AQ_F_1200107_20200529_CMPL_InspRpt (4)

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NORTH CAROLINA DIVISION OF Asheville Regional Office
AIR QUALITY Valdese Weavers, LLC-Lovelady Road Plant
NC Facility ID 1200107
Partial Compliance Evaluation(PCE)Report County/FIPS:Burke/023
Date: 05/29/2020
Facility Data Permit Data
Valdese Weavers,LLC-Lovelady Road Plant Permit 09762/R03
705 Lovelady Road,NE Issued 3/2/2017
Valdese,NC 28690 Expires 2/28/2025
Lat: 35d 45.7562m Long: 8 1 d 32.6161m Class/Status Synthetic Minor
SIC: 2269/Finishing Plants,Nec Permit Status Active
NAILS: 313312/Textile and Fabric Finishing(except Broadwoven Fabric)Mills Current Permit Application(s)None
Contact Data Program Applicability
Facility Contact Authorized Contact Technical Contact SIP
Eddie Atkinson Carson Copeland Eddie Atkinson NSPS: Subpart Dc
Facility Engineer Chief Operating Officer Facility Engineer
[phone] [phone] [phone]
Compliance Data
Comments:
Inspection Date 05/29/2020
Inspector's Name Angela Hopper
Inspector's Signature: Operating Status Operating
Compliance Code Compliance-inspection
Action Code PCE
Date of Signature: / / c� 20 On Site Inspection Result Compliance
Total Actual emissions in TONS/YEAR:
TSP S02 NOX VOC CO PM10 *HAP
2015 7.84 0.0100 2.26 0.5700 1.90 5.14 944.70
2011 7.83 0.0100 2.29 0.6100 2.09 7.83 967.50
*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
Directions
Take I-40E to Exit 113 (Rutherford College). Turn left. Go approximately 2 miles and turn left onto
Lovelady Road. Proceed approximately one mile, and the facility will be located on the right.

Facility Overview
Safety Equipment: Hearing Protection and Safety Shoes
Safety Issue: Forklifts travel throughout the facility;vision of forklift drivers may be limited due to
equipment and storage of items. Care should be taken when touring the facility. The roof of the facility
can be accessed by stairs.
Contact Information
I reviewed the contact information with Mr. Eddie Atkinson from the IBEAM FacFinder report. No
changes or updates need to be made to the contact information at this time. It should be noted that Mr.
Atkinson's office is located at Valdese Weavers Perkins Road facility,not at this facility. Mr. Atkinson's
direct line is(828) 893-4130. Mr.Phil Eller,Plant Engineer for the Lovelady and Cresent Street plants is
the back-up contact for this site should Mr. Atkinson not be available. He can be reached at(828)432-
4244.
Facility Description
Valdese Weavers;Inc. has three permitted facilities in Burke County, along with one unpermitted
weaving plant in Hildebran. The company makes upholstered material for the furniture industry. The
Lovelady Road plant is the company's finishing and distribution center. The Crescent Street plant is
considered the"Prep Plant",where all warping and slashing will be done. The Perkins Road facility
conducts weaving and dyeing. As part of its process,this facility has the following permitted equipment:
three natural gas/No. 2 fuel oil-fired boilers, and three natural gas-fired tenter frames. The facility
operates 3 shifts,24 hours per day,Monday-Friday,with an occasional Saturday or Sunday. This site
has approximately 260 employees including office staff.
Partial Compliance Evaluation Narration
On May 29,2020,I contacted the facility to conduct a partial compliance evaluation via telephone. I
spoke with Mr. Eddie Atkinson,Facility Engineer. No site visit was made due to the Covid-19 stay-in-
place order. The last inspection was conducted by Mr. Michael Koerschner and me,Angela Hopper, on
July 29,2019.
Mr. Atkinson and I discussed if there were any recent changes and/or planned changes at the facility. Mr.
Atkinson said that no changes have been made at the facility since the last inspection. He said that the
facility is using the same coatings. According to Mr. Atkinson,the facility plans to add equipment to
soften fabric later this year. Mr. Atkinson said that the new equipment may or may not share a stack with
equipment already on site. I requested that Mr.Atkinson contact Mr.Michael Koershner of the ARO
DAQ, concerning the softening equipment once the facility has more detailed information on the
equipment and installation.
Emission Sources
Valdese Weavers-Loveday is permitted to operate three natural gas/No.2 fuel-oiled fired NSPS boilers-
Emission Source ID BI,B2 and B3 and three natural-gas fired tenter frames-Emission Source ID TF1,
TF2, and TF3. The facility only operates boiler B 1. The other two boilers are not operational.
The facility has several insignificant/exempt activities including one natural gas-fired calendar process,
five natural-gas fired dryers and one chemical storage and mixing room.
Other Equipment:
The facility operates a large natural gas Biancalani dyer. This dyer has 10 zones and is similar to a
tumble dyer. There are also two natural gas turbine dyers which are used to soften certain fabrics. Each
of the turbine dyers has one stack.

Compliance with specific permit conditions and limitations
• Specific Condition 7: New Source Performance Standards
The three permitted boilers at this facility are subject to NSPS Subpart De. As such,the facility is
required to keep track of each fuel combusted in the boilers,along with fuel supplier certifications that
show sulfur content of the fuel oil to be less than 0.5%by weight. According to Mr. Atkinson,the
facility is maintaining their fuel records(natural gas). There has been no fuel oil has been received nor
combusted by the facility. No fuel oil has been burned at the facility since Valdese Weavers bought it in
2007. Compliance is indicated.
• Specific Conditions 8: Excess Emissions Notification Requirement
The facility is required to report excessive emissions that last for four hours and that result from a
malfunction, breakdown of process or control equipment or any other abnormal conditions. The facility
has not had an excessive emissions event. Compliance is indicated.
• Specific Conditions 10: Toxic Air Pollutant Emissions and Reporting Requirement
Valdese Weavers LLC-Lovelady Road Plant has facility wide hourly emissions limits for ammonia(as
NH3)and formaldehyde. The DAQ approved modeling, submitted by the facility, on September 22,
2008. The facility is required to be constructed and operated in a manner consistent with the approved
computer modeling. Mr. Atkinson and discussed this requirement. He told me that the facility
continues to operate consistent with the approved modeling. Compliance is indicated.
• Specific Condition 12: 40 CFR 63 Subpart JJJJJJ-National Emission Standards for
Hazardous Air Pollutants for Area Sources: Industrial,Commercial,and Institutional
Boilers
The facility has indicated the primary operating scenarios(POS)for the affected sources is firing natural
gas (ID Nos. 131,132, and B3). The facility is not required to comply with most of the JJJJJJ
requirements if they continue to burn natural gas. Once the facility begins to burn fuel oil they will be
required to comply with the JJJJJJ requirement. The facility has no plans to burn fuel oil, only natural
gas. There is currently no fuel oil stored on site. Compliance is indicated.
Recordkeeping Requirements:
The facility is required to record monthly and total annually the gallons of fuel oil combusted and a fuel
supplier's certification shall be kept on-site and made available to DAQ personnel on request. The
facility is not currently burning No. 2 fuel oil. There is no No.2 fuel oil stored on site. The facility has
not burned any No.2 fuel oil since 2007. Mr. Atkinson said that their recording keeping is not being
affected by Covid 19 and is up to date.
Reporting Requirements:
The facility is required to submit an annual report to the DAQ by January 30 of each year regardless of
actual emissions. The report should contain the following information:
A. amount of fuel oil combusted, facility-wide
B. a copy of the fuel supplier certification with the highest sulfur content delivered to the facility
within the previous calendar year.
The 2019 report was received on January 29, 2020, indicating compliance.
The facility is required to submit a semi-annual report to the DAQ. The report should contain the
following information:
A. the name of the oil supplier

B. a statement from the oil supplier that the oil complies with the specification under the definition
of distillate oil and
C. a certified statement signed by the owner or operator of an affected source that the records of fuel
supplier certification submitted represent all of the fuel combusted during the reporting period.
The last semi-annual report was received on January 29, 2020, indicating compliance. No fuel oil had
been burned. I reminded Mr.Atkinson of the semi-annual report that will be due on or before July 30.
Stack Test Review:
Valdese Weavers, LLC-Lovelady Road Plant currently does not have a stack test requirement in their air
permit. No stack test has been performed since the last inspection.
112r Review:
This facility is not subject to 112r.
Five-Year Compliance History
The facility has had no documented violations in the past five-years.
Compliance Assistance
This office will assist the facility with permit applicability on the new softening equipment once the
information is received on the new equipment.
Recommendations:
None.
Compliance Statement:
Valdese Weavers—Lovelady Road facility appears to be in compliance with Air Permit 09762R03.