July 27, 2005 

Wyandotte County Health Department

Department of Air Quality

619 Ann Avenue

Kansas City, Kansas 66101

Attn: Bruce Andersen 

RE: MACT Semi-Annual Reporting for 

Period January 1, 2005 through June 30, 2005 

Dear Mr. Andersen, 

This report includes three separate reports as required by 40 CFR 63 Subparts A and NNN. The 

first report summarizes periods of startup, shutdown, and malfunction where actions taken were 

inconsistent with the plan in accordance with MACT requirements, 40 CFR 63.10(d)(5) and 40 

CFR 63.1386(c). The second report is the “Summary Report – Gaseous and Opacity Excess 

Emission and Continuous Monitoring System Performance” as required in 40 CFR 63.10(e)(3) 

and 40 CFR 63.1386(e). The third report is the “Gaseous and Opacity Excess Emission and 

Continuous Monitoring System Performance Report” as required in 40 CFR 63.10(e)(3) and 40 

CFR 63.1386(e) if monitored parameters deviate more than 1% of the total operating time. Each 

report is labeled appropriately and is for the period January 1, 2005 through June 30, 2005. 

As the responsible official, I certify to the accuracy of this report. If you have any questions 

regarding this information, please contact our Facility Environmental Leader, Sherri Zeller at 

(913) 281-9535. 

Sincerely, 

Rick Copp 

Plant Leader 

Owens Corning – Kansas City Plant 

Kansas City, KS 

Attachment 
Report: Periods of Startup, Shutdown, and Malfunction (SSM) Where Actions Taken were 

Inconsistent with SSM Plan

40CFR63 Subpart NNN

Reporting Period: January 1, 2005 – June 30, 2005 

Owens Corning – Kansas City Plant 

300 Sunshine Road 

Kansas City, KS 66115 

All instances of startup, shutdown and malfunction were dealt with in accordance with the 

facility Startup, Shutdown, and Malfunction Plan. 

Report: Periods of Deviation from the Operations, Maintenance and Monitoring (OMM) 

Plan

40CFR63 Subpart NNN

The following instances are being reported as a deviation of procedures outlined in the facility 

OMM Plan: 

70N HPAF experienced problems with the monitoring equipment during March 2005. 

The monitoring equipment was inaccurately recording operating parameters. The water 

meter was by-passed and a temporary water line was connected to the sprays. The 

records from that period do not necessarily reflect those operating conditions. 

As the responsible official, I certify that the content of this report is accurate. 

Print Name: Rick Copp 

Signature: 

Title: Plant Leader 
Summary Report – Gaseous and Opacity Excess Emission and Continuous Monitoring 

System Performance

40CFR63 Subpart NNN

Reporting Period: January 1, 2005 – June 30, 2005 

Owens Corning – Kansas City Plant 

300 Sunshine Road 

Kansas City, KS 66115 

HAP’s Monitored: The Wool Fiberglass MACT focuses on two surrogate pollutants for control 

of HAP’s from the Fiberglass manufacturing process. Particulate matter is limited to 0.5 lb PM 

per ton of molten glass produced from the glass melting process and formaldehyde is limited to 

1.2 lb per ton of molten glass produced during fiber forming and curing. 

Process Units: In general the fiberglass manufacturing process is composed of a glass-melting 

furnace that melts batch materials into glass. The molten glass is passed through a rotary spin 

(RS) forming process where a fine, glass fiber is produced. Binder is applied to the fiber as it 

forms a “pack” on the surface of a foraminous conveyor. Once collected, the pack passes 

through a curing and cooling process followed by final fabrication and packaging. Tables 1 

through 3 define the manufacturing sources at this facility, including individual processes, 

control devices, and monitored parameters. 

TABLE 1 

 Process Control 

Device 

Monitored Parameter 

K5 

Furnace Glass Melting DEP 

1

st Field – Secondary Voltage 

2

nd Field – Secondary Voltage 

3

rd Field – Secondary Voltage 

Glass Melting Molten Glass Throughput 

 

Line Forming Premix Formulation 

LOI 

Resin Free Formaldehyde 

Molten Glass Throughput 

Curing HPAF – High 

Performance 

Air Filter 

Water Flow 

 
TABLE 2 

 Process Control 

Device 

Monitored Parameter 

70 

Furnace Glass Melting Batch Wetting Water Flow 

Glass Melting Molten Glass Throughput 

 

Line Forming Premix Formulation 

LOI 

Resin Free Formaldehyde 

Molten Glass Throughput 

Curing HPAF – High 

Performance 

Air Filter 

Water Flow 

 

TABLE 3 

 Process Control Device Monitored Parameter 

J5 

Furnace Glass Melting DEP 

1

st Field – Secondary Voltage 

2

nd Field – Secondary Voltage 

3

rd Field – Secondary Voltage 

Glass Melting Molten Glass Throughput 

 

Line Forming 

U3 

 Does not produce a bonded product 

J6-Forming Premix Formulation 

LOI 

Resin Free Formaldehyde 

Molten Glass Throughput 

J6-Curing HPAF – High 

Performance 

Air Filter 

Water Flow 

Emission Data Summary / Operating Hours for Facility

For the period January 1, 2005 – June 30, 2005 the operating hours are: 

K5 Furnace – 4344 hours J5 Furnace – 4344 hours 

K5 Line – 3480.75 hours J6 Line – 3480.75 hours 

70 Furnace – 4344 hours 

70 Line – 3962.37 hours 
Deviations: 

 Hours Deviation % Deviation

K5 Furnace DEP Bypasses 16.42 0.38 

J5 Furnace DEP Bypasses 26.88 0.62 

J5 Furnace DEP Voltage 

• SIR #1 29.90 0.69 

• SIR #3 1.48 0.03 

70 Furnace Batch Wetting/Crown Feed 87.38 2.01 

K5 N HPAF 3.67 0.10 

70 N HPAF 192.98 4.90 

70 S HPAF 31.52 0.80 

J6 Charge HPAF 568.17 14.60 

J6 Discharge HPAF 21.33 0.50 

Based on these operating hours, the following monitoring parameters were over the 1% 

exceedance time: 

70 Furnace Batch Wetting/Crown Feed 2.01 % 

70 N HPAF 4.90 % 

J6 Charge HPAF 14.60 % 

Based on these percentages of deviations, the following monitoring parameter was over the 5% 

exceedance time, thus warranting a Quality Improvement Plan (QIP) per 63.1382(b)(2)(ii) and 

63.10(e)(3)(viii): 

J6 Charge HPAF 568.17 hrs 14.60 % 

These instances will be described in more detail in the Parameter Exceedance Report that 

follows. 

As the responsible official, I certify that the content of this report is accurate. 

Print Name: Rick Copp 

Signature: 

Title: Plant Leader 
Gaseous and Opacity Excess Emission and Continuous Monitoring System Performance 

40CFR63 Subpart NNN

Reporting Period: January 1, 2005 – June 30, 2005 

Owens Corning – Kansas City Plant 

300 Sunshine Road 

Kansas City, KS 66115 

The following instances are being reported as a deviation of a monitored parameter due to 

malfunction or startup/shutdown: 

70 Furnace Batch Wetting/Crown Feed – See Appendix A for Details 

70 N HPAF - See Appendix B for Details 

J6 Charge HPAF - See Appendix C for Details 

As the responsible official, I certify that the content of this report is accurate. 

Print Name: Rick Copp 

Signature: 

Title: Plant Leader 
Appendix A 

70 Furnace Batch Wetting/Crown Feed 
Gaseous and Opacity Excess Emission and Continuous Monitoring System Performance

40CFR63 Subpart NNN

Reporting Period: January 1, 2005 – June 30, 2005 

Owens Corning – Kansas City Plant 

300 Sunshine Road 

Kansas City, KS 66115 

70 Furnace Batch Wetting/Crown Feed:

During the reporting period, the 70 Furnace Batch Wetting/Crown Feed experienced a total of 

87.38 hours of monitoring parameter excursions. The attached table lists dates, and times for the 

deviations. 
70 Batchwetting Deviations 

Owens Corning 

Kansas City, KS 

 

Date 

Beginning 

Time Ending Time Total Hours 

1/13/2005 8:31 9:40 1.15 

1/19/2005 8:10 8:30 0.33 

2/3/2005 8:40 10:05 1.42 

2/4/2005 2:00 16:05 14.08 

2/18/2005 8:45 9:35 0.83 

3/7/2005 10:08 10:49 0.68 

3/16/2005 8:15 10:30 2.25 

3/17/2005 8:30 13:30 5.00 

3/18/2005 7:40 13:45 6.08 

4/23/2005 7:04 7:38 0.57 

4/26/2005 14:20 16:20 2.00 

4/26/2005 16:37 16:53 0.27 

5/11/2005 17:15 21:20 4.08 

5/12/2005 9:10 11:10 2.00 

5/14/2005 0:01 23:59:00 23.97 

5/24/2005 8:24 8:50 0.43 

5/27/2005 8:15 10:00 1.75 

6/10/2005 13:13 14:00 0.78 

6/12/2005 0:00 9:37 9.62 

6/16/2005 12:00 19:00 7.00 

6/17/2005 8:30 10:40 2.17 

6/24/2005 8:00 8:20 0.33 

6/25/2005 7:35 8:10 0.58 

Total Hours 87.38 
Appendix B 

70 N HPAF 
Gaseous and Opacity Excess Emission and Continuous Monitoring System Performance

40CFR63 Subpart NNN

Reporting Period: January 1, 2005 – June 30, 2005 

Owens Corning – Kansas City Plant 

300 Sunshine Road 

Kansas City, KS 66115 

70 N HPAF:

During the reporting period, the 70 N HPAF experienced a total of 192.98 hours of monitoring 

parameter excursions. The attached table lists dates, and times for the deviations. 
70 N HPAF Deviations 

Kansas City, KS 

January 1, 2005 thru June 30, 2005 

 

Deviation Start Time Deviation End Time 

Total 

Minutes 

Line 

Down 

(min) 

Total 

Deviation 

(min) 

08-JAN-05 16:14:01.1 08-JAN-05 18:15:01.0 121 121

08-JAN-05 19:53:01.0 08-JAN-05 20:10:01.1 18 18 

08-JAN-05 20:11:01.1 08-JAN-05 20:28:01.0 17 17 

09-JAN-05 00:11:01.0 09-JAN-05 00:40:01.0 29 29 

09-JAN-05 00:41:01.0 09-JAN-05 05:23:01.0 282 282

09-JAN-05 05:46:01.0 10-JAN-05 15:21:01.0 2007 2007 

10-JAN-05 16:26:01.0 10-JAN-05 16:50:01.0 24 24 

10-JAN-05 16:51:01.0 10-JAN-05 17:50:01.0 59 59 

10-JAN-05 17:51:01.0 10-JAN-05 20:06:01.0 135 135

10-JAN-05 20:30:01.0 12-JAN-05 12:54:01.1 2425 25 2400 

13-JAN-05 00:47:01.0 13-JAN-05 06:32:01.0 345 345

13-JAN-05 10:18:01.0 13-JAN-05 06:32:01.0 289 289

13-JAN-05 15:17:01.0 13-JAN-05 22:06:01.0 409 409

13-JAN-05 22:06:01.0 14-JAN-05 15:00:01.0 1014 1014 

14-JAN-05 22:40:01.0 15-JAN-05 07:09:01.0 509 509

16-JAN-05 09:37:01.0 16-JAN-05 23:13:01.0 788 224 564 

16-JAN-05 22:46:01.0 16-JAN-05 23:13:01.0 27 27 

16-JAN-05 23:28:01.0 16-JAN-05 23:49:01.0 21 21 

17-JAN-05 01:06:01.0 17-JAN-05 07:21:01.1 375 375

17-JAN-05 07:22:01.0 17-JAN-05 07:54:01.0 32 32 

17-JAN-05 07:56:01.0 17-JAN-05 10:05:01.0 129 129

17-JAN-05 10:54:01.0 18-JAN-05 00:41:01.0 827 827

18-JAN-05 02:19:01.0 18-JAN-05 02:34:01.0 15 15 

18-JAN-05 02:41:01.0 18-JAN-05 14:21:28.2 701 701

25-FEB-05 09:02:01.0 25-FEB-05 15:21:01.0 380 380

02-JUN-05 09:40:01.0 02-JUN-05 10:08:01.0 28 28 

03-JUN-05 17:45:01.0 04-JUN-05 07:10:01.0 805 805

06-JUN-05 17:59:01.0 06-JUN-05 18:16:01.0 17 17 

Total Minutes 11579 

Total Hours 192.98 
Appendix C 

J6 Charge HPAF 
Gaseous and Opacity Excess Emission and Continuous Monitoring System Performance

40CFR63 Subpart NNN

Reporting Period: January 1, 2005 – June 30, 2005 

Owens Corning – Kansas City Plant 

300 Sunshine Road 

Kansas City, KS 66115 

J6 Charge HPAF:

During the reporting period, the J6 Charge HPAF experienced a total of 568.17 hours of 

monitoring parameter excursions. The attached table lists dates, and times for the deviations. 

J6 Charge HPAF experienced mechanical problems during January and March 2005. 

Restrictions in the water line caused low flow to the spray tips. Solids in the water also caused 

frequent plugging of the spray tip. 
J6 CHARGE HPAF 

January 1, 2005 through June 30, 2005 

Kansas City, KS 

 

Deviation Start Time Deviation End Time Total Minutes 

Line 

Down 

(min) 

Total 

Deviation 

(min) 

17-JAN-05 15:31:00.2 17-JAN-05 16:21:00.2 50 50 

17-JAN-05 18:26:00.2 18-JAN-05 00:00:00.2 334 334

18-JAN-05 08:25:00.2 18-JAN-05 08:50:00.3 25 25 

18-JAN-05 09:32:00.2 18-JAN-05 10:02:00.2 30 30 

18-JAN-05 10:11:00.2 18-JAN-05 10:54:00.2 43 43 

18-JAN-05 10:56:00.2 18-JAN-05 11:53:00.2 57 57 

18-JAN-05 11:55:00.2 18-JAN-05 14:53:00.2 178 178

18-JAN-05 21:33:00.2 19-JAN-05 04:06:00.1 393 327

19-JAN-05 08:00:00.2 19-JAN-05 08:39:00.2 39 39 

23-JAN-05 13:47:00.2 23-JAN-05 14:11:00.3 24 0 

31-JAN-05 16:29:00.2 31-JAN-05 23:38:00.2 429 429

01-FEB-05 04:58:00.2 01-FEB-05 05:43:00.2 45 45 

01-FEB-05 06:01:00.2 01-FEB-05 23:48:00.2 1067 1067 

02-FEB-05 16:01:00.2 02-FEB-05 16:22:00.2 21 21 

03-FEB-05 04:17:00.2 03-FEB-05 08:00:00.2 223 223

19-FEB-05 15:32:00.2 19-FEB-05 16:02:00.2 30 30 

21-FEB-05 18:15:00.2 23-FEB-05 07:22:00.2 2227 88 2139 

23-FEB-05 07:24:00.2 23-FEB-05 10:08:00.2 164 151 13 

03-MAR-05 22:49:00.2 03-MAR-05 23:17:00.2 28 28 

03-MAR-05 23:19:00.2 05-MAR-05 15:15:00.1 2396 2396 

05-MAR-05 15:32:00.2 05-MAR-05 17:03:00.2 91 91 

05-MAR-05 17:05:00.2 06-MAR-05 15:31:00.2 1346 121 1225 

06-MAR-05 16:05:00.2 06-MAR-05 16:24:00.2 19 19 

06-MAR-05 16:26:00.2 07-MAR-05 15:45:00.1 1397 1397 

07-MAR-05 15:48:00.2 12-MAR-05 08:23:00.2 6755 200 6555 

12-MAR-05 08:25:00.2 12-MAR-05 09:06:00.2 41 41 

12-MAR-05 12:38:00.2 13-MAR-05 04:13:00.2 935 935

13-MAR-05 04:25:00.2 22-MAR-05 07:45:00.2 13160 272 12888 

23-MAR-05 13:49:01.1 24-MAR-05 12:26:00.2 182 182

31-MAR-05 08:25:00.2 31-MAR-05 16:47:00.2 502 502

15-APR-05 03:39:00.2 15-APR-05 07:22:00.2 223 223

16-APR-05 10:29:00.2 16-APR-05 15:23:00.2 294 294
16-APR-05 15:28:00.2 17-APR-05 08:41:00.2 1033 1033 

17-APR-05 21:36:00.2 18-APR-05 08:23:00.2 647 647 0

23-APR-05 15:16:00.2 23-APR-05 15:31:00.2 15 15 

26-APR-05 12:28:00.2 26-APR-05 12:47:00.3 19 19 

27-APR-05 01:11:00.2 27-APR-05 01:28:00.2 17 0 

05-MAY-05 01:18:00.2 05-MAY-05 01:33:00.2 15 15 

06-MAY-05 13:16:00.2 06-MAY-05 15:18:00.2 122 122

11-MAY-05 15:06:00.2 11-MAY-05 15:23:00.2 17 17 

12-MAY-05 04:09:00.2 12-MAY-05 04:59:00.2 50 50 

12-MAY-05 05:18:00.2 12-MAY-05 08:14:00.2 176 106 70 

23-MAY-05 09:13:00.2 23-MAY-05 10:35:00.2 82 82 

28-MAY-05 16:02:00.2 28-MAY-05 23:56:00.2 474 474

31-MAY-05 07:08:00.2 31-MAY-05 07:30:00.2 22 22 

01-JUN-05 07:34:00.2 01-JUN-05 08:09:00.2 35 35 0 

13-JUN-05 04:05:00.2 13-JUN-05 04:21:00.2 16 16 

13-JUN-05 04:27:00.2 13-JUN-05 07:26:00.2 179 179

16-JUN-05 12:14:13.4 16-JUN-05 14:12:00.4 119 119

19-JUN-05 18:25:00.2 19-JUN-05 18:56:00.2 31 31 

Total Minutes 34090 

Total Hours 568.17 
Owens Corning 

300 Sunshine Road 

Kansas City, KS 66115 

January 27, 2006 

Wyandotte County Health Department 

Department of Air Quality 

619 Ann Avenue 

Kansas City, Kansas 66101 

Attn: Bruce Andersen 

RE: Owens Corning Source ID #2090010 

MACT Semi-Annual Reporting for 

Period July 1, 2005 through December 31, 2005 

Dear Mr. Andersen: 

This report includes three separate reports as required by 40 CFR 63 Subparts A and NNN. The 

first report summarizes periods of startup, shutdown, and malfunction where actions taken were 

inconsistent with the plan in accordance with MACT requirements, 40 CFR 63.10(d)(5) and 40 

CFR 63.1386(c). The second report is the “Summary Report – Gaseous and Opacity Excess 

Emission and Continuous Monitoring System Performance” as required in 40 CFR 63.10(e)(3) 

and 40 CFR 63.1386(e). The third report is the “Gaseous and Opacity Excess Emission and 

Continuous Monitoring System Performance Report” as required in 40 CFR 63.10(e)(3) and 40 

CFR 63.1386(e) if monitored parameters deviate more than 1% of the total operating time. Each 

report is labeled appropriately and is for the period July 1, 2005 through December 31, 2005. 

As the responsible official, I certify to the accuracy of this report. If you have any questions 

regarding this information, please contact our Facility Environmental Leader, Sherri Zeller at (913) 

281-9535. 

Sincerely, 

Rick Copp 

Plant Leader 

Owens Corning – Kansas City Plant 

Kansas City, KS 

Attachment 
Report: Periods of Startup, Shutdown, and Malfunction Where Actions Taken were 

Inconsistent with SSM Plan

40CFR63 Subpart NNN

Reporting Period: July 1, 2005 through December 31, 2005 

Owens Corning – Kansas City Plant 

300 Sunshine Road 

Kansas City, KS 66115 

All instances of startup, shutdown and malfunction were dealt with in accordance with the facility 

Startup, Shutdown, and Malfunction Plan. 

Report: Periods of Deviation from the Operations, Maintenance and Monitoring (OMM) 

Plan

40 CFR63 Subpart NNN

There are no instances being reported as a deviation of procedures outlined in the facility OMM 

Plan. 

As the responsible official, I certify that the content of this report is accurate. 

Print Name: Rick Copp 

Signature: 

Title: Plant Leader 
Summary Report – Gaseous and Opacity Excess Emission and Continuous Monitoring 

System Performance

40CFR63 Subpart NNN

Reporting Period: July 1, 2005 through December 31, 2005 

Owens Corning – Kansas City Plant 

300 Sunshine Road 

Kansas City, KS 66115 

HAP’s Monitored: The Wool Fiberglass MACT focuses on two surrogate pollutants for control of 

HAP’s from the Fiberglass manufacturing process. Particulate matter is limited to 0.5 lb PM per 

ton of molten glass produced from the glass melting process and formaldehyde is limited to 1.2 lb 

per ton of molten glass produced during fiber forming and curing. 

Process Units: In general the fiberglass manufacturing process is composed of a glass-melting 

furnace that melts batch materials into glass. The molten glass is passed through a rotary spin 

(RS) forming process where a fine, glass fiber is produced. Binder is applied to the fiber as it 

forms a “pack” on the surface of a foraminous conveyor. Once collected, the pack passes 

through a curing and cooling process followed by final fabrication and packaging. Tables 1 

through 3 define the manufacturing sources at this facility, including individual processes, control 

devices, and monitored parameters. 

<TABLE 1> 

 Process Control 

Device 

Monitored Parameter 

K5 

Furnace Glass Melting DEP 

1

st Field – Secondary Voltage 

2

nd Field – Secondary Voltage 

3

rd Field – Secondary Voltage 

Glass Melting Molten Glass Throughput 

 

Line Forming Premix Formulation 

LOI 

Resin Free Formaldehyde 

Molten Glass Throughput 

Curing HPAF – High 

Performance 

Air Filter 

Water Flow 

 
<TABLE 2> 

 Process Control 

Device 

Monitored Parameter 

70 

Furnace Glass Melting Batch Wetting Water Flow 

Glass Melting Molten Glass Throughput 

 

Line Forming Premix Formulation 

LOI 

Resin Free Formaldehyde 

Molten Glass Throughput 

Curing HPAF – High 

Performance 

Air Filter 

Water Flow 

 

<TABLE 3> 

 Process Control Device Monitored Parameter 

J5 

Furnace Glass Melting DEP 

1

st Field – Secondary Voltage 

2

nd Field – Secondary Voltage 

3

rd Field – Secondary Voltage 

Glass Melting Molten Glass Throughput 

 

Line Forming 

U3 

 Does not produce a bonded product 

J6-Forming Premix Formulation 

LOI 

Resin Free Formaldehyde 

Molten Glass Throughput 

J6-Curing HPAF – High 

Performance Air 

Filter 

Water Flow 

Emission Data Summary / Operating Hours for Facility

For the period July 1, 2005 through December 31, 2005 the operating hours are: 

K5 Furnace – 4416 hours J5 Furnace – 4416 hours 

K5 Line – 4226.25 hours J6 Line – 4012.45 hours 

70 Furnace – 4416 hours 

70 Line – 4092.67 hours 
Deviations: 

 Hours Deviation % Deviation

J5 Furnace DEP Bypasses 17.53 0.04 

K5 Furnace DEP Bypasses 53.69 1.22 

K5 Furnace DEP Voltage 

• SIR #2 654.67 14.82 

J5 Furnace DEP Voltage 

• SIR #1 144.33 3.27 

70 Furnace Batch Wetting/Crown Feed 25.67 0.58 

70 N HPAF 105.00 2.57 

70 S HPAF 24.00 0.60 

J6 Charge HPAF 305.21 7.61 

J6 Discharge HPAF 94.25 2.35 

Based on these operating hours, the following monitoring parameters were over the 1% 

exceedance time: 

K5 Furnace DEP Bypasses 53.69 hrs 1.22 % 

70 N HPAF 105.00 hrs 2.57 % 

J6 Discharge HPAF 94.25 hrs 2.35 % 

J5 Furnace DEP SIR #1 Voltage 144.33 hrs 3.27 %

Based on these percentages of deviations, the following monitoring parameters were over the 5% 

exceedance time, thus warranting a Quality Improvement Plan (QIP) per 63.1382(b)(2)(ii) and 

63.10(e)(3)(viii): 

K5 Furnace DEP SIR #2 Voltage 654.67 hrs 14.82 % 

J6 Charge HPAF 305.21 hrs 7.61 % 

These instances will be described in more detail in the Parameter Exceedance Report that 

follows. 

As the responsible official, I certify that the content of this report is accurate. 

Print Name: Rick Copp 

Signature: 

Title: Plant Leader 
Gaseous and Opacity Excess Emission and Continuous Monitoring System Performance 

40CFR63 Subpart NNN

Reporting Period: July 1, 2005 through December 31, 2005 

Owens Corning – Kansas City Plant 

300 Sunshine Road 

Kansas City, KS 66115 

The following instances are being reported as a deviation of a monitored parameter due to 

malfunction or startup/shutdown: 

K5 Furnace DEP Bypasses – See Appendix A for Details 

As the responsible official, I certify that the content of this report is accurate. 

Print Name: Rick Copp 

Signature: 

Title: Plant Leader 
Appendix A 

K5 Furnace DEP Bypasses 
Gaseous and Opacity Excess Emission and Continuous Monitoring System 

Performance

40CFR63 Subpart NNN

Reporting Period: July 1, 2005 through December 31, 2005 

Owens Corning – Kansas City Plant 

300 Sunshine Road 

Kansas City, KS 66115 

K5 Furnace DEP Bypasses:

During the reporting period, the K5 Furnace DEP experienced a total of 53.69 hours of bypass . 

The attached table lists dates, and times for the deviations. 
K-5 Furnace DEP Bypass Deviations 

Owens Corning 

Kansas City, KS 

 

Date 

Beginning 

Time Ending Time Total Hours 

8/12/2005 20:36 20:40 0.067 

8/12/2005 21:35 21:37 0.033 

9/16/2005 19:59 20:01 0.033 

10/1/2005 1:45 1:50 0.083 

11/8/2005 13:49 13:53 0.067 

11/21/2005 8:40 23:40 15 

11/28/2005-11/29/2005 3:00 2:00 23 

11/30/2005 5:25 11:30 6.08 

12/1/2005 5:25 14:45 9.33 

Total Hours 53.69
Appendix B 

70 N HPAF 
Gaseous and Opacity Excess Emission and Continuous Monitoring System Performance

40CFR63 Subpart NNN

Reporting Period: July 1, 2005 through December 31, 2005 

Owens Corning – Kansas City Plant 

300 Sunshine Road 

Kansas City, KS 66115 

70 N HPAF:

During the reporting period, the 70 N HPAF experienced a total of 105 hours of monitoring 

parameter excursions. The attached table lists dates, and times for all deviations. 
70 N HPAF Deviations 

Owens Corning 

Kansas City, KS 

 

Date 

Beginning 

Time Ending Time Total Hours 

7/22/2005 1st Shift 2nd Shift 8 

8/14/2005-8/19/2005 0:55 0:00 16 

8/21/2005-8/25/2005 22:00 14:59 64 

9/8/2005-9/9/2005 17:00 22:59 9 

10/5/2005-10/6/2005 18:55 5:55 8 

Total Hours 105
Appendix C 

J6 Discharge HPAF 
Gaseous and Opacity Excess Emission and Continuous Monitoring System Performance

40CFR63 Subpart NNN

Reporting Period: July 1, 2005 through December 31, 2005 

Owens Corning – Kansas City Plant 

300 Sunshine Road 

Kansas City, KS 66115 

J6 Discharge HPAF:

During the reporting period, the J6 Discharge HPAF experienced a total of 94.25 hours of 

monitoring parameter excursions. The attached table lists dates, and times for all deviations. 
J6 Discharge HPAF Deviations 

Owens Corning 

Kansas City, KS 

 

Date 

Beginning 

Time Ending Time Total Hours 

7/24/2005-7/28/2005 0:45 23:30 44.98 

7/29/2005 4:00 8:59 4.67 

8/5/2005 0:48 16:47 4.18 

11/4/2005-11/6/2005 5:17 10:16 24 

12/5/2005 11:00 20:00 9 

12/7/2005-12/8/2005 16:00 9:00 6 

12/10/2005-12/11/2005 20:00 22:00 0.42 

12/25/2005-12/26/2005 0:00 1:00 1 

Total Hours 94.25
Appendix D 

J5 Furnace DEP SIR #1 Voltage 
Gaseous and Opacity Excess Emission and Continuous Monitoring System Performance

40CFR63 Subpart NNN

Reporting Period: July 1, 2005 through December 31, 2005 

Owens Corning – Kansas City Plant 

300 Sunshine Road 

Kansas City, KS 66115 

J5 Furnace DEP SIR #1 Voltage:

During the reporting period, the J5 Furnace DEP SIR #1 Voltage experienced a total of 144.33 

hours of monitoring parameter excursions. The attached table lists dates, and times for all 

deviations. 
J-5 1st Field Deviations 

Owens Corning 

Kansas City, KS 

 

Date 

Beginning 

Time Ending Time Total Hours 

7/5/2005 5:58 12:57 7 

7/7/2005 5:58 9:57 4 

7/28/2005 7:00 9:59 3 

9/3/2005 1st Shift 1st Shift 1 

9/4/2005 2nd Shift 2nd Shift 1.33 

10/18/2005 2nd Shift 2nd Shift 3 

10/20/2005 11:56 17:55 3 

11/25/2005-11/26/2005 3rd Shift 1st Shift 5 

12/9/2005-12/10/2005 3rd Shift 1st Shift 3 

12/10/2005 1st Shift 1st Shift 5 

12/10/2005-12/11/2005 2nd Shift 3rd Shift 11 

12/11/2005-12/13/2005 3rd Shift 1st Shift 21 

12/18/2005 1st Shift 2nd Shift 4 

12/19/2005-12/20/2005 2nd Shift 1st Shift 6 

12/20/2005-12/21/2005 3rd Shift 1st Shift 8 

12/23/2005-12/25/2005 2nd Shift 1st Shift 35 

12/25/2005 1st Shift 2nd Shift 10 

12/27/2005-12/28/2005 3rd Shift 1st Shift 4 

12/28/2005 1st Shift 1st Shift 2 

12/28/2005 16:00 18:00 2 

12/29/2005 8:00 11:00 3 

12/29/2005 15:00 17:00 2 

12/30/2005 16:00 17:00 1 

Total Hours 144.33
Appendix E 

K5 Furnace DEP SIR #2 Voltage 
Gaseous and Opacity Excess Emission and Continuous Monitoring System Performance

40CFR63 Subpart NNN

Reporting Period: July 1, 2005 through December 31, 2005 

Owens Corning – Kansas City Plant 

300 Sunshine Road 

Kansas City, KS 66115 

K5 Furnace DEP SIR #2 Voltage:

During the reporting period, the K5 Furnace DEP SIR #2 Voltage experienced a total of 654.67 

hours of monitoring parameter excursions. The attached table lists dates, and times for the 

deviations. It should be noted that all of the deviations were a result of the SIR operating at a 

voltage above the upper limit. Approximately half of these hours can be contributed to a broken 

rapper drive insulator that was found during maintenance conducted in December. The insulator 

was replaced. 
K-5 2nd Field Deviations 

Owens Corning 

Kansas City, KS 

 

Date 

Beginning 

Time Ending Time Total Hours 

9/9/2005-9/10/2005 23:59 7:59 8 

9/10/2005-9/11/2005 18:00 1:59 8 

9/11/2005 10:00 10:59 1 

9/16/2005-9/17/2005 23:00 6:00 7 

9/19/2005-9/21/2005 3:00 2:59 48 

9/22/2005 5:00 20:59 16 

9/23/2005 5:00 15:59 11 

9/23/2005 20:00 20:59 1 

9/24/2005 0:00 3:59 4 

9/27/2005 5:00 6:59 2 

9/27/2005-9/28/2005 22:00 11:59 14 

9/29/2005 23:00 23:59 1 

10/3/2005 0:54 3:54 3 

10/3/2005 6:54 8:54 2 

10/3/2005 10:54 14:54:00 4 

10/3/2005 21:54 22:55 1 

10/4/2005 1:54 12:54 10 

10/18/2005 15:56 18:55 3 

10/19/2005 22:45 23:55 1 

10/28/2005 0:00 0:59 1 

10/29/2005 17:00 21:59 5 

10/31/2005 2:00 23:59 22 

11/1/2005-11/5/2005 0:00 16:16 112 

11/5/2005-11/7/2005 17:17 11:16 42 

11/7/2005-11/10/2005 17:17 17:16 72 

11/10/2005-11/11/2005 18:17 10:16 16 

11/11/2005-11/12/2005 13:17 8:16 19 

11/12/2005-11/13/2005 19:17 23:16 28 

11/14/2005 0:17 5:15 5 

11/14/2005 9:17 10:16 1 

11/14/2005 12:17 21:16 9 

11/15/2005 0:17 2:16 2 
11/19/2005 9:23 12:23 3 

11/22/2005-11/29/2005 17:23 0:59 129 

11/29/2005-11/30/2005 1:59 0:50 23 

11/30/2005 3:59 23:59 14 

12/1/2005 1st Shift 3rd Shift 6.67 

Total Hours 654.67 
Appendix F 

J6 Charge HPAF 
Gaseous and Opacity Excess Emission and Continuous Monitoring System Performance

40CFR63 Subpart NNN

Reporting Period: July 1, 2005 through December 31, 2005 

Owens Corning – Kansas City Plant 

300 Sunshine Road 

Kansas City, KS 66115 

J6 Charge HPAF:

During the reporting period, the J6 Charge HPAF experienced a total of 305.21 hours of 

monitoring parameter excursions. The attached table lists dates, and times for all deviations. 

Approximately 216 hours of these flow deviations are due to a broken flow meter which was not 

reading accurately. Physical checks made periodically of the water flow during these times 

showed that the actual water flow was within acceptable range. Since documentation was not 

kept, these hours are included in the deviation time. 
J6 Charge HPAF Deviations 

Owens Corning 

Kansas City, KS 

 

Date 

Beginning 

Time Ending Time Total Hours 

7/18/2005 7:03 9:57 1.85 

7/18/2005-7/19/2005 23:58 9:57 10 

7/22/2005-7/24/2005 5:59 8:59 17.35 

7/25/2005-7/30/2005 16:00 15:40 92.38 

7/31/2005 0:00 23:59 24 

8/1/2005-8/2/2005 17:10 4:40 17.4 

8/10/2005-8/16/2005 4:48 23:54 124.83 

10/6/2005 7:57 8:56 1 

12/7/2005-12/8/2005 23:00 10:00 7 

12/5/2005-12/6/2005 13:00 0:00 9.4 

Total Hours 305.21

 
July 20, 2006 

Wyandotte County Health Department

Department of Air Quality

619 Ann Avenue

Kansas City, Kansas 66101

Attn: Bruce Andersen 

RE: MACT Semi-Annual Reporting for 

Period January 1, 2006 through June 30, 2006 

Dear Mr. Andersen: 

This report includes three separate reports as required by 40 CFR 63 Subparts A and NNN. The 

first report summarizes periods of startup, shutdown, and malfunction where actions taken were 

inconsistent with the plan in accordance with MACT requirements, 40 CFR 63.10(d)(5) and 40 

CFR 63.1386(c). The second report is the “Summary Report – Gaseous and Opacity Excess 

Emission and Continuous Monitoring System Performance” as required in 40 CFR 63.10(e)(3) 

and 40 CFR 63.1386(e). The third report is the “Gaseous and Opacity Excess Emission and 

Continuous Monitoring System Performance Report” as required in 40 CFR 63.10(e)(3) and 40 

CFR 63.1386(e) if monitored parameters deviate more than 1% of the total operating time. Each 

report is labeled appropriately and is for the period January 1, 2006 through June 30, 2006. 

As the responsible official, I certify to the accuracy of this report. If you have any questions 

regarding this information, please contact our Facility Environmental Leader, Sherri Zeller at 

(913) 281-9535. 

Sincerely, 

Rick Copp 

Plant Leader 

Owens Corning – Kansas City Plant 

Kansas City, KS 

Attachment 
Report: Periods of Startup, Shutdown, and Malfunction where Actions Taken were Inconsistent 

with SSM Plan

40CFR63 Subpart NNN

Reporting Period: January 1, 2006 through June 30, 2006 

Owens Corning – Kansas City Plant 

300 Sunshine Road 

Kansas City, KS 66115 

Although there were startups, shutdowns and malfunctions during this reporting period, all 

actions taken were consistent with the Startup, Shutdown and Malfunction (SSM) Plan. 

Report: Periods of Deviation from the Operations, Maintenance and Monitoring (OMM) Plan

40CFR63 Subpart NNN

There are no instances being reported as deviation of procedures outlined in the facility OMM 

Plan. 

As the responsible official, I certify that the content of this report is accurate. 

Print Name: Rick Copp 

Signature: 

Title: Plant Leader 
Summary Report – Gaseous and Opacity Excess Emission and Continuous Monitoring 

System Performance

40CFR63 Subpart NNN

Reporting Period: January 1, 2006 through June 30, 2006 

Owens Corning – Kansas City Plant 

300 Sunshine Road 

Kansas City, KS 66115 

HAP’s Monitored: The Wool Fiberglass MACT focuses on two surrogate pollutants for control 

of HAP’s from the Fiberglass manufacturing process. Particulate matter is limited to 0.5 lb PM 

per ton of molten glass produced from the glass melting process and formaldehyde is limited to 

1.2 lb per ton of molten glass produced during fiber forming and curing. 

Process Units: In general the fiberglass manufacturing process is composed of a glass-melting 

furnace that melts batch materials into glass. The molten glass is passed through a rotary spin 

(RS) forming process where a fine, glass fiber is produced. Binder is applied to the fiber as it 

forms a “pack” on the surface of a foraminous conveyor. Once collected, the pack passes 

through a curing and cooling process followed by final fabrication and packaging. Tables 1 

through 3 define the manufacturing sources at this facility, including individual processes, 

control devices, and monitored parameters. 

TABLE 1 

 Process Control 

Device 

Monitored Parameter 

K5 

Furnace Glass Melting DEP 

1

st Field – Secondary Voltage 

2

nd Field – Secondary Voltage 

3

rd Field – Secondary Voltage 

Glass Melting Molten Glass Throughput 

 

Line Forming Premix Formulation 

LOI 

Resin Free Formaldehyde 

Molten Glass Throughput 

Curing HPAF – High 

Performance 

Air Filter 

Water Flow 

 
TABLE 2 

 Process Control 

Device 

Monitored Parameter 

70 

Furnace Glass Melting Batch Wetting Water Flow 

Glass Melting Molten Glass Throughput 

 

Line Forming Premix Formulation 

LOI 

Resin Free Formaldehyde 

Molten Glass Throughput 

Curing HPAF – High 

Performance 

Air Filter 

Water Flow 

 

TABLE 3 

 Process Control Device Monitored Parameter 

J5 

Furnace Glass Melting DEP 

1

st Field – Secondary Voltage 

2

nd Field – Secondary Voltage 

3

rd Field – Secondary Voltage 

Glass Melting Molten Glass Throughput 

 

Line Forming 

U3 

 Does not produce a bonded product 

J6-Forming Premix Formulation 

LOI 

Resin Free Formaldehyde 

Molten Glass Throughput 

J6-Curing HPAF – High 

Performance 

Air Filter 

Water Flow 

Emission Data Summary / Operating Hours for Facility

For the period January 1, 2006 through June 30, 2006 the operating hours are: 

K5 Furnace – 4344 hours J5 Furnace – 3648 hours 

K5 Line – 3955 hours J6 Line – 3444 hours 

70 Furnace – 4248 hours 

70 Line – 3948 hours 
Deviations: 

 Hours Deviation % Deviation

J5 Furnace DEP Bypasses 1.02 0.03 

K5 Furnace DEP Bypasses 22.07 0.51 

J5 Furnace DEP Voltage 

• SIR #1 16.00 0.44 

• SIR #2 16.00 0.44 

• SIR #3 16.00 0.44 

K5 Furnace DEP Voltage 

• SIR #1 58.08 1.34 

• SIR #2 0.08 0.00 

• SIR #3 0.08 0.00 

70 Furnace Batch Wetting/Crown Feed 14.02 0.33 

70 N HPAF 54.87 1.39 

J6 Charge HPAF 190.28 5.53 

J6 Discharge HPAF 535.89 15.56 

Based on these operating hours, the following monitoring parameters were over the 1% 

exceedance time: 

K5 Furnace DEP SIR #1 Voltage 58.08 hrs 1.34 % 

70 N HPAF 54.87 hrs 1.39 % 

J6 Charge HPAF 190.28 hrs 5.53 % 

J6 Discharge HPAF 535.89 hrs 15.56 % 

Based on these percentages of deviations, the following monitoring parameter was over 5% 

exceedance time, thus warranting a Quality Improvement Plan (QIP) per 63.1382(b)(2)(ii) and 

63.10(e)(3)(viii): 

J6 Charge HPAF 190.28 hrs 5.53 % 

J6 Discharge HPAF 535.89 hrs 15.56 % 

These instances will be described in more detail in the Parameter Exceedance Report that 

follows. 
As the responsible official, I certify that the content of this report is accurate. 

Print Name: Rick Copp 

Signature: 

Title: Plant Leader 
Gaseous and Opacity Excess Emission and Continuous Monitoring System Performance 

40CFR63 Subpart NNN

Reporting Period: January 1, 2006 through June 30, 2006 

Owens Corning – Kansas City Plant 

300 Sunshine Road 

Kansas City, KS 66115 

The following instances are being reported as a deviation of a monitored parameter due to 

malfunction or startup/shutdown: 

K5 Furnace DEP SIR#1 Voltage – See Appendix A for Details 

70 N HPAF – See Appendix B for Details 

J6 Charge HPAF - See Appendix C for Details 

J6 Discharge HPAF See Appendix D for Details 

As the responsible official, I certify that the content of this report is accurate. 

Print Name: Rick Copp 

Signature: 

Title: Plant Leader 
Appendix A 

K5 Furnace DEP SIR#1 Voltage 
Gaseous and Opacity Excess Emission and Continuous Monitoring System Performance

40CFR63 Subpart NNN

Reporting Period: January 1, 2006 through June 30, 2006 

Owens Corning – Kansas City Plant 

300 Sunshine Road 

Kansas City, KS 66115 

K5 Furnace DEP SIR#1 Voltage:

During the reporting period, the K5 Furnace DEP SIR #1 Voltage experienced a total of 58.08 

hours of monitoring parameter excursions. The attached table lists dates, and times for the 

deviations. 
K-5 Furnace DEP SIR #1 Voltage Deviations 

Owens Corning 

Kansas City, KS 

 

Date Beginning Time Ending Time Total Hours 

1-6-06 00:00 00:05 0.08 

4-13-06 20:35 22:35 (4-14-06) 26.00 

6-12-06 7:00 23:00 16.00 

6-13-06 7:00 23:00 16.00 

 

Total Hours 58.08 
Appendix B 

70 N HPAF 
Gaseous and Opacity Excess Emission and Continuous Monitoring System Performance

40CFR63 Subpart NNN

Reporting Period: January 1, 2006 through June 30, 2006 

Owens Corning – Kansas City Plant 

300 Sunshine Road 

Kansas City, KS 66115 

70 N HPAF:

During the reporting period, the 70 N HPAF experienced a total of 54.87 hours of monitoring 

parameter excursions. The attached table lists dates, and times for all deviations. 
70 N HPAF Deviations 

Owens Corning 

Kansas City, KS 

 

Date 

Beginning 

Time Ending Time

Line Down 

(hrs) Total Hours 

3-3-06 15:00 20:38 0 5.63 

3-4-06 7:00 14:38 (3-6-06) 6.40 49.23 

 

Total Hours 54.86 
Appendix C 

J6 Charge HPAF 
Gaseous and Opacity Excess Emission and Continuous Monitoring System Performance

40CFR63 Subpart NNN

Reporting Period: January 1, 2006through June 30, 2006 

Owens Corning – Kansas City Plant 

300 Sunshine Road 

Kansas City, KS 66115 

J6 Charge HPAF:

During the reporting period, the J6 Charge HPAF experienced a total of 190.28 hours of 

monitoring parameter excursions. The attached table lists dates, and times for all deviations. 

Approximately one half of this time was attributed to a five day period during February when the 

lines were starting to plug. Maintenance was scheduled to run new pipe during J5 downtime. 
J6 Charge HPAF Deviations 

Owens Corning 

Kansas City, KS 

 

Date 

Beginning 

Time Ending Time

Line Down 

(hrs) Total Hours 

1-20-06 15:00 7:00 (1-21-06) 3.48 12.52 

1-23-06 7:00 9:00 0 2.00 

1-25-06 7:00 8:00 0 1.00 

1-29-06 7:00 3:00 0.65 7.35 

1-29-06 23:00 15:00 (1-31-06) 1.82 38.18 

2-8-06 15:00 1:51 (2-13-06) 0 106.85 

3-16-06 15:00 6:48 (3-17-06) 0 15.8 

3-26-06 7:00 18:00 4.42 6.58 

 

Total Hours 190.28 
Appendix D 

J6 Discharge HPAF 
Gaseous and Opacity Excess Emission and Continuous Monitoring System Performance

40CFR63 Subpart NNN

Reporting Period: January 1, 2006 through June 30, 2006 

Owens Corning – Kansas City Plant 

300 Sunshine Road 

Kansas City, KS 66115 

J6 Discharge HPAF:

During the reporting period, the J6 Discharge HPAF experienced a total of 535.89 hours of 

monitoring parameter excursions. The attached table lists dates, and times for all deviations. 

Approximately one hundred hours of this time was attributed to a five day period during January, 

and one hundred hours during February when the lines were starting to plug. Maintenance was 

scheduled to run new pipe during J5 downtime. 
J6 Discharge HPAF Deviations 

Owens Corning 

Kansas City, KS 

 

Date 

Beginning 

Time Ending Time

Line Down 

(hrs) Total Hours 

1-11-06 15:00 23:00 0.95 7.05 

1-12-06 7:00 17:00 (1-13-06) 3.63 30.37 

1-16-06 23:00 23:00 (1-19-06) 2.83 69.17 

1-20-06 7:00 15:00 2.02 5.98 

1-21-06 7:00 15:00 (1-26-06) 4.03 123.97 

1-27-06 7:00 23:00 0.68 15.32 

1-28-06 15:00 23:00 0.40 7.60 

1-29-06 7:00 23:00 1.12 14.88 

1-30-06 7:00 7:00 (1-31-06) 1.82 22.18 

2-8-06 15:00 7:00 (2-13-06) 1.45 110.55 

2-13-06 15:00 7:00 (2-15-06) 0 40.00 

2-15-06 23:00 21:49 (2-16-06) 0 22.82 

3-16-06 15:00 12:48 (3-17-06) 1.93 19.87 

3-23-06 7:00 15:00 (3-24-06) 4.47 27.53 

3-25-06 15:00 15:00 (3-26-06) 5.40 18.60 

 

Total Hours 535.89 
OWENS CORNING KANSAS CITY PLANT 

300 SUNSHINE ROAD 

KANSAS CITY, KANSAS 66115

 

January 23, 2007 

Wyandotte County Health Department

Department of Air Quality

619 Ann Avenue

Kansas City, Kansas 66101

Attn: Bruce Andersen 

RE: MACT Semi-Annual Reporting for 

Period July 1, 2006 through December 31, 2006 

Dear Mr. Andersen: 

This report includes three separate reports as required by 40 CFR 63 Subparts A and NNN. The 

first report summarizes periods of startup, shutdown, and malfunction where actions taken were 

inconsistent with the plan in accordance with MACT requirements, 40 CFR 63.10(d)(5) and 40 

CFR 63.1386(c). The second report is the “Summary Report – Gaseous and Opacity Excess 

Emission and Continuous Monitoring System Performance” as required in 40 CFR 63.10(e)(3) 

and 40 CFR 63.1386(e). The third report is the “Gaseous and Opacity Excess Emission and 

Continuous Monitoring System Performance Report” as required in 40 CFR 63.10(e)(3) and 40 

CFR 63.1386(e) if monitored parameters deviate more than 1% of the total operating time. Each 

report is labeled appropriately and is for the period July 1, 2006 through December 31, 2006. 

As the responsible official, I certify to the accuracy of this report. If you have any questions 

regarding this information, please contact our Facility Environmental Leader, Bob Jeffries 913-

281-9424. 

Sincerely, 

John Becker 

Plant Leader 

Owens Corning – Kansas City Plant 

Kansas City, KS 

Attachment 
Report: Periods of Startup, Shutdown, and Malfunction Where Actions Taken were 

Inconsistent with SSM Plan

40CFR63 Subpart NNN

Reporting Period: July 1, 2006 through December 31, 2006 

Owens Corning – Kansas City Plant 

300 Sunshine Road 

Kansas City, KS 66115 

Although there were startups, shutdowns and malfunctions during this reporting period, all 

actions taken were consistent with the SSM Plan. 

 

Report: Periods of Deviationfrom the Operations, Maintenance and Monitoring (OMM) 

Plan.

40CFR63 Subpart NNN

There are no instances being reported as a deviation of procedures outlined in the facility OMM 

Plan. 

As the responsible official, I certify that the content of this report is accurate. 

Print Name: John Becker 

Signature: 

Title: Plant Leader 
Summary Report – Gaseous and Opacity Excess Emission and Continuous Monitoring 

System Performance

40CFR63 Subpart NNN

Reporting Period: July 1, 2006 through December 31, 2006 

Owens Corning – Kansas City Plant 

300 Sunshine Road 

Kansas City, KS 66115 

HAP’s Monitored: The Wool Fiberglass MACT focuses on two surrogate pollutants for control 

of HAP’s from the Fiberglass manufacturing process. Particulate matter is limited to 0.5 lb PM 

per ton of molten glass produced from the glass melting process and formaldehyde is limited to 

1.2 lb per ton of molten glass produced during fiber forming and curing. 

Process Units: In general the fiberglass manufacturing process is composed of a glass-melting 

furnace that melts batch materials into glass. The molten glass is passed through a rotary spin 

(RS) forming process where a fine, glass fiber is produced. Binder is applied to the fiber as it 

forms a “pack” on the surface of a foraminous conveyor. Once collected, the pack passes 

through a curing and cooling process followed by final fabrication and packaging. Tables 1 

through 3 define the manufacturing sources at this facility, including individual processes, 

control devices, and monitored parameters. 

<TABLE 1> 

 Process Control 

Device 

Monitored Parameter 

K5 

Furnace Glass Melting DEP 

1

st Field – Secondary Voltage 

2

nd Field – Secondary Voltage 

3

rd Field – Secondary Voltage 

Glass Melting Molten Glass Throughput 

 

Line Forming Premix Formulation 

LOI 

Resin Free Formaldehyde 

Molten Glass Throughput 

Curing HPAF – High 

Performance 

Air Filter 

Water Flow 

 
<TABLE 2> 

 Process Control 

Device 

Monitored Parameter 

70 

Furnace Glass Melting Batch Wetting Water Flow 

Glass Melting Molten Glass Throughput 

 

Line Forming Premix Formulation 

LOI 

Resin Free Formaldehyde 

Molten Glass Throughput 

Curing HPAF – High 

Performance 

Air Filter 

Water Flow 

 

<TABLE 3> 

 Process Control Device Monitored Parameter 

J5 

Furnace Glass Melting DEP 

1

st Field – Secondary Voltage 

2

nd Field – Secondary Voltage 

3

rd Field – Secondary Voltage 

Glass Melting Molten Glass Throughput 

 

Line Forming 

U3 

 Does not produce a bonded product 

J6-Forming Premix Formulation 

LOI 

Resin Free Formaldehyde 

Molten Glass Throughput 

J6-Curing HPAF – High 

Performance 

Air Filter 

Water Flow 

Emission Data Summary / Operating Hours for Facility

For the period July 1, 2006 through December 31, 2006 the operating hours are: 

K5 Furnace – 4416 hours J5 Furnace – 4416 hours 

K5 Line – 4075 hours J6 Line – 3990 hours 

70 Furnace – 3864 hours 

70 Line – 3581 hours 
Deviations: 

 Hours Deviation % Deviation

J5 Furnace DEP Bypasses 84.20 1.91 

K5 Furnace DEP Bypasses 101.2 2.29 

K5 Furnace DEP Voltage 

• SIR #1 88.6 2.01 

• SIR #2 24.46 0.55 

• SIR #3 47.43 1.07 

J5 Furnace DEP Voltage 

• SIR #1 349.88 7.92 

• SIR #2 23.73 0.54 

• SIR #3 25.73 0.58 

70 Furnace Batch Wetting/Crown Feed 104.65 2.71 

70 N HPAF 15.00 0.42 

70 S HPAF 28.57 0.80 

J6 Charge HPAF 66.35 1.66 

J6 Discharge HPAF 64.72 1.62 

Based on these operating hours, the following monitoring parameters were over the 1% 

exceedance time: 

J5 Furnace DEP Bypasses 84.20 hrs 1.91 % 

K5 Furnace DEP Bypasses 101.20 hrs 2.29 % 

K5 Furnace DEP Voltage SIR #1 88.60 hrs 2.01 % 

K5 Furnace DEP Voltage SIR #3 47.43 hrs 1.07 % 

J5 Furnace DEP Voltage SIR #1 349.88 hrs 7.92 % 

70 Furnace Batch Wetting/Crown Feed 104.65 hrs 2.71 % 

J6 Charge HPAF 66.35 hrs 1.66 % 

J6 Discharge HPAF 64.72 hrs 1.62 % 

Based on these percentages of deviations, the following monitoring parameters were over the 5% 

exceedance time, thus warranting a Quality Improvement Plan (QIP) per 63.1382(b)(2)(ii) and 

63.10(e)(3)(viii): 

J5 Furnace DEP Voltage SIR #1 349.88 hrs 7.92 % 
These instances will be described in more detail in the Parameter Exceedance Report that 

follows. 

As the responsible official, I certify that the content of this report is accurate. 

Print Name: John Becker 

Signature: 

Title: Plant Leader 
Gaseous and Opacity Excess Emission and Continuous Monitoring System Performance 

40CFR63 Subpart NNN

Reporting Period: July 1, 2006 through December 31, 2006 

Owens Corning – Kansas City Plant 

300 Sunshine Road 

Kansas City, KS 66115 

The following instances are being reported as a deviation of a monitored parameter due to 

malfunction or startup/shutdown: 

J5 Furnace DEP Bypasses – See Appendix A for Details 

K5 Furnace DEP Bypasses – See Appendix B for Details 

K5 Furnace DEP Voltage SIR #1 – See Appendix C for Details 

K5 Furnace DEP Voltage SIR #3 – See Appendix D for Details 

J5 Furnace DEP Voltage SIR #1 – See Appendix E for Details 

70 Furnace Batch Wetting/Crown Feed – See Appendix F for Details 

J6 Charge HPAF – See Appendix G for Details 

J6 Discharge HPAF – See Appendix H for Details 

As the responsible official, I certify that the content of this report is accurate. 

Print Name: John Becker 

Signature: 

Title: Plant Leader 
Appendix A 

J5 Furnace DEP Bypasses 
Gaseous and Opacity Excess Emission and Continuous Monitoring System Performance

40CFR63 Subpart NNN

Reporting Period: July 1, 2006 through December 31, 2006 

Owens Corning – Kansas City Plant 

300 Sunshine Road 

Kansas City, KS 66115 

J5 Furnace DEP Bypasses:

During the reporting period, the J5 Furnace DEP Bypasses experienced a total of 84.20 hours of 

monitoring parameter excursions. The attached table lists dates, and times for all deviations. 

21.25 hours of this was due to the semi-annual inspection and 48 hours were for repairs to the 

rapper and high voltage/low amp problem. Continue to work with the engineers and equipment 

manufacture to reduce repair and malfunction time. 
J5 Furnace DEP Bypasses 

Owens Corning 

Kansas City, KS 

 

Date 

Beginning 

Time Ending Time Total Hours* 

7/25/2006 8:34 8:37 0.05 

8/30/2006 11:49 12:02 0.22 

9/3/2006 8:30 8:45 0.25 

9/12/2006 8:05 8:12 0.12 

9/12/2006 8:22 8:27 0.08 

9/12/2006 13:34 13:38 0.07 

10/6/2006 11:45 11:48 0.05 

10/10/2006 9:12 9:20 0.13 

10/10/2006 10:40 10:42 0.03 

10/24/2006 2:45 24:00 21.25 

10/25/2006 0:00 11:30 11.5 

11/6/2006 13:25 13:28 0.05 

11/13/2006 8:11 11/13/2006 @ 9:08 48.95 

12/13/2006 5:00 5:29 0.48 

12/13/2006 12:50 13:48 0.97 

Total Hours 84.20
Appendix B 

K5 Furnace DEP Bypasses 
Gaseous and Opacity Excess Emission and Continuous Monitoring System Performance

40CFR63 Subpart NNN

Reporting Period: July 1, 2006 through December 31, 2006 

Owens Corning – Kansas City Plant 

300 Sunshine Road 

Kansas City, KS 66115 

K5 Furnace DEP Bypasses:

During the reporting period, the K5 Furnace DEP Bypasses experienced a total of 101.20 hours 

of monitoring parameter excursions. The attached table lists dates, and times for all deviations. 

40 hours downtime required to repair secondary current, 21.8 hours for the semi-annual 

inspection and 13.67 hours to repair the ABB frame. Continue to work with the engineer and the 

equipment manufacture to reduce overall downtime. 
K5 Furnace DEP Bypasses 

Owens Corning 

Kansas City, KS 

 

Date 

Beginning 

Time Ending Time Total Hours*

7/6/2006-7/8/2006 0:00 24:00 40.00 

8/30/2006 11:49 12:02 0.22 

9/3/2006 8:30 8:45 0.25 

9/12/2006 8:05 8:12 0.12 

9/12/2006 8:22 8:27 0.08 

9/12/2006 13:34 13:38 0.07 

10/23/2006 2:49 24:00 21.18 

10/24/2006 0:00 24:00 24.00 

10/25/2006 0:00 0:35 0.58 

11/22/2006 10:43 10:59 0.27 

12/1/2006 21:25 21:55 0.50 

12/1/2006 22:06 22:22 0.27 

12/13/2006 3:05 16:45 13.67 

Total Hours 101.20
Appendix C 

K5 Furnace DEP Voltage SIR#1 
Gaseous and Opacity Excess Emission and Continuous Monitoring System Performance

40CFR63 Subpart NNN

Reporting Period: July 1, 2006 through December 31, 2006 

Owens Corning – Kansas City Plant 

300 Sunshine Road 

Kansas City, KS 66115 

K5 Furnace DEP Voltage SIR #1:

During the reporting period, the K5 Furnace DEP Voltage SIR #1 experienced a total of 88.60 

hours of monitoring parameter excursions. The attached table lists dates, and times for all 

deviations. 63.51 hours were for repairs to correct low volts and high SR along with the ABB to 

repair the frame shift. Continue to work with engineers and equipment manufacture to reduce 

malfunctions and repair time. 
K5 Furnace DEP Voltage SIR #1 Deviations 

Owens Corning 

Kansas City, KS 

 

Date 

Beginning 

Time Ending Time Total Hours 

7/1/2006 0:00 0:21 0.35 

7/7/2006-7/8/2006 0:03 17:03 9.00 

8/1/2006 0:00 0:05 0.08 

10/24/2006 0:00 23:00 7.00 

11/28/2006-11/29/2006 2:08 9:08 29.86 

12/1/2006 7:21 12:21 0.65 

12/4/2006-12/5/2006 11:21 14:00 16.65 

12/11/2006-12/12/2006 7:00 1:00 17.00 

12/13/2006 0:00 15:00 8.00 

Total Hours 88.60

*Bypass time has been deducted from Total Hours of deviation. 
Appendix D 

K5 Furnace DEP Voltage SIR #3 
Gaseous and Opacity Excess Emission and Continuous Monitoring System Performance

40CFR63 Subpart NNN

Reporting Period: July 1, 2006 through December 31, 2006 

Owens Corning – Kansas City Plant 

300 Sunshine Road 

Kansas City, KS 66115 

K5 Furnace DEP Voltage SIR #3:

During the reporting period, the K5 Furnace DEP Voltage SIR #3 experienced a total of 47.43 

hours of monitoring parameter excursions. The attached table lists dates, and times for the 

deviations. 38 hours due to a cooling fan failure and shutdown to repair. Continue to work with 

the engineers and equipment manufacture to reduce malfunctions and repair time. 
K5 Furnace DEP Voltage SIR #3 Deviations 

Owens Corning 

Kansas City, KS 

 

Date Beginning Time Ending Time Total Hours

7/1/2006 0:00 0:21 0.35 

7/7/2006-7/8/2006 0:03 17:03 9.00 

8/1/2006 0:00 0:05 0.08 

10/24/2006 0:00 23:00 7.00 

11/8/2006-11/10/2006 22:08 09:08 24.00 

12/13/2006 1:00 15:00 7.00 

Total Hours 47.43

*Bypass time has been deducted from Total Hours of deviation. 
Appendix E 

J5 Furnace DEP Voltage SIR #1 
Gaseous and Opacity Excess Emission and Continuous Monitoring System Performance

40CFR63 Subpart NNN

Reporting Period: July 1, 2006 through December 31, 2006 

Owens Corning – Kansas City Plant 

300 Sunshine Road 

Kansas City, KS 66115 

J5 Furnace DEP Voltage SIR #1:

During the reporting period, the J5 Furnace DEP Voltage SIR #1 experienced a total of 349.88 

hours of monitoring parameter excursions. The attached table lists dates, and times for all 

deviations. 228 hours was due to a malfunction requiring the controller board to be replaced. 

The equipment manufacture field service was notified to trouble shoot. The control board was 

ordered and shipped. Continue to work with the engineers and equipment manufacture to reduce 

malfunctions and repair time. 
J5 Furnace DEP Voltage SIR #1 Deviations 

Owens Corning 

Kansas City, KS 

 

Date 

Beginning 

Time Ending Time Total Hours

7/18/2006 0:03 4:03 4.00 

10/21/2006-10/22/2006 22:01 13:01 6.00 

10/23/2006 0:01 14:00 0.15 

11/13/2006-11/14/2006 6:08 3:08 13.00 

11/15/2006 2:08 12:08 5.86 

11/16/2006-11/26/2006 13:08 1:08 228.00 

11/26/2006 2:08 4:08 2.00 

11/26/2006 5:08 18:08 13.00 

11/26/2006-11/27/2006 22:08 2:08 1.87 

11/27/2006-11/28/2006 16:08 12:08 20.00 

11/28/2006-11/29/2006 15:08 8:08 17.00 

12/5/2006-12/7/2006 18:00 17:00 39.00 

Total Hours 349.88

*Bypass time has been deducted from Total Hours of deviation. 
Appendix F 

70 Furnace Batch Wetting/Crown Feed 
Gaseous and Opacity Excess Emission and Continuous Monitoring System Performance

40CFR63 Subpart NNN

Reporting Period: July 1, 2006 through December 31, 2006 

Owens Corning – Kansas City Plant 

300 Sunshine Road 

Kansas City, KS 66115 

70 Batch Wetting/Crown Feed:

During the reporting period, the 70 Batch Wetting/Crown Feed experienced a total of 104.65 

hours of monitoring parameter excursions. The attached table lists dates, and times for all 

deviations. 50 hours of this time was due to a crust control issues which required the batch 

wetting to be suspended to allow for resolution of the issue. Investigation to the actual cause 

was not conclusive. 
70 Furnace Crown Feed Deviations 

Owens Corning 

Kansas City, KS 

 

Date 

Beginning 

Time Ending Time Total Hours* 

7/24/2006 8:13 8:55 0.70 

8/1/2006 9:12 9:40 0.46 

8/10/2006 15:05 16:30 1.42 

8/15/2006 8:15 10:20 2.08 

8/17/2006 10:40 11:50 1.17 

9/11/2006 8:30 13:50 5.33 

9/22/2006 13:27 14:01 0.57 

9/26/2006 10:15 11:10 0.92 

10/3/2006 8:15 8:45 0.50 

10/9/2006 9:10 10:40 1.50 

10/10/2006 9:00 9:30 0.50 

12/1/2006 8:05 11:32 3.45 

Total Hours 18.65

70 Furnace Batch Wetting Deviations 

Owens Corning 

Kansas City, KS 

 

Date 

Beginning 

Time Ending Time Total Hours* 

7/23/2006 7:00 8:00 1.00 

8/15/2006 2:47 7:47 5.00 

9/4/2006 11:00 9/6/06 13:27 50.44 

10/4/2006 9:52 14:33 4.64 

10/16/2006 4:52 7:52 3.00 

12/1/2006 0:00 12/2/06 5:55 21.92 

Total Hours 86.00
Appendix G 

J6 Charge HPAF 
Gaseous and Opacity Excess Emission and Continuous Monitoring System Performance

40CFR63 Subpart NNN

Reporting Period: July 1, 2006 through December 31, 2006 

Owens Corning – Kansas City Plant 

300 Sunshine Road 

Kansas City, KS 66115 

J6 Charge HPAF:

During the reporting period, the J6 Charge HPAF experienced a total of 66.35 hours of 

monitoring parameter excursions. The attached table lists dates, and times for all deviations. 
J6 Charge HPAF Deviations 

Owens Corning 

Kansas City, KS 

 

Date 

Beginning 

Time Ending Time Total Hours

9/7/2006-9/8/2006 23:00 5:00 6.00 

9/26/2006-9/27/2006 23:00 7:00 8.00 

9/28/2006-9/29/2006 23:00 23:00 24.00 

10/5/2006 7:00 11:00 16.00 

10/9/2006-10/10/2006 23:00 7:00 8.00 

11/22/2006 15:00 19:21 4.35 

Total Hours 66.35
Appendix H 

J6 Discharge HPAF 
Gaseous and Opacity Excess Emission and Continuous Monitoring System Performance

40CFR63 Subpart NNN

Reporting Period: July 1, 2006 through December 31, 2006 

Owens Corning – Kansas City Plant 

300 Sunshine Road 

Kansas City, KS 66115 

J6 Discharge HPAF:

During the reporting period, the J6 Discharge HPAF experienced a total of 64.72 hours of 

monitoring parameter excursions. The attached table lists dates, and times for all deviations. 
J6 Discharge HPAF Deviations 

Owens Corning 

Kansas City, KS 

 

Date 

Beginning 

Time Ending Time Total Hours

7/17/2006-7/20/2006 10:00 0:00 26.90 

8/22/2006-8/23/2006 21:47 15:47 7.50 

8/25/2006-8/26/2006 22:47 0:47 0.15 

9/21/2006 6:06 23:58 16.16 

10/13/2006-10/14/2006 17:52 7:52 14.00 

Total Hours 64.72
OWENS CORNING Insulating Systems, LLC KANSAS CITY PLANT 

300 SUNSHINE ROAD 

KANSAS CITY, KANSAS 66115

 

July 23, 2007 

Wyandotte County Health Department

Department of Air Quality

619 Ann Avenue

Kansas City, Kansas 66101

Attn: Bruce Andersen 

RE: MACT Semi-Annual Reporting for 

Period January 1, 2007 through June 30, 2007 

Dear Mr. Andersen: 

This report includes three separate reports as required by 40 CFR 63 Subparts A and NNN. The 

first report summarizes periods of startup, shutdown, and malfunction where actions taken were 

inconsistent with the plan in accordance with MACT requirements, 40 CFR 63.10(d)(5) and 40 

CFR 63.1386(c). The second report is the “Summary Report – Gaseous and Opacity Excess 

Emission and Continuous Monitoring System Performance” as required in 40 CFR 63.10(e)(3) 

and 40 CFR 63.1386(e). The third report is the “Gaseous and Opacity Excess Emission and 

Continuous Monitoring System Performance Report” as required in 40 CFR 63.10(e)(3) and 40 

CFR 63.1386(e) if monitored parameters deviate more than 1% of the total operating time. Each 

report is labeled appropriately and is for the period January 1, 2007 through June 30, 2007. 

As the responsible official, I certify to the accuracy of this report. If you have any questions 

regarding this information, please contact our Facility Environmental Leader, Bob Muto at 913-

281-9598. 

Sincerely, 

John Becker 

Plant Leader 

Owens Corning Insulating Systems, LLC – Kansas City Plant 

Kansas City, KS 

Attachment 
Report: Periods of Startup, Shutdown, and Malfunction Where Actions Taken were 

Inconsistent with SSM Plan

40CFR63 Subpart NNN

Reporting Period: January 1, 2007 through June 30, 2007 

Owens Corning – Kansas City Plant 

300 Sunshine Road 

Kansas City, KS 66115 

Although there were startups, shutdowns and malfunctions during this reporting period, all 

actions taken were consistent with the SSM Plan. 

 

Report: Periods of Deviationfrom the Operations, Maintenance and Monitoring (OMM) 

Plan.

40CFR63 Subpart NNN

There are no instances being reported as a deviation of procedures outlined in the facility OMM 

Plan. 

As the responsible official, I certify that the content of this report is accurate. 

Print Name: John Becker 

Signature: 

Title: Plant Leader 
Summary Report – Gaseous and Opacity Excess Emission and Continuous Monitoring 

System Performance

40CFR63 Subpart NNN

Reporting Period: January 1, 2007 through June 30, 2007 

Owens Corning – Kansas City Plant 

300 Sunshine Road 

Kansas City, KS 66115 

HAP’s Monitored: The Wool Fiberglass MACT focuses on two surrogate pollutants for control 

of HAP’s from the Fiberglass manufacturing process. Particulate matter is limited to 0.5 lb PM 

per ton of molten glass produced from the glass melting process and formaldehyde is limited to 

1.2 lb per ton of molten glass produced during fiber forming and curing. 

Process Units: In general the fiberglass manufacturing process is composed of a glass-melting 

furnace that melts batch materials into glass. The molten glass is passed through a rotary spin 

(RS) forming process where a fine, glass fiber is produced. Binder is applied to the fiber as it 

forms a “pack” on the surface of a foraminous conveyor. Once collected, the pack passes 

through a curing and cooling process followed by final fabrication and packaging. Tables 1 

through 3 define the manufacturing sources at this facility, including individual processes, 

control devices, and monitored parameters. 

<TABLE 1> 

 Process Control 

Device 

Monitored Parameter 

K5 

Furnace Glass Melting DEP 

1

st Field – Secondary Voltage 

2

nd Field – Secondary Voltage 

3

rd Field – Secondary Voltage 

Glass Melting Molten Glass Throughput 

 

Line Forming Premix Formulation 

LOI 

Resin Free Formaldehyde 

Molten Glass Throughput 

Curing HPAF – High 

Performance 

Air Filter 

Water Flow 

 
<TABLE 2> 

 Process Control 

Device 

Monitored Parameter 

70 

Furnace Glass Melting Batch Wetting Water Flow 

Glass Melting Molten Glass Throughput 

 

Line Forming Premix Formulation 

LOI 

Resin Free Formaldehyde 

Molten Glass Throughput 

Curing HPAF – High 

Performance 

Air Filter 

Water Flow 

 

<TABLE 3> 

 Process Control Device Monitored Parameter 

J5 

Furnace Glass Melting DEP 

1

st Field – Secondary Voltage 

2

nd Field – Secondary Voltage 

3

rd Field – Secondary Voltage 

Glass Melting Molten Glass Throughput 

 

Line Forming 

U3 

 Does not produce a bonded product 

J6-Forming Premix Formulation 

LOI 

Resin Free Formaldehyde 

Molten Glass Throughput 

J6-Curing HPAF – High 

Performance 

Air Filter 

Water Flow 
Emission Data Summary / Operating Hours for Facility

For the period January 1, 2007 through June 30, 2007 the operating hours are: 

K5 Furnace – 4344 hours J5 Furnace – 1403 hours 

K5 Line – 4023.5 hours J6 Line – 1183.8 hours 

70 Furnace – 1944 hours 

70 Line – 1745.5 hours 

Deviations: 

 Hours Deviation % Deviation

J5 Furnace DEP Bypasses 0.22 0.02 

K5 Furnace DEP Bypasses 34.63 0.80 

70 Furnace Batch Wetting/Crown Feed 51.67 2.66 

70 N HPAF 22.00 1.26 

J6 Charge HPAF 13.40 1.13 

J6 Discharge HPAF 3.00 0.25 

Based on these operating hours, the following monitoring parameters were over the 1% 

exceedance time: 

70 Furnace Batch Wetting/Crown Feed 51.67 2.66 

70 N HPAF 22.00 1.26 

J6 Charge HPAF 13.40 1.13 

Based on these percentages of deviations, the following monitoring parameters were over the 5% 

exceedance time, thus warranting a Quality Improvement Plan (QIP) per 63.1382(b)(2)(ii) and 

63.10(e)(3)(viii): 

There were no deviations above 5%. 
These instances will be described in more detail in the Parameter Exceedance Report that 

follows. 

As the responsible official, I certify that the content of this report is accurate. 

Print Name: John Becker 

Signature: 

Title: Plant Leader 
Gaseous and Opacity Excess Emission and Continuous Monitoring System Performance 

40CFR63 Subpart NNN

Reporting Period: January 1, 2007 through June 30, 2007 

Owens Corning – Kansas City Plant 

300 Sunshine Road 

Kansas City, KS 66115 

The following instances are being reported as a deviation of a monitored parameter due to 

malfunction or startup/shutdown: 

70 Furnace Batch Wetting/Crown Feed – See Appendix A for Details 

70 North HPAF – see Appendix B for Details 

J6 Charge HPAF – See Appendix C for Details 

As the responsible official, I certify that the content of this report is accurate. 

Print Name: John Becker 

Signature: 

Title: Plant Leader 
Appendix A 

70 Furnace Batch Wetting/Crown Feed 
Gaseous and Opacity Excess Emission and Continuous Monitoring System Performance

40CFR63 Subpart NNN

Reporting Period: January 1, 2007 through June 30, 2007 

Owens Corning Insulating Systems, LLC– Kansas City Plant 

300 Sunshine Road 

Kansas City, KS 66115 

70 Batch Wetting/Crown Feed:

During the reporting period, the 70 Batch Wetting/Crown Feed experienced a total of 51.67 

hours of monitoring parameter excursions. The attached table lists dates and times for all 

deviations. 
70 Furnace Crown Feed Deviations 

Owens Corning 

Kansas City, KS 

 

Date 

Beginning 

Time Ending Time Total Hours

2/27/07 10:25 11:56 1.52 

3/3/07 thru 3/4/07 9:30 2:20 4.83 

3/4/07 2:55 8:17 5.37 

3/4/07 14:03 20:05 6.03 

3/22/07 0:57 2:10 1.22 

Total Hours 18.97

70 Furnace Batch Wetting Deviations 

Owens Corning 

Kansas City, KS 

 

Date 

Beginning 

Time Ending Time Total Hours*

2/27/07 thru 2/28/07 12:50 11:48 22.97 

3/7/07 13:35 14:13 0.63 

4/13/07 4:44 4:50 0.10 

4/16/07 14:59 23:59 9.00 

Total Hours 32.70
Appendix B 

70 North HPAF 
Gaseous and Opacity Excess Emission and Continuous Monitoring System Performance

40CFR63 Subpart NNN

Reporting Period: January 1, 2007 through June 30, 2007 

Owens Corning Insulating Systems, LLC – Kansas City Plant 

300 Sunshine Road 

Kansas City, KS 66115 

70 North HPAF:

During the reporting period, the 70 North HPAF experienced a total of 22.00 hours of 

monitoring parameter excursions. The attached table lists the date and time for the deviation. 

70 North HPAF Deviations 

Owens Corning 

Kansas City, KS 

 

Date 

Beginning 

Time Ending Time Total Hours

4/7/07 thru 4/8/07 4:59 2:59 22.00 

Total Hours 22.00
Appendix C 

J6 Charge HPAF 
Gaseous and Opacity Excess Emission and Continuous Monitoring System Performance

40CFR63 Subpart NNN

Reporting Period: January 1, 2007 through June 30, 2007 

Owens Corning Insulating Systems, LLC – Kansas City Plant 

300 Sunshine Road 

Kansas City, KS 66115 

J6 Charge HPAF:

During the reporting period, the J6 Charge HPAF experienced a total of 13.40 hours of 

monitoring parameter excursions. The attached table lists dates and times for all deviations. 

J6 Charge HPAF Deviations 

Owens Corning 

Kansas City, KS 

 

Date 

Beginning 

Time Ending Time Total Hours * 

1/21/07 8:59 22:59 6.00 

2/1/07 to 2/2/07 23:59 23:59 7.40 

Total Hours 13.40 

* Deviation hours do not include periods when the line was not operating. 
OWENS CORNING 

INSULATING SYSTEMS, LLC 

Kansas City Facility

300 Sunshine Road 

Kansas City, Kansas 66115 

1.800.GET.PINKTM

www.owenscorning.com

January 24, 2008 

Wyandotte County Health Department

Department of Air Quality

619 Ann Avenue

Kansas City, Kansas 66101

Attn: Bruce Andersen 

RE: MACT Semi-Annual Reporting for 

Period July 1, 2007 through December 31, 2007 

Dear Mr. Andersen: 

This report includes three separate reports as required by 40 CFR 63 Subparts A and NNN. The 

first report summarizes periods of startup, shutdown, and malfunction where actions taken were 

inconsistent with the plan in accordance with MACT requirements, 40 CFR 63.10(d)(5) and 40 

CFR 63.1386(c). The second report is the “Summary Report – Gaseous and Opacity Excess 

Emission and Continuous Monitoring System Performance” as required in 40 CFR 63.10(e)(3) 

and 40 CFR 63.1386(e). The third report is the “Gaseous and Opacity Excess Emission and 

Continuous Monitoring System Performance Report” as required in 40 CFR 63.10(e)(3) and 40 

CFR 63.1386(e) if monitored parameters deviate more than 1% of the total operating time. Each 

report is labeled appropriately and is for the period July 1, 2007 through December 31, 2007. 

As the responsible official, I certify to the accuracy of this report. If you have any questions 

regarding this information, please contact our Facility Environmental Leader, Bob Jeffries 913-

281-9424. 

Sincerely, 

John Becker 

Plant Leader 

Owens Corning Insulating Systems, LLC – Kansas City

Attachment 
Report: Periods of Startup, Shutdown, and Malfunction Where Actions Taken were 

Inconsistent with SSM Plan

40CFR63 Subpart NNN

Reporting Period: July 1, 2007 through December 31, 2007 

Owens Corning Insulating Systems, LLC 

300 Sunshine Road 

Kansas City, KS 66115 

Although there were startups, shutdowns and malfunctions during this reporting period, all 

actions taken were consistent with the SSM Plan. 

 

Report: Periods of Deviationfrom the Operations, Maintenance and Monitoring (OMM) 

Plan.

40CFR63 Subpart NNN

There are no instances being reported as a deviation of procedures outlined in the facility OMM 

Plan. 

As the responsible official, I certify that the content of this report is accurate. 

Print Name: John Becker

Signature: 

Title: Plant Leader
Summary Report – Gaseous and Opacity Excess Emission and Continuous Monitoring 

System Performance

40CFR63 Subpart NNN

Reporting Period: July 1, 2007 through December 31, 2007 

Owens Corning Insulating Systems, LLC 

300 Sunshine Road 

Kansas City, KS 66115 

HAP’s Monitored: The Wool Fiberglass MACT focuses on two surrogate pollutants for control 

of HAP’s from the Fiberglass manufacturing process. Particulate matter is limited to 0.5 lb PM 

per ton of molten glass produced from the glass melting process and formaldehyde is limited to 

1.2 lb per ton of molten glass produced during fiber forming and curing. 

Process Units: In general the fiberglass manufacturing process is composed of a glass-melting 

furnace that melts batch materials into glass. The molten glass is passed through a rotary spin 

(RS) forming process where a fine, glass fiber is produced. Binder is applied to the fiber as it 

forms a “pack” on the surface of a foraminous conveyor. Once collected, the pack passes 

through a curing and cooling process followed by final fabrication and packaging. Tables 1 

through 3 define the manufacturing sources at this facility, including individual processes, 

control devices, and monitored parameters. 

<TABLE 1> 

 Process Control 

Device 

Monitored Parameter 

K5 

Furnace Glass Melting DEP 

1

st Field – Secondary Voltage 

2

nd Field – Secondary Voltage 

3

rd Field – Secondary Voltage 

Glass Melting Molten Glass Throughput 

 

Line Forming Premix Formulation 

LOI 

Resin Free Formaldehyde 

Molten Glass Throughput 

Curing HPAF – High 

Performance 

Air Filter 

Water Flow 

 
<TABLE 2> 

 Process Control 

Device 

Monitored Parameter 

70 

Furnace Glass Melting Batch Wetting Water Flow 

Glass Melting Molten Glass Throughput 

 

Line Forming Premix Formulation 

LOI 

Resin Free Formaldehyde 

Molten Glass Throughput 

Curing HPAF – High 

Performance 

Air Filter 

Water Flow 

 

<TABLE 3> 

 Process Control Device Monitored Parameter 

J5 

Furnace Glass Melting DEP 

1

st Field – Secondary Voltage 

2

nd Field – Secondary Voltage 

3

rd Field – Secondary Voltage 

Glass Melting Molten Glass Throughput 

 

Line Forming 

U3 

 Does not produce a bonded product 

J6-Forming Premix Formulation 

LOI 

Resin Free Formaldehyde 

Molten Glass Throughput 

J6-Curing HPAF – High 

Performance 

Air Filter 

Water Flow 

Emission Data Summary / Operating Hours for Facility

For the period July 1, 2007 through December 31, 2007 the operating hours are: 

K5 Furnace – 4416 hours J5 Furnace – 0 hours 

K5 Line – 4139.6 hours J6 Line – 0 hours 

70 Furnace – 3792 hours 

70 Line – 3297.3 hours 
Deviations: 

 Hours Deviation % Deviation

70 N HPAF 106.0 3.21 

70 S HPAF 8.00 0.24 

70 Furnace Batch Wetting/Crown Feed 73.05 1.93 

K-5 DEP 1st Field Voltage 10.09 0.23 

K-5 DEP 2nd Field Voltage 11.08 0.25 

K-5 DEP 3rd Field Voltage 58.07 1.31 

DEP Bypass 41.75 0.95 

Based on these operating hours, the following monitoring parameters were over the 1% 

exceedance time: 

70 N HPAF 106.00 3.21 

70 Furnace Batch Wetting/Crown Feed 73.05 1.93 

K-5 DEP 3rd Field Voltage 58.07 1.31 

These instances will be described in more detail in the Parameter Exceedance Report that 

follows. 

As the responsible official, I certify that the content of this report is accurate. 

Print Name: John Becker

Signature: 

Title: Plant Leader
Gaseous and Opacity Excess Emission and Continuous Monitoring System Performance 

40CFR63 Subpart NNN

Reporting Period: July 1, 2007 through December 31, 2007 

Owens Corning Insulating Systems, LLC 

300 Sunshine Road 

Kansas City, KS 66115 

The following instances are being reported as a deviation of a monitored parameter due to 

malfunction or startup/shutdown: 

70 N HPAF – See Appendix A for Details 

70 Furnace Batch Wetting/Crown Feed – see Appendix B for Details 

K-5 DEP 3rd Field Voltage – See Appendix C for Details 

As the responsible official, I certify that the content of this report is accurate. 

Print Name: John Becker

Signature: 

Title: Plant Leader
Appendix A 

70 North HPAF 
Gaseous and Opacity Excess Emission and Continuous Monitoring System Performance

40CFR63 Subpart NNN

Reporting Period: July 1, 2007 through December 31, 2007 

Owens Corning Insulating Systems, LLC 

300 Sunshine Road 

Kansas City, KS 66115 

70 North HPAF:

During the reporting period, the 70 North HPAF experienced a total of 106.00 hours of 

monitoring parameter excursions. The attached table lists dates and times for the deviations. 

70 North HPAF Deviations 

Owens Corning 

Kansas City, KS 

 

Date Beginning Time Ending Time Total Hours 

7-31-07 15:00 24:00 9.00 

8-1-07 8:00 8-2-07 15:00 31.00 

8-2-07 23:00 8-5-07 17:00 66.00 

Total Hours 106.00 
Appendix B 

70 Furnace Batch Wetting/Crown Feed 
Gaseous and Opacity Excess Emission and Continuous Monitoring System Performance

40CFR63 Subpart NNN

Reporting Period: July 1, 2007 through December 31, 2007 

Owens Corning Insulating Systems, LLC 

300 Sunshine Road 

Kansas City, KS 66115 

70 Batch Wetting/Crown Feed:

During the reporting period, the 70 Crown Feed experienced a total of 73.05 hours of monitoring 

parameter excursions. There were no batch wetting excursions. The attached table lists the date 

and time for the deviation. 

70 Furnace Crown Feeding 

Owens Corning 

Kansas City, KS 

Date 

Beginning 

Time Ending Time Total Hours 

7/27/07 11:57 22:15 10.30 

7/28/07 9:00 13:30 4.50 

7/29/07 11:15 11:50 0.58 

8/1/07 13:00 14:20 1.33 

8/1/07 17:30 18:10 0.67 

8/12/07 15:30 16:10 0.67 

8/16/07 12:50 13:00 0.17 

8/25/07 12:30 14:30 2.00 

9/25/07 8:55 12:45 3.83 

9/26/07 8:55 10:40 1.75 

9/26/07 14:45 15:00 0.25 

10/10/07 10:07 10:40 0.55 

10/15/07 10:00 11:30 1.50 

10/17/07 12:20 13:15 0.92 

10/19/07 6:45 10/20/07 10:05 27.33 

10/26/07 8:35 9:15 0.67 

10/30/07 18:35 19:10 0.58 

11/4/07 13:10 11/5/07 0:55 11.75 

12/10/07 15:48 18:00 2.20 

12/27/07 8:45 10:15 1.50 

Total Hours 73.05 
Appendix C 

K-5 DEP 3rd Field Voltage 
Gaseous and Opacity Excess Emission and Continuous Monitoring System Performance

40CFR63 Subpart NNN

Reporting Period: July 1, 2007 through December 31, 2007 

Owens Corning Insulating Systems, LLC 

300 Sunshine Road 

Kansas City, KS 66115 

K-5 DEP 3rd Field Voltage:

During the reporting period, the K-5 DEP 3rd Field Voltage experienced a total of 58.07 hours of 

monitoring parameter excursions. The attached table lists dates and times for all deviations. 

K-5 DEP 3rd Field Voltage Deviations 

Owens Corning 

Kansas City, KS 

 

Date Beginning Time Ending Time Total Hours 

8/28/07 8:00 16:00 8.00 

8/31/07 17:00 23:59 6.98 

9/1/07 0:00 9/2/07 9:00 33.00 

9/11/07 2:25 3:05 0.66 

9/21/07 8:00 4:00 8.00 

11/7/07 1:30 2:55 1.41 

Total Hours 58.07 
OWENS CORNING 

NSULATING SYSTEMS, LLC

Kansas City Facility 

300 SUNSHINE ROAD 

KANSAS CITY, KANSAS 66115

July 23, 2008 

Wyandotte County Health Department

Department of Air Quality

619 Ann Avenue

Kansas City, Kansas 66101

Attn: Bruce Andersen 

RE: MACT Semi-Annual Reporting for 

Period January 1, 2008 through June 30, 2008 

Owens Corning Insulating Systems, LLC - Kansas City Facility 

Dear Mr. Andersen: 

This report includes three separate reports as required by 40 CFR 63 Subparts A and NNN. The 

first report summarizes periods of startup, shutdown, and malfunction where actions taken were 

inconsistent with the plan in accordance with MACT requirements, 40 CFR 63.10(d)(5) and 40 

CFR 63.1386(c). The second report is the “Summary Report – Gaseous and Opacity Excess 

Emission and Continuous Monitoring System Performance” as required in 40 CFR 63.10(e)(3) 

and 40 CFR 63.1386(e). The third report is the “Gaseous and Opacity Excess Emission and 

Continuous Monitoring System Performance Report” as required in 40 CFR 63.10(e)(3) and 40 

CFR 63.1386(e) if monitored parameters deviate more than 1% of the total operating time. Each 

report is labeled appropriately and is for the period January 1, 2008 through June 30, 2008. 

As the responsible official, I certify to the accuracy of this report. If you have any questions 

regarding this information, please contact our Facility Environmental Leader, Bob Jeffries 913-

281-9424. 

Sincerely, 

John Becker 

Plant Leader 

Owens Corning Insulating Systems, LLC - Kansas City

Kansas City, KS 
Attachment 
Report: Periods of Startup, Shutdown, and Malfunction Where Actions Taken were 

Inconsistent with SSM Plan

40CFR63 Subpart NNN

Reporting Period: January 1, 2008 through June 30, 2008 

Owens Corning Insulating Systems, LLC - Kansas City Facility 

300 Sunshine Road 

Kansas City, KS 66115 

Although there were startups, shutdowns and malfunctions during this reporting period, all 

actions taken were consistent with the SSM Plan. 

 

Report: Periods of Deviationfrom the Operations, Maintenance and Monitoring (OMM) 

Plan.

40CFR63 Subpart NNN

There are no instances being reported as a deviation of procedures outlined in the facility OMM 

Plan. 

As the responsible official, I certify that the content of this report is accurate. 

Print Name: John Becker 

Signature: 

Title: Plant Leader 
Summary Report – Gaseous and Opacity Excess Emission and Continuous Monitoring 

System Performance

40CFR63 Subpart NNN

Reporting Period: January 1, 2008 through June 30, 2008 

Owens Corning Insulating Systems, LLC - Kansas City Facility 

300 Sunshine Road 

Kansas City, KS 66115 

HAP’s Monitored: The Wool Fiberglass MACT focuses on two surrogate pollutants for control 

of HAP’s from the Fiberglass manufacturing process. Particulate matter is limited to 0.5 lb PM 

per ton of molten glass produced from the glass melting process and formaldehyde is limited to 

1.2 lb per ton of molten glass produced during fiber forming and curing. 

Process Units: In general the fiberglass manufacturing process is composed of a glass-melting 

furnace that melts batch materials into glass. The molten glass is passed through a rotary spin 

(RS) forming process where a fine, glass fiber is produced. Binder is applied to the fiber as it 

forms a “pack” on the surface of a foraminous conveyor. Once collected, the pack passes 

through a curing and cooling process followed by final fabrication and packaging. Tables 1 

through 3 define the manufacturing sources at this facility, including individual processes, 

control devices, and monitored parameters. 

<TABLE 1> 

 Process Control 

Device 

Monitored Parameter 

K5 

Furnace Glass Melting DEP 

1

st Field – Secondary Voltage 

2

nd Field – Secondary Voltage 

3

rd Field – Secondary Voltage 

Glass Melting Molten Glass Throughput 

 

Line Forming Premix Formulation 

LOI 

Resin Free Formaldehyde 

Molten Glass Throughput 

Curing HPAF – High 

Performance 

Air Filter 

Water Flow 

 
<TABLE 2> 

 Process Control 

Device 

Monitored Parameter 

70 

Furnace Glass Melting Batch Wetting Water Flow 

Glass Melting Molten Glass Throughput 

 

Line Forming Premix Formulation 

LOI 

Resin Free Formaldehyde 

Molten Glass Throughput 

Curing HPAF – High 

Performance 

Air Filter 

Water Flow 

 

<TABLE 3> 

 Process Control Device Monitored Parameter 

J5 

Furnace Glass Melting DEP 

1

st Field – Secondary Voltage 

2

nd Field – Secondary Voltage 

3

rd Field – Secondary Voltage 

Glass Melting Molten Glass Throughput 

 

Line Forming 

U3 

 Does not produce a bonded product 

J6-Forming Premix Formulation 

LOI 

Resin Free Formaldehyde 

Molten Glass Throughput 

J6-Curing HPAF – High 

Performance 

Air Filter 

Water Flow 

Emission Data Summary / Operating Hours for Facility

For the period January 1, 2008 through June 30, 2008 the operating hours are: 

K5 Furnace – 2909.3 hours J5 Furnace – 3798.8 hours 

K5 Line – 2674.4 hours J6 Line – 0 hours 

70 Furnace – 4668.0 hours 

70 Line – 4011.4 hours 
Deviations: 

 Hours Deviation % Deviation

J5 Furnace DEP Bypasses 21.98 0.58 

70 Furnace Batch Wetting/Crown Feed 26.50 0.61 

J5 Furnace DEP SIR 3 45.00 1.18 

Based on these operating hours, the following monitoring parameters were over the 1% 

exceedance time: 

J5 Furnace DEP SIR 3 45.00 1.18 

These instances will be described in more detail in the Parameter Exceedance Report that 

follows. 

As the responsible official, I certify that the content of this report is accurate. 

Print Name: John Becker 

Signature: 

Title: Plant Leader 
Gaseous and Opacity Excess Emission and Continuous Monitoring System Performance 

40CFR63 Subpart NNN

Reporting Period: January 1, 2008 through June 30, 2008 

Owens Corning Insulating Systems, LLC - Kansas City Facility 

300 Sunshine Road 

Kansas City, KS 66115 

The following instances are being reported as a deviation of a monitored parameter due to 

malfunction or startup/shutdown: 

J5 Furnace DEP SIR 3 – See Appendix A for Details 

As the responsible official, I certify that the content of this report is accurate. 

Print Name: John Becker 

Signature: 

Title: Plant Leader 
Appendix A 

J5 Furnace DEP SIR 3 
Gaseous and Opacity Excess Emission and Continuous Monitoring System Performance

40CFR63 Subpart NNN

Reporting Period: January 1, 2008 through June 30, 2008 

Owens Corning Insulating Systems, LLC - Kansas City Facility 

300 Sunshine Road 

Kansas City, KS 66115 

J5 Furnace DEP SIR 3:

During the reporting period, the J5 Furnace DEP SIR 3 experienced a total of 45.0 hours of 

monitoring parameter excursions. A cooling fan motor failed and the SIR was shut down while 

the fan motor was replaced. The time and date of the deviation was: 

February 16, 2008 at 18:47 to February 18, 2008 at 15:47 

No other monitoring parameter excursions occurred during this reporting period. 
OWENS CORNING 

INSULATING SYSTEMS, LLC 

Kansas City Facility

300 Sunshine Road 

Kansas City, Kansas 66115 

1.800.GET.PINKTM

www.owenscorning.com

January 30, 2009 

Ms. Mary Mahaffey 

Compliance and Enforcement Section 

KDHE Bureau of Air and Radiation 

1000 SW Jackson, Suite 310 

Topeka, KS 66612

RE: MACT Semi-Annual Reporting for 

Period July 1, 2008 through December 31, 2008 

Dear Ms Mahaffey: 

This report includes three separate reports as required by 40 CFR 63 Subparts A and NNN. The 

first report summarizes periods of startup, shutdown, and malfunction where actions taken were 

inconsistent with the plan in accordance with MACT requirements, 40 CFR 63.10(d)(5) and 40 

CFR 63.1386(c). The second report is the “Summary Report – Gaseous and Opacity Excess 

Emission and Continuous Monitoring System Performance” as required in 40 CFR 63.10(e)(3) 

and 40 CFR 63.1386(e). The third report is the “Gaseous and Opacity Excess Emission and 

Continuous Monitoring System Performance Report” as required in 40 CFR 63.10(e)(3) and 40 

CFR 63.1386(e) if monitored parameters deviate more than 1% of the total operating time. Each 

report is labeled appropriately and is for the period July 1, 2008 through December 31, 2008. 

As the responsible official, I certify to the accuracy of this report. If you have any questions 

regarding this information, please contact our Facility Environmental Leader, Bob Jeffries 913-

281-9424. 

Sincerely, 

Steve Freimanis 

Plant Leader 

Owens Corning Insulating Systems, LLC – Kansas City

Attachment 

CC: Ms. Patricia Scott, US EPA 

 Mr. Bruce Anderson, Unified Government of Wyandotte County 
Report: Periods of Startup, Shutdown, and Malfunction (SSM) Where Actions Taken were 

Inconsistent with SSM Plan

40CFR63 Subpart NNN

Reporting Period: July 1, 2008 through December 31, 2008 

Owens Corning Insulating Systems, LLC 

300 Sunshine Road 

Kansas City, KS 66115 

Although there were startups, shutdowns and malfunctions during this reporting period, all 

actions taken were consistent with the SSM Plan. 

 

Report: Periods of Deviation from the Operations, Maintenance and Monitoring (OMM) 

Plan.

40CFR63 Subpart NNN

The following instances are being reported as a deviation of procedures outlined in the facility OMM 

Plan. 

1. Based on requirements within the Operations, Maintenance, and Monitoring Plan, an LOI is 

required at least once every 8 hours on each manufacturing line that manufactures MACT 

products. For the three manufacturing lines there were a total of 35 incidents where the duration 

between LOI testing exceeded eight hours 

2. Based on requirements within the Operations, Maintenance, and Monitoring Plan, a density check 

is required at least once every 8 hours on each manufacturing line that manufactures MACT 

products. There were a total of 34 incidents where the duration between density testing exceeded 

eight hours. 

As the responsible official, I certify that the content of this report is accurate. 

Print Name: Steve Freimanis

Signature: 

Title: Plant Leader
Summary Report – Gaseous and Opacity Excess Emission and Continuous Monitoring 

System Performance

40CFR63 Subpart NNN

Reporting Period: July 1, 2008 through December 31, 2008 

Owens Corning Insulating Systems, LLC 

300 Sunshine Road 

Kansas City, KS 66115 

HAP’s Monitored: The Wool Fiberglass MACT focuses on two surrogate pollutants for control 

of HAP’s from the Fiberglass manufacturing process. Particulate matter is limited to 0.5 lb PM 

per ton of molten glass produced from the glass melting process and formaldehyde is limited to 

1.2 lb per ton of molten glass produced during fiber forming and curing. 

Process Units: In general the fiberglass manufacturing process is composed of a glass-melting 

furnace that melts batch materials into glass. The molten glass is passed through a rotary spin 

(RS) forming process where a fine, glass fiber is produced. Binder is applied to the fiber as it 

forms a “pack” on the surface of a foraminous conveyor. Once collected, the pack passes 

through a curing and cooling process followed by final fabrication and packaging. Tables 1 

through 3 define the manufacturing sources at this facility, including individual processes, 

control devices, and monitored parameters. 

<TABLE 1> 

 Process Control 

Device 

Monitored Parameter 

K5 

Furnace Glass Melting DEP 1st Field – Secondary Voltage 

2

nd Field – Secondary Voltage 

3

rd Field – Secondary Voltage 

Glass Melting Molten Glass Throughput 

 

Line Forming Premix Formulation 

LOI 

Resin Free Formaldehyde 

Molten Glass Throughput 

Curing HPAF – High 

Performance 

Air Filter 

Water Flow 

 
<TABLE 2> 

 Process Control 

Device 

Monitored Parameter 

70 

Furnace Glass Melting Batch Wetting Water Flow 

Glass Melting Molten Glass Throughput 

 

Line Forming Premix Formulation 

LOI 

Resin Free Formaldehyde 

Molten Glass Throughput 

Curing HPAF – High 

Performance 

Air Filter 

Water Flow 

 

<TABLE 3> 

 Process Control 

Device 

Monitored Parameter 

J5 

Furnace Glass Melting DEP 1st Field – Secondary Voltage 

2

nd Field – Secondary Voltage 

3

rd Field – Secondary Voltage 

Glass Melting Molten Glass Throughput 

 

Line Forming 

U3 

 Does not produce a bonded 

product 

J6-Forming Premix Formulation 

LOI 

Resin Free Formaldehyde 

Molten Glass Throughput 

J6-Curing HPAF – High 

Performance 

Air Filter 

Water Flow 

Emission Data Summary / Operating Hours for Facility

For the period July 1, 2008 through December 31, 2008 the operating hours are: 

K5 Furnace – 4416 hours J5 Furnace – 4131.2 hours 

K5 Line – 3792.6 hours J6 Line – 1126.6 hours 

70 Furnace – 4416 hours 

70 Line – 3812.1 hours 
 Deviations: Hours Deviation % Deviation

70 Furnace Lost Crust 8.0 0.24 

70 Furnace Batch Wetting/Crown Feed 106.27 2.41 

K-5 DEP 1st Field Voltage 7.37 0.17 

K-5 DEP 2nd Field Voltage 8.37 0.19 

K-5 DEP 3rd Field Voltage 7.37 0.17 

DEP Bypass 20.85 0.47 

J-5 DEP 1st Field Voltage 6.35 0.15 

J-5 DEP 2nd Field Voltage 10.35 0.25 

J-5 DEP 3rd Field Voltage 10.35 0.25 

DEP Bypass 40.80 0.99 

Based on these operating hours, the following monitoring parameters were over the 1% 

exceedance time: 

70 Furnace Batch Wetting/Crown Feed 106.27 hrs 2.41% 

These instances will be described in more detail in the Parameter Exceedance Report that 

follows. 

As the responsible official, I certify that the content of this report is accurate. 

Print Name: Steve Freimanis

Signature: 

Title: Plant Leader
Gaseous and Opacity Excess Emission and Continuous Monitoring System Performance 

40CFR63 Subpart NNN

Reporting Period: July 1, 2008 through December 31, 2008 

Owens Corning Insulating Systems, LLC 

300 Sunshine Road 

Kansas City, KS 66115 

The following instances are being reported as a deviation of a monitored parameter due to 

malfunction or startup/shutdown: 

70 Furnace Batch Wetting/Crown Feed – see Appendix A for Details 

As the responsible official, I certify that the content of this report is accurate. 

Print Name: Steve Freimanis

Signature: 

Title: Plant Leader
Appendix A 

70 Furnace Batch Wetting/Crown Feed 
Gaseous and Opacity Excess Emission and Continuous Monitoring System Performance

40CFR63 Subpart NNN

Reporting Period: July 1, 2008 through December 31, 2008 

Owens Corning Insulating Systems, LLC 

300 Sunshine Road 

Kansas City, KS 66115 

70 Batch Wetting/Crown Feed:

During the reporting period, the 70 Batch Wetting/Crown Feed experienced 106.27 hours of 

monitoring parameter excursions. The 70 Crown Feed experienced a total of 17.60 hours of 

monitoring parameter excursions. There were 88.67 hours of batch wetting excursions. The 

attached tables list the date and time for the deviations. 

70 Furnace Crown Feeding 

Owens Corning 

Kansas City, KS 

Date Beginning Time Ending Time Total Hours 

8/14/08 9:45 10:55 1.17 

8/15/08 13:20 1342 0.37 

8/20/08 4:00 4:25 0.42 

8/20/08 8:00 8:45 0.75 

9/10/08 9:50 10:15 0.42 

10/14/08 2:20 2:55 0.58 

10/22/08 13:33 15:05 1.53 

11/8/08 13:10 17:05 3.92 

12/3/08 9:00 14:18 5.30 

12/5/08 10:08 13:17 3.15 

Total Hours 17.60 
70 Furnace Batch Wetting 

Owens Corning 

Kansas City, KS 

Date Beginning Time Ending Time Total Hours 

7/18/08 21:09 7/19/08 17:09 20.00 

7/20/08 21:09 7/21/08 18:09 21.00 

8/11/08 20:59 8/12/08 16:59 20.00 

8/25/08 19:19 8/26/08 22:59 27.67 

Total Hours 88.67 
OWENS CORNING 

INSULATING SYSTEMS, LLC 

Kansas City Facility

300 Sunshine Road 

Kansas City, Kansas 66115 

1.800.GET.PINKTM

www.owenscorning.com

July 30, 2009 

Wyandotte County Health Department

Department of Air Quality

619 Ann Avenue

Kansas City, Kansas 66101

Attn: Bruce Andersen 

RE: MACT Semi-Annual Reporting for 

Period January 1, 2009 through June 30, 2009 

Dear Mr. Andersen: 

This report includes three separate reports as required by 40 CFR 63 Subparts A and NNN. The 

first report summarizes periods of startup, shutdown, and malfunction where actions taken were 

inconsistent with the plan in accordance with MACT requirements, 40 CFR 63.10(d)(5) and 40 

CFR 63.1386(c). The second report is the “Summary Report – Gaseous and Opacity Excess 

Emission and Continuous Monitoring System Performance” as required in 40 CFR 63.10(e)(3) 

and 40 CFR 63.1386(e). The third report is the “Gaseous and Opacity Excess Emission and 

Continuous Monitoring System Performance Report” as required in 40 CFR 63.10(e)(3) and 40 

CFR 63.1386(e) if monitored parameters deviate more than 1% of the total operating time. Each 

report is labeled appropriately and is for the period January 1, 2009 through June 30, 2009. 

As the responsible official, I certify to the accuracy of this report. If you have any questions 

regarding this information, please contact our Facility Environmental Leader, Bob Jeffries 913-

281-9424. 

Sincerely, 

Steve Freimanis 

Plant Leader 

Owens Corning Insulating Systems, LLC – Kansas City

Attachment 
Report: Periods of Startup, Shutdown, and Malfunction (SSM) Where Actions Taken were 

Inconsistent with SSM Plan

40CFR63 Subpart NNN

Reporting Period: January 1, 2009 through June 30, 2009 

Owens Corning Insulating Systems, LLC 

300 Sunshine Road 

Kansas City, KS 66115 

Although there were startups, shutdowns and malfunctions during this reporting period, all 

actions taken were consistent with the SSM Plan. 

 

Report: Periods of Deviation from the Operations, Maintenance and Monitoring (OMM) 

Plan.

40CFR63 Subpart NNN

The following instances are being reported as a deviation of procedure outlined in the facility 

OMM Plan: 

 

 1. Based on requirements within the OMM Plan, an LOI check is required at least once 

every 8 hours. There were twelve incidences on K-5 and eighteen incidences on 70 

where the duration between the LOI checks exceeded 8 hours. 

 

As the responsible official, I certify that the content of this report is accurate. 

Print Name: Steve Freimanis

Signature: 

Title: Plant Leader
Summary Report – Gaseous and Opacity Excess Emission and Continuous Monitoring 

System Performance

40CFR63 Subpart NNN

Reporting Period: January 1, 2009 through June 30, 2009 

Owens Corning Insulating Systems, LLC 

300 Sunshine Road 

Kansas City, KS 66115 

HAP’s Monitored: The Wool Fiberglass MACT focuses on two surrogate pollutants for control 

of HAP’s from the Fiberglass manufacturing process. Particulate matter is limited to 0.5 lb PM 

per ton of molten glass produced from the glass melting process and formaldehyde is limited to 

1.2 lb per ton of molten glass produced during fiber forming and curing. 

Process Units: In general the fiberglass manufacturing process is composed of a glass-melting 

furnace that melts batch materials into glass. The molten glass is passed through a rotary spin 

(RS) forming process where a fine, glass fiber is produced. Binder is applied to the fiber as it 

forms a “pack” on the surface of a foraminous conveyor. Once collected, the pack passes 

through a curing and cooling process followed by final fabrication and packaging. Tables 1 

through 3 define the manufacturing sources at this facility, including individual processes, 

control devices, and monitored parameters. 

<TABLE 1> 

 Process Control 

Device 

Monitored Parameter 

K5 

Furnace Glass Melting DEP 

1

st Field – Secondary Voltage 

2

nd Field – Secondary Voltage 

3

rd Field – Secondary Voltage 

Glass Melting Molten Glass Throughput 

 

Line Forming Premix Formulation 

LOI 

Resin Free Formaldehyde 

Molten Glass Throughput 

Curing HPAF – High 

Performance 

Air Filter 

Water Flow 

 
<TABLE 2> 

 Process Control 

Device 

Monitored Parameter 

70 

Furnace Glass Melting Batch Wetting Water Flow 

Glass Melting Molten Glass Throughput 

 

Line Forming Premix Formulation 

LOI 

Resin Free Formaldehyde 

Molten Glass Throughput 

Curing HPAF – High 

Performance 

Air Filter 

Water Flow 

 

<TABLE 3> 

 Process Control Device Monitored Parameter 

J5 

Furnace Glass Melting DEP 

1

st Field – Secondary Voltage 

2

nd Field – Secondary Voltage 

3

rd Field – Secondary Voltage 

Glass Melting Molten Glass Throughput 

 

Line Forming 

U3 

 Does not produce a bonded product 

J6-Forming Premix Formulation 

LOI 

Resin Free Formaldehyde 

Molten Glass Throughput 

J6-Curing HPAF – High 

Performance 

Air Filter 

Water Flow 

Emission Data Summary / Operating Hours for Facility

For the period January 1, 2009 through June 30, 2009 the operating hours are: 

K5 Furnace – 4344.0 hours J5 Furnace – 4344.0 hours 

K5 Line – 3005.2 hours J6 Line – 0.0 hours 

70 Furnace – 4001.0 hours 

70 Line – 2878.7 hours 
Deviations: 

 Hours Deviation % Deviation

70 Furnace Batch Wetting/Crown Feed 7.75 0.19 

70 N HPAF 960.00 33.35 

70 S HPAF 32.47 1.13 

K-5 DEP 1st Field Voltage 58.00 1.35 

K-5 DEP 2nd Field Voltage 103.08 2.38 

K-5 DEP 3rd Field Voltage 52.08 1.21 

DEP Bypass 0.50 0.01 

J-5 DEP 1st Field Voltage 16.00 0.37 

J-5 DEP 2nd Field Voltage 16.00 0.37 

J-5 DEP 3rd Field Voltage 16.00 0.37 

DEP Bypass 0.28 0.01 

Based on these operating hours, the following monitoring parameters were over the 1% 

exceedance time: 

70 N HPAF 960.00 33.35 

70 S HPAF 32.47 1.13 

K-5 DEP 1st Field Voltage 58.00 1.35 

K-5 DEP 2nd Field Voltage 103.08 2.38 

K-5 DEP 3rd Field Voltage 52.08 1.21 

These instances will be described in more detail in the Parameter Exceedance Report that 

follows. 

Based on these percentages of deviations, the following monitoring parameters were over 5% 

exceedence time, thus warranting a Quality Improvement Plant (QIP) per 63.1382(b)(2)(ii) and 

63.10(e)(3)(viii): 

70 N HPAF 960.00 33.35% 

As the responsible official, I certify that the content of this report is accurate. 

Print Name: Steve Freimanis

Signature: 

Title: Plant Leader
Gaseous and Opacity Excess Emission and Continuous Monitoring System Performance 

40CFR63 Subpart NNN

Reporting Period: January 1, 2009 through June 30, 2009 

Owens Corning Insulating Systems, LLC 

300 Sunshine Road 

Kansas City, KS 66115 

The following instances are being reported as a deviation of a monitored parameter due to 

malfunction or startup/shutdown: 

70 N HPAF – see Appendix A for Details 

70 S HPAF – see Appendix B for Details 

K-5 DEP 1st Field Voltage – see Appendix C for Details 

K-5 DEP 2nd Field Voltage – see Appendix D for Details 

K-5 DEP 3rd Field Voltage – see Appendix E for Details 

As the responsible official, I certify that the content of this report is accurate. 

Print Name: Steve Freimanis

Signature: 

Title: Plant Leader
Appendix A 

70 N HPAF 
Gaseous and Opacity Excess Emission and Continuous Monitoring System Performance

40CFR63 Subpart NNN

Reporting Period: January 1, 2009 through June 30, 2009 

Owens Corning Insulating Systems, LLC 

300 Sunshine Road 

Kansas City, KS 66115 

70 N HPAF:

During the reporting period, the 70 N HPAF experienced 960 hours of monitoring parameter 

excursions. The plant has had problems with restricted flow through the duct line of the HPAF 

that contributed to these deviations. Steps are being taken to correct this issue. The attached 

tables list the date and time for the deviations. 

70 N HPAF 

Owens Corning 

Kansas City, KS 

Date Beginning Time Ending Time Total Hours 

3/20/09 23:00 07:00 3/21/09 8 

3/21/09 15:00 23:00 3/22/09 32 

3/30/09 23:00 23:00 3/31/09 24 

4/1/09 07:00 15:00 4/6/09 128 

4/9/09 23:00 07:00 4/11/09 32 

4/13/09 15:00 07:00 4/14/09 16 

4/14/09 15:00 07:00 4/15/09 16 

4/15/09 23:00 07:00 4/16/09 8 

4/16/09 23:00 07:00 4/17/09 8 

4/17/09 15:00 15:00 4/20/09 72 

4/21/09 07:00 15:00 4/22/09 32 

4/23/09 15:00 23:00 8 

5/4/09 07:00 15:00 5/5/09 32 

5/6/09 07:00 15:00 8 

5/7/09 07:00 15:00 8 

5/7/09 23:00 07:00 5/9/09 32 

5/9/09 23:00 07:00 5/10/09 8 

5/10/09 23:00 23:00 5/13/09 72 

5/14/09 23:00 07:00 5/15/09 8 

5/16/09 07:00 15:00 8 

5/17/09 23:00 15:00 5/18/09 16 

5/19/09 07:00 15:00 8 

5/19/09 23:00 23:00 5/20/09 24 

5/21/09 07:00 23:00 16 
70 N HPAF 

Owens Corning 

Kansas City, KS 

Date Beginning Time Ending Time Total Hours 

5/22/09 07:00 07:00 5/23/09 24 

5/23/09 15:00 23:00 5/26/09 80 

5/27/09 23:00 07:00 5/28/09 8 

5/30/09 15:00 07:00 5/31/09 16 

5/31/09 15:00 07:00 6/2/09 40 

6/4/09 15:00 23:00 8 

6/5/09 07:00 15:00 8 

6/22/09 15:00 23:00 8 

6/23/09 07:00 15:00 8 

6/23/09 23:00 15:00 6/25/09 40 

6/26/09 07:00 07:00 6/27/09 24 

6/27/09 15:00 15:00 6/28/09 24 

6/28/09 23:00 15:00 6/30/09 40 

6/30/09 23:00 07:00 7/1/09 8 

Total Hours 960 
Appendix B 

70 S HPAF 
Gaseous and Opacity Excess Emission and Continuous Monitoring System Performance

40CFR63 Subpart NNN

Reporting Period: January 1, 2009 through June 30, 2009 

Owens Corning Insulating Systems, LLC 

300 Sunshine Road 

Kansas City, KS 66115 

70 S HPAF:

During the reporting period, the 70 S HPAF experienced 32.47 hours of monitoring parameter 

excursions. The attached tables list the date and time for the deviations. 

70 S HPAF 

Owens Corning 

Kansas City, KS 

Date Beginning Time Ending Time Total Hours 

4/18/09 23:00 07:00 4/19/09 8 

5/25/09 23:00 06:59 5/26/09 7:98 

6/4/09 15:00 23:00 8 

6/29/09 15:00 23:29 8.48 

Total Hours 32.47 
Appendix C 

K-5 FURNACE DEP VOLTAGE FIELD 1 
Gaseous and Opacity Excess Emission and Continuous Monitoring System Performance

40CFR63 Subpart NNN

Reporting Period: January 1, 2009 through June 30, 2009 

Owens Corning Insulating Systems, LLC 

300 Sunshine Road 

Kansas City, KS 66115 

K-5 DEP 1st Field Voltage:

During the reporting period, the K-5 DEP 1st Field Voltage experienced 58.0 hours of monitoring

parameter excursions. The attached tables list the date and time for the deviations. 

K-5 DEP 1st Field Voltage 

Owens Corning 

Kansas City, KS 

Date Beginning Time Ending Time Total Hours 

2/27/09 7:44 21:44 14 

5/19/09 4:03 5/21/09 00:03 44 

Total Hours 58 
Appendix D 

K-5 FURNACE DEP VOLTAGE FIELD 2 
Gaseous and Opacity Excess Emission and Continuous Monitoring System Performance

40CFR63 Subpart NNN

Reporting Period: January 1, 2009 through June 30, 2009 

Owens Corning Insulating Systems, LLC 

300 Sunshine Road 

Kansas City, KS 66115 

K-5 DEP 2nd Field Voltage:

During the reporting period, the K-5 DEP 2nd Field Voltage experienced 103.08 hours of 

monitoring parameter excursions. The attached tables list the date and time for the deviations. 

K-5 DEP 2nd Field Voltage 

Owens Corning 

Kansas City, KS 

Date Beginning Time Ending Time Total Hours 

1/17/09 7:00 15:00 8 

1/18/09 7:00 15:00 1/20/09 56 

2/27/09 6:39 21:44 15.08 

5/19/09 7:00 23:00 16 

5/20/03 15:00 23:00 8 

Total Hours 103.08 
Appendix E 

K-5 FURNACE DEP VOLTAGE FIELD 3 
Gaseous and Opacity Excess Emission and Continuous Monitoring System Performance

40CFR63 Subpart NNN

Reporting Period: January 1, 2009 through June 30, 2009 

Owens Corning Insulating Systems, LLC 

300 Sunshine Road 

Kansas City, KS 66115 

K-5 DEP 3rd Field Voltage:

During the reporting period, the K-5 DEP 3rd Field Voltage experienced 52.08 hours of 

monitoring parameter excursions. The attached tables list the date and time for the deviations. 

K-5 DEP 3rd Field Voltage 

Owens Corning 

Kansas City, KS 

Date Beginning Time Ending Time Total Hours 

2/26/09 06:39 13:39 7 

2/26/09 21:39 3:39 2/27/09 6 

2/27/09 06:39 21:44 15.08 

5/19/09 07:00 23:00 16 

5/20/09 15:03 20:03 5 

5/20/09 22:03 01:03 5/21/09 3 

Total Hours 52.08 
OWENS CORNING 

INSULATING SYSTEMS, LLC 

Kansas City Facility

300 Sunshine Road 

Kansas City, Kansas 66115 

1.800.GET.PINKTM

www.owenscorning.com

January 28, 2010 

Mr. Jeremy Duis 

Compliance and Enforcement Section 

KDHE Bureau of Air and Radiation 

10000 SW Jackson, Suite 310 

Topeka, KS 66612

RE: MACT Semi-Annual Reporting for 

Period July 1, 2009 through December 31, 2009 

Dear Mr. Duis: 

This report includes three separate reports as required by 40 CFR 63 Subparts A and NNN. The 

first report summarizes periods of startup, shutdown, and malfunction where actions taken were 

inconsistent with the plan in accordance with MACT requirements, 40 CFR 63.10(d)(5) and 40 

CFR 63.1386(c). The second report is the “Summary Report – Gaseous and Opacity Excess 

Emission and Continuous Monitoring System Performance” as required in 40 CFR 63.10(e)(3) 

and 40 CFR 63.1386(e). The third report is the “Gaseous and Opacity Excess Emission and 

Continuous Monitoring System Performance Report” as required in 40 CFR 63.10(e)(3) and 40 

CFR 63.1386(e) if monitored parameters deviate more than 1% of the total operating time. Each 

report is labeled appropriately and is for the period July 1, 2009 through December 31, 2009. 

As the responsible official, I certify to the accuracy of this report. If you have any questions 

regarding this information, please contact our Facility Environmental Leader, Natalie 

Brandeberry at 913-281-9525. 

Sincerely, 

Steve Freimanis 

Plant Leader 

Owens Corning Insulating Systems, LLC – Kansas City

Attachment 

cc: Mr. Patricia Scott, US EPA 

 Mr. Bruce Anderson, Unified Government of Wyandotte County 
Report: Periods of Startup, Shutdown, and Malfunction (SSM) Where Actions Taken were 

Inconsistent with SSM Plan

40CFR63 Subpart NNN

Reporting Period: July 1, 2009 through December 31, 2009 

Owens Corning Insulating Systems, LLC 

300 Sunshine Road 

Kansas City, KS 66115 

Although there were startups, shutdowns and malfunctions during this reporting period, all 

actions taken were consistent with the SSM Plan. 

 

Report: Periods of Deviation from the Operations, Maintenance and Monitoring (OMM) 

Plan.

40CFR63 Subpart NNN

The following instances are being reported as a deviation of procedures outlined in the facility 

OMM Plan: 

 1. Based on requirements within the OMM Plan, an LOI check is required 

At least once every 8 hours. There were nine incidences on J-6, eleven incidences on K5, and eight incidences on 70 where the duration between the LOI checks exceeded 8 

hours. 

As the responsible official, I certify that the content of this report is accurate. 

Print Name: Steve Freimanis

Signature: 

Title: Plant Leader
Summary Report – Gaseous and Opacity Excess Emission and Continuous Monitoring 

System Performance

40CFR63 Subpart NNN

Reporting Period: July 1, 2009 through December 31, 2009 

Owens Corning Insulating Systems, LLC 

300 Sunshine Road 

Kansas City, KS 66115 

HAP’s Monitored: The Wool Fiberglass MACT focuses on two surrogate pollutants for control 

of HAP’s from the Fiberglass manufacturing process. Particulate matter is limited to 0.5 lb PM 

per ton of molten glass produced from the glass melting process and formaldehyde is limited to 

1.2 lb per ton of molten glass produced during fiber forming and curing. 

Process Units: In general the fiberglass manufacturing process is composed of a glass-melting 

furnace that melts batch materials into glass. The molten glass is passed through a rotary spin 

(RS) forming process where a fine, glass fiber is produced. Binder is applied to the fiber as it 

forms a “pack” on the surface of a foraminous conveyor. Once collected, the pack passes 

through a curing and cooling process followed by final fabrication and packaging. Tables 1 

through 3 define the manufacturing sources at this facility, including individual processes, 

control devices, and monitored parameters. 

<TABLE 1> 

 Process Control 

Device 

Monitored Parameter 

K5 

Furnace Glass Melting DEP 

1

st Field – Secondary Voltage 

2

nd Field – Secondary Voltage 

3

rd Field – Secondary Voltage 

Glass Melting Molten Glass Throughput 

 

Line Forming Premix Formulation 

LOI 

Resin Free Formaldehyde 

Molten Glass Throughput 

Curing HPAF – High 

Performance 

Air Filter 

Water Flow 

 
<TABLE 2> 

 Process Control 

Device 

Monitored Parameter 

70 

Furnace Glass Melting Batch Wetting Water Flow 

Glass Melting Molten Glass Throughput 

 

Line Forming Premix Formulation 

LOI 

Resin Free Formaldehyde 

Molten Glass Throughput 

Curing HPAF – High 

Performance 

Air Filter 

Water Flow 

 

<TABLE 3> 

 Process Control Device Monitored Parameter 

J5 

Furnace Glass Melting DEP 

1

st Field – Secondary Voltage 

2

nd Field – Secondary Voltage 

3

rd Field – Secondary Voltage 

Glass Melting Molten Glass Throughput 

 

Line Forming 

U3 

 Does not produce a bonded product 

J6-Forming Premix Formulation 

LOI 

Resin Free Formaldehyde 

Molten Glass Throughput 

J6-Curing HPAF – High 

Performance 

Air Filter 

Water Flow 

Emission Data Summary / Operating Hours for Facility

For the period July 1, 2009 through December 31, 2009 the operating hours are: 

K5 Furnace – 4416 hours J5 Furnace – 4416 hours 

K5 Line – 4029.5 hours J6 Line – 1737 hours 

70 Furnace – 4416 hours 

70 Line – 4072.9 hours 
Deviations: 

 Hours Deviation % Deviation

70 Furnace Lost Crust 6.17 0.14 

70 Furnace Batch Wetting/Crown Feed 10.20 0.23 

70 N HPAF 1099.50 27.00 

70 S HPAF 198.58 4.88 

K-5 DEP 1st Field Voltage 5.22 0.12 

K-5 DEP 2nd Field Voltage 2.22 0.05 

K-5 DEP 3rd Field Voltage 6.22 0.14 

DEP Bypass 42.95 0.97 

J-5 DEP 3rd Field Voltage 128.00 2.90 

DEP Bypass 19.32 0.44 

J6 Charge HPAF 20.57 1.18 

J6 Discharge HPAF 137.98 7.94 

Based on these operating hours, the following monitoring parameters were over the 1% 

exceedance time: 

70 N HPAF 1099.50 27.00 

70 S HPAF 198.58 4.88 

J-5 DEP 3rd Field Voltage 128.00 2.90 

J6 Charge HPAF 20.57 1.18 

J6 Discharge HPAF 137.98 7.94 

These instances will be described in more detail in the Parameter Exceedance Report that 

follows. 

Based on these percentages of deviations, the following monitoring parameters were over 5% 

exceedence time, thus warranting a Quality Improvement Plan (QIP) per 63.1382(b)(2)(ii) and 

63.10(e)(3)(viii): 

J6 Discharge HPAF 7.54% 

70 N HPAF 27.00% 

As the responsible official, I certify that the content of this report is accurate. 

Print Name: Steve Freimanis

Signature: 

Title: Plant Leader
Gaseous and Opacity Excess Emission and Continuous Monitoring System Performance 

40CFR63 Subpart NNN

Reporting Period: July 1, 2009 through December 31, 2009 

Owens Corning Insulating Systems, LLC 

300 Sunshine Road 

Kansas City, KS 66115 

The following instances are being reported as a deviation of a monitored parameter due to 

malfunction or startup/shutdown: 

70 N HPAF – See Appendix A for Details 

70 S HPAF – See Appendix B for Details 

J-5 DEP 3rd Field Voltage - See Appendix C for Details 

J6 Charge HPAF - See Appendix D for Details 

J6 Discharge HPAF - See Appendix E for Details 

As the responsible official, I certify that the content of this report is accurate. 

Print Name: Steve Freimanis

Signature: 

Title: Plant Leader
Appendix A 

70 N HPAF 
Gaseous and Opacity Excess Emission and Continuous Monitoring System Performance

40CFR63 Subpart NNN

Reporting Period: July 1, 2009 through December 31, 2009 

Owens Corning Insulating Systems, LLC 

300 Sunshine Road 

Kansas City, KS 66115 

70 N HPAF:

During the reporting period, the 70 N HPAF experienced 1099.50 hours of monitoring parameter 

excursions. The attached tables list the date and time for the deviations. 

70 N HPAF 

Owens Corning 

Kansas City, KS 

Date 

Beginning 

Time Ending Time Total Hours 

7/1/09 0:00 7/1/09 7:00 7.00 

7/1/09 15:00 7/1/09 22:02 7.03 

7/4/09 7:00 7/5/09 2:02 19.03 

7/5/09 15:00 7/5/09 21:45 6.75 

7/7/09 7:00 7/9/09 1:11 42.18 

7/16/09 7:00 7/16/09 15:00 8.00 

7/16/09 23:00 7/17/09 12:06 13.10 

7/18/09 7:00 7/18/09 23:00 16.00 

7/19/09 15:00 7/19/09 22:24 7.40 

7/20/09 7:00 7/20/09 15:00 8.00 

7/21/09 15:00 7/21/09 23:00 8.00 

7/22/09 15:00 7/22/09 23:00 8.00 

7/23/09 7:00 7/25/09 17:28 58.47 

7/27/09 23:00 7/28/09 7:00 8.00 

7/28/09 15:00 7/30/09 18:02 51.03 

7/31/09 15:00 8/1/09 0:00 9.00 

8/1/09 0:00 8/1/09 20:46 20.77 

8/2/09 7:00 8/2/09 23:00 16.00 

8/3/09 15:00 8/4/09 13:50 22.83 

8/5/09 7:00 8/8/09 17:19 82.32 

8/9/09 7:00 8/10/09 14:34 31.57 

8/11/09 23:00 8/12/09 15:00 16.00 

8/12/09 23:00 8/13/09 7:00 8.00 
8/15/09 23:00 8/18/09 6:55 55.92 

8/19/09 23:00 8/20/09 6:04 7.07 

8/20/09 23:00 8/21/09 14:01 15.02 

8/23/09 23:00 8/24/09 12:48 13.80 

8/24/09 23:00 8/25/09 7:00 8.00 

8/25/09 23:00 8/26/09 6:34 7.57 

8/31/09 7:00 8/31/09 21:44 14.73 

9/1/09 0:00 9/1/09 7:00 7.00 

9/2/09 15:00 9/3/09 14:40 23.67 

9/3/09 23:00 9/8/09 5:56 102.93 

9/9/09 7:00 9/9/09 15:00 8.00 

9/11/09 15:00 9/11/09 23:00 7.28 

9/13/09 7:00 9/13/09 15:00 8.00 

9/13/09 23:00 9/14/09 6:24 7.40 

9/14/09 23:00 9/15/09 10:34 11.57 

9/16/09 7:00 9/16/09 19:05 12.08 

9/17/09 15:00 9/17/09 23:00 8.00 

9/18/09 7:00 9/18/09 22:19 15.32 

9/19/09 15:00 9/19/09 21:39 6.65 

9/20/09 7:00 9/20/09 12:48 5.13 

9/21/09 7:00 9/21/09 15:00 8.00 

9/22/09 7:00 9/22/09 15:00 8.00 

9/24/09 7:00 9/25/09 12:48 29.80 

9/25/09 23:00 9/26/09 6:35 7.58 

9/29/09 23:00 9/30/09 7:00 8.00 

10/2/09 23:00 10/4/09 19:00 44.00 

10/24/09 15:00 10/24/09 23:00 8.00 

10/28/09 23:00 10/29/09 7:00 8.00 

10/29/09 23:00 10/30/09 7:00 8.00 

11/5/09 15:00 11/6/09 7:00 16.00 

11/7/09 15:00 11/7/09 21:25 7.42 

11/8/09 7:00 11/8/09 23:00 16.00 

11/9/09 7:00 11/9/09 15:00 8.00 

11/10/09 15:00 11/10/09 21:22 6.37 

11/11/09 15:00 11/12/09 5:59 14.98 

11/17/09 7:00 11/17/09 13:21 6.35 

11/26/09 23:00 11/27/09 5:10 6.17 

12/7/09 7:00 12/7/09 10:06 3.10 

12/9/09 15:00 12/9/09 21:48 6.80 

12/10/09 7:00 12/10/09 15:00 8.00 
12/11/09 7:00 12/11/09 14:20 7.33 

12/11/09 23:00 12/12/09 7:00 8.00 

12/12/09 23:00 12/13/09 13:36 14.60 

12/28/09 7:00 12/28/09 15:00 8.00 

12/29/09 15:00 12/30/09 4:23 13.38 

Total Hours 1099.50 
Appendix B 

70 S HPAF 
Gaseous and Opacity Excess Emission and Continuous Monitoring System Performance

40CFR63 Subpart NNN

Reporting Period: July 1, 2009 through December 31, 2009 

Owens Corning Insulating Systems, LLC 

300 Sunshine Road 

Kansas City, KS 66115 

70 S HPAF:

During the reporting period, the 70 S HPAF experienced 198.58 hours of monitoring parameter 

excursions. The attached tables list the date and time for the deviations. 
70 S HPAF 

Owens Corning 

Kansas City, KS 

Date Beginning Time Ending Time Total Hours 

7/1/09 0:00 7/1/09 14:10 14.17 

7/23/09 23:00 7/24/09 7:00 8.00 

7/25/09 7:00 7/25/09 15:00 8.00 

8/12/09 23:00 8/13/09 7:00 8.00 

8/19/09 23:00 8/20/09 6:04 7.07 

9/16/09 7:00 9/16/09 12:59 4.98 

9/29/09 7:00 9/29/09 15:00 8.00 

10/16/09 15:00 10/16/09 22:54 7.90 

10/23/09 7:00 10/23/09 14:14 7.23 

11/1/09 15:00 11/1/09 18:24 2.40 

11/3/09 15:00 11/3/09 23:00 8.00 

11/5/09 15:00 11/6/09 5:59 14.98 

11/11/09 15:00 11/11/09 23:00 8.00 

11/08/09 23:00 11/19/09 4:19 5.32 

11/26/09 7:00 11/26/09 13:10 6.17 

11/26/09 23:00 11/28/09 5:29 29.48 

11/28/09 23:00 11/29/09 7:00 8.00 

11/30/09 23:00 12/1/09 0:00 1.00 

12/1/09 0:00 12/1/09 6:40 6.67 

12/8/09 7:00 12/8/09 15:00 8.00 

12/9/09 15:00 12/9/09 21:48 6.80 

12/12/09 15:00 12/12/09 22:02 7.03 

12/29/09 15:00 12/30/09 4:23 13.38 

12/31/09 23:00 1/1/10 0:00 1.00 

Total Hours 199.58 
Appendix C 

J-5 DEP 3rd Field Voltage 
Gaseous and Opacity Excess Emission and Continuous Monitoring System Performance

40CFR63 Subpart NNN

Reporting Period: July 1, 2009 through December 31, 2009 

Owens Corning Insulating Systems, LLC 

300 Sunshine Road 

Kansas City, KS 66115 

J5 DEP 3rd Field Voltage:

During the reporting period, the J5 DEP 3rd Field Voltage experienced 128.00 hours of 

monitoring parameter excursions. The attached tables list the date and time for the deviations. 

J-5 DEP 3rd FIELD VOLTAGE 

Owens Corning 

Kansas City, KS 

Date 

Beginning 

Time Ending Time Total Hours 

12/11/09 12:16 12/16/09 20:16 128.00 

Total Hours 128.0 
Appendix D 

J6 CHARGE HPAF 
Gaseous and Opacity Excess Emission and Continuous Monitoring System Performance

40CFR63 Subpart NNN

Reporting Period: July 1, 2009 through December 31, 2009 

Owens Corning Insulating Systems, LLC 

300 Sunshine Road 

Kansas City, KS 66115 

J6 CHARGE HPAF:

During the reporting period, the J6 CHARGE HPAF experienced 20.57 hours of monitoring 

parameter excursions. The attached tables list the date and time for the deviations. 

J6 CHARGE HPAF 

Owens Corning 

Kansas City, KS 

Date Beginning Time Ending Time Total Hours 

9/23/09 1:11 9/23/09 02:11 1.00 

9/23/09 10:11 9/23/09 11:25 1.24 

9-26-09 10:02 9/30/09 10:20 18.33 

Total Hours 20.57 
Appendix E 

J6 DISCHARGE HPAF 
Gaseous and Opacity Excess Emission and Continuous Monitoring System Performance

40CFR63 Subpart NNN

Reporting Period: July 1, 2009 through December 31, 2009 

Owens Corning Insulating Systems, LLC 

300 Sunshine Road 

Kansas City, KS 66115 

J6 DISCHARGE HPAF:

During the reporting period, the J6 DISCHARGE HPAF experienced 137.98 hours of monitoring 

parameter excursions. The attached tables list the date and time for the deviations. 

J6 DISCHARGE HPAF 

Owens Corning 

Kansas City, KS 

Date 

Beginning 

Time Ending Time Total Hours 

9/18/09 7:00 9/23/09 17:59 116.98 

10/15/09 8:05 10/16/09 22:05 14.00 

10/20/09 16:05 10/20/09 23:05 7.00 

Total Hours 137.98