AQ_F_1800463_20211019_CMPL_InspRpt

NORTH CAROLINA DIVISION OF Mooresville Regional Office
AIR QUALITY Wesley Hall Incorporated
NC Facility ID 1800463
Inspection Report County/FIPS: Catawba/035
Date: 10/19/2021
Facility Data Permit Data
Wesley Hall Incorporated Permit 08169/R05
141 Fairgrove Church Road SE Issued 6/19/2014
Hickory,NC 28603 Expires 5/31/2022
Lat: 35d 43.2180m Long: 8ld 15.8870m 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
William Whitener Edward Deal William Whitener
Plant Manager Chief Executive Officer Plant Manager
[phone] [phone] [phone]
Compliance Data
Comments:
Inspection Date 10/19/2021
Inspector's Name Robert Papuga
Inspector's Signature: f�o� �a� /Pr v.. � ,` Operating Status Operating
Compliance Status Compliance-inspection
Action Code FCE
Date of Signature: 10/21/2021 Inspection Result Compliance
Total Actual emissions in TONS/YEAR:
TSP S02 NOX VOC CO PM10 *HAP
2013 0.1400 --- --- 14.40 --- 0.1400 1099.97
2008 0.1800 --- --- 12.53 --- 0.1800 1713.41
*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

Wesley Hall Incorporated
October 19,2021
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Type Action: X Full Compliance _Partial Compliance _Complaint Other:
Evaluation Evaluation/Reinspection Investigation
Data Date submitted for initial review 10/21/2021 IBEAM INFO,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
XXIBEAM Planning,Next Inspection Date 10/01/2023
Directions: From Iredell County, travel Interstate 40 West to Hickory. Take Exit 128, turn right onto
Fairgrove Church Road, and travel approximately 2 miles. The facility is located on the right (just before
railroad tracks) at 141 Fairgrove Church Road.
Safety Equipment/Issues; Safety glasses and safety shoes are required for an inspection at this facility. I
contacted the facility to discuss their current policies concerning COVID-19. The facility requires masks
to be worn while inside the buildings. During this inspection I wore my mask for the entire inspection.
Lat/Long Coordinates: The facility's coordinates on "Map of Regulated AQ Facilities" indicates the
latitude and longitude coordinates are accurate. The coordinates are locked in IBEAM.
1. The purpose of this site visit was to conduct a routine air quality inspection. This facility
manufactures upholstered furniture. This facility also applies finishing material to the exposed
wooden areas of frames that were cut off-site.No wood working is performed at the plant except
for some sanding. The facility is currently operating eight hours per day,Monday through Friday,
and four hours on Saturday. Mr. William Whitener,Plant Manager,talked to me during this
inspection and Mr. Jerry Russell,Finishing Room Supervisor accompanied me during this
inspection.
2. Facility Contact Information:
I verified the facility contact information in IBEAM. An update was needed for the invoice
contact. Sandy Sherer updated the invoice contact in IBEAM.
3. Compliance histor
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.
4. Observations of permitted air emission sources and control devices:
a. Six(6) dry-filter type paint spray booths installed on furniture finishing operations (ES-1,ES-
2,ES-3,ES-4,ES-6, &ES-7)
Observed: Mr. Russell stated that finish is applied to exposed legs and arms of upholstered
furniture. All six spray booths were operating during my inspection and no visible emissions

Wesley Hall Incorporated
October 19,2021
Page 3 of 5
were observed, or odors detected during my inspection.All filters were in place and in good
condition.
b. One dip tank(ES-5)
Observed: Mr. Russell stated that the dip tank is rarely used. Instead, approximately 100
legs are dipped per month and a five-gallon bucket is used in lieu of the dip tank. The leg
dipping process was not being conducted at the time of my inspection.
5. Observations of insignificant air emission sources and control devices listed on the current
>l ermit:
a. None.
6. Observations of air emission sources and control devices not listed on the current permit:
a. None noted.
7. Compliance with specific permit conditions and limitations:
a. Condition A.2. — "Emissions Inventory Requirement". At least 90 days prior to the
expiration date of the permit, the Permittee shall submit the air pollution emission
inventory report. The report shall be submitted to the Regional Supervisor, DAQ. The
report shall document air pollutants emitted for the 2020 calendar year.
Observed: I informed Mr.Whitener that the current permit expires on May 31,2022,
and that an emission inventory report should document air pollutants emitted during
calendar year 2020.
b. Condition A.3. — 15A NCAC 2D .0512 "Particulates from Wood Products Finishing
Plants". Provide adequate duct work and properly designed collectors to control
woodworking particulates.
Observed. The particulate from the furniture finishing is controlled by spray booth
filters. The filters on the paint spray booths appear to be in place and in good condition.
They appeared to adequately control particulate from the overspray. Compliance with
this stipulation is indicated.
C. 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 during my site visit.
Compliance with this stipulation was indicated
d. Condition A.5. — "Notification Requirement". Notify DAQ of excess emission that last
more than four hours that result from a malfunction, a breakdown of process or control
equipment or any other abnormal conditions.
Observed: Mr. Whitener stated that there had been no excess emissions to report.
Compliance with this stipulation was indicated.

Wesley Hall Incorporated
October 19,2021
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e. Condition A.6. - 15A NCAC 2D .0540 "Particulates from Fugitive Dust Emission
Sources" requires the facility to develop and submit a fugitive non-process dust control
plan if the facility cause or contribute to substantive dust complaints.
Observed: No complaints have been received regarding fugitive dust from this facility
during the last 5 years. No fugitive dust emissions were observed during my site visit.
Compliance with this permit condition was indicated.
f. Condition A.7.— 15A NCAC 2D .0958(c), "Work Practices for Sources of VOC's".
Observed: Containers were properly closed, and no spills were observed. Compliance
with this permit condition was indicated.
g. Condition A.8. - 15A NCAC 2Q .0711 "Emission Rates Requiring a Permit," facility-
wide actual toxic air pollutants(TAPS) emissions cannot exceed the Toxic Permit
Emissions Rates(TPERs).
Observed: The Air Permit Review, conducted prior to issuing permit 08169R05 on June
19, 2014, indicates that emissions are well below the TPERs limits. According to Mr.
Whitener and Mr. Russell, there have been no significant changes to production or
products since that time. Compliance is indicated.
8. NSPS/NESHAP Review:
There are no generators or fire pumps on site, therefore they are not subject to NESHAP Subpart
4Z. There are no boilers on site, therefore they are not subject to NESHAP Subpart 6J, and there
are no gasoline storage tanks on site,therefore they are not subject to NESHAP Subpart 6C.
9. Summary of changes needed to the current permit:
Specific Condition and Limitation A. 7. 15A NCAC 2D .0958: Work Practices for Sources of
Volatile Organic Compounds should be removed from the permit during the next revision. The
2D .0958 requirements do not apply to this facility, since it is in Catawba County. The electronic
yellow sheet for permit changes needed has been updated.
10. Compliance assistance offered duringtpection:
None.
11. Section 112(r)applicability:
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.

Wesley Hall Incorporated
October 19,2021
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