AQ_F_0200031_20190621_CMPL_InspRpt

NORTH CAROLINA DIVISION OF Mooresville Regional Office
AIR QUALITY Schneider Mills, Inc.
NC Facility ID 0200031
Inspection Report County/FIPS: Alexander/003
Date: 06/21/2019
Facility Data Permit Data
Schneider Mills,Inc. Permit 04863/R10
1170 Highway 16 North Issued 3/16/2018
Taylorsville,NC 28681 Expires 9/30/2023
Lat: 35d 56.2302m Long: 81d 11.5758m Class/Status Small
SIC: 2221 /Weaving Mills, Synthetics Permit Status Active
NAICS: 31321 /Broadwoven Fabric Mills Current Permit Application(s)None
Contact Data Program Applicability
Facility Contact Authorized Contact Technical Contact SIP
Rufus White Harry McPherson Rufus White MACT Part 63: Subpart ZZZZ
Maintenance Manager Vice-President Maintenance Manager NSPS: Subpart Dc
[phone] [phone] [phone]
Compliance Data
Comments:
Inspection Date 06/21/2019
Inspector's Name Melinda Wolanin
Inspector's Signature: Operating Status Operating
(y� Compliance Code Compliance-inspection
v ' Action Code FCE
Date of Signature: _ Z c� On-Site Inspection Result Compliance
Total Actual emissions in TONS/YEAR:
TSP S02 NOX VOC CO PM10 *HAP
2014 0.1100 0.5500 1.04 0.0500 0.4400 0.0500 3.90
2009 . 1.13 15.83 3.05 0.0700 0.9000 0.5900 22.00
*Highest HAP Emitted in ounds
Five Year Violation History:
Date Letter Type Rule Violated Violation Resolution Date
10/11/2016 NOV Part 63 -NESHAP/GACT Subpart JJJJJJ Industrial, 10/19/2016
Commercial and Institutional Boilers at Area Sources
Performed Stack Tests since last FCE: None
Date Test Results Test Method(s) Source(s)Tested

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Type x Full _Partial Compliance _Complaint Other:
Action: Compliance Evaluation/Reinspection Investigation
Evaluation
Data Date submitted for initial review 7/2/2019 _IBEAM WARNING/OB,NOD,NOV,NRE
Tracking: x IBEAM Document
x IBEAM Inspection, list date inspected _IBEAM LAT/LONG, Facility Locked
x IBEAM Inspection, list date draft is submitted x IBEAM LAT/LONG, Coordinates checked
IBEAM Inspection, pollutants/programs IBEAM Complaint
checked _x_IBEAM Planning,Next Inspection Date
L_ 6/01/2021
Directions: From MRO,travel I-77 north to.I-40 west. Take exit 148 and turn right onto Hwy. 64 west.
In Taylorsville,turn right on Liledoun Rd. This road becomes Highway 16 as it crosses West Main Street.
The facility is located at 1170 Hwy. 16 north.
Safety Equipment: Ear protection is required. Safety glasses and safety shoes are recommended. The
facility does have a sign-in sheet for visitors.
Safety issues:None noted.
Lat/LonE: A review of the facility's coordinates in IBEAM indicates the facility's latitude and longitude
coordinates are accurate.
Email Contacts: There are no changes to the email contacts at this time.
1. The purpose of this site visit was to conduct a routine air quality inspection. I arrived at the
facility at 10:00am on June 21, 2019 for the inspection.This facility manufactures synthetic cloth
for a variety of products including parachutes, flags, and surgical tape. The yarn processing
begins with warping machines,then transitions to yarn slashing, and finally into weaving the yarn
into roles of fabric. A small amount of blue dye is used to help identify fabric defects, but the
final product is undyed material. The facility is currently operating 24 hours per day, 5-6 days per
week, 50 weeks per year. The facility has 265 employees. Mr. Rufus White, Maintenance
Manager, 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:
The facility was issued an NOV on October 11, 2016 for failure to conduct a NESHAP Subpart
JJJJJJ biennial tune-up on the No. 2 fuel oil/No. 4 fuel oil-fired boiler(ID No. B-1).
4. Observations of permitted air emission sources and control devices:
a. ES-SL-1 yarn sizing operation- the slashing department applies a VOC containing textile
sizing to yarn. According to the most recent permit review, 75% of the yarn processed

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receives the textile sizing and the other 25% is processed through a re-beamer without the
textile sizing. Actual VOC emissions for this process are over five tons per year.
Observed.In operation with no visible emissions.
5. Observations of insignificant air emission sources and control devices listed on the current permit:
_ Source
IBA 2 -natural gas-fired boiler(14.7 million BTU per hour maximum heat input rate) subject to
NSPS Subpart Dc
Observed.The boiler is used to supply steam to two sizer dryers. The boiler was in operation with i
ino visible emissions at the time of the inspection. The boiler inspection certificate is located next to j
jthe boiler and identifies the National Board Number as 7700. A tune-up on the boiler was
jconducted May 10, 2018.
IDO-1 - natural as-fired am drying oven 3.5 million Btu per hour maximum heat input rate
�� _ g Y _ Y g ( P p )
1ID0-3 -natural gas-fired yarn drying oven (3.5 million Btu per hour maximum heat input rate)
jIDO-10 -natural gas-fired yarn drying oven(3.0 million Btu per hour maximum heat input rate) i
�Observed. Yarn is drawn through a trough of liquid that coats the yarn, minimizing fraying when
the yarn is processed at other locations at the facility. Then the yarn is sent through the drying
ovens. Previously, a review of the MSD sheets for the coating liquid indicates the material does hot
kcontain any regulated pollutants.
IISC 10 - steam can
1ISC-11 - steam can
IISC-12 -steam can 1
Observed. Did not observe these sources.
I-GEN- diesel-fired engine associated with fire.pump (115 hp) subject to NESHAP Subpart ZZZZ
Observed.The fire pump is tested once a month for 15 to 30 minute and was not in operation at the
;tim' e of the inspection. The most recent tune-up on the fire pump was conducted October 16,2018. j
6. Observations of air emission sources and control devices not listed on the current permit:
a. Electric boiler(Lattner 288 hp; 2880 Kw/hr)The electric boiler is used to provide steam to
the sizer dryers. The electric boiler is used when it is economically beneficial.
Observed. The boiler was not in operation during this inspection.
b. Sizer Dryers. Heat to the sizers is provided by the permitted boiler(I13-2)or the electric
boiler.
Observed. The dryers were in operation during the inspection. As previously stated,the
operation does not use materials with VOCs in the coating liquid.
7. Compliance with specific permit conditions and limitations:
a. Condition A.2.- 2D .0202, "Permit Renewal and Emission Inventory Requirement".At least
90 days prior to the expiration date of this permit,the Permittee shall submit the air pollution

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emission inventory report. The report shall be submitted to the Regional Supervisor and shall
document air pollutants emitted for the 2022 calendar year.
Observed.Not due at this time. Compliance is indicated.
b. Condition A.3. -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
stipulation is indicated.
C. Condition A.4. -2D .0535, "Notification Requirement'. The permittee 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: Based on a records review and conversation with Mr. White, no excess emissions
have occurred at the facility in several years. Compliance with this stipulation is indicated.
d. Condition A.5. 2D .0540, "Particulates from Fugitive Dust Emission Sources". The
permittee shall not cause or allow fugitive dust emissions to cause or contribute to substantive
complaints or excess visible emissions beyond the property boundary.
Observed: There have been no complaints received by MRO concerning the facility and no
fugitive dust emissions were observed at the time of this inspection. Compliance with this
condition is indicated.
e. Condition A.6. The natural gas only boiler(ID No. IB-2; 14.7 million BTU per hour
maximum heat input rate) is subject to 40 CFR 60 Subpart De. The facility diesel-fired fire
pump (I-GEN) is subject to 40 CFR 63 Subpart ZZZZ
Since the boiler(ID No. IB-2) and the fire pump (ID No. I-GEN) are insignificant sources,
the requirements for complying with NSPS Dc and NESHAP Subpart 4Z are not identified in
the air permit.
For the boiler:
i. Record the amount of natural gas combusted during each.month.
ii. Submit the actual date of initial startup postmarked within 15 days of commencing
operation.
Reporting of the date construction is commenced is not required since the boiler is
mass-produced. '
Observed. I observed monthly natural gas records through May 2019. The date of
start-up was April 10, 2018 and the notification was received within 15 days of start-
up.

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For the fire pump:
i. Change the oil and filter every 500 hrs of operation or annually,whichever comes
first.
ii. Inspect the air cleaner every 1,000 hrs of operation or annually,whichever comes
first, and replace as necessary.
iii. Inspect all hoses and belts every 500 hrs of operation or annually,whichever comes
first, and replace as necessary.
iv. Operate and maintain the engine and control device(if any)according to the
manufacturer's emission related written instructions or maintenance plan developed
by the Permittee that minimizes emissions from the engine to the extent practicable.
V. Install a non-resettable hour meter if one is not already installed.
vi. Minimize the engine's time spent at idle during startup and minimize the engine's
startup time to a period needed for appropriate and safe loading of the engine, not to
exceed 30 minutes, after which time the non-startup emission limitations apply.
vii. No time limit on the use in emergency situations. May operate the engine for a
maximum of 100 hrs/yr for maintenance and readiness checks.
Observed.The fire pump is equipped with a non-resettable hour meter. I did not observe the
reading during this inspection, but during the previous inspection,the meter read 668.66
hours. The previous tune-up on the fire pump was conducted October 2017 and the most
recent tune-up was conducted October 16, 2018. Compliance was indicated.
8. NESHAP/NSPS Review
The facility is no longer subject to NESHAP Subpart 6J, since the boiler is natural gas only, but
the facility does have to comply with the requirements for NSPS Dc.
The facility has an insignificant fire pump subject to NESHAP Subpart 4Z.
The facility does not have any gasoline storage tanks;therefore,they are not subject to NESHAP
6C.
9. Summary of changes needed to the current permit:
None.
10. Compliance assistance offered during the inspection:
None.

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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.
MJW:Ihe
c: MRO File
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