AQ_F_0200097_20191121_CMPL_InspRpt

NORTH CAROLINA DIVISION OF Mooresville Regional Office
AIR QUALITY Kincaid Fum.Co.,Inc.,Alexvale Upholstery Div.,
Plant#21
Inspection Report NC Facility ID 0200097
Date: 11/21/2019 County/FIPS: Alexander/003
Facility Data Permit Data
Kincaid Fum. Co.,Inc.,Alexvale Upholstery Div.,Plant#21 Permit 09795/R02
1320 US Hwy 90 East Issued 12/8/2016
Taylorsville,NC 28681 Expires 11/30/2024
Lat: 35d 55.1184m Long: 8ld 9.1452m 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
Lewis Herman,Jr. Michael Hyatt Lewis Herman,Jr. MACT Part 63: Subpart ZZZZNSPS: Subpart.JJJJ
Envir.&Facilities Vice President of Envir. &Facilities
Engineering Manager Operations Engineering Manager
[phone] [phone] [phone]
Compliance Data
Comments:
Inspection Date 11/21/2019
Inspector's Name Ryan Mills
Inspector's Signature: C Operating Status Operating
Compliance Code Compliance-inspection
�c Action Code FCE
Date of Signature: 1 o2 21).41-t___1 On-Site Inspection Result Compliance
Total Actual emissions in T NSIYEAR:
TSP S02 NOX VOC CO PM10 *HAP
2015 0.0300 --- 0.0200 --- --- 0.0000 ---
2010 0.0400 --- 0.0100 --- --- 0.0000 ---
Highest HAP Emitted in pounds
Five Year Violation History:None
Date Letter Tyne Rule Violated Violation Resolution Date
Performed Stack Tests since last FCE:None
Date Test Results Test Method(s) Source(s)Tested

Kincaid Furn. Co., Inc.,.
Alexvale Upholstery Div.,Plant#21
November 21, 2019
Page-2
Type X Full Compliance _Partial Compliance _Complaint Investigation Other:
Action: Evaluation Evaluation/Re-inspection
Data Date submitted for initial review: I2/3/2019 _IBEAM WARNING/OB,NOD,NOV,NRE
Tracking: X IBEAM Inspection, list date inspected X IBEAM Document
X IBEAM Inspection, list date draft is submitted X IBEAM LAT/LONG,Facility Locked
X IBEAM Insp.,pollutants/programs checked X IBEAM LAT/LONG,Coordinates checked
IBEAM Complaint
X IBEAM Planning,Next Insp.Date: 11/01/2021
Directions:
From MRO,travel 1-77 north to 1-40 west. Take exit 148 and turn right onto highway 64 west. Travel
approximately 10 miles and turn right onto Old Mountain Road. Turn left onto highway 90 west. Travel
approximately 3 miles and the facility is located on the right and lower than the road, across the train
tracks, at 1.320 East Hwy 90.
Safety Equipment:
Safety glasses are required. Safety shoes and ear protection are recommended.
Safety Issues:
None noted.
Lat/Long Coordinates:
A review of the facility's coordinates on the updated DEQ website, "Facilities Regulated by Air Quality"
indicated the facility's latitude and longitude coordinates are accurate.
Email Contacts: The email contacts were verified with no changes required.
I. The purpose of this site visit was to conduct a routine air quality inspection.This facility
manufactures upholstered furniture. The facility is currently operating approximately 40 hours per
week with one shift of 95 employees.Mr. Dean Williams,Maintenance Supervisor, accompanied
me during this inspection.
2. Facility Contact Information:
During the inspection,I verified the facility contact information in IBEAM.
3. 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.

Kincaid Furn. Co.,Inc.,
Alexvale"Upholstery Div.,Plant#21
November 21,2019
Page-3
4. Observations of permitted air emission sources and control devices:
Emission Source ,� Control System
" Description Description
ES-1 woodworking operation CD-1 bagfilter(4,820 square feet of filter area);
Observed:,The bag filter system was in operation during this inspection..The woodworking
operations consist primarily of four(4) CNC routers,band sawing, and a"wood-hog"that
grinds larger wood waste into particles small enough to be put in the storage bin. Mr.
Williams stated that the converted tractor trailer, being used to collect wood waste, is
unloaded about every two weeks. All ductwork appeared to be sound and no wood waste was
seen at the trailer loading area. No,visible emissions were observed.
- i
5. Observations of insignificant air emission sources and control devices listed on the current
ermit:
Source Exemption Source of,[Stturce of Title
Re ulation TAPS? ollutants -
g
I-Fire-diesel fuel-fired emergency fire pump 2Q .0102
engine(150 horsepower) subject to 40 CFR Part;(h)(5) Yes Yes
63, Subpart ZZZZ
Observed: This diesel fuel-fired emergency fire pump engine was not in operation during this
inspection. See Condition A.8. below for compliance status.
Fi'�
EN-propane-fired emergency generator(522Q 0102
watts)subject to 40 CFR Part"60,.Subpart (h)(5) Yes Yes
and 40 CFR Part 63, Subpart ZZZZ ;
Observed: This propane-fired emergency generator was not in operation during this {
inspection. See Condition A.8. below for compliance status.
6. Observations of air emission sources and control devices not listed on the current permit:
a. None.
7. Compliance with specific permit conditions and limitations:
a. Condition A.3. 15A NCAC 2D .0512 "Particulates from Wood Products Finishing
Plants". Provide adequate ductwork and properly designed collectors to control
woodworking particulates.
Observed. Wood particulate appeared to be properly controlled. No sawdust waste was
observed at exhaust points around the bag house, and ductwork appears to be sound.
Compliance with this condition is indicated.

Kincaid Furn. Co.,Inc.,
Alexvale Upholstery Div.,Plant#21
November 21, 2019
Page-4
b. 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. Compliance with this
condition is indicated.
C. Condition A.5. 15A NCAC 2D .0535. Permee of a source of excess emissions that last
for more than four hours and'that results from a malfunction, a breakdown of process or
control equipment or any other abnormal conditions,shall notify the Director or his
designee of any such occurrence by 9:00 a.m.Eastern time of the Division's next business
day of becoming aware of the occurrence. ,
Observed.. As per a conversation with Mr. Dean Williams,no excess emissions have
occurred at the facility. Compliance with this condition is indicated.
d. Condition A.6. FUGITIVE DUST CONTROL REQUIREMENT. The Permittee shall
not cause or contribute to substantive complaints or excess visible emissions beyond the
property boundary.
Observed. This office has received no complaints regarding.the facility and no fugitive
dust was observed at the time of this inspection. Compliance with this condition is
indicated.
e. Condition A.7. FABRIC FILTER REQUIREMENTS. Conduct an annual internal
inspection of the bag filter system. In addition, conduct periodic inspections and
maintenance as recommended by the equipment.manufacturer and list corrections made
and dates of actions in a fabric filter log book.
Observed. The facility conducts weekly external checks of the bag filter system
(including ductwork, as well as inlet and outlet ports)and records the results in a log
book. The last baghouse inspection recorded during the previous inspection was
conducted on August 18,2017. During this inspection I reviewed the logbooks and found'
new socks were installed.on May 23, 2018, a new belt on October 9,2018,the bags were
checked on June 2, 2019 and another belt was replaced on June 2, 2019. Compliance
with this condition is indicated.
f. Condition A.8. Federal and State Rules Applicable to Sources Exempted from Air
Permitting Requirements-Your facility is subject to the following federal and state rules:
NSPS Subpart JJJJ-Standards of Performance for Stationary Spark Ignition Internal
Combustion Engines
NESIMP/MACT Subpart ZZZZ--Reciprocating Internal Combustion Engines
r

Kincaid Furn. Co.,Inc.,
Alexvale Upholstery Div.,Plant#21
November 21,2019
Page-5
I-GEN-propane-fired emergency generator(52 kilowatts)subject to 40 CFR Part 60,
Subpart JJJJ and 40 CFR Part 63, Subpart ZZZZ
Observed: The emergency generator is a Kohler model no. 50RECGB, serial no.
SGM32G2MP. Output for this generator is 52 kilowatts or 70 horsepower.The
manufactured date on the face plate is February 24, 2015. The motor is a Chevrolet 305
that is converted to run on liquid propane gas.The engine does have a non-resettable hour
Meter. This generator was installed in February 2016.During the January 2018 inspection
the meter was reading 61.1 hours and during this inspection it was reading 117.7.The
generator has run 56.6 hours since the last inspection.The EPA certification for the
appropriate emission standard based on model year and size is maintained on-site.The
facility is keeping records of any maintenance performed on the generator. The last
maintenance performed was on February 22,2019. (Oil changed,hoses checked, air
cleaner inspected.)
I-Fire-_diesel fuel-fired emergency fire pump engine(150 horsepower) subject to 40
CFR Part 63, Subpart ZZZZ
Observed. The fire pump is required to change oil and filter every 500 hours or
annually, inspect the air cleaner every 1000 hours or annually; and inspect all hoses and
belts every 500 hours or annually. The diesel fire pump has a non-resettable hour meter
which was reading 112.7 hours at the January 2018 inspection. During this inspection,the
meter was reading 128.7 hours. The generator has run 16 hours since the last inspection.
Mr. Williams provided records of maintenance performed on August 6,2018 and August
20, 2019. Compliance with'this condition is indicated.
8. NSPS/NESHAP Review:
The facility was sent a Notification Letter regarding the Subpart 000000 Polyurethane MACT
on November 13,2007. The plant-does not conduct any polyurethane foam gluing or fabrication.
The facility has a propane-fired emergency generator which is subject to NSPS Subpart JJJJ and
NESHAP Subpart ZZZZ. The facility has a diesel fuel-fired emergency fire pump engine which
is subject to NESHAP Subpart ZZZZ.
Also,no gasoline storage tanks are located'at this facility.
9. Summary of changes needed to the current permit:
None.
10. Compliance assistance offered during the inspection:
Mr. Williams and I discussed having the maintenance records for the generator and fire pump
more readily available for future inspections.
I

Kincaid Furn. Co., Inc.,
Alexvale Upholstery Div.,Plant#21
November 21,2019
Page- 6
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.
RCM:lhe
c: MRO File
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