2010 EMISSIONS COMPLIANCE 

SOURCE TEST REPORT 

JOHNS MANVILLE 

WILLOWS, CALIFORNIA 

Prepared For: 

JOHNS MANVILLE 

5916 County Road 49 

Willows, California 95988 

For Submittal to: 

GLENN COUNTY AIR POLLUTION CONTROL DISTRICT 

720 North Colusa Street 

Willows, California 95988 

Prepared By: 

Mark Stanfield 

THE AVOGADRO GROUP, LLC 

2825 Verne Roberts Circle 

Antioch, California 94509 

(925) 680-4300

June 5, 2010

Johns Manville June 5, 2010 

2010 Emissions Compliance Tests 

10133.0 & 1c iii 

SUMMARY INFORMATION 

Source Information

Source Location: Johns Manville 

5916 County Road 49 

Willows, CA 95988 

Contact: Mr. Don Sexton 

Telephone: (530) 934-6273 

Regulatory Agency: Glenn County Air Pollution Control District (GCAPCD) 

Contact: Mr. Kevin Tokunaga 

Telephone: (530) 934-6500 

Units: Process Line 133, Dust Collector 

Process Line 133, Collection Stack 

Process Line 133, Combined Cooling and Curing Stack 

Process: Fiberglass manufacturing 

Purpose: Emissions testing to determine the compliance status of the units 

with respect to the relevant conditions outlined in the authority to 

construct

Procedures: EPA Methods: 1, 2, 3A, 4, 5, 6C, 10, 25A, 29, 202 and OTM-028 

Testing Company Information

Testing Firm: The Avogadro Group, LLC 

 2825 Verne Roberts Circle 

 Antioch, CA 94509 

Contacts: Mr. Jeremy Klosinksi Mr. Erick Mirabella 

 Project Manager General Manager 

Telephone: (925) 381-9302 (925) 680-0935 

Facsimile: (925) 680-4416 (925) 680-4416 

Certifications: ARB Independent Tester 

Test Dates: May 12 and 13, 2010 
Johns Manville June 5, 2010 

2010 Emissions Compliance Tests 

10133.0 & 1c 1 

SECTION 1.0 

INTRODUCTION

The Avogadro Group, LLC (Avogadro) was contracted by Johns Manville (JM) to 

perform a series of air emission compliance tests on the several sources serving Process 

Line 133 at their facility in Willows, California. 

The test program was conducted on May 12 and 13, 2010 by Mark Stanfield, David 

Ramirez, Kris Huckabay and Dustin Carter of Avogadro. Unit operations were 

coordinated by Mr. Donald Sexton of Johns Manville. Mr. Kevin Tokunaga of GCAPCD 

witnessed portions of the testing. 

Testing was performed to determine emissions of the following parameters: 

 Line 133 Baghouse

Emission Compliance Tests

Carbon Monoxide (ppmvd, lb/hr) 

Oxides of Sulfur, SOx as SO2 (ppmvd, lb/hr) 

Total Hydrocarbons (ppmvd, lb/hr) 

Trace Metals (As, Cd, Cr, Pb, Se) 

Total Particulate Matter (lb/hr) 

Gaseous Species as Diluent Gases

Oxygen and Carbon Dioxide (O2 and CO2)

 Line 133 Collection and Cooling/Curing Combined Stacks

Emission Compliance Tests

Total Hydrocarbons (ppmvd, lb/hr) 

Total Particulate Matter (lb/hr) 

Gaseous Species as Diluent Gases

Oxygen and Carbon Dioxide (O2 and CO2)

This report provides descriptions of the facility and test location, descriptions of the 

testing program, test methods and procedures, test results, and a summary of our quality 

assurance program. The tests results are summarized in Tables 1-1 through 1-7. Detailed 

results of individual test runs are presented in Section 4.0. All supporting data including 

field data sheets, laboratory reports, calculations and spreadsheets are located in the 

appendices.
Johns Manville June 5, 2010 

2010 Emissions Compliance Tests 

10133.0 & 1c 2 

TABLE 1-1 

SUMMARY OF GASEOUS TEST RESULTS 

BAGHOUSE STACK 

MAY 12, 2010 

 Results 

Stack Gas Parameters 

O2, % volume dry 20.88 

CO2, % volume dry 0.160 

Moisture cont., % by vol. 1.750 

Stack temp., oF 119.6 

Vol. flow rate, dscfm 25,721 

SOX as SO2

ppmvd 9.78 

lb/hr 2.54 

CO

ppmvd 23.65 

lb/hr 2.70 

TNMHC

ppmvd as CH4 54.37 

lb/hr as CH4 3.53 

lb/hr as C 2.64 
Johns Manville June 5, 2010 

2010 Emissions Compliance Tests 

10133.0 & 1c 3 

TABLE 1-2 

SUMMARY OF PARTICULATE MATTER TEST RESULTS 

BAGHOUSE STACK 

MAY 12, 2010 

 Results 

Stack Gas Parameters 

O2, % volume dry 20.884 

CO2, % volume dry 0.160 

Moisture cont., % by vol. 1.750 

Stack temperature, oF 119.6 

Vol. flow rate, dscfm 25,721 

Particulate Matter (PM) 

F1⁄2 gr/dscf 0.0002 

F1⁄2 lb/hr 0.0424 

B1⁄2 gr/dscf 0.0052 

B1⁄2 lb/hr 1.150 

Total, gr/dscf 0.0053 

Total, lb/hr 1.193 
Johns Manville June 5, 2010 

2010 Emissions Compliance Tests 

10133.0 & 1c 4 

TABLE 1-3 

SUMMARY OF TRACE METALS TEST RESULTS 

BAGHOUSE STACK 

MAY 12, 2010 

 Results 

Stack Gas Parameters 

Vol. flow rate, dscfm 25,660 

Sample volume, dscf 70.636 

O2, % volume dry 20.88 

CO2, % volume dry 0.16 

Moisture cont., % by volume 1.86 

Arsenic

μg/sample 2.000 

μg/dscm 1.008 

lb/hr 9.60E-05 

Cadmium

μg/sample B < 0.300 

μg/dscm B < 0.150 

lb/hr B < 1.44E-05 

Chromium

μg/sample 2.27 

μg/dscm 1.132 

lb/hr 1.09E-04 

Lead

μg/sample J 0.963 

μg/dscm J 0.488 

lb/hr J 4.63E-05 

Selenium

μg/sample 10.300 

μg/dscm 5.165 

lb/hr 4.95E-04 

Notes: ND< - species not detected in sample. Results are calculated using the reporting limit. 

 < - species detected in at least one sample or one sample fraction but not in all samples or fractions. 

B – Estimated concentration (less than reporting limit) in one or more samples or fractions. Results are 

calculated using the reporting limit. 

J - Method blank contamination. The associated method blank contains the target analyte at a reportable level. 
Johns Manville June 5, 2010 

2010 Emissions Compliance Tests 

10133.0 & 1c 9 

SECTION 2.0

SOURCE LOCATION INFORMATION

2.1 FACILITY DESCRIPTION 

Johns Manville operates a fiberglass manufacturing facility located in Willows, 

California. This plant produces light density glass insulation for use in a wide variety of 

residential, commercial and industrial applications. 

2.2 SAMPLING LOCATIONS 

Samples were collected at the outlet of the dust collector serving Process Line 133, from 

sampling ports that meet EPA Method 1 criteria. Samples were also collected at the 

collection stack and cooling/curing combined stack serving Process Line 133 from 

sampling ports that meet EPA Method 1 criteria. Access was provided by stairs and 

ladders to the roof. All stack measurements were confirmed on-site by Avogadro 

personnel. Diagrams of the sampling locations and traverse point locations are presented 

in Appendix C.1. 
Johns Manville June 5, 2010 

2010 Emissions Compliance Tests 

10133.0 & 1c 10 

SECTION 3.0 

TEST DESCRIPTION

3.1 PROGRAM OBJECTIVES 

The test program was conducted to determine compliance with the source testing 

limitations of the ATC issued by the GCAPCD. 

3.2 TEST CONDITIONS 

Testing was performed under normal operating conditions. Operating conditions were 

established and maintained by JM personnel. Avogadro communicated with JM staff 

throughout the testing to ensure that the desired operating conditions were maintained. 

Operating data were collected by JM during the test periods. The process data are 

presented in Appendix C.5. 

3.3 TEST PROGRAM SCHEDULE 

The testing program was completed in 3 days (including set-up time). Mark Stanfield 

served as test team leader for this test program. He was responsible for overseeing all onsite sampling activities, as well as all reporting tasks. The schedule for the testing 

program is presented in Tables 3-1A and 3-1B. 

TABLE 3-1A 

TEST SCHEDULE 

JOHNS MANVILLE 

Day Activity Test Runs Run Duration 

May 12, 2010 

Baghouse stack tests

PM

O2, CO2, SO2, CO

TNMHC

Trace Metals 

Vol. flow rate & moisture 

1, 2, 3 

1, 2, 3 

1, 2, 3 

1, 2, 3 

1, 2, 3 

120 min. ea. 

60 min. ea. 

60 min. ea. 

120 min. ea. 

120 min. ea. 
Johns Manville June 5, 2010 

2010 Emissions Compliance Tests 

10133.0 & 1c 11 

TABLE 3-1B 

TEST SCHEDULE 

JOHNS MANVILLE 

Day Activity Test Runs Run Duration 

May 13, 2010 

Collection stack tests

PM

O2, CO2, TNMHC 

Vol. flow rate & moisture 

1, 2, 3 

1, 2, 3 

1, 2, 3 

120 min. ea. 

60 min. ea. 

120 min. ea. 

Cooling/Curing stack tests

PM

O2, CO2, TNMHC 

Vol. flow rate & moisture 

1, 2, 3 

1, 2, 3 

1, 2, 3 

120 min. ea. 

60 min. ea. 

120 min. ea. 

3.4 TEST PROCEDURES 

The test procedures used in this program are summarized in Tables 3-2A and 3-2B. 

Descriptions of standard procedures are included in Appendix A. Additional information 

on site-specific applications and any modifications to procedures are described in the 

following sub-sections. Where any conflicts exist in the descriptions, the specific 

description here in Section 3.4 will take precedence. 

TABLE 3-2A 

TEST PROCEDURES 

JOHNS MANVILLE 

Parameter Measurement

Principle

Reference

Method

Method

Detection Limit 

O2 Paramagnetism EPA 3A 2% of span 

CO2 Non-dispersive infrared EPA 3A 2% of span 

CO Gas filter correlation EPA 10 2% of span 

SO2 Ultra-violet absorption EPA 6C 2% of span 
Johns Manville June 5, 2010 

2010 Emissions Compliance Tests 

10133.0 & 1c 12 

TABLE 3-2B 

TEST PROCEDURES 

JOHNS MANVILLE 

Parameter Measurement

Principle

Reference

Method

Method

Detection Limit 

TNMHC Flame ionization detection EPA 25A 2% of span 

Trace Metals ICP/MS EPA 29 0.1-1.0 ug/m3

PM Gravimetry EPA 5/OTM-28 0.0002 gr/dscf 

EPA 5/202 0.0002 gr/dscf 

Moisture content Gravimetry EPA 4 -- 

Vol. flow rate Pitot tube / temp. traverse EPA 1, 2 -- 

3.4.1 Gaseous Emissions (Baghouse Stack)

Concentrations of the gaseous constituents of the stack gas (SO2, CO, CO2, and O2) were 

measured using Avogadro’s dry extractive continuous emissions monitor system (CEMS) 

described in Appendix A. This system meets the requirements of EPA and CARB 

methods for gaseous species. Triplicate 60-minute test runs were performed for 

determination of compliance. 

The sample conditioning and delivery system includes components to extract a 

representative sample from the source, remove the moisture and particulate matter from 

the sample stream, and transport the sample to the analyzers. The primary components of 

this subsystem are: 

1) A quartz, titanium, stainless steel or glass probe - heated or insulated as 

necessary to avoid condensation, 

2) Sample filtration – filters located on the probe, pump, and prior to all of the 

analyzers for removal of particulate matter, 

3) Teflon tubing - connecting the probe to the sample conditioner and the 

sample conditioner to the analyzer manifold - heated or insulated as 

necessary to avoid condensation, 

4) Sample conditioner - glass or stainless steel flasks immersed in an ice bath 

to remove the moisture from the sample gas stream, 

5) Vacuum pump - a leak-free pump with Teflon diaphragm to transport the 

sample gas through the system, 

6) Sample manifold - a distribution system, constructed of stainless steel and 

Teflon tubing, to direct sample gas to the analyzers, and 
Johns Manville June 5, 2010 

2010 Emissions Compliance Tests 

10133.0 & 1c 13 

7) Sample flow rate control - a series of rotameters, vacuum gauges and 

pressure gauges connected to the manifold used to maintain the appropriate 

sample flow rates. 

The calibration gas system utilizes only EPA Protocol gases to verify the operation, 

linearity, and range settings of the electronic analyzers. The sample gas system allows 

for the introduction of the protocol gases to the analyzers either directly through the 

manifold (calibration error check - performed once daily) or through the sampling system 

(system bias check - performed with each run). 

The electronic analyzers are rack-mounted and are maintained in the mobile lab. The 

data recording and acquisition system is based on a digital system known as STRATA. It 

includes software for controlling the collection of calibration and emission monitoring 

data, and hardware for connection of the analyzer outputs to the recording system. Test 

results can be provided in three forms: on-site printouts of the digitized data, diskette 

recordings of the digitized data, and printouts of strip charts from the monitoring data. 

3.4.2 Gaseous Emissions (Collection and Cooling/Curing Stacks)

Concentrations of the gaseous constituents of the stack gas (O2 and CO2) were measured 

using Avogadro’s dry extractive continuous emissions monitor system (CEMS) described 

in Appendix A. An integrated bag sample was taken during each test run at each 

location. EPA Protocol gases were used to verify the operation, linearity, and range 

settings of the electronic analyzers. 

3.4.3 Particulate Matter (Baghouse Stack)

Stack gas concentrations of total and filterable particulate matter were measured using 

EPA Methods 5 and 202, and included analysis of the impinger contents for condensible 

particulate matter. Each test run was 120 minutes in duration. 

The filterable “front-half” PM was recovered from the sampling apparatus as described in 

the method. The sample included the nozzle wash, filter, and rinses from the front-half of 

the filter holder. The sample was analyzed gravimetrically to determine the 

concentration of filterable PM. Prior to the sample recovery, the sampling train was 

purged with nitrogen as described in Method 202. 

The “back-half” contents were recovered and analyzed as described in the method 

including the sulfate. A separate sample container was used to collect the impinger 

contents and rinses, sample line, probe wash, and the back-half filter holder wash. Each 

sample was extracted with dichloromethane in a separatory funnel. The analysis included 

gravimetric measurement of the residue from the aqueous and organic fractions. The 

corrected results were used to determine the concentration of condensable particulate 
Johns Manville June 5, 2010 

2010 Emissions Compliance Tests 

10133.0 & 1c 14 

matter. The results of the front and back-half sections were combined and reported as 

total particulate matter. 

3.4.4 Particulate Matter (Collection and Cooling/Curing Stacks)

Stack gas concentrations of total and filterable particulate matter were measured using 

EPA Methods 5 and OTM-028, and included analysis of the impinger contents for 

condensible particulate matter. Each test run was 120 minutes in duration. 

The filterable “front-half” PM was recovered from the sampling apparatus as described in 

the method. The sample included the nozzle wash, filter, and rinses from the front-half of 

the filter holder. The sample was analyzed gravimetrically to determine the 

concentration of filterable PM. 

The OTM-028 test train consisted of four impingers connected in series. The first and 

second impingers were empty, a Teflon filter was placed between the second and third 

impingers and maintained below 85 F, the third impinger contained 100 ml of deionized 

(DI) water, and the fourth contained silica gel. All of the impinger tare weights were 

recorded prior to sampling. All glassware and other components coming in contact with 

the sample were pre-cleaned using hot water and detergent, tap water, methylene chloride 

and DI water, in that order. 

The “back-half” condensable contents were recovered and analyzed according to OTM028. The entire “back-half” sampling system was purged with nitrogen at 20 liters per 

minute for one hour immediately following the end of each test run. The contents of the 

impingers were weighed, recorded and placed into a separate glass sample container 

which included the water rinses of the impingers, sample line, probe and the back-half 

filter holder. Additional methylene chloride rinses were collected. The liquid level was 

marked on the sample containers. The silica gel was also weighed and recorded. 

A field blank sample was collected as described in the method. The field blank involves 

a complete sampling train that was prepared, configured, leak-checked, and recovered in 

the same manner as that for the samples. Field blank samples were submitted for analysis 

with the remaining samples. 

3.4.5 Trace Metals

Concentrations of trace metals in the exhaust stream were determined using EPA Method 

29 modified to exclude measurement of mercury. As mercury was not to be measured, 

the sampling train omitted the two potassium permanganate-containing impingers. 

Samples were analyzed for arsenic (As), cadmium (Cd), chromium (Cr), lead (Pb) and 

selenium (Se). 
Johns Manville June 5, 2010 

2010 Emissions Compliance Tests 

10133.0 & 1c 15 

The samples were digested and analyzed for metals using inductively coupled plasma / 

mass spectroscopy (ICP/MS) analysis. 

3.4.6 Total Hydrocarbon Emissions

Concentrations of total hydrocarbons (THC) were measured using EPA Method 25A. 

The results of the three 60-minute test runs performed at the exhaust stack of the unit 

were averaged for determination of compliance. 

Flame ionization detector (FID) analyzers were used for measurement of the 

concentrations at the exhaust stack of the unit as described in EPA Method 25A. The 

sampling apparatus included a probe of titanium tubing connected by a length of heated 

Teflon tubing to the inlet port of the FID analyzer. The analyzer uses an internal 

sampling pump and a heated oven/analysis section to keep the sample gas at a minimum 

of 180 degrees Celsius (356 °F) throughout the system. The heated line was maintained 

at a minimum of 135 degrees Celsius (275 °F) during the test program to prevent 

condensation.

The analyzers were calibrated with three different concentrations of EPA Protocol gases 

that contain mixtures of methane in air. Results were calculated and presented as carbon 

equivalents.

3.4.7 Volumetric Flow Rate and Moisture Content

Stack gas volumetric flow rates were determined according to EPA Methods 2 and 4. 

Velocity traverses were performed on the exhaust stacks using an S-type Pitot tube and a 

manometer. Velocity traverse data were collected as part of the particulate and trace 

metals emission tests. Similarly, stack gas moisture data were collected in conjunction 

with the particulate and trace metals sampling. The volumetric flow rate results were 

corrected to standard conditions and used with the concentration data to calculate mass 

emission rates. 

3.4.8 Process Data

The plant’s process instrumentation was used to document unit conditions during the test 

runs and is presented in Appendix C.5.