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HomeMy WebLinkAboutAQ_F_0500075_20181127_CMPL_InspRpt NORTH CAROLINA DIVISION OF Winston.Salem Regional Office AIR QUALITY American Emergency Vehicles,Inc.-Remount Facility Inspection Report NC Facility ID 0500075 Date: 11/28/2018 County/FIPS:Ashe/009 Facility Data Permit Data American Emergency Vehicles,Inc.-Remount Facility Permit 10496/R00 101 Gates Lane Issued 5/24/2016 Jefferson,NC 28640 Expires 4/30/2024 Lat: 36d 25.5501m Long: 81d 28.9002m Classification Small SIC: 3711 /Motor Vehicles And Car Bodies Permit Status Active NAICS: 336211 /Motor Vehicle Body Manufacturing Current Permit Application(s)None Contact Data Program Applicability Facility Contact Authorized Contact Technical Contact SR, Gary Graybeal Greg Warmuth Jeff Dreyer Compliance Manager Vice President of Finance Process Control Manager 336)972-7203 336 982-9824 336 982-9824 Compliance Data Comments: Inspection Date 11/27/2018 Inspector's Name Paul E Williams Inspector's Signature: Operating Status Operating Compliance Code Compliance-inspection Action Code FCE Date of Signature: MTH On-Site Inspection Result Compliance Total Actual emissions in TONS/YEAR: TSP S02 NOX VOC CO PM10 *HAP No emissions inventory on record.The emissions inventory is due 01/31/2024. *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 TestZethod Ds Source(s)Tested Permitted Sources .....- -.... ............. ............. .... : ...:::.... ....... .............. ........... ........._............ Emission Emission Source Control Control System Source ID Description System ID Description _. w � ���- wYri w N/A N/A ES-1 Glue Spray Booth ::.. ..:.w.: .:.....:. .�... .:::..w::.:.:.......M .�...�..�:..... .w.w:..:.....................................:...... �w..:...:.......�........�..�a...............N.....�......................�.................. ��....w�...�..�..�.......�.���.....�............ a�....�. .���.�..�w. �.�..� m.........�..�.���. ..�..�...���....� Dry Filter Paint Spray Booth equipped with a ES-2 N/A N/A 3.58 MMBtu/hr Natural Gas-fired Burner,direct-fired x....:NH..�..N...v..:HN.��.:��.�..:�..�. ....N..,r ��,...N..,,�..�,.N..,.�.....�.�.HH...�....��...�.��,.....k.�...�...,��..�.....,�....�...�..�...�..�.....�.H�..........N. ..�,.,�...,..H....N�....���.....�...�.�..H....�..�...��...M....H........ �...�......�,.�,�.��...�.a..�.�..�.....�.H���....,�..��,..�.....�.�......�...,.��.a.���. Dry Filter Prime Spray Booth equipped with a ES-3 N/A N/A 3.11 MMBtu/hr Natural Gas-fired Burner,direct-fired Insignificant/Exempt Activities Source Exem do Source of Source of Title V p n Regulation TA....-........................Ps. Pollu..............................................tants.............. ...... ........ � �... .................... ........... .�. w.�.M..... . .�. � w w� � I-ES-1 -Body Prep Areas equipped with .......... ......��......�m......�.�.........�.. .w�w....�..........�....�...�..�.�..�........�..........�..�.........w............ two(2)Natural Gas-fired Pressure Washers(0.82 MMBtu/hr,total),direct-fired 2Q.0102(c)(2)(E)(i) Yes Yes .......... ........... ........ I-ES-2-Wel...............­...........­­....­­........ ......... ....... ......... ......... ....ding....... O..........---peratio..............ns Introduction On November 27,2018,Paul Williams,Environmental Specialist of the DAQ WSRO, contacted Mr. Gary Graybeal, Compliance Manager,and Mike Absher,Maintenance Manager, of American Emergency Vehicles,Inc.—Remount Facility for an unannounced targeted compliance inspection.This facility was previously inspected,by this inspector, on February 27,2017 and was found to be operating in compliance at that time. American Emergency Vehicles,Inc.— Remount facility replaces existing ambulance chassis and interior cabinetry and currently operates Monday through Thursday 6:30 am to 5:00 pm, 50 weeks/year. This facility also operates,occasionally, on Fridays. Mr. Graybeal confirmed that all IBEAM contacts were accurate. He also stated that business has increased since the prior inspection. Safety Equipment Safety shoes,hearing protection and eye protection are required within manufacturing areas of this facility. Applicable Regulations According to permit Condition A.1,the facility is subject to the following regulations: Title 15A North Carolina Administrative Code(NCAC), Subchapter 2D .0202,2D .0515,2D .0516,2D.0521,2D .0535,2D .0540,2D .0958,2D .1806, and 2Q .0711. The facility is not subject to the RMP requirements of the 112(r)program since it does not use or store any of the regulated chemicals in quantities above the threshold in the rule. The facility is only subject to the General Duty clause of the Section 112(r)program because they do not produce,use or store any regulated chemicals in quantities above their corresponding threshold limits. Discussion This facility takes existing ambulances,removes the body, and remounts them onto a new chassis. The ambulances also receive touch-up painting and new interior cabinets if desired by the customer. Mr. Graybeal stated that ambulances are typically refitted with a new chassis approximately every three to four years. The process begins as ambulances are received and disassembled. The facility then strips the interiors and removes the existing chassis. The rear"box"is then prepped prior to being repainted(if required) in one of the two exempt body prep.areas equipped with two natural gas- fired pressure washers(I-ES-1). These areas were observed but were not in active operation during this inspection. Once the body and box are cleaned of any excess road grime/dirt,they are sent to the exempt welding operations(I-ES-2)where any necessary minor body repairs are made. The welding stations were not in active use during this inspection. If the body and box require repainting,they are prepped and then sent to a dry filter primer spray booth equipped a natural gas-fired burner(ES-3). This primer booth was not in active use during the inspection. After priming,the body and box are painted in the dry filter paint spray booth equipped with a natural gas-fired burner(ES-2). Paint booth ES-2 was observed operating,with no visible emissions detected. The filters, for both spray booths,appeared to be in good condition and were installed with no visible gaps observed. Records indicate that filters are replace on a routine schedule. The facility is also permitted for a glue spray booth(ES-1). This booth is used to glue any cabinetry and/or interior pieces -� that are required to be repaired or replace prior to the body and box being attached to the new chassis. Glue booth ES-1 was not in active operation during this inspection. During this inspection, it was discovered that several sources have been installed since the prior inspection conducted on February 27, 2017. The new sources include; I body prep area(much like source I-ES-1), 1 dry filter spray booth . 1 .. equipped with a direct-fired natural gas burner(akin to source ES-2), a CNC router with and externally exhausting bagfilter emission control device, I MEK(methyl ethyl ketone) recovery unit, and a Kohler IOOkW natural gas-fired emergency generator. Mr. Graybeal stated that the facility has contracted an outside vender(Nixon Power Services of Charlotte) to perform the required maintenance for this unit. This genset is a holdover unit from the previous company that operated within this building(Gates Corp. —facility ID#0500055). The unit's name plate indicated that it is a Kohler model I00RZG(serial#2189208), manufactured in January of 2008. During this inspection the non-resettable hour meter read 269.9 total hours of operation. Mr. Graybeal indicated that the facil ity tests the genset for 10-15 minutes once per week. Mr. Graybeal also stated that as soon as the corporate office notified him of these source additions, he sent the information to their consultant, INENCO, Inc., out of Mooresville, NC. He continued by saying that INENCO was working to process the information and associated calculations for submittal to Air Quality and that he would contact them to find out what their timeframe was. Mr. Graybill sent this inspector an email stating that the source information was submitted to INENCO on March 20, 2018 and that Mr. James Willard II was the designated consultant. The email also contained Mr. Willard's contact information. On the afternoon of November 28`h, Mr. Ryan Osborne, Environmental Consultant for INENCO telephoned this inspector. Mr. Osborne stated that he had been assigned to process American Emergency Vehicles-Remount Facility's added source submittals. He also stated that he planned to have these forms and supporting calculations submitted to DAQ- WSRO by mid-December, at the latest. Permit Conditions/Applicable Regulations Condition A.2 contains 15A NCAC 2D .0202 permit renewal and emissions inventory requirements. The current permit expires April 3 0,2024,and the facility is required to submit a renewal request and air pollution emission inventory report for the 2022 calendar year at least 90 days prior to the expiration of the permit. This condition was discussed with Mr. Graybeal, and future compliance is anticipated. Condition A.3 contains the 15A NCAC 2D .0515 particulate control requirement. This condition sets the maximum allowable particulate emissions using the following two equations: E=4.10 * (P)°67 for P<=30 tons/hr. or E= 5 5 * (P)°11 -40 for P>3 0 tons/hr This rule applies to the glue spray booth(:ES-1), dry filter paint spray booth(ES-2), dry filter prime spray booth(ES-3), exempt body preparation areas(I-ES-1), and exempt welding operations(I-ES-2). According to permit review ROO,the anticipated controlled emission rates are less than the allowable emissions and are shown in the table below.Compliance with this condition is anticipated. _ ...... _... __. _.__ _._. .... kH.k. N.�.:... ..:.»»....kx.:.. .�.�.N .�µ. ...... �w...H....... »�N,.�.�...........N.�:..�.N�.k.M.N...N.:.�...�»....��.,�v�,N....�..�N....w....:..�:�.:H:.:...:...:....A..N�::...N:...�.x:. ::..»..:.�.N........::.��.:..�.�...:.....::..�:.N:: �:.�.:.k.H.:� ..�k�.................,...... .::....�.,.�..�......,:. .,�. Process Weight Rate(P) Allowable Emission Rate Anticipated Controlled Emission Source(ID No.) tons/hr E lb PM/hr E Emission Rate lb PM/hr ...._...._............................ ....�. .. __............. :F_.._........ � � __._ �.. M,..�.�.u.......,....�.,...w..w.w..�......�,.....,....�....w....�...w��.�...........�..,....�...w..w......�.�.�...V...w�...,.�..�.�.....�..�...,�.....�...,�..........�..��...�.,�,.......��.�..�.�..�.vv..M.�...................n s.M._...�..............w.A�...............�,.....�....�...,,.M..�.. Glue Spray Booth ES-1 0.0135 0.229 0.00 _ P Y C rl £ ............................................ ...............................................................................................................................................................................»... ......:........w.................................. _ - Dry Filter Paint Spray Booth(ES-2) 0.0135 0.229 0.0233 �...........w..�....... ��........ ............................................_..w....................., w..................�....................�..,.�.�.................�...........w.�.� �.......................�............0.229.... � . 0.0233 Dr Filter Prime Spray Booth ES 3 0.0135 Y p Y C ) ._ _... Body Prep Areas(I-ES-1) 0 000125 ,w _.............. ._................................ ........................... 0 0099 0.00608 Welding Operations(I-ES-2) ... 0.000185 0 0129 0.0..... . . n,......vmv....nn .,..«.++..n+.,w.,.m..................,....«.,ww..w.wm.m+w....,�,...,.,.,,.w.«.+vw.,ws...w...::...,.....w..w...w........�,.www.w.r �� .«x5 Condition A.4 contains the 15A NCAC 2D .0516 sulfur dioxide control requirement. This condition sets the maximum allowable sulfur dioxide emissions rate to be no more than 2.3 pounds per million Btu heat input.According to permit review ROO,the expected potential emissions are calculated(for all current natural gas combustion sources)to be 0.0006 lb SO2/MMBtu. Compliance with this condition is indicated. 2 Condition A.5 contains the 15A NCAC 2D .0521 visible emissions control requirement. This facility is limited to 20% opacity visible emissions when averaged over a six-minute period. No visible emissions were observed coming from any source vents or stacks during this inspection. Compliance with this condition is indicated. Condition A.6 contains the 15A NCAC 2D .0535 rule which requires the permittee to notify the Director of any excess emissions lasting longer than four hours resulting from a malfunction,breakdown of process or control equipment or any other abnormal conditions.Mr. Graybeal stated that no malfunctions or process upsets have occurred since the prior inspection and no issues are registered to this facility in IBEAM. Compliance with this condition is indicated. Condition A.7 contains the 15A NCAC 2D .0540 fugitive dust control requirement. No fugitive dust was observed traveling beyond the property boundaries during this inspection. According to the DAQ IBEAM database,no complaints have been received regarding fugitive dust emissions at this facility. Compliance with this condition is indicated. Condition A.8 contains the 15A NCAC 2D. 0958 rule which requires the facility to adhere to the required work practices when using any source of volatile organic compounds.As of November 1, 2016, this rule was revised and is currently valid in counties which are not in ambient air quality attainment. This facility is located within Ashe County, which is considered within attainment, so the rule does not presently affect this facility. Condition A.9 contains the 15A NCAC 2D .1806 control and prohibition of odorous emissions requirements.No., objectionable odors were detected during the approach to the facility or at the property boundaries.The facility does not have any previous odor complaints in IBEAM. Compliance with this condition is,indicated. Condition A.10 contains the 15A NCAC 2Q .0711 toxic air pollutant emissions limitation requirement. The following table(from permit review R00) shows the various TPER's calculated to be emitted by this facility and indicates anticipated compliance with this condition. 5 Facility-Wide Pollutant � CAS No. .......... ............... TPER ......................................... '� Expected Actual Emissions* ................................................................ ......... ............... ..Ace.......... ...........................................................taldehyde.................................. 75-07-0 �� 6.8 lb/hr 3.71 x I( lb/hr Acrolein 107-02-8 0.02 lb/hr 4.39 x 10-8 lb/hr .... _............... ....... _ _ _.__._. _..... __ _ .......__........ _ a _ Ammonia �7664-41-7 � �0.68 lb/hr � ..� 0.00781 lb/hr ............_........... ................. ....... ... .................. .: .................. ........ ..... ___ _._ ....... . ..._ __............... ..... ....... .. .. _......_ ....... Benzene �� 71-43-2 �. 8.1 lb/yr � � 0.013 21b/yr_......... ..........._.................. ............. ................ ......... ..........._......._........ _ .........._...._.. __... ?...._........__.. ................ ................................. Benzo(a)pyreneµ� 50-32-8 2.2 lb/yr 5.86 x 10-6 lb/yr __... .................... ......... ..... _ .........�.....�...�....�.....�......�Chromium.....��...w.........��.�.............� ..��...�,H.�.�.�.N..�,..,w..�,..,�. .��....��......�...H �...�.�.�....w...�.��................�..............�...�..�...�.�.............�..�..........�.��...�.�............. ;.�..�...�.....�....�....�.....�......�.....�...�..�.........�....._5�..�.�.............�...�...........�...... ....�....�...... ... ..... ... _ So1CR6 0.013 lb/day _ __ _ 7.93 x 10 lb/day ....�...��...�......_m....�....�.............. Ethyl Acetate�..........�..�.�...�.�...���. ...........,�.....141-78-6.�,�...�,....�. �.�...�.�.................�..�..�...�....�...3 6 lb/hr...w.�..�.....�,...�..�.�..�..�.......� �...��........�..............�............����.�.0.03 63�lb/hr.w...........�.�.��....���.�....�.�....... t F - - ..... 1b/hr 0.000183 lb/hr ............ -------------------- ormaldeh de 50 00 0 Yn-Hexane 110-54-3F77777�.04 ..............�.M,..�...........� 23 lb/day �..�....�....,�..��.....�..M...,�... 1.03 lb/day �.�...�...�,..�.�.., ..................... ...................... 0.6 lb/hr a lb/hr 0 0247.. Hydrogen Fluoride 7664-3 9-3 _ a lb/day 0 2471b/da 0.63 .0 Y Y Man anese MNC other 0.63 lb/day 0 000127 lb/day g Y Y 22.4 lb/hr 3.04 lb/hr Methyl Ethyl Ketone 78-93-3 �.:._ 78 1b/da 3 0.3 71b/da Y Y . _.. .. .. _ _ _ 7.6 lb/hr 0 127 lb/hr Methyl Isobutyl Ketone 108-10-1 __ ' 52 lb/day 1.27 lb/day _ _ _ _ _ _ Nickel Metal 7440-02-0 0.13 lb/day 4.00 x 10-'lb/day ......................... ...... ............._..........__...._................ ....................................._..... 3 P 11 Facility-Wide o utant CAS No. TPER 3 Expected Actual Emissions* _ �.�..�. ..�,�........��........��.�.,........��...... .W...�.,......��.�..��.��...w..M............�. �,.M,,.�,�...�..�..,.�...�.�....�..�........ 14.4�lb/hrw..::�:..�::�..�........�..�.�......� '.......�w.......�...w..,.�..,.w.........�...w.......0.208 lb/hr.......�..�...........�.�.w....�.....�..�w.w... Toluene 108-88-3 ..................... _.........._. _........ ................................ ay 2 08 lb/day ............... ........ ........ .................................... .................... . . .._................ 16.4 lb/hr 0.0711 lb/hr �..... Xylene(mixed isomers) 1330-20-7 �.� 57 lb/day 0.711 lb/day ......._ . ._._. ......... __ _._y. _.. . ........y....._. 'It should be noted that all SDS sheets are kept electronically and print copies are available outside the facility break/lunch room. Records were presented to this inspector which indicated that 1,450-gallons of MEK were ordered/used in 2017, while 1,950-gallons have been utilized thus far in 2018. NSP S/NE SHAD This facility is not subject to 40 CFR 63, Subpart HHHHHH, "Paint Stripping and Miscellaneous Surface Coating Operations",because it does not spray coat any parts made of metal or plastic with coatings containing target HAPs,nor 'does the facility conduct paint stripping operations involving chemical strippers containing methylene chloride(MeCI). This facility is not subject to 40 CFR 63, Subpart XXXXXX, "National Emission Standards for Hazardous Air Pollutants Area Source Standards for Nine Metal Fabrication and Finishing Source Categories"because it is not engaged in the operations in one of the nine source categories listed in this regulation. Furthermore,this facility's NAICS code,336211, is not one of the affected codes listed in this rule. This facility is not subject to 40 CFR Part 63, Subpart IIII, "Surface Coating of Automobiles and Light-Duty Trucks", 40 CFR Part 63, Subpart MNU\IM, "Surface Coating of Miscellaneous Metal Parts and Products"or 40 CFR Part 63, Subpart PPPP, "Surface Coating of Plastic Parts and Products", since these rules apply to facilities that are maj or sources of HAP. The facility is minor source for HAP;therefore,these rules do not apply. This facility is not subject to 40 CFR Part 60, Subpart MM, "Standards of Performance for Automobile and Light Duty -Truck Surface Coating Operations",because ambulances are not considered"light duty trucks." Light duty trucks are l defined in the subpart as motor vehicles rated at 8,4871bs gross vehicle weight or less. Facility-Wide Emissions There is no emissions inventory on record, at this time. The expected and potential emissions(taken from review R00, Leo L. Governale, P.E.,May 24, 2016)are listed in the following table: __ ........_...... ....__ __ .e..n...wn....v.rvw.wn•+ve...+ww..rw.mnr.++mv.vrewmim•.»v...i+r..wnr.nwNrr...nvnv..e..vxnw.+nv..w.w.x......vrm�.rvn....mrw.n SwkNr.w..vm�.v......rv..:mv+N...v...:m.v:..w.er..r..vr..,vv....v.v....w..NH..vr..r...:.•+r..N+..ee.H.......w+vxn..mxm..vw..r...v....r.N.. ..n..v..mv....irr..++i�virvr.e......r�.n�vvmv..wv.rn....r...N..vrx..vke...i..v..........rov...�.xv,.m.mm�HH.rn..wiv..r...w+.Ne.++.wN...v.w�.N.wrve.rnv.....+.vkk�re...v..v. Pollutant 3 Expected Actual Emissions(tons/year) f Potential Emissions uta t p tons/ e ar Y PM 3 0.056 F7.-­. .­...7­...­ 4.13 .......................................................... 04 4 12 ........ ........ PM 10 0. 5 ..,.,,.�..�....�...,�..,.�...H.,..,,�..�,....�....�,,.�..H....,.,.N.....,:.�.:.:�.::..,,.,.H....�,..,.,,.,.,.,»k�.H.H�...N.,.»..k,.,....�.���,.»..........,.N... ..�.....,..»...w,,.....�.,�....�....,.�.,......,�,. ...�HN.�...............�.,..,.....,....,�H....H,.�..H.»..» .,...,,..,...,.,....,,,...,w�,..,....................,� ..H�. .....,,.,�....,�,.,�..., ..�.,.,.. ,.�... .....,,, ........,�,...,...,.. ..a..�..,. �.,. sot 0.001 0.019 NOx 0.24 3.22 ............... ....... N.............................................................................................�. .................................................................................................................. ...............,.....................,..........}...............,...,............................................................k..........................................,.......................................................................... CO 0.21 2.71 10.67 46.73 ..........................._........vOC ............._....._....._...........................................................................F......_........_........................................................................................_............................................. w�.. ...��.��..� .�.�..��. �.....�...�...,� .....�....���......�...��.......... �.w�......�.......�...�..�w..... .��............. �.....�..........�.....,...��........�-.--��... ���m. w m�...�.........�.�. . w.�..�...�.� � � � w w .w .� �... �.�.� HAPTotat............................._.._.... 0.549 f........ 2 405 _ _ HAPHi h 0.208 0.911 Tol ene est u Facility Considerations/Issues Several sources have been installed since the prior inspection conducted on February 27, 2017. The new sources include; I body prep area (much like source I-ES-1), I dry filter spray booth equipped with a direct-fired natural gas 4 J burner(akin to source ES-2), a CNC router with and externally exhausting bagfilter emission control device, I MEK (methyl ethyl ketone), recovery unit, and a Kohler IOOkW natural gas-fired emergency generator. Mr. Graybeal stated that the facility has contracted an outside vender to perform the required maintenance for this unit. This genset is a holdover unit from the previous company that operated within this building(Gates Corp. —facility#0500055). The unit's name plate indicated that it is a Kohler model IOORZG(serial#2189208). manufactured in January of 2008. INENCO, Inc., of Mooresville,NC, has been retained by the facility to perform the required calculations and submit the required forms so that these sources can be added to the current permit. Stack Testing No stack testing has ever been conducted at this facility. 5-Year Compliance History This facility has not been issued and NOD,NOV or NOV/RE within the past 5 years. Conclusion Based on visual observations and records reviewed,American Emergency Vehicles,Inc.—Remount Facility appears to be operating in compliance with all applicable Air Quality standards and regulations,pending source information and supporting calculations being submitted by INENCO,Inc. 5 NORTH CAROLINA DIVISION OF Winston.Salem Regional Office AIR QUALITY American Emergency Vehicles,Inc.-Remount Facility Inspection Report NC Facility ID 0500075 Date: 11/28/2018 County/FIPS:Ashe/009 Facility Data Permit Data American Emergency Vehicles,Inc.-Remount Facility Permit 10496/R00 101 Gates Lane Issued 5/24/2016 Jefferson,NC 28640 Expires 4/30/2024 Lat: 36d 25.5501m Long: 81d 28.9002m Classification Small SIC: 3711 /Motor Vehicles And Car Bodies Permit Status Active NAICS: 336211 /Motor Vehicle Body Manufacturing Current Permit Application(s)None Contact Data Program Applicability Facility Contact Authorized Contact Technical Contact SR, Gary Graybeal Greg Warmuth Jeff Dreyer Compliance Manager Vice President of Finance Process Control Manager 336)972-7203 336 982-9824 336 982-9824 Compliance Data Comments: Inspection Date 11/27/2018 Inspector's Name Paul E Williams Inspector's Signature: Operating Status Operating Compliance Code Compliance-inspection Action Code FCE Date of Signature: MTH On-Site Inspection Result Compliance Total Actual emissions in TONS/YEAR: TSP S02 NOX VOC CO PM10 *HAP No emissions inventory on record.The emissions inventory is due 01/31/2024. *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 TestZethod Ds Source(s)Tested Permitted Sources .....- -.... ............. ............. .... : ...:::.... ....... .............. ........... ........._............ Emission Emission Source Control Control System Source ID Description System ID Description _. w � ���- wYri w N/A N/A ES-1 Glue Spray Booth ::.. ..:.w.: .:.....:. .�... .:::..w::.:.:.......M .�...�..�:..... .w.w:..:.....................................:...... �w..:...:.......�........�..�a...............N.....�......................�.................. ��....w�...�..�..�.......�.���.....�............ a�....�. .���.�..�w. �.�..� m.........�..�.���. ..�..�...���....� Dry Filter Paint Spray Booth equipped with a ES-2 N/A N/A 3.58 MMBtu/hr Natural Gas-fired Burner,direct-fired x....:NH..�..N...v..:HN.��.:��.�..:�..�. ....N..,r ��,...N..,,�..�,.N..,.�.....�.�.HH...�....��...�.��,.....k.�...�...,��..�.....,�....�...�..�...�..�.....�.H�..........N. ..�,.,�...,..H....N�....���.....�...�.�..H....�..�...��...M....H........ �...�......�,.�,�.��...�.a..�.�..�.....�.H���....,�..��,..�.....�.�......�...,.��.a.���. Dry Filter Prime Spray Booth equipped with a ES-3 N/A N/A 3.11 MMBtu/hr Natural Gas-fired Burner,direct-fired Insignificant/Exempt Activities Source Exem do Source of Source of Title V p n Regulation TA....-........................Ps. Pollu..............................................tants.............. ...... ........ � �... .................... ........... .�. w.�.M..... . .�. � w w� � I-ES-1 -Body Prep Areas equipped with .......... ......��......�m......�.�.........�.. .w�w....�..........�....�...�..�.�..�........�..........�..�.........w............ two(2)Natural Gas-fired Pressure Washers(0.82 MMBtu/hr,total),direct-fired 2Q.0102(c)(2)(E)(i) Yes Yes .......... ........... ........ I-ES-2-Wel...............­...........­­....­­........ ......... ....... ......... ......... ....ding....... O..........---peratio..............ns Introduction On November 27,2018,Paul Williams,Environmental Specialist of the DAQ WSRO, contacted Mr. Gary Graybeal, Compliance Manager,and Mike Absher,Maintenance Manager, of American Emergency Vehicles,Inc.—Remount Facility for an unannounced targeted compliance inspection.This facility was previously inspected,by this inspector, on February 27,2017 and was found to be operating in compliance at that time. American Emergency Vehicles,Inc.— Remount facility replaces existing ambulance chassis and interior cabinetry and currently operates Monday through Thursday 6:30 am to 5:00 pm, 50 weeks/year. This facility also operates,occasionally, on Fridays. Mr. Graybeal confirmed that all IBEAM contacts were accurate. He also stated that business has increased since the prior inspection. Safety Equipment Safety shoes,hearing protection and eye protection are required within manufacturing areas of this facility. Applicable Regulations According to permit Condition A.1,the facility is subject to the following regulations: Title 15A North Carolina Administrative Code(NCAC), Subchapter 2D .0202,2D .0515,2D .0516,2D.0521,2D .0535,2D .0540,2D .0958,2D .1806, and 2Q .0711. The facility is not subject to the RMP requirements of the 112(r)program since it does not use or store any of the regulated chemicals in quantities above the threshold in the rule. The facility is only subject to the General Duty clause of the Section 112(r)program because they do not produce,use or store any regulated chemicals in quantities above their corresponding threshold limits. Discussion This facility takes existing ambulances,removes the body, and remounts them onto a new chassis. The ambulances also receive touch-up painting and new interior cabinets if desired by the customer. Mr. Graybeal stated that ambulances are typically refitted with a new chassis approximately every three to four years. The process begins as ambulances are received and disassembled. The facility then strips the interiors and removes the existing chassis. The rear"box"is then prepped prior to being repainted(if required) in one of the two exempt body prep.areas equipped with two natural gas- fired pressure washers(I-ES-1). These areas were observed but were not in active operation during this inspection. Once the body and box are cleaned of any excess road grime/dirt,they are sent to the exempt welding operations(I-ES-2)where any necessary minor body repairs are made. The welding stations were not in active use during this inspection. If the body and box require repainting,they are prepped and then sent to a dry filter primer spray booth equipped a natural gas-fired burner(ES-3). This primer booth was not in active use during the inspection. After priming,the body and box are painted in the dry filter paint spray booth equipped with a natural gas-fired burner(ES-2). Paint booth ES-2 was observed operating,with no visible emissions detected. The filters, for both spray booths,appeared to be in good condition and were installed with no visible gaps observed. Records indicate that filters are replace on a routine schedule. The facility is also permitted for a glue spray booth(ES-1). This booth is used to glue any cabinetry and/or interior pieces -� that are required to be repaired or replace prior to the body and box being attached to the new chassis. Glue booth ES-1 was not in active operation during this inspection. During this inspection, it was discovered that several sources have been installed since the prior inspection conducted on February 27, 2017. The new sources include; I body prep area(much like source I-ES-1), 1 dry filter spray booth . 1 .. equipped with a direct-fired natural gas burner(akin to source ES-2), a CNC router with and externally exhausting bagfilter emission control device, I MEK(methyl ethyl ketone) recovery unit, and a Kohler IOOkW natural gas-fired emergency generator. Mr. Graybeal stated that the facility has contracted an outside vender(Nixon Power Services of Charlotte) to perform the required maintenance for this unit. This genset is a holdover unit from the previous company that operated within this building(Gates Corp. —facility ID#0500055). The unit's name plate indicated that it is a Kohler model I00RZG(serial#2189208), manufactured in January of 2008. During this inspection the non-resettable hour meter read 269.9 total hours of operation. Mr. Graybeal indicated that the facil ity tests the genset for 10-15 minutes once per week. Mr. Graybeal also stated that as soon as the corporate office notified him of these source additions, he sent the information to their consultant, INENCO, Inc., out of Mooresville, NC. He continued by saying that INENCO was working to process the information and associated calculations for submittal to Air Quality and that he would contact them to find out what their timeframe was. Mr. Graybill sent this inspector an email stating that the source information was submitted to INENCO on March 20, 2018 and that Mr. James Willard II was the designated consultant. The email also contained Mr. Willard's contact information. On the afternoon of November 28`h, Mr. Ryan Osborne, Environmental Consultant for INENCO telephoned this inspector. Mr. Osborne stated that he had been assigned to process American Emergency Vehicles-Remount Facility's added source submittals. He also stated that he planned to have these forms and supporting calculations submitted to DAQ- WSRO by mid-December, at the latest. Permit Conditions/Applicable Regulations Condition A.2 contains 15A NCAC 2D .0202 permit renewal and emissions inventory requirements. The current permit expires April 3 0,2024,and the facility is required to submit a renewal request and air pollution emission inventory report for the 2022 calendar year at least 90 days prior to the expiration of the permit. This condition was discussed with Mr. Graybeal, and future compliance is anticipated. Condition A.3 contains the 15A NCAC 2D .0515 particulate control requirement. This condition sets the maximum allowable particulate emissions using the following two equations: E=4.10 * (P)°67 for P<=30 tons/hr. or E= 5 5 * (P)°11 -40 for P>3 0 tons/hr This rule applies to the glue spray booth(:ES-1), dry filter paint spray booth(ES-2), dry filter prime spray booth(ES-3), exempt body preparation areas(I-ES-1), and exempt welding operations(I-ES-2). According to permit review ROO,the anticipated controlled emission rates are less than the allowable emissions and are shown in the table below.Compliance with this condition is anticipated. _ ...... _... __. _.__ _._. .... kH.k. N.�.:... ..:.»»....kx.:.. .�.�.N .�µ. ...... �w...H....... »�N,.�.�...........N.�:..�.N�.k.M.N...N.:.�...�»....��.,�v�,N....�..�N....w....:..�:�.:H:.:...:...:....A..N�::...N:...�.x:. ::..»..:.�.N........::.��.:..�.�...:.....::..�:.N:: �:.�.:.k.H.:� ..�k�.................,...... .::....�.,.�..�......,:. .,�. Process Weight Rate(P) Allowable Emission Rate Anticipated Controlled Emission Source(ID No.) tons/hr E lb PM/hr E Emission Rate lb PM/hr ...._...._............................ ....�. .. __............. :F_.._........ � � __._ �.. M,..�.�.u.......,....�.,...w..w.w..�......�,.....,....�....w....�...w��.�...........�..,....�...w..w......�.�.�...V...w�...,.�..�.�.....�..�...,�.....�...,�..........�..��...�.,�,.......��.�..�.�..�.vv..M.�...................n s.M._...�..............w.A�...............�,.....�....�...,,.M..�.. Glue Spray Booth ES-1 0.0135 0.229 0.00 _ P Y C rl £ ............................................ ...............................................................................................................................................................................»... ......:........w.................................. _ - Dry Filter Paint Spray Booth(ES-2) 0.0135 0.229 0.0233 �...........w..�....... ��........ ............................................_..w....................., w..................�....................�..,.�.�.................�...........w.�.� �.......................�............0.229.... � . 0.0233 Dr Filter Prime Spray Booth ES 3 0.0135 Y p Y C ) ._ _... Body Prep Areas(I-ES-1) 0 000125 ,w _.............. ._................................ ........................... 0 0099 0.00608 Welding Operations(I-ES-2) ... 0.000185 0 0129 0.0..... . . n,......vmv....nn .,..«.++..n+.,w.,.m..................,....«.,ww..w.wm.m+w....,�,...,.,.,,.w.«.+vw.,ws...w...::...,.....w..w...w........�,.www.w.r �� .«x5 Condition A.4 contains the 15A NCAC 2D .0516 sulfur dioxide control requirement. This condition sets the maximum allowable sulfur dioxide emissions rate to be no more than 2.3 pounds per million Btu heat input.According to permit review ROO,the expected potential emissions are calculated(for all current natural gas combustion sources)to be 0.0006 lb SO2/MMBtu. Compliance with this condition is indicated. 2 Condition A.5 contains the 15A NCAC 2D .0521 visible emissions control requirement. This facility is limited to 20% opacity visible emissions when averaged over a six-minute period. No visible emissions were observed coming from any source vents or stacks during this inspection. Compliance with this condition is indicated. Condition A.6 contains the 15A NCAC 2D .0535 rule which requires the permittee to notify the Director of any excess emissions lasting longer than four hours resulting from a malfunction,breakdown of process or control equipment or any other abnormal conditions.Mr. Graybeal stated that no malfunctions or process upsets have occurred since the prior inspection and no issues are registered to this facility in IBEAM. Compliance with this condition is indicated. Condition A.7 contains the 15A NCAC 2D .0540 fugitive dust control requirement. No fugitive dust was observed traveling beyond the property boundaries during this inspection. According to the DAQ IBEAM database,no complaints have been received regarding fugitive dust emissions at this facility. Compliance with this condition is indicated. Condition A.8 contains the 15A NCAC 2D. 0958 rule which requires the facility to adhere to the required work practices when using any source of volatile organic compounds.As of November 1, 2016, this rule was revised and is currently valid in counties which are not in ambient air quality attainment. This facility is located within Ashe County, which is considered within attainment, so the rule does not presently affect this facility. Condition A.9 contains the 15A NCAC 2D .1806 control and prohibition of odorous emissions requirements.No., objectionable odors were detected during the approach to the facility or at the property boundaries.The facility does not have any previous odor complaints in IBEAM. Compliance with this condition is,indicated. Condition A.10 contains the 15A NCAC 2Q .0711 toxic air pollutant emissions limitation requirement. The following table(from permit review R00) shows the various TPER's calculated to be emitted by this facility and indicates anticipated compliance with this condition. 5 Facility-Wide Pollutant � CAS No. .......... ............... TPER ......................................... '� Expected Actual Emissions* ................................................................ ......... ............... ..Ace.......... ...........................................................taldehyde.................................. 75-07-0 �� 6.8 lb/hr 3.71 x I( lb/hr Acrolein 107-02-8 0.02 lb/hr 4.39 x 10-8 lb/hr .... _............... ....... _ _ _.__._. _..... __ _ .......__........ _ a _ Ammonia �7664-41-7 � �0.68 lb/hr � ..� 0.00781 lb/hr ............_........... ................. ....... ... .................. .: .................. ........ ..... ___ _._ ....... . ..._ __............... ..... ....... .. .. _......_ ....... Benzene �� 71-43-2 �. 8.1 lb/yr � � 0.013 21b/yr_......... ..........._.................. ............. ................ ......... ..........._......._........ _ .........._...._.. __... ?...._........__.. ................ ................................. Benzo(a)pyreneµ� 50-32-8 2.2 lb/yr 5.86 x 10-6 lb/yr __... .................... ......... ..... _ .........�.....�...�....�.....�......�Chromium.....��...w.........��.�.............� ..��...�,H.�.�.�.N..�,..,w..�,..,�. .��....��......�...H �...�.�.�....w...�.��................�..............�...�..�...�.�.............�..�..........�.��...�.�............. ;.�..�...�.....�....�....�.....�......�.....�...�..�.........�....._5�..�.�.............�...�...........�...... ....�....�...... ... ..... ... _ So1CR6 0.013 lb/day _ __ _ 7.93 x 10 lb/day ....�...��...�......_m....�....�.............. Ethyl Acetate�..........�..�.�...�.�...���. ...........,�.....141-78-6.�,�...�,....�. �.�...�.�.................�..�..�...�....�...3 6 lb/hr...w.�..�.....�,...�..�.�..�..�.......� �...��........�..............�............����.�.0.03 63�lb/hr.w...........�.�.��....���.�....�.�....... t F - - ..... 1b/hr 0.000183 lb/hr ............ -------------------- ormaldeh de 50 00 0 Yn-Hexane 110-54-3F77777�.04 ..............�.M,..�...........� 23 lb/day �..�....�....,�..��.....�..M...,�... 1.03 lb/day �.�...�...�,..�.�.., ..................... ...................... 0.6 lb/hr a lb/hr 0 0247.. Hydrogen Fluoride 7664-3 9-3 _ a lb/day 0 2471b/da 0.63 .0 Y Y Man anese MNC other 0.63 lb/day 0 000127 lb/day g Y Y 22.4 lb/hr 3.04 lb/hr Methyl Ethyl Ketone 78-93-3 �.:._ 78 1b/da 3 0.3 71b/da Y Y . _.. .. .. _ _ _ 7.6 lb/hr 0 127 lb/hr Methyl Isobutyl Ketone 108-10-1 __ ' 52 lb/day 1.27 lb/day _ _ _ _ _ _ Nickel Metal 7440-02-0 0.13 lb/day 4.00 x 10-'lb/day ......................... ...... ............._..........__...._................ ....................................._..... 3 P 11 Facility-Wide o utant CAS No. TPER 3 Expected Actual Emissions* _ �.�..�. ..�,�........��........��.�.,........��...... .W...�.,......��.�..��.��...w..M............�. �,.M,,.�,�...�..�..,.�...�.�....�..�........ 14.4�lb/hrw..::�:..�::�..�........�..�.�......� '.......�w.......�...w..,.�..,.w.........�...w.......0.208 lb/hr.......�..�...........�.�.w....�.....�..�w.w... Toluene 108-88-3 ..................... _.........._. _........ ................................ ay 2 08 lb/day ............... ........ ........ .................................... .................... . . .._................ 16.4 lb/hr 0.0711 lb/hr �..... Xylene(mixed isomers) 1330-20-7 �.� 57 lb/day 0.711 lb/day ......._ . ._._. ......... __ _._y. _.. . ........y....._. 'It should be noted that all SDS sheets are kept electronically and print copies are available outside the facility break/lunch room. Records were presented to this inspector which indicated that 1,450-gallons of MEK were ordered/used in 2017, while 1,950-gallons have been utilized thus far in 2018. NSP S/NE SHAD This facility is not subject to 40 CFR 63, Subpart HHHHHH, "Paint Stripping and Miscellaneous Surface Coating Operations",because it does not spray coat any parts made of metal or plastic with coatings containing target HAPs,nor 'does the facility conduct paint stripping operations involving chemical strippers containing methylene chloride(MeCI). This facility is not subject to 40 CFR 63, Subpart XXXXXX, "National Emission Standards for Hazardous Air Pollutants Area Source Standards for Nine Metal Fabrication and Finishing Source Categories"because it is not engaged in the operations in one of the nine source categories listed in this regulation. Furthermore,this facility's NAICS code,336211, is not one of the affected codes listed in this rule. This facility is not subject to 40 CFR Part 63, Subpart IIII, "Surface Coating of Automobiles and Light-Duty Trucks", 40 CFR Part 63, Subpart MNU\IM, "Surface Coating of Miscellaneous Metal Parts and Products"or 40 CFR Part 63, Subpart PPPP, "Surface Coating of Plastic Parts and Products", since these rules apply to facilities that are maj or sources of HAP. The facility is minor source for HAP;therefore,these rules do not apply. This facility is not subject to 40 CFR Part 60, Subpart MM, "Standards of Performance for Automobile and Light Duty -Truck Surface Coating Operations",because ambulances are not considered"light duty trucks." Light duty trucks are l defined in the subpart as motor vehicles rated at 8,4871bs gross vehicle weight or less. Facility-Wide Emissions There is no emissions inventory on record, at this time. The expected and potential emissions(taken from review R00, Leo L. Governale, P.E.,May 24, 2016)are listed in the following table: __ ........_...... ....__ __ .e..n...wn....v.rvw.wn•+ve...+ww..rw.mnr.++mv.vrewmim•.»v...i+r..wnr.nwNrr...nvnv..e..vxnw.+nv..w.w.x......vrm�.rvn....mrw.n SwkNr.w..vm�.v......rv..:mv+N...v...:m.v:..w.er..r..vr..,vv....v.v....w..NH..vr..r...:.•+r..N+..ee.H.......w+vxn..mxm..vw..r...v....r.N.. ..n..v..mv....irr..++i�virvr.e......r�.n�vvmv..wv.rn....r...N..vrx..vke...i..v..........rov...�.xv,.m.mm�HH.rn..wiv..r...w+.Ne.++.wN...v.w�.N.wrve.rnv.....+.vkk�re...v..v. Pollutant 3 Expected Actual Emissions(tons/year) f Potential Emissions uta t p tons/ e ar Y PM 3 0.056 F7.-­. .­...7­...­ 4.13 .......................................................... 04 4 12 ........ ........ PM 10 0. 5 ..,.,,.�..�....�...,�..,.�...H.,..,,�..�,....�....�,,.�..H....,.,.N.....,:.�.:.:�.::..,,.,.H....�,..,.,,.,.,.,»k�.H.H�...N.,.»..k,.,....�.���,.»..........,.N... ..�.....,..»...w,,.....�.,�....�....,.�.,......,�,. ...�HN.�...............�.,..,.....,....,�H....H,.�..H.»..» .,...,,..,...,.,....,,,...,w�,..,....................,� ..H�. .....,,.,�....,�,.,�..., ..�.,.,.. ,.�... .....,,, ........,�,...,...,.. ..a..�..,. �.,. sot 0.001 0.019 NOx 0.24 3.22 ............... ....... N.............................................................................................�. .................................................................................................................. ...............,.....................,..........}...............,...,............................................................k..........................................,.......................................................................... CO 0.21 2.71 10.67 46.73 ..........................._........vOC ............._....._....._...........................................................................F......_........_........................................................................................_............................................. w�.. ...��.��..� .�.�..��. �.....�...�...,� .....�....���......�...��.......... �.w�......�.......�...�..�w..... .��............. �.....�..........�.....,...��........�-.--��... ���m. w m�...�.........�.�. . w.�..�...�.� � � � w w .w .� �... �.�.� HAPTotat............................._.._.... 0.549 f........ 2 405 _ _ HAPHi h 0.208 0.911 Tol ene est u Facility Considerations/Issues Several sources have been installed since the prior inspection conducted on February 27, 2017. The new sources include; I body prep area (much like source I-ES-1), I dry filter spray booth equipped with a direct-fired natural gas 4 J burner(akin to source ES-2), a CNC router with and externally exhausting bagfilter emission control device, I MEK (methyl ethyl ketone), recovery unit, and a Kohler IOOkW natural gas-fired emergency generator. Mr. Graybeal stated that the facility has contracted an outside vender to perform the required maintenance for this unit. This genset is a holdover unit from the previous company that operated within this building(Gates Corp. —facility#0500055). The unit's name plate indicated that it is a Kohler model IOORZG(serial#2189208). manufactured in January of 2008. INENCO, Inc., of Mooresville,NC, has been retained by the facility to perform the required calculations and submit the required forms so that these sources can be added to the current permit. Stack Testing No stack testing has ever been conducted at this facility. 5-Year Compliance History This facility has not been issued and NOD,NOV or NOV/RE within the past 5 years. Conclusion Based on visual observations and records reviewed,American Emergency Vehicles,Inc.—Remount Facility appears to be operating in compliance with all applicable Air Quality standards and regulations,pending source information and supporting calculations being submitted by INENCO,Inc. 5