the processes from that listed in the Emissions Equipment Table has occurred during this inspection cycle. Name/Ownership/Location Change: No changing the facility name, ownership or location from that as listed in this Registration. Emissions Increase: Facility has not increased emissions such that the 25 ton per year emission threshold would be expected to be exceeded. Liability: An Air Emission Sources Registration shall not alter or affect the power of the Commission, Secretary of the Department, or Governor or the liability of an owner or operator of a facility for any violation of the applicable requirements. Department of Environmental Quality Inspections:No refusal of entry to any representative of the DEQ. Environmental Management Commission(EMC) Re lations: Bally Refrigerated Boxes, Inc. is complying with applicable EMC Regulations. Particulates from Miscellaneous Industrial Processes: (15A NCAC 02D .0515) Particulate matter emissions from the emission sources are being controlled by approved ES-1 one paint spray booth CD-1 1,iM square feet of dry panel filters equipped with one Fairless spray gun Filters were last changed on 7/15/2020. Control of Visible Emissions: (15A NCAC 2D .0521) -Visible emissions of emission sources were evaluated with zero percent opacity. Y�� r r.t• 1 'tA Excess Emissions Notification Requirements: (15A NCAC 2D .0535) - Bally Refrigerated Boxes, Inc. must report excess emissions of any regulated pollutant lasting more than four(4)hours, and that result from a malfunction,to the Division of Air Quality by 9 am of the next working day. Fugitive Dust Control Requirement: (15A NCAC 2D .0540)—Fugitive emissions were not observed beyond the property boundary and no substantive complaints have been received by DAQ. Control of Emissions from Abrasive Blasting: (15A NCAC 2D .0541) -Abrasive blasting operation is conducted indoors and not vented to the atmosphere. Maximum Achievable Control Technologv Subpart ZZZZ (4Z)IES-Gen-1 has been taken out of service. IES-Gen-2 is an emergency generator, hours of operation logs are attached. Bally is complying with the requirements of Subpart ZZZZ, annual maintenance preformed on 7/28/20. Generally Available Control Technology. XXXXXX (6X) - Abrasive blasting and welding operations. Management Practices A The abrasive blasting operation is conducted inside the facility in a blasting cabinet enclosure equipped With a bag-filter vented inside. Bag-filter is maintained according to manufacturer's instructions. As required by 40 CFR 63.11516(f),the following management practices are required to minimize the emissions of the metal fabrication and finishing hazardous air pollutants (MFHAPs: cadmium, chromium, v lead,or nickel>0.1 %in welding rod or manganese> 1.0%in welding rod):No welding rods are currently being used. Per 40 CFR 63.11516 (f)(1) Bally Refrigerated Boxes, Inc. is operating all equipment associated with welding operations according to manufacturer's instructions. A copy of the manufacturer's specifications is maintained on site. y Per 40 CFR 63.11516 (f)(2), Bally Refrigerated Boxes, Inc.is using gas metal arc welding (GMAW) processes that reduced fume generation capabilities. a Monitoring Requirements Bally Refrigerated Boxes, Inc. performs visual determinations of fugitive emissions, as specified in 40 CFR 63.11517(b). Most recent quarterly observations were performed on 5/19/20,with no visible fugitive emissions detected. Record Keeping Wielding wire usage log was reviewed during the inspection. Reporting Requirements Annual Compliance Certification(ACC)was received on January 21,2020 with no deviations reported for CY 2017, copy attached. Inspection Summary From the observed information,recommend accept this facility as operating in compliance with applicable EMC Air Quality Regulations at this time.