AQ_F_0200014_20210421_CMPL_InspRpt

NORTH CAROLINA DIVISION OF Mooresville Regional Office
AIR QUALITY Craftmaster Furniture,Inc.
NC Facility ID 0200014
Inspection Report County/FIPS: Alexander/003
Date: 04/21/2021
Facility Data Permit Data
Craftmaster Furniture,Inc. Permit 05456/RI 1
221 Craftmaster Road Issued 5/24/2018
Hiddenite,NC 28636 Expires 4/30/2026
Lat: 35d 53.9750m Long: 8ld 5.0200m 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
Beth Propst Kevin Mann Kevin Mann MACT Part 63: Subpart ZZZZ
Director of HR Vice President of Vice President of
NSPS: Subpart IIII
[phone] Operations Operations
[phone] [phone]
Compliance Data
Comments:
Inspection Date 04/21/2021
Inspector's Signature: 94`'r"a ./ ab ogx Inspector's Name Ryan Mills
Operating Status Operating
Date of Signature:April 21,2021 Compliance Status Compliance-inspection
Action Code FCE
Inspection Result Compliance
Total Actual emissions in TONS/YEAR:
TSP S02 NOX VOC CO PM10 *HAP
2017 --- --- --- 10.72 --- --- 299.43
2012 --- 0.0000 4.88 0.0000 --- 397.42
*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

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April 21, 2021
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Type X Full Compliance _Partial Compliance _Complaint Other:
Action: Evaluation Evaluation/Reinspection Investigation
Data Date submitted for initial review 4/21/2021 _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 4/l/2023
Directions: From MRO,travel I-77 north to 1-40 west,take exit 148,turn right onto Hwy. 64 West,
travel approximately 8 miles,turn right onto Old Mountain Road. Travel 0.5 miles and turn right onto
Hwy 90 in Hiddenite. Travel approximately 0.5 miles and turn left onto Craftmaster Road,and the facility
is located on the left.
Safety Equipment: Safety glasses are required and steel toe shoes are recommended for an inspection at
this facility.
Safety Issues: None noted.
Facility Latitude/Longitude Coordinates: A review of the"Facilities Regulated by Air Quality"on the
DAQ website indicated the facility's location is accurate and matches the facility's latitude and longitude
coordinates listed in IBEAM.No changes to the latitude and longitude coordinates of this facility are
needed in IBEAM.
Email Contacts: The facility email contacts were checked and no changes were needed.
1. The purpose of this site visit was to conduct a routine air quality inspection. This facility
manufactures upholstered furniture. The facility is normally operating one 8-hour shift per day,
five days per week for 50 weeks per year. However, due to a shortage of foam the facility is
down to only operating three(3)days a week in the front office. For the past three(3)weeks the
facility has not been operating at all due to the shortage. I conducted this inspection via phone,
email and FaceTime with Mr.Kevin Mann,Vice President of Operations. This facility currently
employs 315 people which is up from 276 from the last time this facility was inspected. Mr.
Mann stated that if they were able to find enough employees they would have enough work for
375 people for the next six months, 5 days a week,without any further orders coming in.
2. Facility Contact Information:
During the inspection I verified the facility contact information in IBEAM. No changes were
needed.
3. Covid-19Information:
Currently visitors are allowed into the facility. Masks are required. The facility states that
social distancing is enforced. Teleworking of its employees and staff that are able is being highly
encouraged.A records review was conducted via email. I reviewed the permit with Mr.Mann
over the telephone. A tour of the facility was conducted via FaceTime and then I conducted a
drive-by of the facility on April 21,2021. I took the DEQ DAQ Screening Tool survey before
going onsite for the observation of permitted equipment on April 21,2021.

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April 21, 2021
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4. Compliance history file review:
No problems have been noted in the last five years by DAQ,prior to this inspection. The current
compliance status is discussed in the following sections.
5. Observations of permitted air emission sources and control devices:
Emission Emission Source Control
Source ID Description System ID
SB-I, SB-2, SB-3, SB-4 ff(4)dry-filter type spray booths installed on a wood N/A
furniture finishing operation
Observed: Spray booths SB-I, SB-2 and SB-4 were in operation,but SB-3 is only used occasionally for touch up
work. These spray booths were observed by using Apple FaceTime. All of the filters were in place and in good
condition. The filters are cleaned at least once a week and replaced at least once a month according to the readings
on the Magnahelic gauges. The filters currently being used consist of an eight layer slit and expanded paper baffle.
Spray Booth 1

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Spray Booth 2
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Spray Booth 3
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April 21, 2021
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Spray Booth 4
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6. Observations of insignificant air emission sources and control devices listed on the current
ep rmit:
Source Exemption
Regulation
IESB-1 -natural gas-fired boiler(1.875 million Btu per hour maximum heat input) 2Q .0102
�(h)(l)(B)
Observed: I did not observe this source. The source is located behind the building in a shed. It is referred to as a
heat exchanger by the facility. It is a PowerFlame Inc. Model C2-GO-15, serial no. 129052832. This boiler only
runs on natural gas.
I-FP -diesel-fired emergency fire pump engine(275 hp) 12Q .0102 (h)(5)
Observed: I did observe the fire pump which is located near the road entering the plant. The fire pump was not in
operation. Please see NSPS/NESHAP discussion below for more information.
7. Observations of air emission sources and control devices not listed on the current permit:
a. None noted.
8. 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 2024 calendar year.

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April 21, 2021
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Observed: The report is not due at this time. Compliance with this permit condition is
indicated.
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: All the operational spray booths appeared to adequately control particulate
from the overspray. No woodworking operations are located at this facility. Compliance
with this permit condition 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 onsite
observation on April 21,2021. Compliance with this permit condition is indicated.
d. Condition A.5.— 15A NCAC 2D .0535, "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. Mann stated that there had been no excess emissions to report.
Compliance with this permit condition is indicated.
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.
No fugitive dust emissions were observed during the inspection. Compliance with this
permit condition is indicated.
f. Condition A. 7.— 15A NCAC 2D .1806"Control and Prohibition of Odorous Emissions".
As required by 15A NCAC 2D .1806 "Control and Prohibition of Odorous Emissions"
the Permittee shall not operate the facility without implementing management practices
or installing and operating odor control equipment sufficient to prevent odorous
emissions from the facility from causing or contributing to objectionable odors beyond
the facility's boundary.
Observed:No odors were detected outside the facility during my onsite visit on April 21,
2021. Compliance with this permit condition is indicated.
g. Condition A. 8. -Federal and State Rules Applicable to Sources Exempted from Air
Permitting Requirements -The facility is subject to the following federal and state rules:
40 CFR 60-NSPS -- Subpart IIII-- Standards of Performance for Stationary
Compression Ignition Internal Combustion Engines as well as 40 CFR 63 -
NESHAP/MACT -- Subpart ZZZZ--Reciprocating Internal Combustion Engines.

Craftmaster Furniture Corporation
April 21, 2021
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Observed: The facility has one (1)diesel-fired emergency fire pump (ID.No. I-FP)that
is subject to the 4Z MACT and is considered a new engine. The identification plate
indicates that the John Deere engine's Model Number is 608IAF001, Serial No.
RG6081A187036, and Equipment Model No. is JW6H-UF28 is a 275 HP engine. It was
manufactured by John Deere on 11/21/2008.
The NSPS Subpart IIII applicability requirement for the compression ignition engines is
if the fire pump engine is constructed after 7/11/2005 and manufactured after 7/1/2006.
Since the fire pump was manufactured and installed after these dates,the fire pump is
subject to NSPS Subpart IIII and considered a new engine. Table 3 of 40 CFR 60
Subpart IIII states that 2008 stationary fire pump engines must be certified if>750 HP.
The footnote says that engines between 50 and 600 HP are not required to certify the
engine until 3 model years following the model year indicated in Table 3. Therefore,the
fire pump does not have to be a certified EPA pump. However, Table 4 of 40 CFR 60
Subpart IIII states that despite not being certified,the 2008 engine that falls in the
category of 175 to 300 HP must meet emissions requirements of NMHC+NOx 10.5
g/KW-hr(7.8 g/HP-hr), 3.5 (2.6)CO and 0.54 (0.40)PM. The engine meets the
emissions requirements of Table 4.
Currently the fire pump is tested routinely for short durations due to discharge piping
constraints. Approximately every two weeks the fire pump is operated for about five
minutes. The non-resettable hour meter showed the engine reading was at 55.4 hours and
during the last inspection on March 26,2019 the meter was reading 51.5 hours. (The
engine was only run for 3.9 hours in the two years since the last inspection. This is an
average of 2-3 minutes per week). The fire pump is serviced yearly with the last two
service dates being January 20,2021 and January 17, 2020.
The fire pump is considered a new engine with regard to NESHAP Subpart 4Z. As a
result,the fire pump complies with NESHAP Subpart 4Z by complying with NSPS
Subpart 4I.
Picture of Hour Meter on the Fire Pump (Reading 55.4 hours)
HOURS3.5
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Picture of New Filters on Fire Pump
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Annual Fire Pump Engine Maintenance Report
R& F servicav,U t.' F.0 Box 3Z8 frm S.C. 29063
A� L_ L FIRE PUMP-ENGI-(E M ATNTENANCE REPORT Phone [phone]
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heck 1 Repair Miner La a Cp.a f Repair Miw Peaks
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Replace,Ci iGallon I SAC tat hock Qen 1 Cagt¢ition(Vista]PACs And Hoses
pia Sam*Am"r.(oplioaa) izchwk AnFil vox(1fApplk1bb)t!QF
filwck Inhibitor(HApplicable)
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heck Fnet Ls`mAnd Chwk Engine Wsia Heater For Prope Operation
umpCoartc hum For Leaks (IfAppiicablc)
tarsal]t,specriots 4FCortantir:atiaeGrowth Rcplaze Coalan[Fitter(UAWicalt c)
inspoet Ard Liakr cats Cos?ant Analysis(Opti anal)
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LZYDC Starter Drarrjj9 VDC Prow OTWation
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Spsaific Gravity Rsaddog host f Ckan fikw Eiemeat Condition-n Type
Check Khoo Bath pmfl ao&Cables k£xi*ustSy*n For Laks
Check BatteryCkw pr Volts Chork Conneati[omAnd Condid ms OfPipieg
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Check Electrical Conacctians Drain Willer 0f Cer0F cation(Whm Required)
MGMK ffNMVMST4TATWN A D PK0TECi 0j4$Y$TEM
Check Arid Riurd RAW199 As l-oIlows COKPLUFE SYSTEItf TFSTaYC WILL ONLY BE �
7achon etcr: IL Hour Meter:p��� PCRFbRIHlf ff WJETII CU91Ol4fERAU7MORIZATION
oil P A'[7 lsiA R. K
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Aram-OL_ NPAz� Crank allow Alud Observe
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tCk oil Sewhg Dcv�iot For Proper 'Lit 5ykmi Bark In Auto
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_Vperation
Check Ovrr Crank Alarm
Chook liucuu=rtt Panel Emergency Alrtrm
Anal Ligbu For Prnpc flperation
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Craftmaster Furniture Corporation
April 21,2021
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9. NSPS/NESHAP Review:
The facility is subject to 40 CFR Part 63 Subpart ZZZZ as well as 40 CFR Part 60 Subpart IIII.
Both of these are discussed above in Condition A.8.No gasoline storage tanks are located on the
property.
10. Summary of changes needed to the current permit:
None.
11. Compliance assistance offered during the inspection:
None.
12. 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.
13. Compliance determination:
Based on my observations,this facility appeared to be in compliance with the applicable air
quality regulations at the time of the inspection.
RCM:
c: MRO File
https://ncconnect.sharepoint.com/sites/DAQ-MRO/Counties/ALEXANDER/00014/INSPECT 20210421.docx