Document r1Mo9gnJgo3p001zMqBGwVqq

DATE: SUBJECT: FROM: THRU: TO: UNITED STATES ENVIRONMENTAL PROTECTION AGENCY REGIONS 77 WEST JACKSON BOULEYARD CIDCAGO, ILLINOIS 60604 APR 2 4 2019 CLEAN AIR ACT INSPECTION REPORT Midwest Pipe Coating, Inc., Schererville, Indiana Sarah Clark, Environmental Engineer AECAB (IL/IN) Nathan Frank, Section Chief AECAB (IL/IN) File BASIC INFORMATION Facility Name: Midwest Pipe Coating, Inc. (Midwest Pipe) Facility Location: 925 Kennedy Ave, Schererville, Indiana, 46375 Date oflnspection: April 8, 2019 EPA lnspector(s): 1. Sarah Clark, Environmental Engineer 2. Eleanor Kane, Environmental Engineer Other Attendees 1. Lisa Brown, Air Compliance Inspector, Indiana Department of Environmental Management (IDEM) 2. Scott Luke Mitrisin, Air Compliance Inspector, IDEM 3. Jerome Prnzin, Safety/Engineer Manager, Midwest Pipe Contact Email Address: pruzinj@midwest-pc.com Purpose of Inspection: Assess compliance with the Clean Air Act and Federally Enforceable State Operating Permit Facility Type: Metal pipe/rebar abrasive cleaning and coating plant Arrival Time: 8:15 AM CDT Departure Time: 11 :00 AM CDT Inspection Type: D Announced Inspection OPENING CONFERENCE IZ1 Credentials Presented IZ1 CBI warning to facility provided The following information was obtained verbally from Mr. Pruzin unless otherwise noted. Company Ownership: Since approximately 1965, Midwest Pipe has been owned by a parent company named C.S. McCrossan. Process Description: Midwest Pipe's operations consist primarily of abrasion cleaning and applying coatings to metal pipe and rebar. There are three Thin Film lines (Thin Film I-III) and a Rebar Coating line, all of which apply powder coatings. Thin Film I-III process -inch to 4-inch, 2-inch to 48-inch, and 2-inch to 24inch diameter pipe or bar, respectively. The Thin Film process follows this order: pressure wash if needed; pre-heat to remove moisture; abrasive clean exterior of pipe in a Wheelabrator using steel grit; grind if needed; blowout if needed to remove residual particulates; heat to approximately 500F; spray coating on exterior of pipe; water quench; label with ink printer; transfer to exit racks for shipping. The Rebar Coating line functions similarly. While the Thin Film lines process a single pipe or bar at a time, the Rebar Coating line can process up to 8 bars ranging in size from #3 to #11 bar (3/8-inch to 11/8-inch). The coatings consist of a fluidized powder/air mixture. Thin Film I can apply one coating, called fusion-bond epoxy (FBE), while Thin Film II and III can apply FBE as well as a second coating, called abrasion-resistant overlay (ARO), in series. Thin Film I and II use natural gas-fired ovens while Thin Film III and the Rebar Coating line use induction heating. In Building #4, Midwest Pipe houses their LD. (Inner Diameter) and O.D. (Outer Diameter) Paint Lines, in which liquid coatings are applied to pipe and cured. In the LD. Paint Line, liquid coating (usually one with a glossy finish for improving flow through the pipe) is spray-applied while in the O.D. Paint Line, the liquid coating (usually an abrasion-resistant coating called Powercrete) is applied by hand. These Paint Lines can process pipe that has already been processed through a Thin Film line. The I.D. line includes its own abrasion cleaning step using a mobile 'stinger.' Dust collectors are used to control particulate emissions from most abrasive cleaning, blowout, and spray coating applications. Page 2 of6 Staff Interview: This Midwest Pipe facility employs approximately 130 people and usually operates 20 hours per day, 5 days per week. The additional ARO spray-coaters on Thin Film II and III can be rolled into and out of the process line as needed. The ARO spray-coater was added to Thin Film II about 15 years ago whereas Thin Film III included both the FBE and ARO spray coaters when the line was constructed about 5 years ago. When the Thin Film III FBE and ARO spray coaters were initially installed, each spray coater used 'integral' dust control (i.e., the spray booth and filter were one unit), but Mr. Pruzin said that the close proximity of the filters to the hot pipe led to the filters clogging often. Last year, Midwest Pipe switched to using a separate spray booth and dust collector for both the FBE and ARO coatings. Liquid coatings arrive in 55-gallon drums. Midwest Pipe uses methylethyl ketone and isopropyl alcohol as cleaning solvents. Mr. Pruzin conducts daily differential magnehelic and visible emission readings. Mr. Pruzin tracks solvent usage for estimating emissions of volatile organic compounds (VOCs), and he estimates tbe hazardous air pollutant (HAP) and VOC emissions from coatings based on emails he receives from the operations manager, who tracks coating usage. Mr. Pruzin reports these emissions on Midwest Pipe's quarterly reports. TOUR INFORMATION EPA toured the facility: Yes Data Collected and Observations: Only Thin Film III, the Rebar Coating Line, and the O.D./I.D. Paint Lines were operational during our tour. We started our tour of Building 1, where we first observed the Thin Film I from start to finish. Wheelabrator was installed in approximately 1965. Mr. Pruzin said that grit can escape out of the open ends of the Wheelabrator. The natural gas-fired oven reaches approximately 600F. The FBE powder is hopper fed from super sacs and pumped into the fluid bed, where the powder is mixed with air into a fluidized mixture prior to spray coating. The FBE spray booth uses an electric potential to direct and apply the coating. The sprayers are situated around the entire circumference of the pipe. The dust collector exhausts outside. There was an open ceiling vent and open door near the Thin Film I FBE spray booth. See photos #1-#8. Also in Building 1, we observed Thin Film II from start to finish. Mr. Pruzin said that grit can escape out of the open ends of this Wheelabrator, too. The blowout station has a separate dust collector from that of the Wheelabrator. The natural gas-fired oven reaches 2000F; a higher temperature is needed because the pipe is larger than that processed in Thin Film I. The fixed FBE and mobile ARO spray booths each have a dedicated dust collector that exhaust outside. In Thin Film II, the pipe can rotate, allowing for the sprayers to be positioned along one single face of the spray booth. there was an open door by the spray booths. The dust collectors for the blast Page 3 of6 cleaners used in Thin Film I and Thin Film II are situated outside and exhaust outside. See photos #9-#14. We walked past Building 2, which according to Mr. Pruzin, is dedicated to 'yard support,' such ' 1 ~ . s 1 ,~ S ' m; _r~panng 1wnm::r m ot: m,t::u. 1ur .sru.pp111g. In Building 3, we observed Thin Film III blast cleaning, blow out, preheating, FBE spray application, and quench. The pipe passes through two 'orange boxes' which contain the induction heating elements used to preheat the pipe. We observed the dust collector used to control emissions from the FBE spray coat which exhausts indoors. The dust collector was operating at differential pressures (dPs) of3.8 inches of water in the collector filter and 1.5 inches of water in the final filter. The ARO line was not connected or running at the time of our inspection. At the immediate outlet of the FBE spray booth, we observed the application of a yellow powder used to mark the bars with a yellow stripe. We observed fumes rising from this process. A long, small diameter, flexible duct led from the yellow-stripe application to a small dust collector which exhausted indoors. Mr. Pruzin checked with the employees to confinn that this dust collector was running; however, we could not hear the dust collector, nor were we able to collect a dP reading because there was no readout for us to check. A fabric canopy is positioned over the pipe at the exit of the FBE spray booth. A circular duct connected to this canopy that lead out a vent in the nearby wall. See photos and video #15-#24. Also in Building 3, we observed the entire Rebar Coating Line. The blast cleaner dust collector, which exhausts indoors, was operating at a dP of2.2 inches of water. The Rebar is preheated to approximately 500F through induction heating. The spray booth dust collector, which exhausts outside, was operating at a dP of 2.1 inches of water. See photos #25-#28. Entry into Building 4 required a respirator, so we only observed the activities in Building 4 from the doorways. The air inside was hazy. We observed the hand-application of a black coating at the O.D. Paint Line. We observed a fume hood at the end of the I.D. Paint Line. On the I.D. side of the building, we observed shelves of cans and pallets of barrels as well as what appeared to be a barrel tilted into another. See photos #29-#31. Photos and/or Videos: were taken during the inspection. Field Measurements: were not taken during this inspection. RECORDS REVIEW I. Summary of operations 2. Plant layout Page 4 of6 CLOSING CONFERENCE Requested documents: Safety data sheets and/or technical/product data sheets for the primary coatings Most recent stack test report Summary of operations Any notification sent to IDEM when the two powder collectors on the Thin Film Ill line were replaced March 2019 magnehelic/dP readings 2019 Ql (Jan-March) liquid coating usage Copy of 2019 QI quarterly report with supporting documentation SIGNATURES 1 Report Author: ~~=~\c<il=,,l,.:,=~~=W-=i..=1,=~~--_ Date: Section Chief: --~/_,''4-;6-,_~ ~{_'~/_'-____ Date: / 1:.\- \cf- 2019 ';//4?0(rj 7 T Page 5 of6 Facility Name: Midwest Pipe Coating, Inc. Facility Location: 925 Kennedy Ave, Schererville, Indiana Date oflnspection: April 8, 2019 APPENDICES AND ATTACHMENTS I. Appendix A: Digital Image Log Page 6 of6 Facility Name: Midwest Pipe Coating, Inc. Facility Location: 925 Kennedy Ave, Schererville, Indiana Date of Inspection: April 8, 2019 APPENDIX A: DIGITAL IMAGE LOG 1. Inspector Name: Sarah Clark 3. Company/Facility Name: Midwest Pine Coatinll, Inc. 5. Number of Images: 31 2. Date(s) oflnspection: April 8, 2019 4. Street Address, City, State: 925 Kennedv Ave, Schererville, Indiana 6. Archival Record Location: CD-R labeled as "Midwest Pipe, Schererville, IN, Insoection Photos, Aoril 8, 2019" Image Number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 File Name P4080001.JPG P4080002.JPG P4080003.JPG P4080004..TPG P4080005.JPG P4080006.JPG P4080007.JPG P4080008.JPG P4080009.JPG P408001 0.JPG P408001 l.JPG P4080012.JPG P4080013.JPG P4080014.JPG P4080015.JPG P4080016.JPG P4080017.JPG P4080018.JPG P4080019.JPG P4080020.MOV P4080021.JPG P4080022.JPG P4080023.JPG P4080024.JPG Date and Time (CDT) 4/8/2019 9:36 4/8/2019 9:36 4/8/2019 9:37 4/8/2019 9:39 4/8/2019 9:39 4/8/2019 9:40 4/8/2019 9:42 4/8/2019 9:42 4/8/2019 9:50 4/8/2019 9:50 4/8/2019 9:51 4/8/2019 9:51 4/8/2019 9:53 4/8/2019 10:00 4/8/2019 10:10 4/8/2019 10:10 4/8/2019 10:11 4/8/2019 10:11 4/8/2019 10: 11 4/8/2019 10:12 4/8/201910:16 4/8/2019 10:16 4/8/2019 10:18 4/8/2019 10:18 Description of Image Thin Film I FBE spray coater Thin Film I FBE spray coater Thin Film I FBE spray coater dust collector maonehelic <'aw,e Thin Film I fluid bed (powder/air mixing) Thin Film I powder coating and hopper Thin Film I spray coater ceiling vent Thin Film I FBE spray coater area Thin Film I FBE spray coater area Thin Film II FBE spray coater Thin Film 11 ARO spray coater Thin Film 11 ARO spray coater dust collector duct Thin Film II ARO spray coater dust collector Thin Film II ARO spray coater tracks Dust collectors for abrasive cleaners on Thin Film I (left) and II frillht) Thin Film III FBE spray coater Thin Film III FBE spray coater dust collector ma=ehelic <>au!les Thin Film III FBE spray coater dust collector Thin Film III FBE spray coater dust collector exhaust Thin Film III FBE spray coater dust collector duct (left), ARO sprav coater dust collector duct (ri<'ht) Thin Film III FBE spray coater outlet, yellow stripe annlication fumes Thin Film III FBE outlet, canopy and duct Thin Film III FBE outlet, yellow stripe application Yellow stripe application dust collector Yellow stripe application dust collector Appendices Page 1 of 2 Facility Name: Midwest Pipe Coating, Inc. Facility Location: 925 Kennedy Ave, Schererville, Indiana Date oflnspection: April 8, 2019 25 P4080025.JPG 4/8/201910:21 Rebar Coating Line blast cleaner dust collector dP 26 P4080026.JPG 4/8/2019 10:22 Rebar Coating Line spray coater dust collector dP 27 P4080027.JPG 4/8/2019 10:23 Rebar Coating Line spray coater 28 P4080028.JPG 4/8/2019 10:23 ----- Rebar Coating Line spray coater dust collector 29 P4080029.JPG 4/8/2019 I0:29 Building 4, view from I.D. Paint Line side 30 P4080030.JPG 4/8/2019 I0:31 Cans, drums at I.D. Paint Line 31 P4080031.JPG 4/8/201910:31 Drums at I.D. Paint Line Appendices Page 2 of 2