AQ_F_1800419_20210323_ST_STO-Rpt

NORTH CAROLINA DIVISION OF Mooresville Regional Office
AIR QUALITY Prysmian Cables and Systems USA,LLC
NC Facility ID 1800419
Stack Test Observation Report County/FIPS:Catawba/035
Date: 03/23/2021
Facility Data Compliance Data
Prysmian Cables and Systems USA,LLC Observation Date 3/23/2021
2512 B Penny Road Observer's Name Emily Supple
Claremont,NC 28610 Operating Status Operating
Lat: 35d 42.1680m Long: 81d 9.2538m Action Code
SIC: 3229/Pressed And Blown Glass,Nec
NAILS: 327212/Other Pressed and Blown Glass and Glassware Manufacturing
Contact Data Permit Data
Facility Contact Authorized Contact Technical Contact Permit 07334/T29
Rick Miller Steve Linden Glenn Peterson Issued 12/16/2019
Environmental Safety Plant Manager Fiber Plant Director Expires 11/30/2024
Manager [phone] Classification Title V
[phone] Permit Status Active
Inspector's Signature: bn4 I Suppte VP Comments:
Date of Signature: 3/29/2021
Type Action: _Full Compliance _Partial Compliance _Complaint Other: Stack Test 2021-019ST
Evaluation Evaluation/Reinspection Investigation
Data Tracking: Date submitted for initial review 3/29/2021 _IBEAM WARNING/OB,NOD,NOV,NRE
X IBEAM Document
IBEAM Inspection,list date inspected _IBEAM LAT/LONG,Facility Locked
IBEAM Inspection,list date draft is submitted _IBEAM LAT/LONG,Coordinates checked
IBEAM Inspection,pollutants/programs checked IBEAM Complaint
IBEAM Planning,Next Inspection Date
Directions: Take I-77 to I-40 West. Left on Exit 135 into Claremont. Right on Main Street and after about 0.5
miles turn left onto Penny Drive. Go to the back of the facility for entrance.
Safety Equipment: Safety glasses and safety shoes are required.
Safety Issues: Due to the COVID-19 pandemic,the facility is currently limiting visitors onsite. This test
was observed virtually via Microsoft Teams.
I. This facility manufactures glass fibers and fiber optic cable. This facility operates with four
shifts,24 hours per day, seven days per week, and employs about 400 people. The purpose of this
site visit was to observe the stack tests being conducted on the large torch over-cladding units
(Cells 4 and 5; ID No. ES-9) and the new technology torch over-cladding units(Cells 5, 6, and 7;
ID No. ES-9a)The over-cladding units(ES-9a) are controlled by a hydrated lime scrubber(2DS),

Prysmian Cables and Systems USA,LLC
March 23,2021
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which is a bagfilter with lime as a scrubbing medium. The facility must test the over-cladding
units with associated dry scrubber(ID ID No. 2DS)and over-cladding units with associated dry
scrubber(ID No. IDS) for dry scrubber control efficiency for NOx. Permit Condition 2.2 -A.1.a.
states"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."In addition,Permit Condition 2.2 -
A.l.c. requires"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."Permit
condition 2.2 -B.l.c. states"NOx uncontrolled emissions from individual new technology torch
over-cladding units(Cells 5, 6, and 7; ID No. ES-9a) 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."
2. The testing protocol was submitted to this office on December 15,2020 and approved by SSCB
on January 28,2021. The facility contracted McHale Environmental to perform testing using
EPA Method 7E for nitrogen oxides emissions from the over-cladding units(ID Nos. ES-9 and
ES-9a). The facility initially proposed that testing would occur February 16,2021. On February
10,2021,Mr. Rick Miller,Environmental Safety Manager, contacted me to inform me that the
test will occur instead on March 23,2021, due to issues with obtaining adequate materials for
production.
3. I called Mr. Miller via Microsoft Teams on Thursday,March 5,2020 at approximately 8:00 AM
to view the test virtually. McHale Environmental had begun the first test run on over-cladding
unit ES-9a. Mr. Miller used the video on his phone to show me the stack testing set up. It
appeared as though the probe was placed in a way to collect stack gas prior to entering the
scrubber. Mr. Miller then attempted to show me video of the cabinets in operation during the test.
There were connection issues with the video feed, so Mr. Miller reported the number of cabinets
in operation during the test and emailed me a copy of the production spreadsheet at the end of the
day. It appeared that 17 of the 20 cabinets,which vent to over-cladding unit ES-9a,were in
operation during most of the testing. Units would periodically enter a"set-up"period during
which the cabinet would not be in operation while being loaded with new production material.
4. Real time emissions data was gathered via Microsoft Teams video call and via phone call with
Mr.Mike Dickerson with McHale Environmental. The following data was gathered from the ES-
9a testing:
Run Time of NOx(ppm) %02 %CO2
Observation
1 8:21 am 223 20.6 0
2 10:27am 262 20.6 0.04
3 11:30am 251 20.6 0.07
5. For over-cladding unit ES-9,I did not observe the stack test probe location. Mr. Miller indicated
that 6 of the 7 cabinets that vent to over-cladding unit ES-9 were in operation during this test. The
following data was gathered via phone call with Mr.Mike Dickerson with McHale
Environmental from the ES-9 testing:

Prysmian Cables and Systems USA,LLC
March 23,2021
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Run Test Start Average NOx Average%02 Average
Time m) %CO2
1 12:45 m 143.8 20.58 0.17
2 2:02 m 154.8 20.57 0.28
3 3:19 m 149.04 20.53 0.29
6. From what I observed,it appears that the testing was completed in compliance with the approved
testing method.
EJS:
https://nceonnect.sharepoint.com/sites/DAQ-MRO/Counties/CATAVMA/00419/STK OBSERV-ED_20210323.docx