AQ_F_1200107_20190729_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
Inspection Report County/FIPS:Burke/023
Date: 07/30/2019
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: 81d 32.6161m Class/Status Synthetic Minor
SIC: 2269/Finishing Plants,Nee Permit Status Active
NAILS: 313312/Textile and Fabric Finishing(exceptBroadwoven 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 07/29/2019
Inspector's Name Angela Hopper
Inspector's Signature: r' Operating Status Operating
f' Compliance Code Compliance-inspection
Action Code FCE
Date of Signature: J 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 inpounds)
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
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 [phone]. 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 2 shifts, 6 days a week, 24 hours per day. This site has approximately 150 employees.
Inspection Narrative
On July 29, 2019, Mr. Michael Koerschner and I traveled to the facility to conduct an annual routine
compliance inspection. We met and toured the facility with Mr. Phil Eller,Plant Engineer. Mr. Eddie
Atkinsonjoined us for the tour shortly after the tour began. We arrived on site around 10 am and were on
site for approximately 1 hour and 15 minutes.
The following permitted equipment was observed during inspection_
Emission Emission Source Notes
Source ID Descril
B1 (NSPS), B2 (NSPS), three natural gas/No. 2 Only one boiler(B1)was operating during the
And B3 (NSPS) fuel oil-fired boilers inspection,firing on natural gas with no visible
(33.5 million Btu per emissions. Although there are three boilers on-site
hour maximum heat (from the old Carolina Mills plant),the facility does
input rate,each) not operate B2 or B3. It was previously reported to j
DAQ personnel that the facility has no intentions of
burning fuel oil at this site. B2 and B3 are currently;
being used for spare parts.
j TF1, TF2 and TF3 three natural gas-fired
The tenter frames were observed in operation with
tenter frames(8.4, 6.0 no visible emissions. Each of the tenter frames has
and 7.0 million Btu per
hour maximum heat 12 stacks. TF I and TF2 were applying a latex
input rate,respectively) topical coating and TF3 was in wash only mode.
Tenter Frames Zones and Temperature Observations:

Each of the Tenter Frames have a series of zones. Each of the zones have a different operating
temperature. These temperatures vary depending on the fabric and the product being applied to the fabric.
TF 2 has 6 zones. During the inspections,zone temperatures for TF2 ranged from 188-240 degrees F.
TF1 has 10 zones. TF 3 has 8 zones.
Compliance with specific permit conditions and limitations
• Specific Condition 6: Visible Emissions Control Requirement j
All equipment at this facility has a 20%opacity limitation. No visible emissions were observed at the
time our visit. The facility has previously had visible emission issues from the Tenter Frames. After
receiving an Informational Letter concerning visible emissions from TF1 in 2018,the facility has
increased the frequency of cleaning all the TF stacks from bi-monthly to weekly.
Tenter Frame-New Processes
Several years ago,the facility changed one of the processes for their tenter frames to meet customer
demands. It appears,the new process requires a lower temperature, lower fan rate and a latex application
(which may include latex that has been recycled). Some visible emissions from the tenter frames stacks
have been observed by DAQ personnel since the facility began this process. A more detailed process
description can be found in the facility's file. In addition, another relatively new product, Crypton, is
being used at the facility. During a previous inspection,this product was described as "like putting a
sheet of plastic" on the fabric and an anti-micro bacterial. Crypton is a trademark product. During this
inspection,TF 1 and TF2 were processing a topical latex coating stain repellent to the top of the fabric.
TF3 was in a wash only mode. I requested and received the SDSs for all the current latex type coatings.
• 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. The fuel records (natural
gas)were reviewed. No fuel oil has been received nor combusted by the facility. Compliance is
indicated. According to Mr. Eller, no fuel oil has been burned at the facility since Valdese
Weavers bought it in 2007. j
• 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 9: Fugitive Dust Control Requirement
The facility cannot cause or allow fugitive dust emissions to cause or contribute to substantive
complaints or excess visible emissions beyond the property boundary. During inspection, no
fugitive dust emissions were observed. 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. The facility appears to operating 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. B 1, B2, and 133). 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 at
this time.
Compliance with general condition:
• General Condition 15: Permit Retention Requirement
This condition requires the facility to retain a current copy of the air permit at the site. It must be
made available to personnel of the DAQ, upon request. The facility keeps a copy of their current
air permit on site.
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.
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 2018 report was received on January 28, 2019, 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 28,2019, indicating compliance. No fuel oil had
been burned. Mr. Atkinson told us that the July report had already been mailed.
Insignificant/Exempt Activities
Source Notes
I Cal one natural gas fired calender process The calendar process was observed not in
(0 19 =Btu/hour maximum heat input rate) operation. This equipment is currently for sale.
I-Dry - five natural gas-fired dryers (2.81 Two of five dryers were observed not in operation.
mmBtu/hour maximum heat input rate, According to facility personnel,the dryers are
combined) currently not used very often.

i'
i The storage and mixing room was not observed. I-
Mix was added to the insignificant/exempt
I-Mix—one chemical storage and mixing room activities list during the recent permit renewal. The
facility now has a designated storage and mixing
room for all the chemicals used on site. The
facility calls this room the Finishing Drug 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.
t
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: j
This facility is not subject to 112r.
Five-Year Compliance History
The facility has had no documented violations in the past five-years.
Recommendations:
None.
Compliance Statement:
At the time of inspection,Valdese Weavers—Lovelady Road facility appeared to be in compliance with
Air Permit 09762R03.
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