PermitNo: 147-97-TV (R2) U013 Emissions Points:

ID Description

E13A Gasoline Tank#1 E13B Gasoline Tank#2 El3C Gasoline Tank#3 E13D Two (2) Fueling Stations PlantID: 0072

U013 Emission Points Applicable Allowable Emission/ Control Requirement Equipment Standard Device 7.15 Stage I vapor recovery system N/A 7.15 Stage I vapor recovery system N/A 7.15 Stage I vaporrecovery system N/A See Comment 2 ORVREquipped Vehicles N/A and 3 U013 Control Equipment: There are no control devices associated with EmissionUnitU013.

SCH Page 94 of 130 03-31-2011

### PermitNo: 147-97-TV (R2) PlantID: 0072 U013 Specific Conditions: 

### S1. Standards 

### (Regulation 2.16, section 4.1.1)


### a. VOC
1. 

### Storage tanks, Emission Points E13A through E13C, shall be equipped withthe following: (Regulation 7.15, section 3.1)



### b. TAC 

### a) A submerged fill pipe; (Regulation 7.15, section 3.1.1) b) Ifthe gasoline storage tank is equipped with a separate gauge well, a gauge well drop tube shall be installed which extends to within six inches of the bottom of the tank; (Regulation 7.15, section 3.1.2) c) Vent line restrictions on the affected facility; and (Regulation 7.15, section 3.1.3) d) Vapor balance system and vaportight connections onthe liquid fill and vaporreturn hoses. The cross-sectional area ofthe vaporreturn hose and any other vapor return passages in the circuit connecting the vapor space in the service station tank to that ofthe truck tank must be at least 50% ofthe liquid fill hose cross-sectional area for each tank and free of flow restrictions to achieve acceptable recovery. The vapor balance equipment must be maintained according to the manufacturer's specifications. The type, size and design ofthe vapor balance system are subject to the approval of the District. (Regulation 7.15, section 3.1.4)

The owner or operator shall not allow any TAC emissiOns to exceed environmentally acceptable levels whether specifically establishedbymodeling or derived from default de minimis levels. (Regulation 5.01, section 3.) (See Comment 1) S2. Monitoring 

### (Regulation 2.16, section 4.1.9.1.2)

SCH a. VOC 

### Storage tanks: To demonstrate ongoing compliance with Regulation 1.05, Section 4, the owner or operator shall monitor the quantity of gasoline used to fuel vehicles. a) The owner or operator shall monthly: Page 95 of 130 03-31-2011PermitNo: 147-97-TV (R2) Plant ID: 0072 1) Checkthe storage tankfill points for tightness; 2) If a two point vapor recovery system on the storage tank, check rubber gaskets for tears, verify spring loaded valves properly operate and tank refill caps have rubber gaskets in good condition; replace any damagedparts; and b) The owner or operator shall annually: Verifypressure vacuumvalve onventpipe is operatingproperly annually and replace any damaged part. c) The owneror operatormust complete all repairs within 5 working days. b. TAC See Comment 1. S3. Record Keeping (Regulation 2.16, section 4.1.9.2)


### a. VOC
1. The owner or operator shall record total monthly gasoline throughput and make these records available to the District upon request. ii. The owner or operator shall maintain records ofthe monthly and annual inspections. These records shall contain the date and time of the inspection; who performed the inspection; and the results of the inspection. b. TAC The owner or operator shallkeep a record ofthe Material SafetyData Sheet (MSDS) for each TAC-containingmaterial in this emissionunit. (See Comment 1) S4. Reporting (Regulation 2.16, section. 4.1.9.3)
a. VOC See General PermitReporting Requirements. b. TAC There are no routine reportingrequirements forthis equipment. (See Comment 1) SCH Page 96 of 130 03-31-2011PermitNo: 147-97-TV (R2) Plant ID: 0072 U013 Comments 1. The emissions from a motor vehicle fueling orrefuelingprocess and process equipment for gasoline and other liquid fuels are de minimis under STAR. (Regulation 5.01, section 1.6.6.) 2. The Districtreviewed a letter dated January 18,2007 regardingthe current applicability of Stage II Vapor Recovery. EPAhas provided guidance that vehicle productionplants doing initial fueling ofvehicle comply with vaporrecovery requirements bymeans of ORVRrequirements for compliant vehicles. The District concurs thatthe external vapor recovery system as required bythe applicable Title V operatingpermitfor LAP is not required for fueling vehicles with ORVR. 3. Regulation 6.40 does not applyto the initial fueling ofnewmotorvehicles at a motor vehicle assembly facility per section 2.1.2.

SCH Page 97 of 130 03-31-2011PermitNo: 147-97-TV (R2) Plant ID: 0072 U014 and U022 Emission Unit Description: Paint Equipment Cleaning Operations U014 and U022 Applicable Regulations: Federally Enforceable Regulations Regulation Title Applicable Sections 1.05 Compliance with Emission Standards and 1, 3, 4 and 5 Maintenance Requirements 6.18 Standards ofPerformance for SolventMetal 1though 4 CleaningEquipment 7.25 Standards ofPerformance forNew Source Using 1through 5 Volatile Organic Compounds 40 CPR 63 General Provisions 63.1 through 63.16 SubpartA 40 CPR 63 NationalEmission Standards for Hazardous Air SubpartIIII Pollutants: Surface Coating ofAutomobiles and 1, 2, 3, 4, 7 and 8 Light-DutyTrucks
District Only Enforceable Regulations Regulation Title Applicable Sections 1.18 Rule Effectiveness 1through 3 5.01 General Provisions 1through 4 5.14 Hazardous AirPollutants and Source Categories 1 and 2 Methodologyfor DeterminingBenchmark 5.20 Ambient Concentration ofa Toxic Air 1through 6 Contaminant 5.21 Environmental Acceptabilityfor ToxicAir 1through 5 Contaminants Procedures for Determiningthe Maximum 5.22 Ambient Concentration ofa Toxic Air 1through 5 Contaminant 5.23 Categories ofToxic Air Contaminants 1through 6

SCH Page 98 of 130 03-31-2011PermitNo: 147-97-TV (R2) Plant ID: 0072 U014 and U022 Emission Points: U014 and U022 Emission Points ID Description Applicable Allowable Emission/ Control Requirement Equipment Standard Device
PaintEquipment 7.25 See Specific Conditions S1.a. E14A N/A CleaningBooth 40 CPR 63 Subpart lUI Section 63.3094 PaintEquipment 7.25 See Specific Conditions S1.a. E22A Purging andPlant N/A Cleaning 40 CPR 63 Subpart lUI Section 63.3094 SolventMetal See Specific Conditions S1.a.iii N/A Cleaning 6.18 N/A Equipment U014 and U022 ControlDevices: There are no control devices associated withEmissionUnit U014 andU022.

SCH Page 99 of 130 03-31-2011PermitNo: 147-97-TV (R2) PlantID: 0072 U014 and U022 Specific Conditions
S1. Standards (Regulation 2.16, section 4.1.1)

SCH a. VOC i. ApplicatorPaintPurging: The automatic spray applicators will incorporate a purge paint and solvent recovery system that will collect the purged materials. ii. The owner or operator of a cold cleaner to clean non-paint or non-sealer related equipment using volatile organic compounds (VOC) shall, install, maintain, and operate the control equipment as follows: The cold cleaner shall be equipped with a tightly fitting cover that is free ofcracks, holes, or other defects. Ifthe solvent is agitated or heated, then the cover shall be designed so that it can be easily operated with 1 hand. (Regulation 6.18, section 4.1.1) The cold cleaner shall be equippedwith a drainage facility that is designed so that the solvent that drains off parts removed from the cleaner will return to the cold cleaner. The drainage facility may be external if the District determines that an internal type cannot fit into the cleaning system. (Regulation 6.18, section 4.1.2) A permanent, conspicuous label summarizing the operating requirements specified in Specific Condition Sl.b. shall be installed on or near the cold cleaner. (Regulation 6.18, section4.1.3) Ifused, the solvent spray shall be a fluid stream, not a fine, atomized, or shower type spray, at a pressure that does not cause excessive splashing. Flushing ofparts using a flexible hose or other flushing device shall be performed only withinthe freeboard area ofthe cold cleaner. Solvent flow shall be directed downward to avoid turbulence atthe air-solvent interface and to prevent solvent from splashing outside of the cold cleaner. (Regulation 6.18, section4.1.4) Work area fans shall be located and positioned so that they do not blow across the opening ofthe cold cleaner. (Regulation 6.18, section 4.1.6) The solvent-containing portion of the cold cleaner shall be free of all liquid leaks. Auxiliary cold cleaner equipment such as pumps, water separators, steam traps, or distillation units shall not have any visible liquid leaks, visible tears, or cracks. (Regulation 6.18, section 4.1.8) The owner or operator shall observe at all times the following operating Page 100 of130 03-31-2011PermitNo: 147-97-TV (R2) PlantID: 0072

SCH b. TAC requirements: (Regulation 6.18, section 4.2) Waste solvent shall neither be disposed ofnor transferred to another party in a manner such that more than 20% by weight ofthe waste solvent can evaporate. Waste solvent shall be stored only in a covered container. A covered container may contain a device that allows pressure relief, but does not allow liquid solventto drain from the container. (Regulation 6.18, section 4.2.1) The solvent level in the cold cleaner shall not exceed the fill line. (Regulation 6.18, section 4.2.2) The cold cleaner cover shall be closed whenever a part is not being handled inthe cold cleaner. (Regulation 6.18, section4.2.3) Parts to be cleaned shall be racked or placed into the cold cleaner in a mannerthatwill minimize drag-out losses. (Regulation 6.18, section4.2.4) Cleaned parts shall be drained for at least 15 seconds or until dripping ceases, whichever is longer. Parts having cavities or blind holes shall be tipped or rotated while thepart is draining. Duringthe draining, tipping, or rotating, the parts shall be positioned so that the solvent drains directly backto the cold cleaner. (Regulation 6.18, section 4.2.5) A spill during solvent transfer shall be cleaned immediately, and the wipe rags or other sorbent material shall be immediately stored in a covered container for disposal or recycling, unless enclosed storage ofthese items is not allowed by fire protection authorities. (Regulation 6.18, section 4.2.6) Sponges, fabric, wood, leather, paper products, and other absorbent material shall not be cleaned in a cold cleaner. (Regulation 6.18, section 4.2.7) The owner or operator shall not operate a cold cleaner used to clean nonpaint or non-sealer related equipment using a solvent with a vapor pressure that exceeds 1.0 mm Hg (0.019 psi) measured at 20°C (68°F). (Regulation 6.18, section 4.3.2)

The owner or operator shall not allow any TAC em1sswns to exceed environmentally acceptable levels whether specifically established by modeling or derived from default de minimis levels. (Regulation 5.01, section 3.)
c. HAP
Page 101 of130 03-31-2011PermitNo: 147-97-TV (R2) Plant ID: 0072 1. The owner or operator shall follow the workpractices specified in 40 CFR 63 Subpart IIII, Specific Condition Sl.b and c. to minimize VOC emissions from purge and cleaning operations.
11. See LAP FordMotor CompanyMACT Standards Section. S2. Monitoring (Regulation 2.16, section 4.1.9.1.2)
a. VOC See Specific Condition S1.a. b. TAC See Specific Condition S3.b.
c. HAP See LAP FordMotor CompanyMACTMonitoring Section. S3. Record Keeping (Regulation 2.16, section4.1.9.2)
a. VOC
1. See Specific Condition Sl.a. ii. The owner or operator shall maintain records that include the following for eachpurchase: (Regulation 6.18, section4.4.2)

b. TAC 1) The name and address ofthe solvent supplier, 2) The date ofthe purchase, 3) The type ofthe solvent, and 4) The vaporpressure ofthe solventmeasured in mmHg at 20 aC (68°F).

The owner or operator shall keep a record ofthe Material SafetyData Sheet (MSDS) for eachTAC-containingmaterial in this emissionunit.
c. HAP See LAP Ford Motor CompanyMACTRecordkeeping Section. S4. Reporting (Regulation 2.16, section 4.1.9.2) SCH Page 102 of 130 03-31-2011PermitNo: 147-97-TV (R2) PlantID: 0072 a. VOC See General PermitReporting Requirements. 

### b. TAC The owner or operator shall submit a plant-wide emissions-based EA Demonstration to the District showing compliance with theplant-wide EA goals of7.5 new and existing, 3.8 for all new combined, and 1 for each process when a change occurs that increases emissions above De minimus orpreviouslymodeled values.
c. HAP See LAP FordMotor CompanyMACTReportingRequirements. U014 and U022 Comments 1. Specific Conditions involving work practice standards only have no monitoring, record keeping and reporting requirements, as suchwould be impractical. 2. The aqueous cold cleaners that contain no VOCs are not subjectto Regulation 6.18.

SCH Page 103 of130 03-31-2011PermitNo: 147-97-TV (R2) PlantID: 0072 U015 Emission UnitDescription: SealerDeck U015 Applicable Regulations: FederallyEnforceableRegulations Regulation Title Applicable Sections 1.05 Compliance with Emission Standards and 1, 3, 4 and 5 Maintenance Requirements 7.59 Standards ofPerformance forNew SourceUsing 1through 5 Volatile Organic Compounds 40 CFR63 General Provisions 63.1 through 63.16 SubpartA 40 CFR 63 NationalEmission Standards for Hazardous Air Subpart IIII Pollutants: Surface Coating ofAutomobiles and 1, 2, 3, 4, 7 and 8 Light-Duty Trucks
District Only Enforceable Regulations Regulation Title Applicable Sections 1.18 Rule Effectiveness 1through 3 5.01 General Provisions 1through 4 5.02 Adoption ofNationalEmission Standards for 1, 3, 4 and 5 Hazardous Air Pollutants 5.14 Hazardous AirPollutants and Source Categories 1and 2 Methodology for DeterminingBenchmark 5.20 Ambient Concentration ofa Toxic Air 1through 6 Contaminant 5.21 Environmental Acceptabilityfor Toxic Air 1through 

### 5 Contaminants Procedures for Determiningthe Maximum 5.22 Ambient Concentration ofa Toxic Air 1through 5 Contaminant 5.23 Categories ofToxic Air Contaminants 1through 6

SCH Page 104 of 130 03-31-2011PermitNo: 147-97-TV (R2) U015 Emission Points:

ID Description

E15A SealerApplication
N/A Sealers and Deadeners (otherthan glass bonding) Plant ID: 0072

U015 Emission Points Applicable Allowable Emission/ Control Requirement Equipment Standard Device
7.59 3.5 lbs/gal N/A Section 40 CFR 63.3090 (c) 40 CFR 63 or63.3091 (c) N/A Subpart IIII 0.01lbVOC per lb of adhesive and sealermaterial U015 ControlDevices: There are no control devices associatedwithEmissionUnitU015.

SCH Page 105 of 130 03-31-2011PermitNo: 147-97-TV (R2) PlantID: 0072 U015 Specific Conditions
S1. Standards (Regulation 2.16, section 4.1.1)
a. VOC
1. The owner or operator shall not cause or allowthe emission ofVOC from any affected facility resulting from the coating of metallic surfaces in excess of3.5 lb VOC/gal ofcoating, excludingwater and exempt solvents, as applied for extreme performance coatings. (Regulation 7.59, section 3.1.3)
11. See Louisville Assembly Plant, Ford Motor Company Plant-wide Applicability Limit (PAL). b. TAC The owner or operator shall not allow any TAC emtsswns to exceed environmentally acceptable levels whether specifically established bymodelingor derived from default de minimis levels. (Regulation 5.01, section 3.)
c. HAP See LAP FordMotor CompanyMACT Standards Section. S2. Monitoring (Regulation 2.16, section4.1.9.1.2)
a. VOC See Specific Condition S3.a. b. TAC See Specific Condition S3.b.
c. HAP See LAP FordMotor Company MACTMonitoring Section. S3. Record Keeping (Regulation 2.16, section 4.1.9.2)

SCH a. VOC
1. The owner or operator of an affected facility subject to this regulation shall maintain records that include, but not be limited to, the following: Page 106 of 130 03-31-2011PermitNo: 147-97-TV (R2) PlantID: 0072

b. TAC (Regulation 7.59, section 6.1) 1) The regulation and section number applicable to the affected facility for whichthe records are beingmaintained, 2) The application method and substrate type (metal, plastic, etc.), 3) The amount and type of coatings (including catalyst and reducer for multi-component coatings) and solvent (including exempt compounds) used at each point ofapplication during the averaging period. The District may specifically authorize the usage record to reflect a period longer than the compliance averaging period, with the usage prorated for each compliance averaging period by a method approved by the District. In this case, the usage record period shall notexceed 1calendarmonth, 4) TheVOC content as applied in each coating and solvent, 5) The date, or usage record period, for each application of coating and solvent, 6) The amount of surface preparation, clean-up, wash-up of solvent (including exempt compounds) used and the VOC content ofeach material used during the averaging period. The District may specifically authorize the usage record to reflect a period longer than the compliance averaging period, with the usage prorated for each compliance averaging period by a method approved by the District. In this case, the usage record period shall not exceed 1 calendarmonth.

The owner or operator shallkeep arecord ofthe Material SafetyData Sheet (MSDS) for eachTAC-containingmaterial in this emissionunit.
c. HAP See LAP FordMotor CompanyMACTRecordkeeping Section. S4. Reporting (Regulation 2.16, section 4.1.9.3)
a. VOC See General PermitReportingRequirements. 

### b. TAC SCH Page 107 of 130 03-31-2011PermitNo: 147-97-TV (R2) Plant ID: 0072

SCH The owner or operator shall submit a plant-wide emissions-based EA Demonstration to the District showing compliance with the plant-wide EA goals of7.5 new and existing, 3.8 for all new combined, and 1 for each process when a change occurs that increases emissions above De minimus or previously modeled values.
c. HAP See LAP FordMotor CompanyMACTReporting Requirements.

Page 108of130 03-31-2011PermitNo: 147-97-TV (R2) PlantID: 0072 U016 Emission UnitDescription: Final Repair Spray Booth; infrared curing, and spotrepair bays for repairing coatingon vehicles U016 Applicable Regulations: FederallyEnforceable Regulations Regulation Title Applicable Sections 1.05 Compliance with Emission Standards and 1,3,4and5 Maintenance Requirements 7.01 General Provisions 7.2 7.08 Standards ofPerformance forNewProcess Operations 1through 3 40 CFR60 General Provisions 63.1 through 63.16 SubpartA 40 CFR 60 NationalEmission Standards ofPerformance for SubpartMM Automobile and Light DutyTruck Surface 60.390 through 60.397 Coating Operations 40 CFR 63 General Provisions 63.1 through 63.16 SubpartA 40 CFR 63 National Emission Standards for Hazardous Air Subpart IIII Pollutants: Surface Coating ofAutomobiles and 1, 2, 3 ,4, 7 and 8 Light-Duty Trucks

SCH Page 109 of 130 03-31-2011PermitNo: 147-97-TV (R2) PlantID: 0072 District OnlyEnforceable Regulations Regulation Title Applicable Sections 1.18 Rule Effectiveness 1through 3 5.01 General Provisions 1through4 5.02 Adoption ofNationalEmission Standards for 1,3,4and5 Hazardous AirPollutants 5.14 Hazardous AirPollutants and Source Categories 1and 2 Methodologyfor DeterminingBenchmark 5.20 Ambient Concentration ofa Toxic Air 1through 6 Contaminant 5.21 Environmental Acceptabilityfor ToxicAir 1through 5 Contaminants Procedures for Determiningthe Maximum 5.22 Ambient Concentration ofa Toxic Air 1through 5 Contaminant 5.23 Categories ofToxic Air Contaminants 1through 6

SCH Page 110 of 130 03-31-2011PermitNo: 147-97-TV (R2) U016 Emission Points:

ID Description

E16A FinalRepair Booth

E16B Final Repair Oven

SCH PlantID: 0072

U016 Emission Points Applicable Allowable Emission/ Control Requirement Equipment Standard Device 40 CFR 60 Subpart MM See Specific Conditions S1.a. 6.17 and 7.01 <20% 7.08 2.34lb/hr a. 0.6 lbs HAP/GACS C16A Or b. 1.1 lbs HAPs/GACS 40 CFR 63 Subpart IIII (the above limits are applicable to a group ofemissions sources and are different depending upon whether compliance is demonstrated with

(a) orwithout (b) final repair) 40 CFR 60 SubpartMM 6.17 and 7.01 See Specific Conditions S1.a. <20% 7.08 < 300 ppm a. 0.6 lbs HAP/GACS N/A Or b. 1.1 lbs HAPs/GACS 40 CFR 63 SubpartIIII (the above limits are applicableto a group ofemissions sources and are different depending upon whether compliance is demonstrated with

(a) orwithout (b) final repair)

Page 111 of 130 03-31-2011PermitNo: 147-97-TV (R2) PlantID: 0072 U016 Emission Points ID Description Applicable Allowable Emission/ Control Requirement Equipment Standard Device 40 CFR 60 SubpartMM See Specific Conditions S1.a 6.17 and 7.01 <20% 7.08 2.34 lb/hr E16C FinalRepair a. 0.6 lbs HAP/GACS N/A SpotPaint Or b. 1.1 lbs HAPs/GACS 40 CFR 63 SubpartIIII (the above limits are applicable to a group ofemissions sources and are different depending upon whether compliance is demonstrated with

(a) orwithout (b) final repair) U016 Control Devices: ID Description Performance StackiD Indicator C16A Fabric Filter N/A Sl87 and S188

SCH Page 112 of 130 03-31-2011PermitNo: 147-97-TV (R2) Plant ID: 0072 U016 Specific Conditions 1. Standards (Regulation 2.16, section 4.1.1)

SCH a. VOC 

### i. The owner or operator shall be subject to the emission limit of 4.8 lbs VOC/gal (0.58 kg/1) of coating, less water and exempt solvents. (40 CFR60.3092, Regulation 7.01 section 7.2 and Regulation 6.1, section 3.4)
11. See Louisville Assembly Plant, Ford Motor Company Plant-wide ApplicabilityLimit (PAL). b. 

### PM
1. See Louisville Assembly Plant, Ford Motor Company Plant-wide ApplicabilityLimit (PAL). ii. The owner or operator shall not allow PM emissions to exceed 2.34 lb/hr. (Regulation 7.08, section 3.1.2) (See Comment 1)
111. The owner oroperator shall not operate the Final Repair Boothunless the particulate filters are installed and operatingproperly.
c. Opacity The owner or operator shall not allow visible emissions to equal or exceed 20% opacity. (Regulation 7.08, section 3.1.1) d. HAP See LAP Ford Motor CompanyMACT Standards Section.


### e. NOx The owner or operator shall not cause to be discharged into the atmosphere from any affected facility orfrom any airpollution control equipment installed on any affected facility anyNOx fumes in excess of300ppmbyvolume expressed as N02. (Regulation 7.08, section4) (See Comment 2) 

### f. TAC The owner or operator shall not allow any TAC emissiOns to exceed environmentally acceptable levels whether specifically establishedby modeling or derived from default de minimis levels. (Regulation 5.01, section 3.) Page 113 of 130 03-31-2011

### PermitNo: 147-97-TV (R2) Plant ID: 0072 S2. Monitoring 

### (Regulation 2.16, section 4.1.9.1.2)

SCH a. VOC 

### i.

ii.

Where:Monitor ongoing compliance by calculating monthly, a daily a volume weighted average ofthe coatings used. Procedures used for this determination shall be those of''Protocol for DeterminingDailyVolatile Organic CompoundEmissionRate ofAutomobile and Light-DutyTruck Topcoat Operations," EPA-450/3-88-018 (Docket ID

### No. OAR-2002 -0093 and Docket ID

### No. A-2001-22) Use EPAMethod 24 to determine the amount ofVOC inthe Coating. The following equation may be used as an alternate methodto demonstrate compliance:

n 

### V. C. VOC 

### =

# s _I _I w 

# v i=l t VOCw 

### = the daily weighted average coating VOC content, as applied; and less water and exempt solvents, expressed in pounds ofVOC per gallon of coating.
n 

### = number ofdifferent coatings used on a coating line a given day. V1 

### = the volume of each coating used on a coating line, as applied and less water and exempt solvents, a given day. C 1 

### = the VOC content of each coating used on a coating line, as applied and less water and exempt solvents, a given day. Vt 

### = total volume ofall coatings applied each day on a coating line, less water and exempt solvents.
111. 

### Meetthe standards specified in 40 CFR 60.392, as calculated, usingthe prescribedtransfer efficiency of40 CFR 60.393(c)(l)(i)(C) for the monthlyweighted average mass ofVOC emittedpervolume ofapplied coating solids. b. PM 

### The owner or operator shall follow good operating practices for the particulate filters, including monthly inspection, routine maintenance as recommended bythe manufacturer, andpromptrepair ofany defects. Page 114 of 130 03-31-2011PermitNo: 147-97-TV (R2) PlantID: 0072 c. Opacity See Specific Condition S2.b. 

### d. HAP See LAP Ford Motor CompanyMACTMonitoring Section.
e. NOx There are no monitoringrequirements for NOx compliance. (See Comment 2) 

### f. TAC See Specific Condition S3.f. S3. Record Keeping (Regulation 2.16, section 4.1.9.2)

SCH a. VOC Perform record keeping for VOCs for 40 CFR 60.395 and 1.05, Section4: 1) Record monthlythe daily quantity andtype ofpaintwithdrawn from the topcoat paint circulation system for use inthe final repair operationusing the methodology specified in S2.a. 2) Monthly, determinethe dailyVOC emissions based onthetopcoat and final repairrecords. 3) As an altemative to daily material usage records, the owner oroperator may utilize an appropriate material usage factor determined to be acceptablebythe District. (See Comment 3) 4) The owner or operator shall continuously record the incinerator combustion temperature during coating operations for thermal incineration or the gas temperature upstream and downstream of the incinerator catalystbed during coating operations for catalytic incineration. 

### b. PM
1. The owneroroperator shallkeep a record that showsthe date and the name ofthe personwho inspected the filters and iffilters were replaced.
11. Proper operation of the fabric filter shall be ensured by maintaining records of inspections and routine maintenance activities and shall make these records available to·the District upon request. A demonstration that Page 115 of130 03-31-2011PermitNo: 147-97-TV (R2) Plant ID: 0072 proper operation ofthe fabric filter has occurred satisfies this compliance requirement for the standard specified inS1.b.ii. above.
c. Opacity See Specific Condition S3.b. d. HAP See LAPFord Motor CompanyMACTRecordkeeping Section.
e. 

### NOx There are no record keeping requirements forNOx compliance. (See Comment2) 

### f. TAC The owner or operator shall keep arecord ofthe Material SafetyData Sheet (MSDS) for eachTAC-containingmaterial in this emissionunit. S4. Reporting (Regulation 2.16, section 4.1.9.2)

SCH a. VOC
1. See General PermitReporting Requirements.
11. Forthe control devices, the owneroroperator shall clearlyidentify all deviations from permitrequirements. Ifno deviations occurin that reportingperiodthen the owner oroperator shall report a negative declaration with the following information: 1) EmissionUnit number and Control ID number; 2) The beginning and ending date ofthe reportingperiod; 3) Identification ofthe operatingparameters beingmonitored; 4) Number, duration, and cause ofall exceedances ofthe parameters; and 5) Description ofthe corrective action taken for each exceedance.
111. Perform reporting for VOCs for 40 CPR 60.395 and 1.05, Section 4: 1) The owner or operator shall report the volume weighted average mass of VOC per volume of applied coating solids for each affected facility. 2) The owner or operator shall notifY the Administrator 30 days in advance ofany testbyMethod 25. Page 116 of 130 03-31-2011PermitNo: 147-97-TV (R2) PlantID: 0072 

### b. PM
1. Any deviation from the requirement to perform monthly visible inspections ofthe boothPMfilter system;
11. The dates that filters were replaced or a declaration that there were no filters replaced duringthe reportingperiod; and
111. See General Permit ReportingRequirements.


### c. Opacity See Specific Condition S4.b. 

### d. HAP See LAP Ford Motor CompanyMACT Reporting Requirements.
e. NOx There are no reporting requirements for NOx compliance. (See Comment 2) 

### f. TAC The owner or operator shall submit a plant-wide emissions-based EA Demonstration to the District showing compliance with theplant-wide EA goals of7.5 new and existing, 3.8 for all new combined, and 1for each process when a change occurs that increases emissions above De minimus or previously modeled values. U016 Comment 1. Compliance with this requirement is demonstrated through a mass balance approach or engineering estimate. 2. The District has performed a one-time NOx compliance demonstration using AP-42 emission factors and combusting natural gas, and the emission standard cannot be exceeded. Therefore, there are no monitoring, record keeping, and reporting requirements withrespect to NOx emission limits. 3. The District has deemed 0.5% as an appropriate material usage factor for Emission Unit U016.

SCH Page 117 of 130 03-31-2011PermitNo: 147-97-TV (R2) Plant ID: 0072 U023 Emission UnitDescription: Phosphate Operation U023 Applicable Regulations: District Only Enforceable Regulations Regulation Title Applicable Sections 5.01 General Provisions 1through 4 5.14 Hazardous AirPollutants and Source Categories 1and 2 Methodologyfor DeterminingBenchmark 5.20 Ambient Concentration ofa Toxic Air 1through 6 Contaminant 5.21 EnvironmentalAcceptabilityfor Toxic Air 1through 5 Contaminants Procedures for Determiningthe Maximum 5.22 Ambient Concentration ofa Toxic Air 1through 5 Contaminant 5.23 Categories ofToxic Air Contaminants 1through 6 U023 Emission Points: U023 Emission Points ID Description Applicable Allowable Emission/ Control Requirement Equipment Standard E1000 Phosphate 5.01 See Specific Conditions S3. El001 Phosphate Dump 5.01 See Specific Conditions S3. Tank U023 Control Devices: There are no control devices associated with Emission Unit U023. Device N/A N/A

SCH Page 118 of 130 03-31-2011PermitNo: 147-97-TV (R2) PlantID: 0072 U023 Specific Conditions S1. Standards (Regulation 2.16, section 4.1.1) TAC The owner or operator shall not allow any TAC emissions to exceed environmentally acceptable levels whether specifically established bymodeling or derived from default de minimis levels. (Regulation 5.01, section 3.) S2. Monitoring (Regulation 2.16, section 4.1.9.1.2) TAC See Specific Condition S3. S3. Record Keeping (Regulation 2.16, section4.1.9.2) TAC The owner or operator shall keep a record ofthe Material SafetyData Sheet (MSDS) for each TAC-containingmaterial in this emission unit. S4. Reporting (Regulation 2.16, section 4.1.9.2)

SCH TAC The owner or operator shall submit aplant-wide emissions-based EA Demonstration to the District showing compliance with theplant-wide EA goals of7.5 new and existing, 3.8 for all new combined, and 1 for each process when a change occurs that increases emissions above De minimus orpreviouslymodeled values.

Page 119 of 130 03-31-2011PermitNo: 147-97-TV (R2) Plant ID: 0072 U025 Emission UnitDescription: Twelve (12) DirectHeatExchangers U025 Applicable Regulations: FEDERALLY ENFORCEABLE REGULATIONS Regulation Title Applicable Sections 7.08 Standards ofPerformance for New IndirectHeat 1through 4 Exchangers Reasonable Available Control Technology 6.42 Requirements for Major Volatile Organic 1.2, and 2 through 5 Compound
District OnlyEnforceable Regulations Regulation Title Applicable Sections 5.01 General Provisions 1through 4 Methodologyfor DeterminingBenchmark 5.20 Ambient Concentration ofa Toxic Air 1through 6 Contaminant 5.21 Environmental Acceptabilityfor ToxicAir 1through 5 Contaminants Procedures for Determiningthe Maximum 5.22 Ambient Concentration ofa Toxic Air 1through 5 Contaminant 5.23 Categories ofToxic Air Contaminants 1through 6 U025 Emission Points: U025 Emission Points ID Description Applicable Regulation Control Device 5.21 E25 DirectHeatExchangers 6.42 N/A 7.08 U025 Control Devices: There are no control devices associated withEmission Unit U025.

SCH Page 120 of 130 03-31-2011PermitNo: 147-97-TV (R2) PlantID: 0072 U025 Specific Conditions Sl. Standards (Regulation 2.03, section 5.1)
a. PM The owner or operator shall not allow PM emissions to exceed 2.34 lb/hr. (Regulation 7.08, section 3.1.2) (See Comment 1) b. Opacity The owner or operator shall not allow visible emissions to equal or exceed 20% opacity. (Regulation 7.08, section 3.1.1)
c. NOx
1. The owner or operator shall not allow or cause the plant-wide NOx emissions to exceed 99 tons during any consecutive 12-month period in orderto staybelowNOxRACT applicabilitythresholds. ii. The owner or operator shall notallow NOx emissions to exceed 300 ppm by volume expresses as N02. (Regulation 7.08, section 4.1.) (See Comment 4) 

### d. TAC The owner or operator shall not allow any TAC emissiOns to exceed environmentally acceptable levels whether specifically established by modeling or derived from default de minimis levels. (Regulation 5.01, section 3.) S2. Monitoring (Regulation 2.03, section 5.1)
a. PM There are no monitoringrequirements for PMcompliance. (See Comment 1) b. Opacity See Comment2.
c. NOx See Specific Condition S3.c. 

### d. TAC
SCH Page 121 of 130 03-31-2011PermitNo: 147-97-TV (R2) See Comment 3. PlantID: 0072
S3. Record Keeping (Regulation 2.03, section 5.1) The owner or operator shall maintain the required records for a minimum of5 years and make the records readily available to the Districtupon request.
a. PM There are no record keeping requirements for PM compliance for this equipment. (See Comment 1) 

### b. Opacity There are no record keeping requirements for Opacity compliance for this equipment. (See Comment2)
c. NOx
1. The owner or operator shall calculate and record the monthly and 12 consecutive monthplant-wide NOx emissions for each month in the report period. ii. See Comment4. d. TAC See Comment 3. S4. Reporting (Regulation 2.03, section 5.1)

SCH a. PM See Comment 1. b. Opacity See Comment2.
c. NOx
1. The owner or operator shall report the monthly and 12 consecutive month plant-wideNOx emissions for each month in the reportperiod.
11. See PALReporting Requirements. Page 122 of 130 03-31-2011

### PermitNo: 147-97-TV (R2) Plant ID: 0072 d. TAC 

### The owner or operator shall submit a plant-wide 

### emissions-based EA Demonstration to the District showing compliance with theplant-wide 

### EA goals of7.5 new and existing, 3.8 for all new combined, and 1for each process when a change occurs that increases emissions above De minimus or previously modeled values. U025 Comments 

### 1. The District has performed a one-time PM compliance demonstration for the space heater, using AP-42 emission factors and combusting natural gas, and the emission standards cannot be exceeded. Therefore, there are no monitoring, record keeping, and reporting requirements for this space heater with respectto PM emission limits. 2. The District has determined that using a natural gas fired boiler will inherently meet the 20% opacity standard. Therefore, the company is not required to perform periodic monitoringto demonstrate compliance with the opacity standard. 3. STAR Regulation 5.01, section 1.6.7 states the TACs from natural combustion are De Minimis. 4. The District performed a onetime compliance demonstration for NOx and the 300 ppm standard cannotbe exceededuncontrolled.

SCH Page 123 of 130 03-31-2011

### PermitNo: 147-97-TV (R2) PlantID: 0072 

### Ford LAP Plant-wide Permit Shield 

### The owner or operator is hereby granted a permit shield that shall apply as long as the owner or operator demonstrates ongoing compliance with all conditions ofthis permit. Compliance with the conditions ofthis permit shall be deemed compliance with all applicable requirements ofthe regulations cited in this permit as ofthe date of issuance, pursuant to Regulation 2.16, section 4.6.1. Off-permitDocuments Document 

### Rule Effectiveness Plan 10 April1995
Alternative Operating Scenarios 

### The owner or operator did not request to operate under any alternative operating scenarios in its Title V permit application. InsignificantActivities Description Quantity Basis Internal combustion Various Regulation 2.02, Section 2.2 engines fixed ormobile Presses extruding Various Regulation 2.02, Section 2.3.1 metal/mineral/wood Brazing, soldering or Various Regulation 2.02, Section 2.3.4 welding equipment Woodworking, except for conveying, hogging, or Various Regulation 2.02, Section 2.3.5 burning wood/sawdust Lab venting and exhaust systems (nonradioactive Various Regulation 2.02, Section 2.3.11 materials) Ventilation systems- Various Regulation 2.02, Section 2.3.12 bakeries & restaurants Washing or drying fabricated metal or glass; Various Regulation 2.02, Section 2.3.15 non VOC use; no oil or solid fuel Residential/domestic Various Regulation 2.02, Section 2.3.12 equipment Portable diesel orgasoline Various Regulation 2.02, Section 2.3.23 storage tanks 

### SCH Page 124 of 130 03-31-2011PermitNo: 147-97-TV (R2) Plant ID: 0072 InsignificantActivities Description Quantity Basis Diesel fuel storage tanks Various Regulation 2.02, Section 2.3.25 (emergency use only) Closed pressure storage 2 Regulation 2.02, Section 2.3.26 vessels Portable tote tanks for raw Tote tanks are kept closed when not in use. Emissions from tanks material shipment of Various solvent

- based coatings are negligible, and are accounted for by process material balance. Backup generators for emergencypower.(< 500 2 Generators normal use is very low and HP <500 HP. hrs/year) WastewaterPretreatment 1 Emissions insignificant system. FluidFill (hydraulic fluids, Emissions insignificant due to lowvaporpressure ofmaterials oil, anti-freeze) and Various Lubricating operations. used. Miscellaneous maintenance procedures including lubrication, grinding, Various Negligible emissions cleaning, woodworking, etc. Directheat exchangers <1 Various Regulation 2.02, Section 2.1.1 MMBtu/hr
a. Insignificant Activities are only those activities or processes falling into the general categories defined in District Regulation 2.02, Section 2, and not associated with a specific operation or process for which there is a specific regulation. Equipment associated with a specific operation or process (Emission Unit) shall be listed with the specific process even though there may be no applicable requirements. Information contained in the permit and permit summary shall clearly indicate that those items identified with negligible emissions have no applicable requirements.

SCH b. Activities identified in District Regulation 2.02, Section 2, may not require a permit and may be insignificant with regard to application disclosure requirements butmay still have generally applicable requirements that continueto applyto the source.
c. For all insignificant activities that emit regulated air pollutants for which the company has accepted a plant-wide synthetic minor limit, the company shall maintain sufficient records to calculate the emissions and report those emissions in the quarterly compliance reports and the annual emissions inventory report. d. The InsignificantActivities table is correct as ofthe date the permit was proposed for review by the USEPA, Region 4. The company shall submit an updated list of Page 125 of 130 03-31-2011PermitNo: 147-97-TV (R2) PlantID: 0072

SCH insignificant activities annually with the Title V compliance certificationpursuant to DistrictRegulation 2.16, section 4.3.5.3.6.
e. In lieu ofrecording annual throughputs for each Insignificant Activity, the owner or operator may elect to report the Potential To Emit quantity listed in the Insignificant Activities table as the annual emission for each piece ofequipment, since the emissions from the source's Insignificant Activities are minor.

Page 126 of 130 03-31-2011

### PermitNo: 147-97-TV (R2) 

### Ford LouisvilleAssembly Plant ComplianceAssurance Monitoring (CAM) Plan PROCESS/OPERATIONAL RESTRICTION(S) 

### Plant ID: 0072



### 1. The thermal oxidizerused to control VOC emissions from the coating operations shall be operated to maintain a combustion chamber temperature of no more than 50 degrees Fahrenheit below the average combustion temperature during the most recent acceptable performance test and shall have a minimum design retention time of 0.5 seconds. The minimum temperature requirement may be based upon a 3 hour average. 

### (64.6(c)(1)(i),(ii)) 2. 

### The carbon adsorber used to control VOC emissions from the coating operations shall be operated to maintain a desorption gas inlet temperature of no more than 15 degrees Fahrenheit below the average desorption gas inlet temperature during the most recent acceptable performance test. The minimum temperature requirement may be based upon a 3 hour average. 

### (64.6(c)(1)(i),(ii)) 3. When relying on add-on control devices to demonstrate compliance with the emission requirements ofthis permit (i.e., control efficiency credit), the permittee may use nonzero control efficiencies for any period of time in which a deviation or excursion (including a deviation during startup, shutdown, or malfunction) from an operating limit occurs. Ifcompliance with the emission limits is achieved, then no enforceable deviation or excursion will have occurred. 

### (64.6(b))
MONITORING/RECORDKEEPING 

### Records shall be maintained on file for aperiod offive years. 

### 1. Temperature measurements ofthe thermal oxidizer combustion chamber shall be made at least once every 15 minutes and recorded during operation of the associated coating operations. (

### 64.6(c )(1)(i),(ii)) 2. Temperature measurements ofthe concentrator desorption gas inlet shall be made and recorded at least once every 15 minutes during operation of the associated coating operations. (

### 64.6(c )(1)(i),(ii)) 3. Ifcoating operations can continue operating during a control device bypass, the bypass shall be monitored such that the valve or closure method cannot be opened without creating an alarm condition for which a record shall be made. Records ofthe bypass line that was open and the length of time the bypass was open during operation of the associated coating operations shall be kept on file. 

### (64.3(a)(2)) 4. The CAM O&M plan shall be updated as necessary to reflect any necessary changes. All records and activities associated with the O&M plan shall be kept on file for a period of SCH Page 127 of 130 03-31-2011PermitNo: 147-97-TV (R2) Plant ID: 0072 at least five years. (64.6(c)(l)(i),(ii), 64.7(e)) REPORTING 1. Each quarterly report for monitoring and deviations shall identify the number, duration and cause of any excursions ofthese requirements and the corrective actions taken. If there were no excursions in the reportingperiod, then this report shall include a statement thatthere were no excursions. (40 CFR64.9(a)(2)(i)) OTHERREQUIREMENT(S) For the purposes of Compliance Assurance Monitoring (CAM), excursions will be defined as follows: (64.6(c)(2))
a. A temperature excursion is defined as a confirmed three-hourperiod during which the average fails to meetthe specifiedtemperature requirements. b. A monitoring excursion is defined as a failure to properlymonitor as required. c. A monitoring excursion can also be defined as failure to properly implement and/or maintain the O&Mplan.
Elements ofan O&Mplan- CAM General

- Keep records ofmaintenance inspections which include the dates ofthe inspections and the dates and reasons for repairs ifmade. The following items shall be addressed in an O&MPlan for each respective control device usedto demonstrate compliance with applicable VOC emissions limits.
RTO's • Validation ofoperation ofeachthermocouple aminimum ofonce every 12 months or thermocouple replacement. • *Perform aheat exchange/heattransfer media inspection a minimum ofonce every 18 months, or • *Perform an inspection ofthe valve seals condition once every 18 months and verify valve timing/synchronization through visual observation (orthrough an alarm system) once every 18 months. Carbon Adsorbor • Validation ofoperation ofeach thermocouple aminimum ofonce every 12 months or thermocouple replacement. • Perform semi-annual observations to confirm thatthe carbon adsorbor is rotating (ifa rotary carbon adsorbor) andthatthe desorption fan is operating. • *Perform internal observation ofadsorbent materials for contamination and erosion a minimum ofonce every 18 months. SCH Page 128 of 130 03-31-2011PermitNo: 147-97-TV (R2) PlantID: 0072 • Observe and record the pressure drop across the carbon adsorbor a minimum ofonce every calendar quarter. 

## *Thisrequirement is satisfied ifaperformancetest (i.e., stacktest) has beenperformed.

SCH Page 129 of 130 03-31-2011

### PermitNo: 147-97-TV (R2) Plant ID: 0072 

### AttachmentA: Processes Added/Removed/Modified from Compliance Ford Motor Company LouisvilleAssembly Plant This sheet covers the periodfrom
_______to ______ _ EmissionPoint (Note 1) Equipment Description

(Note 1) Change Category (Note 1) Equipment Action (Note 2) Date ofAction (Note 3)

Note 1:

Note 2: Note 3:

SCH Description of equipment being added/removed/modified including emission point identification and category of change. This log shall include any equipment/process that is added or removed from the calculation of annual emtsswns. Any equipment being added, removed, or modified form the emissions must be listed. Ifequipment is being added, list date ofcommencementofoperation (including startup). Ifequipment is beingremoved, list date ofremoval from installation. Page 130 of 130 03-31-2011PermitNo: 147-97-TV (R2) 

## Louisville Metro AirPollution Control District 850 BarretAve., Louisville, Kentucky 40204 March 31, 2011 

## Title V Statement ofBasis Company: FordMotor Company-Louisville AssemblyPlant PlantLocation: 2000 FernValleyRoad, Louisville, Kentucky 40213 Plant ID: 0072

DateApplication Received: 07 August 2008 Application Number: 11042 DateofProposed Permit: 03/31/2011 DistrictEngineer: Shannon Clemons Hosey PermitNo: 147-97-TV (R2) Plant ID: 0072 SIC Code: 3711 NAICS: 336112 AFS: 00072 Introduction: This permit will be issued pursuant to: (1) Regulation 2.16, (2) Title 40 ofthe Code ofFederal Regulations Part 70, and (3) Title V ofthe Clean AirAct Amendments of 1990. Its purpose is to identify and consolidate existingDistrict and Federal air requirements and to provide methods of determining continued compliancewiththeserequirements. Jefferson County is classified as an attainment area for lead (Pb), sulfur dioxide (S02), nitrogen dioxide (N02 ), carbonmonoxide (CO), 1hr and 8 hr ozone (03), and particulate matter less than 10 microns (PM10); and is a non-attainment area for particulate matter less than 2.5 microns (PM2.s). Application Type/PermitActivity: [ ] Initial Issuance [ ] PermitRevision [ ] Administrative [ ] Minor [ ] Significant [ ] PermitRenewal [X] Construction Compliance Summary: [X] Compliance certification signed [ ] Source is outofcompliance [ ] Compliance schedule included [X] Source is operating in compliancePermitNo: 147-97-TV (R2) Plant ID: 0072


### I. Source Information

SCH 

### 1. 

### Product Description: Manufacture ofautomobiles. 

### 2. Process Description: Vehicle bodies are assembled andprimed inthe body shop. A variety ofsealers are applied to the bodies which are thenpainted. Wax is applied to certainbodyparts. Next, windshields and backlights are installed, then a structural adhesive is usedto bond glass to the bodies. 

### 3. Site Determination: There are no other facilities that are contiguous or adjacent and under common control. 

### 4. Emission Unit Summary: Emission Unit EquipmentDescription U002-U004 Five (5) Boilers U008 Volatile Organic Liquid Storage Tanks U009 Glass Installation UOlO E-Coat Operation UOll Guidecoat Operation U012 Topcoat Operation U013 Plant-wideProductFueling U014/U022 PaintEquipment Cleaning Operation U015 SealerDeck U016 Final Repair SprayBooth U023 Phosphate Operation U025 Twelve (12) Direct HeatExchangers 

### 5. Fugitive Sources: There are no fugitive emissions. 

### 6. Permit Revisions:

2 of 36 03-31-2010PermitNo: 147-97-TV (R2) PlantID: 0072 Public Revision Issue Notice Attachment No. Date Date Type No./Page No. Description N/A 10/6/2000 4/23/2000 Initial Entire Permit Initial Permit Issuance R1 9/17/2010 7/19/2010 Initial/ Entire Permit 5 yearRenewal; Renewal Incorporate PAL, STAR TAC requirements, RO change, DRE for E-coatcontrol device change and 112(1) Part 1 & 2 applications. R2 3/31/2011 NA Admin Pages 43,45 Revisionto Revision and 50 include permit 229-96-0, add NOxRACT language and correctMethanol TankVapor Pressure

7. Emission Summary: Pollutantthattriggered ActualEmissions (tpy) Major Source Status Pollutant 2008 Data (based on PTE) 

## co 32.02 Yes NOx 38.11 Yes 

## so2 0.23 No PM 3.77 No 

## voc 273.0 Yes Single HAP> 1tpy SCH 3 of 36 03-31-2010PermitNo: 147-97-TV (R2) PlantID: 0072 

### Pollutant that triggered Actual Emissions (tpy) Major Source Status Pollutant 2008 Data (based on PTE) Methanol 2.43 Yes



### Xylene 9.1 Yes 

### Toluene 1.93 Yes 

### Ethylbenzene 1.84 Yes



### Total HAPs 21.78 Yes 

### 8. Applicable Requirements: [X] PSD [ ] NSR [X] NSPS 

### [X] SIP [X] MACT [ ] Other [ ] NESHAPS [X] District-Origin 

### 9. Future MACT Requirements: The federal regulation 40 CFR 63, Subpart DDDDD has been vacated since June 8, 2007, therefore the boiler MACT requirements will notbe included inthis permit. 

### 10. Referenced Federal Regulations in Permit: 40 CFR 63 Subpart IIII

40 CFR 63 SubpartDe

40 CFR63 SubpartEEEE 40 CFR 60 Subpart MM

40 CFR 63 Subpart ZZZZ National Emission Standards for Hazardous AirPollutants

- Surface Coating of Automobile and LightDutyTrucks Standards ofPerformance for Small Industrial-Commercial-Institutional Steam GeneratingUnits Organic Liquids Distribution Operations National Emission Standards of Performance for Automobile and LightDuty Truck Surface Coating Operations National Emissions Standards for Hazardous AirPollutants for StationaryReciprocating Internal CombustionEngines 

### II. Regulatory Analysis 1. Acid Rain Requirements: The source is not subjectto the AcidRainProgram. SCH 

### 4 of 36 03-31-2010

### PermitNo: 147-97-TV (R2) PlantID: 0072

SCH 

### 2. Stratospheric Ozone Protection Requirements: Title VI ofthe CAAA regulates ozone depleting substances and requires aphase-out oftheir use. This rule applies to any facility that manufactures, sells, distributes, or otherwise uses any ofthe listed chemicals. This source does not manufacture, sell, or distribute any ofthe listed chemicals. The source's use oflisted chemicals is that in fire extinguishers, chillers, air conditioners and otherHVAC equipment. 

### 3. Prevention of Accidental Releases 112(r): The source does not manufacture, process, use, store, or otherwise handle one or more ofthe regulated substances listed in 40 CFR Part 68, Subpart F, and District Regulation 5.15, Chemical Accident Prevention Provisions, in a quantity in excess of the corresponding specifiedthreshold amount. 

### 4. Basis ofRegulation Applicability
a. Plant-wide The source is subject to a plant-wide PAL limit of 1316 tons of VOC during any consecutive 12-monthperiod. The source is subject to aplant-wide PAL limit of21.2 tons ofPMduring any consecutive 12-monthperiod. The source is subject to a plant-wide PAL limit of 21.2 tons of 

### PMw during any consecutive 12-monthperiod. The source is subject to a plant-wide PAL limit of 17.2 tons of 

### PM2.s during any consecutive 12-monthperiod. The source is subject to aplant-wide PAL limit of99 tons ofNOx during any consecutive 12-monthperiod. The source is subject to a plant-wide PAL limit of 39.33 tons of S02 during any consecutive 12-monthperiod. The source is subject to a plant-wide PAL limit of 151.4 tons of CO during any consecutive 12-monthperiod. Regulations 5.01, 5.21, and 5.23 (STAR Program) establishes requirements for environmental acceptability of toxic air contaminants (TACs) and the requirement to comply with all applicable emission standards. 5 

### of 36 03-31-2010PermitNo: 147-97-TV (R2) PlantID: 0072

PIPE

E02A

E04A

E04B

E05

SCH The owner or operator shall not allow any TAC emissions to exceed environmentally acceptable levels whether specifically established by modeling or derived from default de minimis levels. (Regulation 5.01, section 3.) The TAC emissions from the combustion ofnatural gas are considered to be "de minimis emissions" by the District. This includes all of the emissions from a process or process equipment for which the only emissions are the products of combustion ofnatural gas, such as from a natural gas-fired boiler or turbine, but does not include the other emissions from a process or process equipment that are not the products of the combustion ofnatural gas. (Regulation 5.01, section 1.6.7) 

### b. Emission UnitU002-U004- Five Boilers
1. 

### Equipment:
Installation Applicable Capacity Date Regulation Basis forApplicability Boilers with heat generating capacities greater 6.07 than 1mmbtu/hr, modified before April9,1972, 146 MMBtu/hr 1954 are subjectto Regulation 6.07 for PM and S02. Boilers emitting large amounts ofNOxare 6.42 subjectto Regulation 6.42 for major nitrogen oxides emitting facilities. 7.06 Boilers with heat generating capacities greater 6.42 than 1mmbtu/hr, modified after April9,1972, are 63.6 MMBtu/hr 1995 subjectto Regulation 7.06 for PMand S02. 40 CFR60 SubpartDC Boilers emitting large amounts ofNOxare 7.06 subject to Regulation 6.42 for major nitrogen 6.42 oxides emitting facilities. 63.6 MMBtu/hr 1995 Standards ofPerformance for Small Industrial- 40 CFR60 Subpart DC Commercial-Institutional Steam Generating Units Boilers with heat generating capacities greater 7.06 than 1mmbtu/hr, modified after April9,1972, are 33.5 MMBtu/hr subject to Regulation 7.06 for PMand S02. each 1996 40 CFR60 Standards ofPerformance for Small IndustrialSubpartDC Commercial-Institutional Steam Generating Units

6 of 36 03-31-2010PermitNo: 147-97-TV(R2) PlantiD: 0072

SCH 11. Standards/Operating Limits
a. PM i. See Permit245-09-C (R1) PAL limits.
11. The emission standard for PM is determined in accordance with Regulation 6.07, section 3.1 and 7.06, section4.1.4 b. Opacity Regulation 6.07, section 3.2 and 7.06, section 5.1.1 establishes an opacity standard ofless than 20%.
c. 

### S02
1. SeePermit 245-09-C (R1) PAL limits. ii. For Emission Point E02A the emission standard for S02 is determined in accordance with Regulation 6.07, section4.1. iii. For Emission Point E04A, E04B and E05 the emission standard for 

## so2 is determined m accordance withRegulation 7.06, section 5.1.1.
IV. Emission Points E04A, E04B and E05 are subjectto 40 CFR 60, Subpart De. However, there is no S02 emission standard for natural gas fired boilers in SubpartDe. d. NOx Regulation 6.42 requires the owner or operator shall not allow the NOx emissions to exceed 99 tons during any consecutive 12-monthperiod in orderto avoidNOxRACT.
111. Monitoring
a. PM Maintainrecords ofmonthly natural gas and/or otherfuel usage. 7 of 36 03-31-2010PermitNo: 147-97-TV (R2)
b. PlantID: 0072 Opacity Regulation 6.07 and 7.06 does not require any specific monitoring requirements for opacity, however, Regulation 2.16, section 4.1.9.1. requires sufficient monitoring to assure ongoing compliance with the terms and conditions ofthe permit.
c. 

### S02 Regulation 6.07 and 7.06 does not require any specific monitoring requirements for S02 , however, Regulation 2.16, section 4.1.9

### .I. requires sufficient monitoring to assure compliance with the terms and conditions of the permit. d. NOx Maintain records of monthly fuel usage, and use AP-42 emission factors and/or fuel analysis data, to calculate monthly emissions. iv. Record Keeping

SCH a. PM See PMMonitoring. b. Opacity Regulation 6.07 and 7.06 does not require any specific record keeping requirements for opacity, however, Regulation 2.16, section 4.1.9.2. requires sufficient record keepingto assure compliance withthe terms and conditions ofthe permit.
c. 

### S02 40 CFR 60, Subpart De requires records ofthe amount of fuel combusted each month. Regulation 6.07 and 7.06 does not require any specific record keeping requirements for S02, however, Regulation 2.16, section 4.1.9.2. requires 8 of 36 03-31-2010PermitNo: 147-97-TV (R2) Plant ID: 0072

PIPE E08AMethanol Tank

SCH sufficient record keeping to assure compliance with the terms and conditions ofthepermit. d. NOx The source shall calculate and record the monthly and 12 consecutive month plant-wide NOx emissions for each month in the reportperiod.


### v. Reporting
a. 

### PM Regulation 2.16, section 4.1.9.3. requires sufficient reporting requirements to assure compliance with the terms and conditions ofthe permit. The source shall report any deviations from the permit. 

### b. Opacity Regulation 2.16, section 4.1.9.3. requires sufficient reporting requirements to assure compliance with the terms and conditions ofthepermit.
c. 

### S02 There are no periodic compliance reporting requirements for S02. d. NOx Regulation 2.16, section 4.1.9.3. requires sufficient reporting requirements to assure compliance with the terms and conditions ofthepermit.


### c. Emission UnitU008- Volatile OrganicLiquid StorageTanks
Installation Applicable Capacity Date Regulation Basis for Applicability

6,000 2002 7.12 VOC storage tanks greaterthan 250 gallon capacity are subject


### 9 of 36 03-31-2010

### PermitNo: 147-97-TV (R2) PlantID: 0072

PIPE E08G UG Solvent Tank E08MAnti-Freeze Tank E08NPower Steering Fluid Tank E080BrakeFluid Tank E08P Diesel Fuel Tank



### SCH Installation Applicable Capacity Date Regulation Basis for Applicability

10,000 1986 7.12 to Regulation 7.12 for VOC which were installed after April 19, 1972. 20,000 1990 7.12 20,000 1990 7.12 6,000 1980 7.12 20,000 After 1972 7.12

11. 

### Standards/OperatingLimits 

# voc 1) Regulation 7.12, section 3.3 requires submerged fill ifthe materials have an as stored vapor pressure of 1.5 psia or greater. Regulation 7.12 applies due to the size ofthe tanks, however, since the vapor pressure as stored is less than 1.5 psia there are no applicable emission or equipment standards. 2) See Permit 245-09-C (R1) PAL limits
111. 

### Monitoring 

# voc The source is required to monitor and maintain records of the material stored in each storage vessel. Ifthe contents ofthe storage vessels are changed, a record shall be made ofthe new contents, the new vapor pressure, andthe date ofthe change in service.
IV. 

### Record Keeping 

# voc The source shall maintain records of the material stored in each storage vessel. Ifthe contents ofthe storage vessels are changed, a 10 of 36 03-31-2010

### PermitNo: 147-97-TV (R2) Plant ID: 0072 record shall be made ofthe new contents, the new vapor pressure, and the date ofthe change in service.
v. Reporting 

# voc There are no Emission Unit specific compliance reporting requirements for the tanks. The source is required to report the throughput for purposes of demonstrating ongoing compliance with the plant-wide PAL VOC emission limit. d. Emission UnitU009- Glass Installation

PIPE E009 Glass, Windshield, and BackLights Installation



### SCH 1. 

### Equipment:
Installation Applicable Capacity Date Regulation Basis for Applicability The glass installation operation N/A 1994 7.59 is subjectto the VOC emission standard in Regulation 7.59 and was installed after September 1, 1976.
11. 

### Standards/OperatingLimits 

# voc 1) Regulation 7.59, section 3.1.3 requires the source shall not cause or allow the emission of VOC from any affected facility resulting from the coating of metallic surfaces in excess of 0.42 kg of VOC/1 (3.5 lb VOC/gal) of coating, excluding water and exempt solvents, as applied for extreme performance coatings. 2) See Permit 245-09-C (Rl)PAL limits
111. 

### Monitoring 

# voc

11 

### of 36 03-31-2010PermitNo: 147-97-TV (R2) PlantID: 0072 Regulation 2.16, section 4.1.9

### .I. requires sufficient monitoring to assure ongoing compliance with the terms and conditions of the permit.
IV. 

### Record Keeping 

## voc 1) Regulation 7.59, section 6.1 and Regulation 2.16, section 4.1.9.2. requires sufficient record keeping to assure compliance withthe terms and conditions ofthe permit. 2) Regulation 2.16, section 4.1.9.2. requires the source to monitor the plant-wide VOC emissions during each consecutive 12-month period to assure the emissions of VOC remain belowtheplant-wide PAL limit.


### v. Reporting 

## voc Regulation 2.16, section 4.1.9.3. requires sufficient reporting requirements to assure compliance with the terms and conditions ofthepermit.


### e. Emission UnitUOlO- E-CoatOperation
1. 

### Equipment

PIPE Capacity Installation Applicable Basis for Applicability Date Regulation 40 CFR63 Subpart Subpart IIII Hazardous Air IIII Pollutants: Surface Coating of E 1 OA E-CoatDip N/A 1996 Automobiles and Light. Tank 40 CFR60 Subpart MM 40 CFR63 Subpart Subpart MM establishes standards for National Emission Standards of IIII Performance for Automobile and E10B E-Coat Oven N/A 1988 LightDuty Truck Surface Coating 40 CFR60 Subpart MM Operations.

SCH 12 of 36 03-31-2010PermitNo: 147-97-TV (R2) PlantID: 0072

E10C E-Coat Oven (3'd Pass)

E10D E-CoatDump Metal AST

E17A E-Coat Scuff Booth

SCH 40 CFR63 Subpart IIII N/A 1996 40 CFR60 Subpart MM 40 CFR63 Subpart IIII N/A 1996 40 CFR60 Subpart MM ForRegulation 7.08 the scuff NIA 1989 boothis subject to PMemission 7.08 standard and was installed after September 1, 1976. ii. Standards/Operating Limits
a. VOC 1) The E-Coat Operation is subject is subject to 40 CPR Part 63, Subpart IIII

- Surface Coating of Automobiles and Light-Duty Trucks and 40 CPR 60, Subpart MM - National Emission Standards of Performance for Automobile and Light Duty Truck Surface Coating Operations section 60.392 emission limits. 2) See Permit245-09-C (R1) PAL limits b. PM 1) The PM limits are calculated per Regulation 7.08, section 3.1.2. The equation to calculate the emission limits is E 

### = 3.59P0

·62
, where P is expressed in tons/hr. 2) See Permit245-09-C (R1) PAL limits
c. Opacity Regulation 7.08, section 3.1.2. establishes an opacity standard ofless than20%. 13 of 36 03-31-2010PermitNo: 147-97-TV (R2) Plant ID: 0072

SCH iii. Monitoring
a. VOC 40 CFR Part 63, Subpart IIII - Surface Coating of Automobiles and Light-Duty Trucks and 40 CFR 60, Subpart MM National Emission Standards of Performance for Automobile and Light Duty Truck Surface Coating Operations sections 60.392 establishes monitoring requirements. b. PM Regulation 7.08 does not require any specific monitoring requirements for PM, however, Regulation 2.16, section 4.1.9.1. requires sufficient monitoring to assure ongoing compliancewiththeterms and conditions ofthepermit.
c. Opacity Regulation 7.08 does not require any specific monitoring requirements for opacity, however, Regulation 2.16, section 4.1.9.1. requires sufficient monitoring to assure compliance withtheterms and conditions ofthe permit. iv. Record Keeping
a. VOC 40 CFR Part 60, Subpart MM - National Emission Standards ofPerformance for Automobile and Light Duty Truck Surface Coating Operations sections 60.3095 and 40 CFR Part 63

- Surface Coating ofAutomobiles and Light Duty Trucks establishes record keeping requirement. Regulation 2.16, section 4.1.9.2 establishes record keeping requirements to assure ongoing compliance with the terms and conditions ofthepermit. b. PM See PMMonitoring.
14 of 36 03-31-2010PermitNo: 147-97-TV (R2) Plant ID: 0072


### c. Opacity Regulation 7.08 does not require any specific record keeping requirements for opacity, however, Regulation 2.16, section 4.1.9.2. requires sufficient record keeping to assure ongoing compliance with the terms and conditions ofthepermit.
v. Reporting
a. VOC Regulation 2.16, section 4.1.9.3. establishes reporting requirements to assure ongoing compliance with the terms and conditions ofthe permit. 

### b. PM Regulation 7.08 does not require any specific reporting requirements for PM, however, Regulation 2.16, section 4.1.9.3. requires reporting to assure compliance with the terms and conditions ofthe permit.
c. Opacity Regulation 7.08 does not require any specific reporting requirements for opacity, however, Regulation 2.16, section 4.1.9.3. requires reporting to assure compliance with the terms and conditions ofthe permit. f. Emission UnitUOll- Guidecoat Operation 

### i. Equipment:

PIPE Capacity Installation Applicable Basis for Applicability Date Regulation EllA Guidecoat Subpart IIII Hazardous Air 40 CFR63 Subpart Pollutants: Surface Coating of PaintBooth and Air N/A 1988 IIII Automobiles andLight-Duty SupplyHose Trucks

SCH 15 of 36 03-31-2010PermitNo: 147-97-TV (R2) PlantID: 0072 SubpartNIMNational Emission 40 CFR 60 Subpart Standards ofPerformance for MNI Automobile and LightDutyTruck Surface Coating Operations establishes standards. ForRegulation 7.08 the scuff 7.08 booth is subject to PMemission standard and was installed after E11B Touchup and N/A 1988 September 1, 1976. BlackoutBooth The guidecoat operation is subject 7.59 to the VOC emission standard in Regulation 7.59 and was installed after September 1, 1976. 40 CFR 63 Subpart SubpartIIII Hazardous Air III! Pollutants: Surface Coating of EllC Guidecoat 40 CFR 60 Subpart Automobiles and Light-Duty Ovens (1st and znd N/A 1988 MM Trucks Pass) 7.08 SubpartMMNational Emission Standards ofPerformance for 40 CFR 63 Subpart Automobile andLightDutyTruck Surface Coating Operations IIII establishes standards. EllD Guidecoat N/A 1988 40 CFR60 Subpart Oven (3'd Pass) MM ForRegulation 7.08 the equipment is subjectto PMemission standard 7.08 and was installed after September 1, 1976. 40 CFR63 Subpart Subpart !IIIHazardous Air III! Pollutants: Surface Coating of Automobiles and Light-Duty Trucks E11E/E12G Guidecoat/Topcoat N/A 1988 SubpartMMNational Emission Paint Kitchen 40 CFR60 Subpart Standards ofPerformance for MM Automobile and LightDuty Truck Surface Coating Operations establishes standards.
ForRegulation 7.08 the scuff ElSA Guidecoat N/A 1989 7.08 boothis subjectto PMemission ScuffBooth standard and was installed after September 1, 1976.

SCH 16 of 36 03-31-2010

### PermitNo: 147-97-TV (R2) PlantID: 0072

SCH ii. Standards/Operating Limits
a. VOC 

### 1) The Guidecoat Operation is subject to 40 CFR Part 63, Subpart IIII

- 

### Surface Coating ofAutomobiles and Light-Duty Tmcks and 40 CFR 60, Subpart MM - 

### National Emission Standards ofPerformance for Automobile and Light Duty Tmck Surface Coating Operations section 60.392 emission limits. 2) Regulation 7.59, section 3.1.3 requires the source shall not cause or allow the emission ofVOC from any affected facility resulting from the coating of metallic surfaces in excess of0.42 kg ofVOC/1 (3.5 lb of VOC/gal) of coating, excluding water and exempt solvents, as applied for extreme performance coatings. 3) See Permit 245-09-C (R1) PAL limits 

### b. PM 

### 1) The PM limits are calculated per Regulation 7.08, section 3.1.2. The equationto calculate the emission limits is E = 3.59P0

·62
, 

### where P is expressed in tons/hr. 2) See Permit 245-09-C (R1) PAL limits
c. Opacity 

### Regulation 7.08, section 3.1.2. establishes an opacity standard ofless than 20%. iii. Monitoring


### a. VOC 

### 40 CFR Part 63, Subpart IIII

- 

### Surface Coating of Automobiles and Light-Duty Trucks and 40 CFR 60, Subpart MM National Emission Standards of Performance for Automobile and Light Duty Tmck Surface 17 of 36 03-31-2010PermitNo: 147-97-TV (R2) PlantID: 0072 Coating Operations sections 60.392 establishes monitoring requirements. 

### b. PM Regulation 7.08 does not require any specific monitoring requirements for PM, however, Regulation 2.16, section 4.1.9.1. requires sufficient monitoring to assure ongoing compliance withthe terms and conditions ofthepermit.
c. 

### Opacity Regulation 7.08 does not require any specific monitoring requirements for opacity, however, Regulation 2.16, section 4.1.9.1. requires sufficient monitoring to assure compliance withtheterms and conditions ofthe permit.
IV. Record Keeping

SCH a. VOC 1) 40 CPR Part 60, Subpart MM -National Emission Standards ofPerformance for Automobile and Light Duty Truck Surface Coating Operations sections 60.3095 and 40 CPR Part 63

- Surface Coating of Automobiles and Light-Duty Trucks establishes record keeping requirement. Regulation 2.16, section 4.1.9.2 establishes record keeping requirements to assure ongoing compliance with the terms and conditions ofthepermit. 2) Regulation 7.59, section 6.1 and Regulation 2.16, section 4.1.9.2. requires sufficient record keepingto assure compliance with the terms and conditions of thepermit. b. PM See PMMonitoring.
c. 

### Opacity

18 of 36 03-31-2010PermitNo: 147-97-TV (R2) Plant ID: 0072 Regulation 7.08 does not require any specific record keeping requirements for opacity, however, Regulation 2.16, section 4.1.9.2. requires sufficient record keeping to assure ongoing compliance with the terms and conditions ofthepermit.


### v. Reporting
a. VOC Regulation 2.16, section 4.1.9.3. establishes reporting requirements to assure ongoing compliance with the terms and conditions ofthe permit. 

### b. PM Regulation 7.08 does not require any specific reporting requirements for PM, however, Regulation 2.16, section 4.1.9.3. requires reporting to assure compliance with the terms and conditions ofthe permit.


### c. Opacity. Regulation 7.08 does not require any specific reporting requirements for opacity, however, Regulation 2.16, section 4.1.9.3. requires reporting to assure compliance with the terms and conditions ofthe permit. 

### g. Emission UnitU012- Topcoat Operation
1. 

### Equipment:

PIPE Capacity Installation Applicable Basis for Applicability Date Regulation ForRegulation 7.08 the scuff 7.08 booth is subjectto PMemission standard and was installed after E12ANorthMain September 1, 1976. The topcoat operation is subject to EnamelBooth and N/A 1985 the VOC emission standard in Air Supply 7.59 Regulation 7.59 and was installed after September 1, 1976. 40 CFR 63 Subpart Subpart IIII Hazardous Air IIII Pollutants: Surface Coating of SCH 19 of 36 03-31-2010PermitNo: 147-97-TV (R2) Plant ID: 0072 Automobiles and Light-Duty Trucks Subpart MMNational Emission 40 CFR 60 Subpart Standards ofPerformance for Automobile and Light Duty Truck MM Surface Coating Operations establishes standards. Subpart IlliHazardous Air 40 CFR 63 Subpart Pollutants: Surface Coating of IIII Automobiles and Light-Duty Trucks E12B North Main N/A 1985 Enamel Oven Subpart MMNational Emission 40 CFR 60 Subpart Standards ofPerformance for MM Automobile and LightDutyTruck Surface Coating Operations establishes standards. ForRegulation 7.08 the scuff 7.08 booth is subjectto PMemission standard and was installed after September 1, 1976. Subpart IIII Hazardous Air 40 CFR 63 Subpart Pollutants: Surface Coating of E12C South Main N/A 1985 IIII Automobiles and Light-Duty Enamel Booth Trucks SubpartMMNational Emission 40 CFR 60 Subpart Standards ofPerformance for Automobile andLightDuty Truck MM Surface Coating Operations establishes standards. ForRegulation 7.08 the scuff 7.08 booth is subjectto PMemission standard and was installed after E12D Air Supply and September 1, 1976. Oven N/A 1985 SubpartMM establishes standards for National Emission Standards of 40 CFR 60 Subpart Performance for Automobile and MM LightDuty Truck Surface Coating Operations. ForRegulation 7.08 the scuff 7.08 booth is subject to PMemission standard and was installed after E12F Air Supply September 1, 1976. N/A 1985 House and Oven Subpart MM establishes standards 40 CFR 60 Subpart for National Emission Standards of Performance for Automobile and MM LightDutyTruck Surface Coating Operations. SCH 20 of 36 03-31-2010

### PermitNo: 147-97-TV (R2) Plant ID: 0072

E11E/E12G Guidecoat/Topcoat Kitchen

E12HTopcoat Scuff Booth

E12ITuTone/Repair ScuffBooth



### SCH SubpartMM establishes standards for National Emission Standards of N/A 1988 40 CFR 60 Subpart Performance for Automobile and MM LightDutyTruck Surface Coating Operations. ForRegulation 7.08 the scuff N/A 1985 7.08 booth is subjectto PMemission standard and was installed after September 1, 1976.
ForRegulation 7.08 the scuff N/A 1985 7.08 booth is subjectto PMemission standard and was installed after September 1, 1976.
ii. Standards/OperatingLimits
a. VOC 

### 1) The Topcoat Operation is subject is subject to 40 CPR Part 63, Subpart IIII

- 

### Surface Coating of Automobiles and Light-Duty Trucks and 40 CPR 60, Subpart MM - 

### National Emission Standards of Performance for Automobile and Light Duty Truck Surface Coating Operations section 60.392 emission limits. 2) Regulation 7.59, section 3.1.3. requires the source shall not cause or allow the emission ofVOC from any affected facility resulting from the coating of metallic surfaces in excess of0.42 kg ofVOC/1 (3.5 lb of VOC/gal) of coating, excluding water and exempt solvents, as applied for extreme performance coatings. 3) See Permit 245-09-C (R1) PAL limits b. PM 1) 

### The PM limits are calculated per Regulation 7.08, section 3.1.2. The equationto calculate the emission
21 of 36 03-31-2010PermitNo: 147-97-TV (R2) Plant ID: 0072

SCH limits is E tons/hr. 3.59P0

·62
, where P is expressed in 2) See Permit245-09-C (Rl) PAL limits
c. Opacity Regulation 7.08, section 3.1.2. establishes an opacity standard ofless than 20%. iii. Monitoring
a. VOC 40 CFR Part 63, Subpart IIII

- Surface Coating of Automobiles and Light-Duty Trucks and 40 CFR 60, Subpart 

### MM National Emission Standards of Performance for Automobile and Light Duty Truck Surface Coating Operations sections 60.392 establishes monitoring requirements. b. PM Regulation 7.08 does not require any specific monitoring requirements for PM, however, Regulation 2.16, section 4.1.9.1. requires sufficient monitoring to assure ongoing compliancewiththeterms and conditions ofthepermit.
c. Opacity Regulation 7.08 does not require any specific monitoring requirements for opacity, however, Regulation 2.16, section 4.1.9.1. requires sufficient monitoring to assure compliance withthe terms and conditions ofthe permit. iv. Record Keeping
a. VOC 1) 40 CFR Part 60, Subpart MM -National Emission Standards ofPerformance for Automobile andLight Duty Truck Surface Coating Operations sections 60.3095 and 40 CFR Part 63

- Surface Coating of 22 of 36 03-31-2010PermitNo: 147-97-TV (R2) PlantID: 0072 Automobiles and Light-Duty Trucks establishes record keeping requirement. Regulation 2.16, section 4.1.9.2 establishes record keeping requirements to assure ongoing compliance with the terms and conditions ofthepermit. 2) Regulation 7.59, section 6.1 and Regulation 2.16, section 4.1.9.2. requires sufficientrecord keeping to assure compliance with the terms and conditions of the permit. 3) Regulation 2.16, section 4.1.9.1 requires the source to monitor the plant-wide VOC emissions during each consecutive 12-month period to assure the emissions of VOC remain below the plant-wide PALlimit. b. PM See PMMonitoring.
c. Opacity Regulation 7.08 does not require any specific record keeping requirements for opacity, however, Regulation 2.16, section 4.1.9.2. requires sufficient record keeping to assure ongoing compliance with the terms and conditions ofthe permit.
v. Reporting

SCH a. VOC Regulation 2.16, section 4.1.9.3. establishes reporting requirements to assure ongoing compliance with the terms and conditions ofthe permit. 

### b. PM Regulation 7.08 does not require any specific reporting requirements for PM, however, Regulation 2.16, section 4.1.9.3. requires reporting to assure compliance with the terms and conditions ofthepermit. 23 of 36 03-31-2010PermitNo: 147-97-TV (R2) Plant ID: 0072



### c. Opacity Regulation 7.08 does not require any specific reporting requirements for opacity, however, Regulation 2.16, section 4.1.9.3. requires reporting to assure compliance with the terms and conditions ofthe permit. 

### g. Emission UnitU013 -Plant-wideProductFueling

PIPE
E13A Gasoline Tank#1

EBB Gasoline Tank#2

E13C Gasoline Tank#3
E13D Two Fueling Stations with Vapor Recovery

SCH Installation Applicable Capacity Date Regulation Basis for Applicability Standards ofPerformance for Gasoline Transferto New 20,000 gallons 1990 7.15 Service Station Storage Tanks (Stage I Vapor Recovery) Standards ofPerformance for Gasoline Transferto New 20,000 gallons 1990 7.15 Service Station Storage Tanks (Stage I Vapor Recovery) Standards ofPerformance for Gasoline Transfer to New 20,000 gallons 1990 7.15 Service Station Storage Tanks (Stage I Vapor Recovery) N/A 1994 7.25 OR VREquipped Vehicles

11. 

### Standards/OperatingLimits 

# voc Regulation 7.15 requires that storage tanks shall be equipped with the following:
a. A submerged fill pipe; b. If the gasoline storage tank is equipped with a separate gauge well, a gauge well drop tube shall be installed which extends to within six inches ofthe bottom ofthe tank; c. Vent line restrictions on the affected facility; and

24 of 36 03-31-2010PermitNo: 147-97-TV (R2) PlantID: 0072

SCH 

### d. Vapor balance system and vapor tight connections on the liquid fill and vapor return hoses. The cross-sectional area of the vapor return hose and any other vapor return passages in the circuit connecting the vapor space in the service station tankto that ofthe trucktank must be at least 50% of the liquid fill hose cross-sectional area for each tank and free of flow restrictions to achieve acceptable recovery. The vapor balance equipment must be maintained according to the manufacturer's specifications. The type, size and design ofthe vapor balance system are subjectto the approval ofthe District.
111. Monitoring 

# voc Regulation 7.15 does not require any specific monitoring requirements for VOC, however, Regulation 2.16, section 4.1.9.1. requires sufficient monitoring to assure ongoing compliance with the terms and conditions ofthe permit. iv. Record Keeping 

# voc Regulation 7.15 does not require any specific record keeping requirements for VOC, however, Regulation 2.16, section 4.1.9.2. requires sufficient record keeping to assure ongoing compliance withthe terms and conditions ofthe permit.
v. Reporting 

# voc Regulation 2.16, section 4.1.9.3. establishes reporting requirements to assure ongoing compliance with the terms and conditions ofthe permit.

25 of 36 03-31-2010

### PermitNo: 147-97-TV (R2) PlantID: 0072 

### h. Emission UnitU014/U022- PaintEquipment Cleaning Operation

PIPE

E14 Paint Equipment CleaningBooth

E22APaint EquipmentPurging andPlant Cleaning

SolventMetal Cleaning Equipment



### SCH Installation Applicable Capacity Date Regulation Basis for Applicability This regulation applies to each existing auto and truck manufacturing facility which N/A 1985 7.25 was in being or had a construction permit issued by the Districtbefore June 13, 1979 This regulation applies to each existing auto andtruck manufacturing facility which N/A 1976 7.25 was in being orhad a construction permit issued by the Districtbefore June 13, 1979 Standards ofPerformance for Gasoline Transferto New N/A N/A 6.18 Service Station Storage Tanks (Stage I Vapor Recovery) 

### ii. 

### Standards/OperatingLimits 

## voc 1) The source shall follow the procedure below to minimize VOC emissions from purge and cleaning operations under Regulation 7.25, section 3. 2) For all cold solvent parts washers, the source shall comply with the standards ofRegulation 6.18, sections 4.1 through 4.3.
111. 

### Monitoring 

## voc Regulation 2.16, section 4.1.9.1. requires sufficient monitoring to assure ongoing compliance with the terms and conditions of the permit.
IV. 

### Record Keeping 26 of 36 03-31-2010

### PermitNo: 147-97-TV (R2) PlantID: 0072


# voc Regulation 2.16, section 4.1.9.2. requires sufficient record keeping to assure ongoing compliance with the terms and conditions ofthe permit.


### v. Reporting 

# voc Regulation 2.16, section 4.1.9.3. establishes reportingrequirements to assure ongoing compliance with the terms and conditions ofthe permit. i. 

### Emission UnitU015- SealerDeck

PIPE
ElSA Sealer Application

Sealers and Deadeners (other than glass bonding)



### SCH Installation Applicable Capacity Date Regulation Basis for Applicability The sealer operation is subjectto the VOC emission N/A 1994 7.59 standard inRegulation 7.59 and was installed after September 1, 1976. Subpart IIII establishes 40 CFR63 Subpart standards for Hazardous Air N/A N/A Pollutants: Surface Coating IIII ofAutomobiles and LightDuty Trucks
11. 

### Standards/OperatingLimits 

# voc 1) Regulation 7.59, section 3.1.3. requires the source shall not cause or allow the emission of VOC from any affected facility resulting from the coating of metallic surfaces in excess of 3.5 lb VOC/gal of coating, excluding water and exempt solvents, as applied for extreme performance coatings. 2) See Permit 245-09-C PAL limits
27 of 36 03-31-2010PermitNo: 147-97-TV (R2) PlantID: 0072 iii. 

### Monitoring 

# voc Regulation 2.16, section 4.1.9.1. requires sufficient monitoring to assure ongoing compliance with the terms and conditions of the permit. 

### iv. Record Keeping 

# voc 1) Regulation 7.59, section 6.1 and Regulation 2.16, section 4.1.9.2. requires sufficient record keeping to assure compliance with the terms and conditions ofthe permit. 2) Regulation 2.16, section 4.1.9.2. requires the source to monitor the plant-wide VOC emissions during each consecutive 12-month period to assure the emissions of VOC remain belowtheplant-wide PAL limit.


### v. Reporting 

# voc Regulation 2.16, section4.1.9.3. establishes reporting requirements to assure ongoing compliance with the terms and conditions ofthe permit. j. 

### Emission UnitU016- FinalRepair SprayBooth; infrared curing, and spot repair bays for repairing coating on vehicles
Installation Applicable PIPE Capacity Date Regulation Basis for Applicability 7.08 ForRegulation 7.08 the scuff booth is subjectto PM 40 CFR63 Subpart emission standard and was E16A Final Repair N/A 1982 IIII installed after September 1, Booth 1976. 40 CFR60 Subpart MM Subpart IIII establishes E16B Final Repair N/A 1982 7.08 standards for Hazardous Air Oven Pollutants: Surface Coating SCH 28 of 36 03-31-2010PermitNo: 147-97-TV (R2) PlantID: 0072

PIPE

SCH Installation Applicable Capacity Date Regulation Basis for Applicability 40 CFR63 Subpart ofAutomobiles and LightIIII Duty Trucks SubpartMMestablishes 40 CFR60 Subpart standards forNational Emission Standards of MM Performance for Automobile and LightDuty Truck Surface CoatingOperations.
11. Standards/OperatingLimits
a. VOC 1) TheE-Coat Operation is subjectto 40 CPRPart 60, Subpart IIII

- Surface Coating ofAutomobiles and Light-Duty Trucks. 40 CPR 60, Subpart IIII section 60.392 emission limits. 2) See Permit245-09-C (R1) PALlimits b. PM 1) The PM limits are calculated per Regulation 7.08, section 3.1.2. The equation to calculate the emission limits is E 

### = 3.59P0

·62
, where P is expressed in tons/hr. 2) See Permit 245-09-C (R1) PAL limits
c. Opacity Regulation 7.08, section 3.1.2. establishes an opacity standard ofless than 20%. iii. Monitoring
a. VOC

29 of 36 03-31-2010PermitNo: 147-97-TV (R2) PlantID: 0072 40 CPR Part 60, Subpart IIII

- Surface Coating of Automobiles and Light-Duty Trucks sections 60.392 establishesmonitoringrequirements. b. PM Regulation 7.08 does not require any specific monitoring requirements for PM, however, Regulation 2.16, section 4.1.9.1. requires sufficient monitoring to assure ongoing compliancewiththe terms and conditions ofthe permit.
c. Opacity Regulation 7.08 does not require any specific monitoring requirements for opacity, however, Regulation 2.16, section 4.1.9.1. requires sufficient monitoringto assure compliance withthe terms and conditions ofthepermit. iv. Record Keeping

SCH a. VOC 1) 40 CPR Part 60, Subpart IIII

- Surface Coating of Automobiles and Light-Duty Trucks sections 60.395 establishes record keeping requirement. Regulation 2.16, section 4.1.9.2. establishes record keeping requirements to assure ongoing compliance withthe terms and conditions ofthe permit. 2) Regulation 2.16, section 4.1.9.2. requires the source to monitor the plant-wide VOC emissions during each consecutive 12-month period to assure the emissions of VOC remain below the plant-wide PAL limit. b. PM SeePMMonitoring.
c. Opacity Regulation 7.08 does not require any specific record keeping requirements for opacity, however, Regulation 30 of 36 03-31-2010PermitNo: 147-97-TV (R2) Plant ID: 0072 2.16, section 4.1.9.2. requires sufficient record keeping to assure ongoing compliance with the terms and conditions ofthe permit.
v. Reporting
a. VOC Regulation 2.16, section 4.1.9.3. establishes reporting requirements to assure ongoing compliance with the terms and conditions ofthepermit. 

### b. PM Regulation 7.08 does not require any specific reporting requirements for PM, however, Regulation 2.16, section 4.1.9.3. requires repmting to assure compliance with the terms and conditions ofthepermit.
c. Opacity Regulation 7.08 does not require any specific reporting requirements for opacity, however, Regulation 2.16, section 4.1.9.3. requires reporting to assure compliance with the terms and conditions ofthe permit. 

### k. Emission UnitU025- Twelve (12) Direct HeatExchangers

ID
E25

SCH U025 Emission Points Description Applicable Regulation Control Device 6.42 DirectHeatExchangers 7.08 N/A
ii. Standards/Operating Limits
a. PM The PM limits are calculatedperRegulation 7.08, section 3.1.2. The equationto calculate the emission limits is E 

### = 31 of 36 03-31-2010PermitNo: 147-97-TV (R2) PlantID: 0072 3.59P0

·62
, wherePis expressed in tons/hr. The maximum throughput is less than 1,000 pounds perhour; therefore, the PMemission standard is 2.34 lb/hr. b. Opacity Regulation 7.08, section 3.1.1. establishes an opacity standard ofless than 20%.
c. NOx Per Regulation 6.42, the owner or operator shall not allow or cause theplant-wide NOx emissions to equal or exceed 100 tons during any consecutive 12-month period in order to avoidNOxRACT. iii. Monitoring

IV.

SCH a. PM There are no compliance monitoring requirements for this equipment. The potential uncontrolled PM emissions are less thanthe applicable emission standard. b. Opacity Regulation 7.08 does not require any specific monitoring requirements for opacity, however, Regulation 2.16, section 4.1.9.1. requires sufficientmonitoring to assure compliance with the terms and conditions ofthepermit.
c. NOx

a. Regulation 7.08 does not require any specific monitoring requirements for NOx, however, Regulation 2.16, section 4.1.9.1. establishes monitoring requirements to assure ongoing compliance with the terms and conditions of the permit. Record Keeping· PM
32 of 36 03-31-2010PermitNo: 147-97-TV (R2) PlantID: 0072 There are no compliance record keeping requirements for this equipment. The potential uncontrolled PM emissions are less than the applicable emission standard. b. Opacity Regulation 7.08 does not require any specific monitoring requirements for opacity, however, Regulation 2.16, section 4.1.9.2. requires reporting to assure compliance with the terms and conditions ofthe permit.
c. NOx Regulation 7.08 does not require any specific record keeping requirements for NOx, however, Regulation 2.16, section 4.1.9.2. requires sufficient record keeping to assure ongoing compliance with the terms and conditions of the permit.
v. Reporting

SCH a. PM There are no routine compliance reporting requirements for this equipment. The potential uncontrolled PM emissions are less thanthe applicable emission standard. b. Opacity Regulation 7.08 does not require any specific reporting requirements for opacity, however, Regulation 2.16, section 4.1.9.3. requires reporting to assure compliance with the terms and conditions ofthe permit.
c. NOx Regulation 7.08 does not require any specific reporting requirements for NOx, however, Regulation 2.16, section 4.1.9.3. requires reporting to assure compliance with the terms and conditions ofthe permit.

33 of 36 03-31-2010

### PermitNo: 147-97-TV (R2) Plant ID: 0072 III. OtherRequirements 

### 1. Temporary Sources: The source did not request to operate any temporary facilities. 2. ShortTermActivities: The source did notreport ant shortterm activities. 

### 3. Emissions Trading: N/A 4. 

### Alternative Operating Scenarios: The source did not request to operate under any alternative operating scenarios. 5. Compliance Status: Ford Motor Company-Louisville AssemblyPlant is required to submit their annual Compliance Certification to the District on or before April 15th ofeach calendar year. As ofthe effective date ofPermit 245-09-C (Rl), there are no compliance schedules in effect orprogress reports required. 6. InsignificantActivities InsignificantActivities Description Quantity Basis Internal combustion engines Various Regulation 2.02, Section 2.2 fixed ormobile Presses extruding Various Regulation 2.02, Section 2.3.1 metal/mineral/wood Brazing, soldering or Various Regulation 2.02, Section 2.3.4 welding equipment Woodworking, except for conveying, hogging, or Various Regulation 2.02, Section 2.3.5 burning wood/sawdust Lab venting and exhaust systems (non radioactive Various Regulation 2.02, Section2.3.11 materials) Ventilation systems
- Various Regulation 2.02, Section 2.3.12 bakeries & restaurants Washing ordrying fabricated metal orglass; non Various Regulation 2.02, Section 2.3.15 VOC use; no oil or solid fuel


### SCH 34 of 36 03-31-2010PermitNo: 147-97-TV (R2) Plant ID: 0072 InsignificantActivities Description Quantity Basis ResidentiaVdomestic Various Regulation 2.02, Section 2.3.12 equipment Portable diesel or gasoline Various Regulation 2.02, Section 2.3.23 storage tanks Diesel fuel storage tanks Various Regulation 2.02, Section 2.3.25 (emergency use only) Closed pressure storage 2 Regulation 2.02, Section 2.3.26 vessels Portabletote tanks for raw Tote tanks are kept closed whennot in use. Emission from tanks material shipment ofsolvent Various

- based coatings are negligible, and are accounted for byprocess material balance. Backup generators for emergencypower.(< 500 2 Generators normal use is very low and HP <500 HP. hrs/year) Wastewater Pretreatment 1 Emissions insignificant system. FluidFill (hydraulic fluids, Emissions insignificant due to lowvaporpressure ofmaterials oil, anti-freeze) and Various Lubricating operations. used. Miscellaneous mainten-ance procedures includ-ing Various Negligible emissions lubrication, grinding, cleaning, woodworking, etc. Directheat exchangers <1 Various Regulation 2.02, Section 2.1.1 MMBtu/hr

a. Insignificant Activities are only those activities or processes falling into the general categories defined in District Regulation 2.02, Section 2, and not associated with a specific operation or process for which there is a specific regulation. Equipment associated with a specific operation or process (Emission Unit) shall be listed with the specific process even though there may be no applicable requirements. Information contained in the permit and permit summary shall clearly indicate that those items identified with negligible emissions have no applicable requirements. b. Activities identified in District Regulation 2.02, Section 2, may not require a SCH 35 of 36 03-31-2010

### PermitNo: 147-97-TV (R2) Plant ID: 0072

SCH permit and may be insignificant with regard to application disclosure requirements butmay still have generally applicable requirements that continue to applyto the source.
c. For all insignificant activities that emit regulated air pollutants for which the company has accepted a plant-wide synthetic minor limit, the company shall maintain sufficient records to calculate the emissions and report those emissions in the quarterly compliance reports and the annual emissions inventoryreport. d. The Insignificant Activities table is correct as ofthe date the permit was proposed for review bythe USEPA, Region 4. The company shall submit an updated list of insignificant activities annuallywith the Title V compliance certificationpursuant to District Regulation 2.16, section4.3.5.3.6.
e. In lieu ofrecording annual throughputs for each Insignificant Activity, the owner or operator may elect to report the Potential To Emit quantity listed in the Insignificant Activities table as the annual emission for each piece ofequipment, since the emissions from the source's Insignificant Activities are minor.

36 of 36 03-31-2010

### LouisvilleMetro AirPollution Control District 850 BarretAvenue Louisville, Kentucky 40204-1745 

## PAL ConstructionPermit PermitNo: 245-09-C (R1) Effective Date: 03/3112011 Expiration Date: 07/30/2020 Plant ID: 0072 PermitFee: $0
Permissionis hereby givenbythe Louisville Metro Air Pollution Control Districtto construct the process(es) and equipment describedherein which are located at: FordMotor Company-LouisvilleAssemblyPlant 2000FernValley Road Louisville, Kentucky 40213 The applicable procedures of District Regulations 2.03 and 2.05 regarding review by the U.S. EPA andpublic participation have beenfollowed in the issuance ofthis permit. Based onreview of the application on file with the District, permission is given to operate under the conditions stipulated herein. If 

### a renewal permit is not issued prior to the expiration date, the owner or operator may continue to operate in accordance with the terms and conditions of this permit beyond the expiration date, provided that a complete renewal application is submitted to the District no earlier than eighteen (18) months and no later than one-hundred eighty (180) days priorto the expiration date.

PermitWriter:

Administratively Complete: Date ofPublic Notice: Shannon Clemons Hosey

09/20/2005 and 10/06/2008 06/11/2010 

# -(JoJ)J(kL AirPollution Control OfficerPermitNo: 245-09-C (Rl) PlantID: 0072 Table ofContents PAL/Title V PermitRevisions/Changes
......................................................................................... 4 Abbreviations and Acronyms
......................................................................................................... 5 Preamble
......................................................................................................................................... 6 General Conditions
......................................................................................................................... 7 Plant-wide ApplicabilityLimits
.................................................................................................... 16 Plant-wide ApplicabilityLimit (PAL) Specific Conditions
............................................. 16 PALMonitoring and Record Keeping Requirements
....................................................... 18 PALPermitRequirements
................................................................................................ 22 PAL ComplianceDemonstration
...................................................................................... 25 PALReporting Requirements
........................................................................................... 28 PALPerformance Testing
................................................................................................. 29 Plant-wide ApplicabilityLimits Comments
..................................................................... 31 Louisville AssemblyPlant, FordMotor CompanyMaximumAchievable Control Technology (MACT) Requirements
..................................................................................................... 32 STARRequirements
..................................................................................................................... 40 U002

- U004 Emission UnitDescription: Five Boilers
............................................................... 42 U002

- U004 Regulations
................................................................................................. 42 U002

- U004 Control Devices
.......................................................................................... 43 U002

- U004 Specific Conditions
..................................................................................... 44 U002

- U004 Comments
................................................................................................... 4 7 U008 EmissionUnitDescription: Volatile Organic Liquid Storage Tanks
................................ 49 U008 Applicable Regulations
........................................................................................... 49 U008 Emission Points
....................................................................................................... 50 U008 Control Device
........................................................................................................ 50 U008 Specific Conditions
................................................................................................. 51 U008 Comments
............................................................................................................... 52 U009 EmissionUnitDescription: Glass Installation
................................................................... 53 U009 Applicable Regulations
........................................................................................... 53 U009 EmissionPoints
....................................................................................................... 54 U009 Control Devices
....................................................................................................... 54 U009 Specific Conditions
................................................................................................. 55 U010 EmissionUnitDescription: E-Coat Operation
................................................................... 58 UOlO Applicable Regulations
........................................................................................... 58 U010 Emission Points
..................................................................................,.................... 59 UOlO Control Devices
....................................................................................................... 60 UO10 Specific Conditions
................................................................................................. 61 UO10 Comments
..........................................................................................................'
..... 67 UOll Emission Unit Description: Guidecoat Operation
.............................................................. 68 UOll Applicable Regulations
........................................................................................... 68 UOll Emission Points
....................................................................................................... 70 U011 Control Devices
....................................................................................................... 71 U011 Control Devices
....................................................................................................... 71 UO 11 Specific Conditions
................................................................................................. 72 UO 11 Comments
............................................................................................................... 79 SCH Page 2 of 130 03-31-2011PermitNo: 245-09-C (R1) PlantID: 0072 U012 Emission UnitDescription: Topcoat Operation
................................................................. 80 U012 Applicable Regulations
........................................................................................... 80 U012 Emission Points
....................................................................................................... 82 U012 ControlDevices
....................................................................................................... 85 U012 Specific Conditions
................................................................................................. 86 U012 Comments
............................................................................................................... 92 U013 Emission UnitDescription: Plant-wide ProductFueling
................................................... 93 U013 Applicable Regualtions
........................................................................................... 93 UO13 Emissions Points
..................................................................................................... 94 U013 Control Equipment
.................................................................................................. 94 UO 13 Specific Conditions
................................................................................................. 95 U013 Comments
............................................................................................................... 97 U014 and U022 EmissionUnitDescription: PaintEquipment Cleaning Operation
................... 98 U014 and U022 Applicable Regulations
.......................................................................... 98 UO 14 and U022 EmissionPoints
...................................................................................... 99 UO14 and U022 Control Devices
...................................................................................... 99 U014 and U022 Specific Conditions
.............................................................................. 100 U014 and U022 Comments
............................................................................................. 103 UO 15 Emission UnitDescription: SealerDeck
......................................................................... 104 U015 Applicable Regulations
......................................................................................... 104 U015 Emission Points
..................................................................................................... 105 U015 Control Devices
..................................................................................................... 105 U015 Specific Conditions
............................................................................................... 106 U016 Emission UnitDescription: Final Repair SprayBooth
.................................................... 109 U016 Applicable Regulations
......................................................................................... 109 U016 Control Devices
..................................................................................................... 112 U016 Specific Conditions
............................................................................................... 113 U016 Comments
..................................'
........................................................................... 117 U023 Emission UnitDescription: Phosphate Operation
........................................................... 118 U023 Applicable Regulations
......................................................................................... 118 U023 EmissionPoints
..................................................................................................... 118 U023 Control Devices
..................................................................................................... 118 U023 Specific Conditions
............................................................................................... 119 U025 Emission UnitDescription: Twelve (12) Direct HeatExchangers
.................................. 120 U025 Applicable Regulations
......................................................................................... 120 U025 EmissionPoints
..................................................................................................... 120 U025 Control Devices
..................................................................................................... 120 U025 Specific Conditions
............................................................................................... 121 U025 Comments
............................................................................................................. 123 Permit Shield
............................................................................................................................... 124 Alternative Operating Scenarios
................................................................................................. 124 InsignificantActivities
................................................................................................................ 124 Compliance Assurance Monitoring
............................................................................................ 127 AttachmentA
.............................................................................................................................. 130

SCH Page 3 of 130 03-31-2011PermitNo: 245-09-C (R1) Plant ID: 0072 PAL/Title V Permit Revisions/Changes Revision Issue Public Attachment No. Date Notice Date Type No./Page No. Description NA 7/30/2010 6/11/2010 Initial EntirePermit PAL, STAR TAC requirements, RO change, DRE forE-coat control device change and 112(J) Part 1 & 2 applications. R1 3/31/2011 NA Admin Pages 43 and Revision to include Revision 50 permit229-96-0 and correctMethanol Tank VaporPressure
Application # Date Type 9761 09/09/2004 TVRevision (MultiRequest) 9509 08/28/2003 TVRevision (Stage II)Request 10016 07/22/2005 TVAdmin Change 10457 07/22/2005 TVRenewal 10789 12/07/2007 TVRevisionRequestDREforE-Coat System ControlDevice 11033 07/17/2008 TVRevisionRequestReportingRevision 11042 08/07/2008 TV 

### IPALRenewal application

- Updated 11230 03/06/2009 112(J) Part 1& 2 applications 11319 04/30/2009 TVRO Change

SCH Page 4 of 130 03-31-2011PermitNo: 245-09-C (R1) Abbreviations and Acronyms AFS

- Airs Facility Subsystem AIRS

- Aerometric Information Retrieval System APCD

- AirPollution Control District ASL

- Adjusted SignificantLevel atm
- Atmosphere BACT- BestAvailable Control Technology Btu

- BritishThermal Unit CEMS

- Continuous EmissionMonitoring System CAAA- Clean AirActAmendments (15 November 1990) HAP

- Hazardous AirPollutant hr

- hour lbs

- Pounds 

### I - Liter MACT- MaximumAchievable Control Technology m - Meter mg - Milligram mm - Millimeter MM - Million MOCS- Management ofChange System NAICS- NorthAmericanIndustry Classification System NSR

- New Source Review

- Nitrogen oxides NOx NSPS PAL PM - New Source Performance Standards

- Plant-wideApplicabilityLimit

- Particulate Matter PM10 - Particulate matter less than 10 microns ppm - Partspermillion PSD

- Prevention ofSignificantDeterioration PMP

- Preventive Maintenance Plan psia

- Poundsper square inch absolute RACT- Reasonably Available Control Technology SC

- Specific Condition SIC

- Standard Industrial Classification SIP

- State ImplementationPlan S02

- Sulfur dioxide TAC -ToxicAir Contaminant TAL

- Threshold AmbientLimit TAP

- Toxic AirPollutant tpy
- Tons per year UTM

- Universal Transverse Mercator VOC

- Volatile Organic Compound

SCH Page 5 of 130 Plant ID: 0072

03-31-2011PermitNo: 245-09-C (R1) PlantID: 0072 Preamble Title V ofthe Clean Air Act Amendments of 1990 required EPA to create an operating permit program for implementation by state or local air permitting authorities. The purposes of this program are (1) to require an affected company to assume full responsibility for demonstrating compliance with applicable regulations; (2) to capture all of the regulatory information pertainingto an affected company in a single document; and (3) to make permits more consistent with each other. A company is subject to the Title V program if it meets any of several criteria related to the nature or amount of its emissions. The Title V operating permit specifies what the affected company is, how it may operate, what its applicable regulations are, how it will demonstrate compliance, and what is required ifcompliance is not achieved. In Jefferson County, Kentucky, the AirPollution ControlDistrict (APCDJC) is responsible for issuingTitle V permitsto affected companies and enforcing local regulations and delegated federal and state regulations. EPA may enforce federal regulations but not "District OnlyEnforceable Regulations". Title V offers the public an opportunityto review and commenton a company's draftpermit. It is intended to help the public understand the company's compliance responsibility under the Clean Air Act. Additionally, the Title 

### V process provides a mechanism to incorporate new applicable requirements. Such requirements are available to the public for review and commentbefore they are adopted. Title V Permit general conditions define requirements which are generally applicable to all Title V companies under the jurisdiction of APCDJC. This avoids repeating these requirements in every section ofthe company's Title V permit. Company-specific conditions augmentthe general conditions as necessary; these appear in the sections ofthepermit addressing individual emission units or emissionpoints. The general conditions include references to regulatory requirements that may not currently applyto the company, butwhichprovide guidance for potential changes at the company or inthe regulations during the life of the permit. Such requirements may become applicable if the companymakes certainmodifications or a new applicable requirementis adopted. Whenthe applicability ofa section or subpart ofa regulation is unclear, a clarifying citation will be made in the company's Title V permit at the emission unit/point level. Comments may also be added atthe emissionunit/point level to give further clarification or explanation. The source's Title V permitmay include a currenttable of"insignificant activities." Insignificant activities are defined in District Regulation 2.16 section 1.22, as of the date the permit was proposed for review by U.S. EPA, Region 4. Insignificant activities identified in District Regulation 2.02, Section 2 may be subject to size or production rate disclosure requirements pursuant to Regulation 2.16 section 3.5.4.1.4. Insignificant activities identified in District Regulation 2.02, Section 2 shall comply with generally applicable requirements as requiredbyRegulation 2.16 section 4.1.9.4. SCH Page 6 of 130 03-31-2011

### PermitNo: 245-09-C (R1) Plant ID: 0072 General Conditions 1. 

### Compliance

- The owner or operator shall comply with all applicable requirements and with all terms and conditions of this permit. Any noncompliance shall constitute a violation ofthe Act, State and Districtregulations and shall cause the source to be subject to enforcement actions including, but not limited to, the termination, revocation and reissuance, or revision of this permit, or denial of a permit application to renew this permit. Notwithstanding any other provision in the Jefferson County portion of the Kentucky SIP approved by EPA,- any credible evidence may be used for the purpose of establishing whether the owner or operator is in compliance with, has violated, or is in violation ofany suchplan. (Regulation 2.16, sections 4.1.3, 4.1.13.1 and 4.1.13.7) 2. Compliance Certification

- The owner or operator shall certify, annually or more frequently ifrequired in applicable regulations, compliance with the terms and conditions contained in this permit, including emission limitations, standards, or work practices. This certification shall meet the requirements of Regulation 2.16, sections 3.5.11 and 4.3.5. The owner or operator shall submit the annual compliance certification directly to the following address as well as to the District, as set forth in Regulation 2.16, section 4.3.5.4: 

### USEPA -RegionIV AirEnforcementBranch AtlantaFederal Center 61 Forsyth Street Atlanta, GA 30303-8960 3. Compliance Schedule - A compliance schedule must meet the requirements of Regulation 2.16, section 3.5.9.5. The owner or operator shall submit a schedule of compliance for each emission unit that is not in compliance with all applicable requirements. A schedule ofcompliance shall be supplemental to, and shall not condone noncompliance with, the applicable requirements on which it is based. For each schedule ofcompliance, the owner or operator shall submit certifiedprogress reports at least semiannually, or at a more frequent period ifspecified in an applicable requirement or by the District in accordance with Regulation 2.16 section 4.3.4. The progress reports shall contain:
a. Dates for achieving the activities, milestones, or compliance required in the schedule of compliance, and dates when activities, milestones, or compliance were achieved. b. An explanation ofwhy dates in the schedule ofcompliance were not or will not be met, andpreventive or corrective measures adopted. 4. Duty to Supplement or Correct Application

- Ifthe owner or operator fails to submit relevant facts or has submitted incorrect information in the permit application, it shall, SCH Page 7 of 130 03-31-2011

### PermitNo: 245-09-C (Rl) Plant ID: 0072 upon discovery ofthe occurrence, promptly submit the supplementary facts or corrected information in accordance with Regulation 2.16, section 3.4. 5. EmergencyProvision
a. An emergency shall constitute an affirmative defense to an enforcement action brought for noncompliance with technology-based emission limitations. The affirmative defense ofemergency shall be demonstrated through properly signed, contemporaneous operatinglogs, or otherrelevant evidence that:
1. 

### An emergency occurred and that the owner or operator can identify the cause ofthe emergency.
11. 

### Thepermittedfacility was atthe time beingproperly operated. iii. During the period ofthe emergency the owner or operator expeditiously took all reasonable steps, consistent with safe operating practices, to minimize levels of emissions that exceeded the emission standards or other requirements in this permit. iv. The owner or operator submitted notice meeting the requirements of Regulation 1.07 of the time when emissions limitations were exceeded because ofthe emergency. This notice must fulfill the requirement ofthis condition, and must contain a description of the emergency, any steps taken to mitigate emissions, and any corrective actions taken. b. 

### In an enforcement proceeding, the owner or operator seeking to establish the occurrence ofan emergencyhas the burden ofproof.
c. This condition is in addition to any emergency or upset provision contained in an applicable requirement. (Regulation 2.16, sections 4.7.1 through 4.7.4) 6. Emission Fees Payment Requirements

- The owner or operator shall pay annual emission fees in accordance with Regulation 2.08. Failure to paythe emissions fees when due shall constitute a violation ofDistrictRegulations. Such failure is subject to penalties and an increase in the fee ofan additional 5%per month up to a maximum of25% ofthe original amount due. In addition, failure to pay emissions fees within 60 days ofthe due date shall automatically suspend this permit to operate until the fee is paid or a schedule for payment acceptable to the Districthas been established. (Regulation2.08, section 1.3) 7. Emission Offset Requirements

- The owner or operator shall comply with the requirements ofRegulation 2.04. 8. EnforceabilityRequirements- Except for the conditions that are specifically designated as "District Only Enforceable Conditions", all terms and conditions of this permit, SCH Page 8 of 130 03-31-2011

### PermitNo: 245-09-C (R1) Plant ID: 0072 including any provisions designed to limit a source's potential to emit, are enforceable by EPA and citizens as specified underthe Act. (Regulation 2.16, sections 4.2.1 and 4.2.2) 9. EnforcementAction Defense


### a. It 

### shall not be a defense for the owner or operator in an enforcement action that it would have been necessary for the owner or operator to halt or reduce the permitted activity in order to maintain compliance with the conditions of this permit. b. The owner or operator's failure to halt or reduce activity may be a mitigating factor in assessing penalties for noncompliance if the health, safety or environmental impacts ofhalting or reducing operations would be more serious than the impacts ofcontinued operation. (Regulation 2.16, sections 4.1.13.2 and 4.1.13.3) 10. Hazardous Air Pollutants and Sources Categories

- 

### The owner or operator shall complywiththe applicable requirements ofRegulations 5.02 and 5.14. 11. Information Requests

- 

### The owner or operator shall furnish to the District, within a reasonable time, information requested in writing by the District, to determine whether cause exists for revising, revoking and reissuing, or terminating this permit, or to determine compliance with this permit. The owner or operator shall also furnish, upon request, copies ofrecords required to be kept by this permit. (Regulation 2.16, section 4.1.13.6) If information is submitted to the District under a claim of confidentiality, the source shall submit a copy ofthe confidential information directly to EPA. (Regulation 2.07, section 1 0.2) 12. InsignificantActivities 

### -The owner or operator shall:
a. Notify the District in a timely manner ofany proposed change to an insignificant activitythatwould require apermitrevision. (Regulation 2.16, section 5) b. Submit a current list ofinsignificant activities by April 15 ofeach year with the annual compliance certification, including an identification ofthe additions and removals of insignificant activities that occurred during the preceding year. (Regulation 2.16, section 4.3.5.3.6) 13. Inspection and Entry

- 

### Upon presentation of credentials and other documents as required by law, the owner or operator shall allow the District or an authorized representative to perform the following during reasonable hours:

SCH a. Enterthe premises to inspect any emissions-related activity or records required in this permit. Page 9 of 130 03-31-2011PermitNo: 245-09-C (R1) Plant ID: 0072 b. Have access to and copyrecords required bythis permit.
c. Inspect facilities, equipment (including monitoring and air pollution control equipment), practices, or operations regulated orrequiredbythis permit. d. Sample ormonitor substances orparametersto assure compliance withthis permit or any applicable requirements. (Regulation2.16, section4.3.2) 14. Monitoring and Related Record Keeping and Reporting Requirement

- The owner or operator shall comply with the requirements ofRegulation 2.16, section 4.1.9. The owner or operator shall submit all required monitoring reports at least once every three months, unless more frequent reporting is required by an applicable requirement. The reporting period shall be January 1stthrough March 31, April1 through June 30th, July 1stthrough September 30 and October 1 through December 31st ofeach calendar year. All reports shall be postmarked by the 60th day following the end of each reporting period. If surrogate operating parameters are monitored and recorded in lieu of emission monitoring, then an exceedance ofmultiple parameters may be deemed a single violation by the District for enforcement purposes. All reports shall include the company name, plant ID number, and the beginning and ending date of the reporting period. The compliance reports shall clearly identify any deviation from a permit requirement. All quarterly compliance reports shall include the following certification statement per Regulation 2.16.

SCH "Based on information and beliefformed after reasonable inquiry, I certify that the statements and information in this document are true, accurate, and complete". Signature and title ofcompanyresponsible official. Ifa change in the "Responsible Official" (RO) occurs during the term ofthis permit, the owner or operator shall provide written notification (Form 9400-A and Form AP-0208) to the District within 30 calendar days following the date a change in the designated RO occurs for this facility. The quarterly compliance reports are due on or before the following dates of each calendaryear: ReportingPeriod January 1through March 30 April 1through June 30 July 1through September 30 October 1through December 31 Note: 1The date for leap years is February 29. Page 10 of 130 ReportDue Date May 30th August 29th November 29th March 1st!

03-31-2011PermitNo: 245-09-C (R1) PlantID: 0072 15. 

### Off-permit Documents

- Any applicable requirements, including emission limitations, control technology requirements, or work practice standards, contained in an off-permit document cannot be changed without undergoing the permit revision procedures in Regulation 2.16, Section 5. (Regulation 2.16, section 4.1.5) 16. 

### Operational Flexibility

- The owner or operator may make changes without permit revision in accordance with Regulation 2.16, section 5.8. 17. 

### Permit Amendments (Administrative)

- This permit can be administratively amended bythe Districtin accordance with Regulation 2.16, sections 2.3 and 5.4. 18. 

### Permit Application Submittal

- The owner or operator shall submit a timely and complete application for permit renewal or significant revision. Ifthe owner or operator submits a timely and complete application then the owner or operator's failure to have a permit is not a violation until the District takes formal action on this permit application. This protection shall cease to apply if, subsequent to completeness determination, the owner or operator fails to submit, by the deadline specified in writing by the District, additional information required to process the application as required byRegulation 2.16, sections 3 and 5.2. 19. 

### Permit Duration

- This permit is issued for a fixed term of5 years, in accordance with Regulation 2.16, section 4.1.8.3. 20. 

### Permit Renewal, Expiration and Application

- Permit renewal, expiration and application procedural requirements shall be in accordance withRegulation 2.16, sections 4.1.8.2 and 5.3. This permitmayonly be renewed in accordance with section 5.3. 21. 

### Permit Revisions -No permit revision shall be required under any approved economic incentives, marketable permits, emissions trading and other similarprograms orprocesses for changesthat areprovidedfor in thepermit. (Regulation 2.16, section4.1.16) 22. 

### Permit Revision Procedures (Minor)

- Except as provided in 40 CFRPart 72, the Acid Rain Program, this permit may be revised in accordance with Regulation 2.16, section 5.5. 23. 

### Permit Revision Procedures (Significant)

- A source seeking to make a significant permit revision shall meet all the Title V requirements for permit applications, issuance and Permit renewal, in accordance with Regulation 2.16, section 5.7, and all other applicable DistrictRegulations. 24. 

### Permit Revocation and Termination by the District

- The District may terminate this permit only upon written request of the owner or operator. The District may revoke a permit for cause, in accordance with Regulation 2.16, section 5.11.1.1 through 5.11.1.5. For purposes of Section 5, substantial or unresolved noncompliance includes, but is not limitedto: SCH Page 11 of 130 03-31-2011

### PermitNo: 245-09-C (R1) PlantID: 0072 a. Knowingly operating process or air pollution control equipment in a manner not allowed by an applicable requirement or that results in excess emissions of a regulated airpollutantthatwould endangerthe public orthe environment. b. Failure or neglect to furnish information, analyses, plans, or specifications required bythe District.
c. Knowingly making any false statement in anypermit application. d. Noncompliance withRegulation 1.07, section 4.2; or
e. Noncompliance with KRS Chapter 77. 

### 25. 

### Permit Shield

- The permit shield shall apply 

### m accordance with Regulation 2.16, section 4.6.1. 26. 

### Prevention of Significant Deterioration ofAir Quality

- The owner or operator shall comply withthe requirements ofRegulation2.05. 27. 

### Property Rights

- This permit shall not convey property rights of any sort or grant exclusive privileges in accordance with Regulation 2.16, section 4.1.13.5. 28. 

### Public Participation

- Except for modifications qualifying for administrative permit amendments or minor permit revision procedures, all permit proceedings shall meet the requirements ofRegulations 2.07, Section 1; and 2.16, sections 5.1.1.2 and 5.5.4. 29. 

### Reopening For Cause

- This permit shall be reopened and revised by the District in accordance withRegulation 2.16 section 5.9. 30. 

### Reopening for Cause by EPA

- This permit may be revised, revoked and reissued or terminated for cause by EPA in accordance with Regulation 2.16 section 5.10. 31. 

### Risk Management Plan (112(r))- For each process subjectto Section 112(r) ofthe Act, the owner or operator shall comply with 40 CPR Part 68 and Regulation 5.15. 32. 

### Severability Clause

- The conditions of this permit are severable. Therefore, if any condition ofthis permit, or the application ofany condition ofthis permitto any specific circumstance, is determined to be invalid, the application ofthe condition in question to other circumstances, as well as the remainder of this permit's conditions, shall not be affected. (Regulation 2.16, section 4.1.12) 33. 

### Stack Height Considerations

- The owner or operator shall comply with the requirements ofRegulation 2.10. 34. 

### Startups, Shutdowns, and Upset Conditions Requirements

- The owner or operator shall complywith the requirements ofRegulation 1.07. SCH Page 12 of 130 03-31-2011PermitNo: 245-09-C (R1) PlantID: 0072 35. Submittal ofReports, Data,Notifications, and Applications
a. Applications, reports, test data, monitoring data, compliance certifications, and any other document required by this permit as set forth in Regulation 2.16 sections 3.1, 3.4, 3.5, 4.1.13.6, 5.8.5 and 5.11.7 shall be submittedto: 

### LouisvilleMetroAirPollution ControlDistrict 850BarretAve Louisville,KY40204-1745 b. Documents which are specifically required to be submitted to EPA as set forth in Regulation 2.16 sections 3.3, and 5.8 .5 shall be mailed to EPA at the following address: 

### USEPA -RegionIV APTMD-12thfloor AtlantaFederal Center 61 Forsyth Street Atlanta, GA 30303-3104 36. Other Applicable Regulations

- The owner or operator shall comply with all applicable requirements ofthefollowing: 

# I Regulation 

# I Title 

# I 1.01 General Provisions 1.02 Definitions 1.03 Abbreviations And Acronyms 1.04 Performance Tests 1.05 ComplianceWithEmissions Standards And MaintenanceRequirements 1.06 Source Self-Monitoring andReporting 1.07 Emissions During Shutdowns, Malfunctions, Startups, and Emergencies 1.08 Administrative Procedures 1.09 Prohibition ofAirPollution 1.10 Circumvention 1.11 Control ofOpenBurning 1.14 Control ofFugitiveParticulateEmissions 2.01 General Application 2.02 AirPollutionRegulation Requirements and MinorFacilityExemptions 2.03 PermitRequirements- Non-Title V Construction and Operating Permits and Demolition/ RenovationPermits 2.07 PublicNotification for Title V, PSD, and Other Offset Permits; SIP Revisions; and Use of Emission Reduction Credits 2.09 Causes for Permit Suspension SCH Page 13 of 130 03-31-2011PermitNo: 245-09-C (R1) PlantID: 0072 Title I 2.10 StackHeight Considerations 2.11 Air Quality Model Usage 2.16 Title V OperatingPennits 4.01 General Provisions for EmergencyEpisodes 4.02 Episode Criteria 4.03 General AbatementRequirements 4.07 EpisodeReportingRequirements 6.01 General Provisions (Existing Affected Facilities) 6.02 EmissionMonitoring for Existing Sources 7.01 General Provisions (NewAffectedFacilities)


### District Only Enforceable: ation Title 1.12 Control ofNuisances 1.13 Control ofObjectionable Odors 2.08 EmissionFee, PermitFees and PennitRenewal Procedures 5.01 Standards for Toxic Air Contaminants and Hazardous AirPollutants 5.20 Methodology for DeterminingBenchmarkAmbient Concentration ofa Toxic AirContaminant 5.21 Environmental Acceptability for ToxicAir Contaminants 5.22 Procedures for Determining theMaximumAmbient Concentration ofa Toxic Air Contaminant 5.23 Categories ofToxic Air Contaminants 37. 

### Stratospheric Ozone Protection Requirements

- Any facility having refrigeration equipment, including air conditioning equipment, which uses a Class I or II substance (listed in 40 CPR 82, SubpartA, Appendices A and B), and any facility which maintains, services, or repairs motor vehicles using a Class I or II substance as refrigerant must comply with all requirements of40 CPR 82, Subparts A, B, and F. Those requirements include the following restrictions:

SCH a. Any facility having any refrigeration equipment normally containing fifty (50) pounds ofrefrigerant, or more, must keep servicing records documenting the date and type ofall service and the quantity of any refrigerant added according to 40 CPR 82.166; b. No person repairing or servicing a motor vehicle may perform any service on a motor vehicle air conditioner (MV AC) involving the refrigerant for such air conditioner unless the person has been properly trained and certified as provided in 40 CPR 82.34 and 40 CPR 82.40, and properly uses equipment approved accordingto 40 CPR 82.36 and40 CPR 82.38, and complies with 40 CPR 82.42; Page 14 of 130 03-31-2011PermitNo: 245-09-C (R1) PlantID: 0072

SCH c. No person may sell or distribute, or offer for sale or distribution, any substance listed as a Class I or II substance in 40 CFR 82, SubpartA, Appendices A and B, except in compliance with 40 CFR 82.34(b), 40 CFR 82.42, and/or 40 CFR 82.166. d. No person maintaining, serv1cmg, repamng, or disposing of appliances may knowingly vent or otherwise release into the atmosphere any Class I or II substance used as a refrigerant in such equipment and no other person may open appliances (except MV ACs as defined in 40 CFR 82.152) for service, maintenance, or repair unless the person has been properly trained and certified according to 40 CFR 82.161 and unless the person uses equipment certified for that type ofappliance according to 40 CFR 82.158 and unless theperson observes the practices set forth in 40 CFR 82.156 and 40 CFR 82.166;
e. No person may dispose of appliances (except small appliances, as defined in 40 CFR 82.152) without using equipment certified for that type of appliance according to 40 CFR 82.158 and without observing the practices set forth in 40 CFR 82.156 and 40 CFR 82.166; 

### f. No person may recover refrigerant from small appliances, MV ACs and MVAClike appliances (as defined in 40 CFR 82.152), except in compliance with the requirements of40 CFR 82 SubpartF; g. If the permittee manufactures, transforms, imports, or exports, a Class I or II substance (listed in 40 CFR 82, Subpart A, Appendices A and B), the permittee is subject to all requirements as specified in 40CFR82 Subpart A, Production and Consumption Controls. (Regulation 2.16, section 4.1.5)

Page 15 of 130 03-31-2011PermitNo: 245-09-C (R1) PlantID: 0072 LouisvilleAssemblyPlant,Ford MotorCompanyPlant-wideApplicabilityLimit (PAL):
FEDERALLYENFORCEABLE REGULATIONS Regulation Title Applicable Sections PermitRequirements Non-Title 

### V Construction and 2.03 OperatingPermits and Demolition/Renovation 1, 2, 3, 4, & 5 Permits 2.05 Prevention ofSignificantDeterioration ofAir Quality 1 40 CPR 52.21 Approval and Promulgation ofImplementationPlans

Plant-wideApplicabilityLimits Pollutant Tons/Year**



## voc 1,316 PM 21.2 PMIO 21.2 

### PM2.s 17.2 NOx 99.0 S02 39.33 

## co 151.4 

### ** Represents a 12-monthrolling total
Sl. Plant-wideApplicability Limit (PAL) Specific Conditions (Regulation 2.05, section 1 & Regulation 2.03)

SCH a. Under the provisions ofthis PAL, ifthe permittee adds a new emission unit or modifies an existing unit, the unit would not be subject to major NSR (nonattainment or PSD) as long as the PAL emission limits (ton per year limits in the above table) are notexceeded. b. Operational and EquipmentModifications 1) Ford Motor Company Louisville Assembly Plant is authorized to perform the physical or operational changes, or changes deemed consistent with those physical or operational changes, without applying for or obtaining a construction permit or amendment from the permitting authority pursuant to Regulation 2.03 as long as the PAL is notexceeded. 2) The permittee shall maintain a log ofequipment installed and/or modified and the date on which construction and/or modification and operation began. In addition, the permittee shall maintain a log of equipment Page 16 of 130 03-31-2011

### PermitNo: 245-09-C (R1) Plant ID: 0072

SCH removed from the installation and the date on which it was removed. The log must account for all equipment present at the installation at any given time. AttachmentA, or equivalent forms may be used for this purpose. 3) 1fthe permittee wishes to make physical or operational changes that are not deemed consistent with the physical or operations changes listed in this construction permit and are not exempt from the construction permit rule, then the permittee must first apply for and obtain a construction permitor amendment.
c. Notification ofActual Construction ofChange: Ford Motor Company Louisville Assembly Plant shall submit written notification to the permitting authority at least ten days priorto the actual construction change to or addition of any emission unit covered by this PAL permit that are not excluded under Specific Condtions S1.h. The notification shall contain the following: 1) Detailed description ofthe physical or operational change including the effect on existing equipment; 2) A plant layout diagram with representation of existing equipment and physical or operational changes; 3) A schedule ofconstruction activities relatedto the change; 4) A statement of applicability for any New Source Performance Standard, National Emissions Standard of Hazardous Air Pollutants and /or state regulations not identified as core requirements in the operatingpermit; 5) An emissions calculation sheet for the change; 6) A statement ofverification that the physical or operational change will not result in installation emissions that exceed the limitations stated in Specific Conditions Sl.b.; and 7) A summary ofthe impact analysis on the capture efficiency as outlined in Specific Condition S2.i. for those units where compliance with an applicable emission limit or standard is dependent upon the use of the control device. d. Portions of the notification such as descriptions of changes and associated applicability determination shall become an enforceable part ofthis construction permitupon receipt bythe permitting authority.
e. The permitting authority may disapprove any activitythat has not demonstrated to Page 17 of 130 03-31-2011

### PermitNo: 245-09-C (Rl) Plant ID: 0072 the satisfaction of the Program to be related to the changes. At the time, the permittee shall cease construction ofthe change until an appropriate authorization ofthe activities is obtained (such as a constructionpermit, ifnecessary). f. Notification ofActual Start-up ofChange: Ford Motor Company Louisville Assembly Plant shall submit written notification to the permitting authority at least ten days priorto the actual start-up or operation of any change listed in this PAL permit. The notification shall contain the following: 1) Reference to the notification of actual construction including date of notification and briefdescription ofchange; 2) Verification that the physical or operational change was completed as described in the original notification; and 3) Scheduled date operations will be commenced. g. It 

### is a violation ofthis construction permit for Ford Motor Company Louisville Assembly Plant to construct, modify or operate the installation not in accordance withthe notification Specific Condtions S1.f. h. The notification letter identified in c. and f. above is not required for sources that are otherwise exempt from the requirement to obtain a permit or are included in the list ofinsignificant sources in the Appendix to this Title V Operating Permit. S2. 

### PAL Monitoring and Record Keeping Requirements (Regulation 2.05, section 1 & 

### Regulation 2.03)

SCH a. The permittee shall maintain a copy of all records necessary to determine compliance.with requirements of the PAL, including a determination of each emission unit's monthly and twelve-month rolling total emissions, for five years from the originating date ofsuch record. b. The permittee shall retain a copy ofthe following records for the duration ofthe PAL effective periodplus five years: 1) A copy ofthe PALpermit application and any applications for revisions to the PAL; and 2) Each annual certification ofcompliance pursuant to Title V and the data relied on in certifying compliance.

Page 18 of 130 03-31-2011PermitNo: 245-09-C (R1) Plant ID: 0072

SCH 3) Copies ofany notification for any new or modified emission units that is not subject to the requirement to obtain a Permit to Construct under the provisions ofthe PAL.
c. Thepermittee shall monitor all emissionunits at the facility in accordance with the specific monitoringrequirements contained in each emissionunit. d. Ford Motor Company Louisville Assembly Plant shall submit a quarterly emissions report to the permitting authority within 60 days after the end ofeach reportingperiod. The reports shall containthe following information: 1) Identification ofowner and operator and the permit number; 2) Total annual emissions in tons per year based on a 12-month rolling total for each month inthe reportingperiod. 3) A summary of all data relied upon, including but not limited to, any QualityAssurance or Quality Control data, in calculating the monthly and annual PM, 

### PMw, PM2.5, NOx, S02, CO and VOC emissions; 4) A list ofany emissions units modified or added to the installation during theprecedingthree-monthperiod; 5) The number, duration, and cause of any deviations or monitoring malfunctions, and any corrective action taken; 6) A notification of shutdown of any monitoring system, whether the shutdown was permanent or temporary, the reason for the shutdown, the anticipated date that the monitoring system will be fully operational or replaced with another monitoring system, and whether the emissions unit monitored by the monitoring system continued to operate, and the calculations ofthe emissions. 7) A signed statement by the responsible official certifying the truth, accuracy, and completeness ofthe informationprovided inthe report.
e. QualityAssurance/Quality Control: Following completion of the initial performance test reports, Ford Motor Company Louisville Assembly Plant shall maintain an operation and maintenance plan on site at all times. A table ofcontents ofthe plan shall be submitted to the permitting authority with sixty (60) days ofreceipt ofthe performance testreports required of Specific Condition S6.c. The plan should be detailed, specific to the Louisville AssemblyPlant and includethe following information: Page 19 of 130 03-31-2011

### PermitNo: 245-09-C (R1) Plant ID: 0072

SCH 1) A preventative maintenance program for avoidance of excess emissions which shall include all maintenance activities, with inspection schedule, repair actions, and replacements inventory. 2) A range ofoperating conditions and outletvariables for normal operation. 3) A summary of operating conditions and outlet variables for all control equipment that will be monitored for malfunction or breakdown and a description of the method of detecting and informing responsible personnel of any malfunction or breakdowns, including alarm systems, lights and other indicators. 4) A description ofthe generic corrective procedures thatwill be taken in the event ofa malfunction or breakdown in order to restore compliance with the applicable emission limitations and permit conditions (e.g. reducing of productionrate). f. 

### Capture and Control Equipment: The specified control device (e.g. thermal oxidizer, carbon adsorber, and /or fluidized bed carbon concentrator) must be in use at all times when a control efficiency is claimed for compliance with the VOC emissions limitation. When a control efficiency is claimed, the control device shall be operated in accordance with applicable specifications and with the temperature range determined in Specific Conditions S6. g. Thermal Oxidizer Requirements: 1) The operating temperature shall be continuously monitored and recorded when a control efficiency is claimed for compliance with the VOC emissions limitation. The operating temperature of the thermal oxidizer shall be maintained on a rolling 3-hour average within 50 degrees Fahrenheit ofthe average temperature ofthe oxidizer recorded during the compliance test specified in Specific Condition S6. The acceptable temperature range may be reestablished by performing a new set of emission tests. The most recent sixty months of records shall be maintained on-site and shall be made immediately available upon request. 2) An assessment ofthermal oxidizer valve operation and leakage shall be conducted as part of the maintenance and inspection activities, at least annually. h. CarbonAdsorber andFluidized Bed Concentrator Requirements: 1) Ford Motor shall monitor the desorption gas inlet temperature on the Page 20 of 130 03-31-2011

### PermitNo: 245-09-C (Rl) Plant ID: 0072

SCH carbon adsorption and/or the SCR temperature on a fluidized bed concentrator unit with an appropriate monitoring device to ensure that the device is operating properly when a control efficiency is claimed for compliance with the VOC emissions limitation. 2) For each carbon adsorption device and/or fluidized bed concentrator unit, the monitoring device required in 1) above shall be identified, the parameters that will be monitored (e.g. desorption temperature), the frequency that the unit is monitored, and the temperature range as determined in Specific Condition S6 for each control device.
1. 

### Capture EquipmentRequirements: 1) Ford Motor shall evaluate changes that involve em1ss10ns directed to emission control equipment where compliance with an applicable emission limit or standard is dependent upon the use ofthe control device subject to the change for potential impacts to emission control equipment capture efficiency. This evaluation shall include the following: i. An impact analysis ofthe change on the capture efficiency; ii. A determination ofthe need for a new capture efficiencytestbased onthe impact analysis; iii. A summary ofthe evaluation to be included in the Notification of Actual Construction as stated in Specific Condition S

### I.e. 2) Within 180 days ofstartup ofnewprojects, FordMotor shall develop a monitoringplanfor each capture system (booth) that:
1. 

### Identifies the operating parameter(s) to be monitored to assure capture efficiency, ii. Explains why this parameter is appropriate for demonstrating ongoing compliance, 111. 

### Identifies the specific monitoringprocedures, and iv. Specifies the operating parameter value or range ofvalues (or the procedures for establishing the values) that shall be maintained to demonstrate capture efficiency is beingmaintained. 3) FordMotor shall install and maintain, for any intermittently controllable work station, a system to monitor when bypass ofthe control device system occurs whilethe work station is in operation. 4) FordMotor shall maintain an operating and maintenance log for the capture and control systems (enclosures and thermal oxidizers) for a period of(60) sixtymonths which shall include the following:
1. 

### Incidents of malfunction, with impact on emissions, duration of Page 21 of 130 03-31-2011PermitNo: 245-09-C (R1) PlantID: 0072 event, probable cause, and corrective actions; and 11. Maintenance activities, with inspection schedule, repair actions, and replacement, etc. 111. A written record of regular inspection schedule, the date and results of all inspections including any actions or maintenance activities thatresult from thatinspection. 

### j. Ford Motor LAP has the flexibility to change any oftheir control devices as long as Ford Motor can demonstrate to the District upon request that the new equipmenthas the same orbetter control efficiency as the current control devices. The requirement for the same orbetter control efficiency applies onlyto situations where compliance with an applicable emission limit or standards is dependent upon the use ofa control device. S3. PAL PermitRequirements (Regulation 2.05, section 1 & Regulation 2.03)

SCH a. The PAL shall be effective for ten years. The PAL term commences on the date of issuance of the PAL permit (245-09-C (R1)). The PAL shall also remain effective during the periods ofreview ofTitle V renewal applications regardless ofthe status ofthe application orpermit shield. b. Reopening ofthe ConstructionPermit: 1) The permitting authority may reopen this construction permit to accomplish the following actions: i. Revise to reflect an increase in the PAL as outlined in Specific Condition S3.k. ii. Reduce the PAL to reflect newly applicable Federal and/or State requirements with compliance dates after the issuance of this constructionpermit. iii. Reduce the PAL if the permitting authority determines that a reduction is necessary to avoid causing or contributing to a National Ambient Air Quality Standard or Prevention of Significant Deterioration increment violation, or to an adverse impact on airquality. 2) All reopening that increase the PAL level are required to be placed on public notice for at least a thirty (30) day period for submittal ofpublic comment.
c. PermitApplication SubmissionRequirements: Ifthe permittee chooses to renew this PAL, the permittee shall submit a complete application between six and eighteen months prior to the expiration ofthe PAL. This PAL shall not expire until a revised PAL permit is issued if a complete Page 22 of 130 03-31-2011

### PermitNo: 245-09-C (Rl) PlantID: 0072

SCH application is received by Louisville Metro Air Pollution Control District within the time frame specified. d. PALRenewal Requirements: 1) 

### A complete application shall consist of written documentation and/or calculations for the following item:
1. 

### Aproposed PAL level; ii. A list of all emissions units with applicable Federal or State requirements; 111. 

### The potential emissions ofall current equipment at the installation; iv. Identification ofthe baseline period; v. Baseline actual emissions; and vi. A complianceplan for the proposedPAL. 2) The permitting authority will have the final authority to setthe newplantwide 

### emissions limitationbased onthe following guidelines: i. Ifthe baseline actual emissions at the time ofrenewal are equal to or greater than eighty percent of the PAL, the PAL may be renewed at the same level. 11. 

### The PAL may not be set at a level that is greater than the potential to emit ofthe entire installation. iii. The PAL shall be adjusted to account for any applicable State or Federal requirement with a compliance date that occurs during effective period ofthis PAL. IV. 

### A PAL level higherthan the current PAL level cannotbe approved unless otherwise approvedthrough Specific Condition S3.j. 3) Any request to renew the PAL level is required to be placed on public notice for at least a thirty (30) day period for submittal ofpublic comment.
e. A complete application shall consist ofa proposed allowable emission limitation for each emissions unit (or each group ofemissions units) by distributing the PAL allowable emissions for the installation among each ofthe emissions units that existed under the PAL. Ifthe PAL had not yet been adjusted for an applicable requirement that became effective during the PAL effective period, such distribution shall be made as ifthe PALhad been adjusted. f. The PAL limits for each regulated pollutant will remain in effect until a revised permit is issued bythe AirPollution Control District. g. Any physical change or change in the method ofoperation at the installation that meets the definition ofmajor modification will be subject to major construction permittingrequirements. Page 23 of 130 03-31-2011

### PermitNo: 245-09-C (R1) Plant ID: 0072

SCH h. Ford Motor Company Louisville Assembly Plant shall continue to comply with any State or Federal applicable requirements that may have applied either during the PAL effective period orpriorto the PAL effective period. i. Anyphysical change in orchange in the method ofoperation ofa major stationary source that maintains its total source-wide emissions belowthe PAL level:
1. 

### Is not a majormodification for the PAL pollutant; ii. Does not have to be approvedthrough the PSD program; and iii. Is not subject to the provisions addressing restrictions on relaxing enforceable emission limitations thatthe major stationary source used to avoid applicability ofthe majorNSRprogram. 

### J. Increase ofthe PAL duringtheEffective Period: 1) If Ford Motor Company Louisville Assembly Plant wishes to alter this construction permit to allow the installation to emit more than the limit of any one ofthe regulated pollutants, Ford Motor shall submit a complete application to request an increase in the PAL meeting all the requirements for a major modification. 2) A complete application shall consist of written documentation and/or calculations to accomplishthe follow items: i. Identify the emissions units contributing to the increase in emissions so as to cause Ford Motor emissions to equal or exceed the PAL. 11. 

### Determine the Best Available Control Technology (BACT) equivalent controls for each emission unit using current technology. 111. 

### Demonstrate that the sum ofthe baseline actual emissions ofthe small emissions units, plus the sum of the baseline actual emissions of the new or modified emissions units exceeds the PAL. iv. Comply with the provisions of a current BACT analysis for all emissions unit(s) identified in Specific Condition S3.j.(2)i. 3) The revised PAL level shall be placed on public notice for at least thirty (30) dayperiod for submittal ofpublic comment. k. Operational Requirements from Previous Construction Permits: (See Comment 3) 1) Upon request bythe Air Pollution Control District, FordMotor Company Louisville Assembly Plant shall supplyto the AirPollution Control District a drawing showingrooftop locations ofcurrentprocess exhaust Page 24 of 130 03-31-2011PermitNo: 245-09-C (R1) stacks. PlantID: 0072 2) Each stackmust be identifiedby the associated source operation name and a short code that Fordchooses. 3) There must be a unique code for all stacks associated with each new emissionunit. S4. PAL ComplianceDemonstration (Regulation 2.05, section 1 & Regulation 2.03)

SCH The owner or operator shall maintain records and emission calculations as described below to demonstrate compliance with the PAL. Further, compliance with all other permit conditions and applicable regulations identified within this permit shall be demonstrated usingthe methods prescribed for eachEmissionUnit and for each Emission Point.
a. Emissions calculations to demonstrate compliance with the PAL include VOC, PMIPM10/PM2.s, CO, S02 and NOx emissions from startups, shutdowns, and malfunctions. b. The permittee shall determine monthly VOC, PM/PM10/PM25, CO, S02 and NOx emissions in accordance with the Monitoring and Record Keeping Requirements for each emissions unit for the purpose of summing plant-wide VOC, PM/PM10/PM25, CO, 

### SOz and NOx emissions and determining the rolling, 12- month emissions for eachpollutant.
c. Compliance with applicable emission rates for the e-coat, guidecoat and topcoat systems can be demonstrated based upon the recordkeeping and emissions calculation methods described in "Protocol for Determining Daily Volatile Organic Compound Emission Rate ofAutomobile and Light-Duty Truck Topcoat Operations," EPA-450/3-88-018 (Docket ID No. OAR-2002-0093 and Docket ID No. A-2001-22). The same infmmation can be utilized to determine monthly emissionrates for support ofPAL compliance. d. Compliance with annual emission rates for sealer, black-out/wax, glass installation and purge/cleaning solvent operations, and all other VOC emission units, shall be demonstrated using mass balance calculation methods. Monthly material usage data and the applicable VOC content of each material shall be maintained.
e. Compliance with mass VOC emission limitations for sealer, black-out/wax, glass installation and purge/cleaning solvent operations, shall be demonstrated using mass balance calculation methods. Monthly material usage data and the applicable VOC content ofeach material shall be kept. Daily emission rates shall be determined byprorating monthly usage based on dailyproduction levels. Page 25 of 130 03-31-2011PermitNo: 245-09-C (R1) Plant ID: 0072

SCH n VOC Value= 

## S U; 

## Y; (1- 

### C; D;) i=l Where: U = material usage V = VOC content C = capture efficiency D = destruction efficiency i = number ofoperating days The owner or operator shall correct capture and destruction efficiency values as appropriate to reflect equipment malfunction, downtime or other periods of reduced performance. Daily usage of each material shall be prorated from monthlyvalues based on dailyproduction: U = U PDaily

Daily Monthly P Monthly Where: Uoaily =materialusage for aparticularcalendar day UMonthiy = recorded material usage for aparticularmonth Poaily = recorded vehicle production for aparticularday PMonthly = total vehicle productionfor aparticularmonth For these operations, the VOC content ofeach material used shall be determined using U.S. EPA Reference Method 24, manufacturer's formulation data, or an approved alternative method. f. To demonstrate compliance with the PAL emission limits, the permittee may use either ofthe following: VOCEmissionRateAnnualEmission Calculation (tons VOC/year) (12 month rolling timeperiod)

Page 26 of 130 03-31-2011PermitNo: 245-09-C (R1) PlantID: 0072

SCH 

### VOC Emission Rate Annual Emission Calculation (tons VOC/year) (12 month rolling timeperiod)

The owner or operator shall update and correct capture and destruction efficiency values as appropriate to reflect equipment malfunction, downtime, or other periods ofreducedperformance. g. To demonstrate compliancewith

### plant-wideNOx emission limits and to determine PM, PM 10 and PM2 .5 emissions associated withnatural gas combustion, the owner or operator shall maintain monthly 

### plant-wide natural gas usage records. Emissions shall be determined using prorated usage rates and appropriate U.S. EPAAP-42 EmissionFactors orvendor emissions data.

n 

### NOx IPMaValue 

## =LUiEF(l Ci)**i~l** Where: a=PM subscriptfor total PM,

### PMw, orPM2.s 

### U= material usage EF = emission factor C = control efficiency i = number ofoperatingmonths h. To demonstrate compliance with annual 

### plant-wide PM/PM10/PM25 emissions associated with surface coating operations, the owner or operator shall maintain monthly

### plant-wide coating usage records. Emissions shall be determined using materials usage rates, solids content, transfer efficiency and particulate control device efficiency, or some combination ofthese parameters. As an alternative, the facility may rely on stack test data* or design criteria ifsuch data is available and canprovide a more process-specific emission estimationtechnique. *Stack test results used for PM2.s shall not include condensable particulate matter as specified in 40 CFR Part 51.166 as the permit is issued prior to January 1, 2011. 

### i. Thepermittee shall complete the calculations specified in S4.a. through h. no later than 30 days after the end ofthe month for which emissions are being calculated. The permittee shall report to the Air Pollution Control District, 850 Barret Ave, Louisville, KY 40204, no later than ten (10) days after the calculations are complete for the month during which the records indicate that the source exceeds the limitations ofthe PAL. Page 27 of 130 03-31-2011

### PermitNo: 245-09-C (Rl) PlantID: 0072 

### J. The permittee shall keep documentation of any emissiOn factors used to demonstrate compliance with the PAL. Emission factors must be obtained from the most recent edition ofAP-42, Compilation ofAirPollutant Emission Factors, the most recent stack performance test results, a mass balance approach using the Material Safety Data Sheets (MSDS) of all materials, and/or by a method approved bythe permitting authority. k. 

### The permittee shall keep documentation ofany overall control efficiencies used to demonstrate compliance with the PAL. Overall control efficiency is theproduct of the capture efficiency and control efficiency ofthe pollution control device. 

### 1. Operational Requirement: The permittee shall keep the solvents and cleaning solutions in sealed containers whenever the materials are not in use. The permittee shall provide and maintain suitable easily read permanent markings on all solvent and cleaning solution containers used withthis equipment. SS. PAL Reporting Requirements 

### (Regulation 2.05, section 1 & 

### Regulation 2.03)

SCH The owner or operator shall submit a summary ofrequired monitoring reports at least once every three months, unless more frequent reporting is required by an applicable requirement.
a. Quarterly report: The reporting period shall be January 1stthrough March 31, April I 

### through June 301 h, 

### July 1stthrough September 30 and October 1through December 31st ofeach calendar year. All reports shall be postmarked by the 60th day following the end ofeach reportingperiod.
1. 

### The identification ofowner and operator, the facility ID, and thepermittoConstructnumbers or any applicable permit-to-install. 11. 

### Total annual emissions (tons per year) based on a twelve-month rolling total for each month in the reportingperiod. 111. 

### A summary ofthe data relied upon, including, but not limited to, any quality assurance or quality control data, in calculating the monthly and annual PAL pollutant emissions. A copy ofthe data relied upon shall be maintained on site for a minimumperiod ofthree years. iv. A list of any emissions units modified or added to the major stationary source during the preceding six-month period (including exempt and insignificant sources). v. The number, duration, and cause of any deviations or monitoring malfunctions (otherthan the time associated with zero and span calibration checks), and any corrective action taken. Page 28 of 130 03-31-2011

### PermitNo: 245-09-C (Rl) Plant ID: 0072 v1. A notification of a shutdown of any monitoring system, whether the shutdown was permanent or temporary, the reason for the shutdown, the anticipated date that the monitoring system will be fully operational or replaced with another monitoring system, and whether the emissions unit monitored by the monitoring system continued to operate, and the calculation of the emissions of the monitored pollutant or the number determined bymethod included in thePALpermit vii. A signed statement by the responsible official certifying the truth, accuracy, and completeness ofthe informationprovided in the report. b. Deviation report: The major stationary source owner or operator shall promptly submit reports of any deviation from or exceedance of the PAL requirements, including periods where no monitoring is available. The deviation reports shall be submitted within the time limits prescribed by Regulation 1.06. The reports shall contain the following information: 1. The identification of owner and operator, the facility ID, and the permit numbers for any applicable permits; 11. 

### ThePALrequirementthat experiencedthe deviation or the exceedance; iii. Emissions resulting from the deviation orthe exceedance; and iv. A signed statement by the responsible official certifying the truth, accuracy, and completeness ofthe informationprovided inthe report.
c. Re-validationresults: The owner or operator shall submit to the Louisville Metro AirPollution Control District the results of any re-validation test or method within three months after completion ofsuchtest ormethod. S6. PAL Performance Testing 

### (Regulation 2.05, section 1 & 

### Regulation 2.03)

SCH a. Ford Motor shall conduct performance tests on existing control devices in the following table and any future control devices used for compliance with the PAL in accordance withthe schedule identified in item c. below.

Control Device Thermal Oxidizer LocationDescription E-Coat Oven RTO E-Coat Oven (3rd Pass) RTO E-Coat Oven (1st and 2nd Pass) Guidecoat Oven (1st and 2nd Pass) Guidecoat Oven (3rd Pass) North Main Enamel Oven RTO North Main Enamel Booth RTO

Page 29 of 130 03-31-2011

### PermitNo: 245-09-C (R1) PlantID: 0072

SCH CarbonAdsorber South Main EnamelBoothRTO South Main Enamel Oven RTO North Main Enamel Booth South Main Enamel Booth Ford Motor shall determine the VOC destruction and /or removal efficiencies and operating parameters ofthese control devices when all the processed controlled by these devices are in normal operation. b. For each capture system, Ford Motor shall: 1) Confirm that the capture system continues to meet the requirements of EPA Method 204 from an approved performance test with no changes to operatingparameters, or 2) Conduct a performance test to determine the capture efficiency and establish the value or range of values for the selected operating parameter(s) when all the processes controlled by these devices are in normal operation.
c. Within the initial 1 0-year term ofthis PAL permit and at least within 10 years of the most recent performance tests, Ford Motor Company Louisville Assembly Plant shall: 1) Conduct performance tests to verify the operating parameters and/or control efficiencies ofthe control devices; and 2) Confirm the capture efficiencies of the total or partial enclosures by Specific Condition S6.b.1) or S6.b.2). 3) The emission testing requirements are designed to obtain representative emission testing. However, it is recognized that circumstances or other reasons may arise that would necessitate changes to the testing requirements. Therefore, upon mutual agreement between the permittee and the District, the testing requirements specified in this permit may be changed. For any control device installed subsequentto the issuance ofthis construction permit, performance tests shall be preformed no laterthan 180 days after initial start-up ofthe control equipment. d. Testing shall be conducted in accordance with the procedures outlined in Specific Condition S6.e. Ford Motor shall maintain a record of the results of all performance tests required by Specific Condition S6.a. and S6.b. Page 30 of 130 03-31-2011PermitNo: 245-09-C (Rl) Plant ID: 0072 e. ProposedTestPlan: 1) A completed Proposed Test Plan must be submitted to the Air Pollution Control District, within thirty (30) days prior to the proposed test date so that the District may arrange a pretest meeting, if necessary, and assure thatthe test date is acceptable for an observerto bepresent. The Proposed Test Plan may serve the purpose of notification and must be approved priorto conductingthe required emissiontesting. 2) A copy of a written report of the performance test results shall be submitted to the District within thirty (30) days of completion of any required testing, unless an extension is requested and approved by the District. The extension mustbe submitted in writing at least ten days prior to the thirty (30) day deadline. The report must include legible copies of raw data sheets, analytical instrument laboratory data and complete sample calculations from the required U.S. EPA Method for at least one sample run. 3) The test report is to fully account for all operational and emission parameters addressed both in the construction permit conditions as well as in any other applicable state or federal rules orregulations. Plant-wideApplicability Limits Comments 1. The Plant-wide Applicability Limit(s) (PAL) are set at levels equal to the baseline determination submitted by Ford Motor Company February 2, 2009 and historical actual emission levels. 2. The PAL permit provisiOns (under Regulation 2.05 Prevention of Significant Deterioration ofAir Quality) have been adopted by the Louisville Metro Air Pollution Control District (LMAPCD). "Baseline actual emissions" as of a particular date are generally defined as "rate ofemissions, in tons per year, of a regulated NSR pollutant, that the unit actually emitted during any consecutive twenty-four (24) month period selected by the owner or operator within the ten (10) year period beginning on or after November 15, 1990, and immediately preceding the earlier of the date the owner or operator begins actual construction of the project or the date a complete permit application is received bythe agency". 3. This actionwill allow departmentpersonnelto identify which source is not meeting regulatoryrequirements, ifthe situation occurs.

SCH Page 31 of 130 03-31-2011

### PermitNo: 245-09-C (R1) Plant ID: 0072 Louisville Assembly Plant, Ford Motor Company Maximum Achievable Control Technology (MACT) Requirements: 40 CFR63 Subpart 1111- Surface Coating ofAutomobiles and LightDuty Trucks 

### Sl. Standards 

### (Regulation 2.16, section 4.1.1)

SCH HAPs


### a. The permittee shall choose to complywith one ofthe following HAPs limits: 

### i. 0.60 lbs HAPs/GACS on a calendar month basis: 

### E-Coat, guidecoat, topcoat, glass bondingprimer, and glass bonding adhesive operations plus all coatings and thinners, except for deadener materials and for adhesive and sealer materials that are not components of glass bonding systems, used in coating operations in thepaint shop. (40 CFR 63.3091(a))
11. 

### 1.10 lbs HAPs/GACS on a calendar month basis: 

### guidecoat, topcoat, glass bonding primer, and glass bonding adhesive operations plus all coatings and thinners, except for deadener materials and for adhesive and sealer materials that are not components ofglass bonding systems, used in coating operations in the paint shop. (40 CFR 63.3091(b)) The permittee may choose to comply with the emission limit specified by Sl.b. only ifE-Coatmeets either ofthe following requirements. (40 CFR 63.3092)
a. Each individual material added to E-Coat contains no more than 1.0 percent by weight ofany organic HAP and no more than 0.10 percent by weight of any OSHA-defined carcinogenic organic HAP; or, b. The emissions from all E-Coatbake ovens are captured and ducted to the oven thermal oxidizer which achieves a minimum destruction efficiency ofat least 95 percent (by weight).
111. 

### 0.01 lbs HAPs per lb ofcoating on a calendar month basis 

### for sealers, deadeners and adhesive materials that are not components of glass bonding systems. b. The permittee shall develop and implement a work practice plan to minimize the organic HAP emissions from the storage, mixing and conveying of coatings, thinners, and cleaning materials used in, and waste materials generated by, all coating operations for which an emission limit has been established above. The work practice plan must specify practices and procedures to ensure that, at a minimum, the following elements are implemented consistent with the Page 32 of 130 03-31-2011PetmitNo: 245-09-C (Rl) Plant ID: 0072

SCH requirements of40 CPR 63.3094. The permittee shall complywiththe applicable workpracticeplans at all times. (40 CPR63.3094) i. All organic-HAP-containing coatings, thinners, cleaning materials, and waste materials mustbe stored in closed containers. 11. Spills of organic-HAP containing coatings, thinners, cleaning materials, and waste materials must be minimized. iii. Organic-HAP-containing coatings, thinners, cleaning materials, and waste materials must be conveyed from one location to another in closed containers orpipes. 1v. Mixing vessels, other than day tanks equipped with continuous agitation systems, which contain organic-HAP-containing coatings and other materials must be closed except when adding to, removing, or mixing the contents. v. Emissions oforganic HAP must be minimized during cleaning ofstorage, mixing, and conveying equipment. vi. Organic HAP emissions from cleaning and from purging of equipment associated with all coating operations subject to emission limits in Sl.a and Sl.b. above mustbe minimizedby addressing: 1) Vehicle bodywipepursuantto 40 CPR 63.3094(c)(l)(i); 2) Coating linepurgingpursuantto 40 CPR 63.3094(c)(l)(ii); 3) Coating system flushing pursuantto 40 CPR 63.3094(c)(l)(iii); 4) Cleaning of spray booth grates pursuant to 40 CPR 63.3094(c)(1)(iv); 5) Cleaning of spray booth walls pursuant to 40 CPR 63.3094(c)(1)(v); 6) Cleaning of spray booth equipment pursuant to 40 CPR 63.3094(c)(1)(vi); 7) Cleaning of external spray booth areas pursuant to 40 CPR 63.3094(c)(1)(vii); 8) Additional housekeeping measures pursuant to 40 CPR 63.3094(c)(1)(viii). The permittee may choose to comply with an alternative to the work practice standard, after receiving prior approval from the US EPA in accordance with 40 CPR 63.6(g). (40 CPR 63.3100(c), 40 CPR 63.4493(b), and (c)), (40 CPR 63.094(d))
c. Revisions to the work practice plan likewise do not represent revisions to the facility's Renewable Operating Permit. Copies ofthe current work practice plan and any earlier plan developed within the past five years are required to be made available for inspection and copying by the LMAPCD upon request. (40 CPR 63.3094)(e)(f)) d. For any coating operation(s) for which HAP emission reductions due to the use of add-on control equipment are relied upon to demonstrate compliance with the Page 33 of 130 03-31-2011

### PermitNo: 245-09-C (R1) PlantID: 0072 emission limits above, the permittee shall meet the operating limits specified in Table 1 of40 CFR 63 Subpart IIII as identified below. The operating limits in Table 1 apply to the emission capture and add-on control systems on the coating operations. The permittee must establish the operating limits during the performance test according to the requirements in 40 CFR 63.3167. The operating limits shall be met at all times after they are established, except for periods of startup, shutdown and malfunction. (40 CFR 63.3093, 40 CFR 63.3100(b), (d) and Table 1)

Add-On Control Operating Limit Device 

### The average combustion temperature in any 3-hour Thermal Oxidizer period must not fall belowthe combustion temperature limit established accordingto 40 CFR 63.3167(a). Concentrators, The average desorption gas inlettemperature in any 3- Including Zeolite hourperiod must not fall belowthe limit established Wheels and Rotary according to 40 CFR 63.3167(e). CarbonAdsorbers S2. Monitoring 

### (Regulation 2.16, section 4.1.1)

SCH a. For any coating operation(s) for which HAP emission reductions due to the use of add-on control equipment are relied upon to demonstrate compliance with the emission limits above, the permittee shall develop and implement a written startup, shutdown and malfunction plan (SSMP) in accordance with 40 CFR 63.6(e)(3) and submit to the District. This plan must address the startup, shutdown and corrective actions in the event of a malfunction of any emission capture system or add-on control device upon which compliance with any ofthe emission limits above depends. The SSMP must also address any coating operation equipment that may cause increased emissions or that would affect capture efficiency ifthe process equipment malfunctions, such as conveyors that move parts among enclosures. (40 CFR 63.3100(£)) b. For any coating operation(s) for which HAP emissionreductions due to the use of add-on control equipment are relied upon to demonstrate compliance with the emission limits above, the permittee shall operate and maintain all affected emission units including any emission capture system or add-on control device upon which compliance with any of the emission limits above. At all times, including periods of startup, shutdown, and malfunction, the owner or operator must operate and maintain any affected source, including associated air pollution control equipment and monitoring equipment, in a manner consistent with safety and good air pollution control practices for minimizing emissions. During a period of startup, shutdown, or malfunction, this general duty to minimize emissions requires that the owner or operator reduce emissions from the affected source to the greatest extent which is consistentwith safety and good air pollution control practices. The general duty to minimize emissions during a period of Page 34 of 130 03-31-2011

### PermitNo: 245-09-C (R1) PlantID: 0072 startup, shutdown, or malfunction does not require the owner or operator to achieve emission levels that would be required bythe applicable standard at other times ifthis is not consistent with safety and good air pollution control practices, nor does it require the owner or operator to make any further efforts to reduce emissions if levels required by the applicable standard have been achieved. Determination ofwhether such operation and maintenance procedures are being used will be based on information available to the Administrator which may include, but is not limited to, monitoring results, review of operation and maintenance procedures, review of operation and maintenance records, and inspection ofthe source. (40 CFR 63.3100(d))
c. For any coating operation(s) for which HAP 

### emission reductions due to the use of add-on control equipment are relied upon to demonstrate compliance with the emission limits above, the permittee shall maintain a log detailing the operation and maintenance of any emission capture system, add-on control device, or continuous parameter monitor upon which compliance with any ofthe emission limits above depends. The log shall coverthe periodbetween the compliance date specified in 40 CPR 

### 63.3083 and the date when the initial emission capture system and add-on control device performance tests have been completed, as specified in 40 CPR

### 63.3160. (40 CFR 63.3100(e)) S3. Recordkeeping 

### (Regulation 2.16, section 4.1.1)

SCH Records required in this section shall be maintained on file for aperiod offive years. ( 40 CPR 

### 63.3131) The permittee shall maintain, at a minimum, the following records as of the applicable compliance date:
a. A copy ofeach notification and report that is submitted to comply with 40 CPR 

### Part 63, Subpart IIII 

### and the documentation supporting each notification and report as specified in 40 CPR 

### 63.3130(a). (40 CFR 63.3130(a)). b. A 

### current copy ofinformation provided by materials suppliers or manufacturers, such as manufacturer's formulation data, or test data used to determine the mass fraction of organic HAP for each coating, thinner and cleaning material, the density for each coating and thinner, and the volume fraction ofcoating solids for each coating. (40 CFR 63.3130(b)).
c. Monthlyrecords ofthe following: i. For each coating or thinner used in E-Coat, guidecoat, topcoat, glass bonding primer, and glass bonding adhesive operations plus all coatings and thinners, the volume used in each month, the mass fraction organic HAP 

### content, the density, and the volume fraction of solids. (40 CPR 

### 63.3130(c)(l))
Page 35 of 130 03-31-2011

### PermitNo: 245-09-C (R1) Plant ID: 

### 0072

SCH ii. For each deadener material, and NGB Sealers and Adhesives used, the mass used in each month and the mass organic HAP content. (40 CPR 63.3130(c)(3)) 111. 

### Calculations ofthe organic HAP emission rate for E-Coat, guidecoat, and topcoat in pounds per gallon of applied coating solids. If permittee chooses to comply with the option identified in l.ii, arecord ofthe weight fraction of each organic HAP in each material added to E-Coat. These calculations and records must include raw data, algorithms, and intermediate calculations. Ifthe "Protocolfor Determining Daily Volatile Organic Compound Emission Rate ofAutomobile and Light-Duty Truck Topcoat Operations," EPA-450/3-88-018 (Docket ID 

### No. OAR-2002 0093 and Docket ID 

### No. A-2001-22), is used, all data input to this protocol must be recorded. Ifthese data are maintained as electronic files, the electronic files, as well as any paper copies must be maintained. ( 40 CPR 63.3130(c)(4), 40 CPR 63.3163, 40 CPR 63.3173) IV. 

### Calculation ofthe average monthly mass organic HAP content in pounds per pound ofcoating, separately for deadener materials and NGB Sealers and Adhesives. (40 CPR 63.3130(c)(5), 40 CPR 63.3152) v. The name, volume, mass fraction organic HAP content and density of each cleaningmaterial used. (40 CPR 63.3130(6)(d)- (f)) 

### d. Any additional records pertaining to deviations; startup, shutdown or malfunctions; emission capture systems; performance testing; capture and control efficiency determinations; transfer efficiency determinations; and work practice plans for any emission capture system or add-on control device upon which compliance with any ofthe emission limits in I.1 through 4 depends, pursuant to 40 CPR 63.3130(g) through (n). (40 CPR 63.3130(6)(g)- (n)) i. Records pertaining to the design and operation ofcontrol and monitoring systems for any emission capture system or add-on control device upon which compliance with any of the emission limits in SC I.l through 4 depends must be maintained on-site for the life of the equipment in a location readily available to plant operators and inspectors. (40 CPR 63.3130(0

### )(6)) II. 

### The permittee shall compile all required records and complete all required calculations in a format acceptable to the Louisville Metro Air Pollution Control District and make them available bythe end ofthe calendar month following each compliance period unless otherwise specified in any monitoring/recordkeeping condition. 111. 

### The permittee may rely upon the results ofcapture, destruction or transfer efficiencytests that have been previously conductedupon written approval from the District. Any suchprevious tests must meetthe criteria identified in 40 CPR 63.3160(c)(1) through (3). (40 CPR 63.3160) IV. 

### The permittee shall install, operate and maintain each continuous parametric monitoring system in accordance with the applicable provisions of40 CPR 63.3168. (40 CPR 63.3168) Page 36 of 130 03-31-2011

### PermitNo: 245-09-C (R1) PlantID: 0072

SCH v. The permittee shall demonstrate continuous compliance with the operating limits specified in Table 1 to Subpart IIII of Part 63 for any emission capture system or add-on control device upon which compliance with any of the emission limits in the above table depends, pursuant to 40 CPR 63.3163 and 40 CPR 63.3173 using the method(s) described below: ( 40 CPR 63.3163,40 CPR 63.3173 and Table 1) Add-On Control Operating Limit: Continuous Compliance Device: Demonstration Method 

### a. Collectthe combustion The average combustion temperature data according temperature in any 3- to 40 CPR 63.3168(c); hourperiod must not fall b. Reduce the datato 3-hour Thermal Oxidizer belowthe combustion block averages; and temperature limit c. Maintain the 3-hour established accordingto average combustion 40 CPR 63.3167(a). temperature at or above temperature limit. a. Collectthe temperature Concentrators, The average desorption data accordingto 40 CPR IncludingZeolite gas inlettemperature in 63.3168(±); Wheels and any 3-hourperiod must b. Reduce the datato 3-hour Rotary Carbon not fall belowthe limit block averages; and Adsorbers established accordingto c. Maintain the 3-hour 40 CPR 63.3167(e). average temperature at or above the temperature limit.
IX. 

### For any coating operation(s) for which HAP 

### emission reductions due to the use of add-on control equipment are relied upon to demonstrate compliance with the emission limits above, the permittee shall monitor or secure the valve or closure mechanism controlling each bypass line for each capture system upon which compliance with any of the emission limits in the table above depends in a non-bypass mode such that the valve or closure mechanism cannot be opened without creating a record that it was opened. The method used to monitor or secure the valve or closure mechanism must meet one ofthefollowing: (40 CPR 63.3168(b)(1)) 1. Flow control position indicator requirements pursuant to 40 CPR 63.3168(b)(1)(i); 2. Car-seal or lock-and-key valve closures requirements pursuant to 40 CPR 63.3168(b)(1)(ii); 3. Valve closure monitoring requirements pursuant to 40 CPR 63.3168(b)(1

### )(iii); Page 37 of 130 03-31-2011PermitNo: 245-09-C (R1) 4. PlantID: 0072 Automatic shutdown system requirements pursuant to 40 CPR 63.3168(b)(1)(iv). Ifanybypass line is opened, a description ofwhythe line was opened and the length oftime it remained open mustbe included inthe semi-annual compliance reports required in 40 CPR63.3168(b) S4. Reporting (Regulation 2.16, section 4.1.1)
a. The permittee shall submit applicable notifications specified in 40 CPR 63.7(b) and (c), 63.8(f)(4) and 63.9(b) through (e) and (h), as specified in 40 CPR 63.3110. (40 CPRPart 63, Subparts A and IIII) b. For any emission capture system oradd-on control device upon which compliance with any ofthe emission limits in the above table depends, for which a startup, shutdown, or malfunction occurs during the quarterly reporting period, the permittee shall submit a SSMP report as specified in 40 CPR 63.3120(c). (40 CPR 63. 3120(c), 40 CPR 63.10(d)) S5. Testing (Regulation 2.16, section 4.1.1)

SCH a. Thepermittee shallperformthe applicable performancetests and compliance demonstrations in accordance with40 CPR 63.3150-3152,40 CPR 63.3160-3161, 40 CPR 63.3163-3168, 40 CPR 63.3170-3171, and 40 CPR63.3173. (40 CPR Part 63, SubpartIIII) b. The permittee shall determine the mass fraction of each organic HAP for each material used according to the procedures established under 40 CPR 63.3151(a)(1) through (5). The permittee may use US EPA Method ALT-017 as an alternative for any material used, after demonstrating that its use as an alternative test methodology for that material, has been approved by the US EPA pursuantto the requirements of40 CPR 63.3151(a)(3) and 40 CPR 63.7. (40 CPR 63.7, 40 CPR 63.3151)
c. For any emission capture system or add-on control device upon which compliance with any of the emission limits in the above table depends, the permittee shall submit all performance test reports for emission capture systems and add-on control devices, and reports of transfer efficiency tests as required by 40 CPR 63.3120(b). (40 CPR 63.3120(b))

Page 38 of 130 03-31-2011

### PermitNo: 245-09-C (R1) PlantID: 0072 40 CFR 63 Subpart EEEE- Organic Liquids Distribution Operations (OLD) 

### In the event that the permittee changes the materials in an existing affected storage tank that contains an organic liquid is equal to or greater than 5,000 gallons in such a way that the annual average true vapor pressure ofthe total organic hazardous air pollutant is above 4.0 psia, the permittee shall be subject to additional requirements pursuant to 40 CPR Part 63 Subpart EEEE and shall ensure compliance with those requirements. (40 CPR 63.2346)
a. For each existing affected storage tank that contains an organic liquid with a capacity of less than 5,000 gallons, records must be kept ofthe identity ofthe tank and the capacity ofthe tank (in gallons). Affected tanks are those tanks that contain organic liquid with a HAP content of5 percent or greater by weight, as defined under 40 CPR §63.2406 and Table 1of40 CPRPart 63 SubpartEEEE. 63.2343(a) b. For each existing affected storage tank that contains an organic liquid with a capacity of more than 5,000 gallons and contains an organic liquid with a HAP content of5 percent or greaterbyweight, the following records mustbe kept: i. The identity ofthetank and the capacity ofthetank (in gallons), 11. 

### The tank contents 111. 

### The annual average true vaporpressure ofthe total organic hazardous airpollutant in the organic liquid (as defined under 40 CPR §63.2406 and Table 1 of40 CPR Part 63 SubpartEEEE). (40 CPR 63.2343(b))
c. These records mustbe kept up-to-date and available for inspection. (40 CPR 63.2343) d. All compliance records, notifications and reports, and any updates to those records, shall be retained for five years withtwo years ofrecords on site. (40 CPR 63.2394(b) and (c)) OLD MACT Reporting Requirements


### a. For each existing affected storage tankthat has a capacity ofmore than 5,000 gallons, the permittee must submit an Initial Compliance Report 

### that contains the following information (40 CPR 63.2343(b) and 63.2386):

SCH 1. 

### Company name and address. ii. Statement by a responsible official, including the official's name, title and signature, certifying that, based on information and beliefformed after reasonable inquiry, the statements and information in the report are true, accurate and complete. 111. 

### A listing of all existing affected storage tanks greater than 5,000 gallons that contain an organic liquid where the annual average true vaporpressure ofthe total organic hazardous air pollutant (as defined under Table 1 of 40 CPR Part 63 SubpartEEEE) is below 4.0 psia.
Page 39 of 130 03-31-2011

### PermitNo: 245-09-C (R1) Plant ID: 0072 b. The permittee must submit a subsequent Compliance Report if any of the following occurs (40 CFR 63.2343(b)(2)(i)):
1. 

### The permittee changes the materials in an existing affected storage tank that has a capacity equal to or greater than 5,000 gallons in such a way that the annual average true vapor pressure ofthe total organic hazardous air pollutant is above 4.0 psia. 11. 

### The permittee installs a new affected storage tank with a capacity equal to or greaterthan 5,000 gallons. iii. There are changes to the informationreported.
c. Each subsequent Compliance Report shall be submitted withthe next Title V semi-annual report. (40 CFR 63.2386(e)) 40 CFR63 Subpart ZZZZ- 

### National Emissions Standards for Hazardous AirPollutants for StationaryReciprocating Internal CombustionEngines There are no applicable requirements or notification requirements under Subpart ZZZZ as all of the units are considered existing emergency generators less than 500 HP. An existing emergency stationary RICE does nothave to meetthe requirements ofthis subpart and subpartA ofthis part. No initial notification is necessary. (40 CFR 64.6590(b)(3)
General Permit Reporting Requirements 

### (Regulation 2.16, section4.1.9.3) The owner or operator shall report quarterly the following:
a. Emission UnitID number and Control ID number; b. The beginning and ending date ofthe reportingperiod; c. Identification ofthe operatingparameters being monitored; d. Number, duration, and cause ofall exceedances (or a negative declaration, ifnone); and e. Description ofthe corrective actiontaken for each exceedance. STARRequirements:
DISTRICT ONLY ENFORCEABLE REGULATIONS Regulation Title Applicable Sections 

### 5.01 General Provisions 1through 4 Methodology for DeterminingBenchmark 5.20 Ambient Concentration ofaToxic Air 1through 6 Contaminant 5.21 Environmental Acceptability for Toxic Air 1

### through 5 Contaminants SCH Page 40 of 130 03-31-2011PermitNo: 245-09-C (R1) PlantID: 0072 DISTRICT ONLY ENFORCEABLE REGULATIONS Regulation Title Applicable Sections Procedures for Determiningthe Maximum 5.22 Ambient Concentration ofa Toxic Air 1through 5 Contaminant 5.23 Categories ofToxic Air Contaminants 1through 6

a. The owner or operator shall submit with the notification of construction for any new emission unit the STAREA Demonstration for all Category 1 through Category 4 TACs emitted from that emissionunit. b. The owner or operator shall submit aplant-wide emissions-based EA Demonstration to the District showing compliance with theplant-wide EA goals of7.5 new and existing, 3.8 for all new combined, and 1 for each process when a change occurs that increases emissions above Deminimus orpreviouslymodeled values.
c. If the TAC does not have an established BAC or De minimus value, the owner or operator shall calculate and report these values. The following form may be used for determiningBAC and De minimus values:

SCH http://vvww.louisvilleky.gov/NR/rdonlyres/121AAADA-9838-4057-ADFC88CD95Al4937/0/BAC Worksheet.pdf

Page 41 of 130 03-31-2011PermitNo: 245-09-C (R1) Plant ID: 0072 U002- U004 Emission Unit Description: Five Boilers U002 - U004 Applicable Regulations:
FEDERALLY ENFORCEABLE REGULATIONS Applicable Regulation Title Sections 6.42 Reasonable Available ControlTechnology 1.2, and 2 Requirements for MajorVolatile Organic Compound through 5 7.06 Standards ofPerformance forNewIndirectHeat 1through 4 Exchangers 40 CPR 60 GeneralProvisions 60.1 through SubpartA 60.18 40 CPR 60 Standards ofPerformance for Small Industrial- 60.48c SubpartDe Commercial-Institutional Steam GeneratingUnits
District OnlyEnforceableRegulations Regulation Title Applicable Sections Methodologyfor DeterminingBenchmark 5.20 Ambient Concentration ofaToxic Air 1through 6 Contaminant 5.21 Environmental Acceptabilityfor Toxic Air 1through 5 Contaminants Procedures for Determiningthe Maximum 5.22 AmbientConcentration ofa Toxic Air 1through 5 Contaminant 5.23 Categories ofToxic Air Contaminants 1through 6 7.02 FederalNew Source Performance Standards 1.23, 2 through 5 Incorporated byReference

SCH Page 42 of 130 03-31-2011PermitNo: 245-09-C (R1) U002 - U004 Emission Points: U002- U004 Equipment

Emission Description

Point

E02A Boiler less than 100 MMBtu/hr

One (1) Cleaver-Brooks dockboiler (No. 1); E04A rated at 63.6 MMBtu/hr; installed in 1995; natural gas-fired withpropane backup.

One (1) Cleaver-Brooks boiler (No.2); 63.6 E04B MMBtu/hr, installed 1995; natural gas-fired, withpropane backup.

Two (2) hotwaterboilers; 33.5 MMBtu/hr E05 each, installed 1996; natural gas-fired Plant ID: 0072

Applicable Control Regulation 

### ID 7.06 5.21 NA 6.42 40 CPR 60 SubpartDe 7.06 5.21 N/A 6.42 40 CPR 60 SubpartDe 7.06 5.21 N/A 6.42 40 CPR 60 SubpartDC 7.06 N/A 5.21 40 CPR 60 SubpartDC U002 - U004 ControlDevices: There are no control devices associated withEmission UnitU002

- U004.

SCH Page 43 of 130 03-31-2011

### PermitNo: 245-09-C (R1) Plant ID: 

### 0072 U002- U004 Specific Conditions 

### S1. Standards 

### (Regulation 2.16, section 4.1.1)

SCH a. PM
1. 

### For Emission Points E04A, E04B and E05: The owner or operator shall not cause to be discharged into the atmosphere from that affected facility particulate matter in excess of0.29 pounds per million BTU actual total heat input. (Regulation 7.06, section 4.1.4) (See Comment 1) ii. See Louisville Assembly Plant, Ford Motor Company Plant-wide Applicability Limit (PAL) b. Opacity
1. 

### For indirect heat exchangers subject to Regulation 7.06, the owner or operator shall not allow or cause the particulate emissions into the open air from any indirect heat exchanger which is greater than twenty percent (20%) opacity except for:
11. 

### For indirect heat exchangers with a heat input capacity of less than 250 million BTU/hr, a maximum of40% opacity shall be permissible for not more than two consecutive minutes in any 60 consecutive minutes; iii. For indirect heat exchangers with heat input capacity of less than 250 million BTU/hr, a maximum of40% opacity shall be permissible for not more than six consecutive minutes in any 60 consecutive minutes during cleaningthe fire box orblowing soot; or iv. For emissions from an indirect heat exchanger during building a new fire for the period required to bring the boiler up to operating conditions provided the method used is that recommended by the manufacturer and the time does not exceedthe manufacturer's recommendations. (Regulation 7.06, section 4.2)

1. 

### The owner or operator shall not cause to be discharged into the atmosphere from that affected facility any gases which contain sulfur dioxide in excess of0.99 pounds per million BTU actual total heat input for combustion of liquid and gaseous fuels. (Regulation 7.06, section 5.1.1) (See Comment 1)
Page 44 of 130 03-31-2011PermitNo: 245-09-C (R1) PlantID: 0072 11. See Louisville Assembly Plant, Ford Motor Company Plant-wide ApplicabilityLimit (PAL). d. NOx 

### i. The owner or operator shall not allow or cause the plant-wide NOx emissions to exceed 99 tons during any consecutive 12-month period in order to stay below NOx RACT applicability thresholds. (Regulation 6.42)(See Comment 6)
11. ForEmissionPoints E04A, E04B and E05:

e. TAC The owneror operator shall not allow or causeNOx emission to exceed 37 tonsperboiler duringMarch 1through October 31.

The owner or operator shall not allow any TAC em1sswns to exceed environmentally acceptable levels whether specifically establishedbymodeling or derived from default de minimis levels. (Regulation 5.01, section 3.) S2. Monitoring (Regulation 2.16, section 4.1.9.1.2)

SCH a. PM For emission points E02A, E04A, E04B and E05, the owner or operator shall maintainrecords ofmonthlynatural gas and/or other fuel usage. b. Opacity There are no monitoringrequirements for Opacity compliance. (See Comment 2)

40 CFR 60 Subpart DC monitoring requirements for S02 compliance. (See Comment 1) 

### i. The owner or operator shall keep records ofthe amount offuel com busted during each month. (40 CFR 60.48c(g)(2)) 11. The owner or operator shall monthly calculate the prorated fuel usage of the boiler by correlating the design heat input capacity of all natural gas fired units at the plant ifthe individual fuel usage for each boiler is not known. (EPA Letter datedMarch 7, 2002) (See Comment 3) d. NOx Page 45 of 130 03-31-2011PermitNo: 245-09-C (R1) PlantID: 0072 Maintain records ofmonthly fuel usage, and use AP-42 emission factors and/or fuel analysis data, to calculate monthlyemissions.
e. TAC See Comment4. S3. Record Keeping (Regulation 2.16, section 4.1.9.2)
a. PM See Specific Condition S2.a. b. Opacity There are no record keeping requirements for Opacity compliance. (See Comment 2)

See Specific Condition S2.c. d. NOx The owner or operator shall calculate andrecordthe monthly and 12 consecutive monthplant-wideNOx emissions for eachmonth in the reportperiod.


### e. TAC See Comment4. S4. Reporting (Regulation 2.16, section 4.1.9.3)

SCH a. PM See PAL Repmiing Requirements, there are no additional reporting requirements for demonstrating compliancewithRegulation 7.06. b. Opacity There are no reportingrequirements for Opacity compliance. (See Comment 2)

See PAL Reporting Requirements, there are no additional reporting requirements for demonstrating compliance withRegulation 7.06. Page 46 of 130 03-31-2011PermitNo: 245-09-C (R1) PlantID: 0072 d. NOx See PAL ReportingRequirements.
e. TAC See Comment4. S5. Testing (Regulation 2.16, section 4.1.9.3)
a. PM There are no testingrequirements for PMcompliance. b. Opacity There are no testingrequirements for Opacity compliance.

There are no testing requirements for S02 compliance. d. NOx Withinthe initial10-yearterm ofthis PALpermit, the owner or operator shall test at least onceto establish an emissionfactor for emissionpoints E04A and E04B.
e. TAC There are no testingrequirements for TAC compliance. U002 - U004 Comments 1. The District has performed a one-time PM and S02 compliance demonstration for the boiler, using AP-42 emission factors and combusting natural gas, and the emission standards cannot be exceeded. Therefore, there are no monitoring, record keeping, and reportingrequirements forthis boilerwithrespectto PM and S02 emission limits. 2. The District has determined that using a natural gas fired boiler will inherently meet the 20% opacity standard. Therefore, the company is not required to perform periodic monitoringto demonstrate compliance with the opacity standard. 3. The federal regulation 40 CPR 63, Subpart DDDDD was vacated on June 8, 2007, therefore the District has not included the boiler MACT requirements in this permit. The company has submitted the Part 1 and Part 2 of the 112j permit application for the SCH Page 47 of 130 03-31-2011

### PermitNo: 245-09-C (R1) Plant ID: 0072 vacated boiler MACT (40 CFR 63 Subpart DDDDD), dated on March 5, 2009 and May 8, 2009 respectively. The District is evaluatinghowto implement this requirement. 4. The TAC emissions from the combustion ofnatural gas are considered to be "de minimis emissions" by the District. This includes all ofthe emissions from a process or process equipment for which the only emissions are the products ofcombustion ofnatural gas, such as from anatural gas-fired boiler orturbine, but does not include the other emissions from a process or process equipment that are not the products of the combustion of natural gas. (Regulation 5.01, section 1.6.7) 5. In a letter dated March 7, 2002 from EPA Region 4, EPA has identified certain types of alternative record keeping requirements for units that are regulated under 40 CFR 60 Subpart De (Standards of Performance for Small Industrial-Commercial-Institutional Steam Generating Units) that can be approved by the District without additional input from EPA. 6. This PALpermit supercedes constructionpermit#623-94-C and the plant-wideNOx limit is replacingthe 39.9tpy PSD/NSRNOx avoidance limit for the two (2) CleaverBrooksboilers (E04A and E04B). 7. Ford currently has a 146 MM Btu/hr boiler emission point E02A, however to keep 40 CFR 60, Subpart Db from being applicable, Ford can only install additional boilers totaling less than 100 MMBtu/hr.

SCH Page 48 of 130 03-31-2011PermitNo: 245-09-C (Rl) Plant ID: 0072 U008 Emission UnitDescription: Volatile Organic Liquid Storage Tanks U008 Applicable Regulations: FederallyEnforceableRegulations Regulation Title Applicable Sections 1.05 Compliance with Emission Standards and 1,2,3,4,5 Maintenance Requirements 7.12 Standard ofPerformance for New Storage 1though 5; 7 and 8 Vessels for Volatile Organic Compounds

District Only Enforceable Regulations Regulation Title Applicable Sections 1.18 Rule Effectiveness 1through 3 5.01 General Provisions 1through 4 5.14 Hazardous Air Pollutants and Source Categories 1and 2 5.21 Environmental Acceptabilityfor ToxicAir 1through 5 Contaminants Procedures for Determiningthe Maximum 5.22 Ambient Concentration ofaToxic Air 1through 5 Contaminant 5.23 Categories ofToxic Air Contaminants 1through 66

SCH Page 49 of 130 03-31-2011PermitNo: 245-09-C (R1) U008 Emission Points:

ID Description 6000 gallon E08A Methanol Tank 10,000 gallon UG E08G SolventTank
E08M 20,000 gallon AntiFreeze Tank
E08N 20,000 gallon Power SteeringFluidTank
E080 6000 gallon Brake Fluid Tank
E08P 20,000 gallon Diesel Fuel Tank PlantID: 0072

U008 Emission Points Applicable AllowableEmission/ Control Requirement Equipment Standard Device 5.21 7.12 SubmergedFill N/A 5.21 N/A VaporPressure 

### < 1.5 psia 7.12 5.21 N/A VaporPressure 

### < 1.5 psia 7.12 5.21 VaporPressure 

### < 1.5 psia N/A 7.12 5.21 VaporPressure 

### < 1.5 psia N/A 7.12 5.21 VaporPressure 

### < 1.5 psia N/A 7.12
U008 Control Devices: There are no control devices associated withEmissionUnitU008.

SCH Page 50 of 130 03-31-2011PermitNo: 245-09-C (Rl) PlantID: 0072 U008 Specific Conditions S1. Standards (Regulation 2.16, section 4.1.1)


### a. VOC 

### i. See Louisville Assembly Plant, Ford Motor Company Plant-wide ApplicabilityLimit (PAL).
II. The owner or operator shall not store materials with an as stored vapor pressure ofgreaterthan or equal to 1.5 psia, however ifthe vaporpressure ofthe VOC, as stored, is equal to or greater than 1.5 psi, as a minimum, it shall be equipped with a permanent submerged fill pipe. (Regulation 7.12, section 3) b. TAC The owner or operator shall not allow any TAC emissions to exceed environmentally acceptable levels whether specifically established by modeling or derived from default de minimis levels. (Regulation 5.01, section 3.) S2. Monitoring (Regulation 2.16, section 4.1.9.1.2)
a. VOC See Specific Condition S3.a.i. b. TAC See Specific Condition S3.b. S3. Record Keeping (Regulation 2.16, section 4.1.9.2)

SCH a. VOC 

### i. The owner or operator shall maintain records ofthe material stored in each storage vessel. Ifthe contents ofthe storage vessels are changed, a record shall be made ofthe new contents, the new vapor pressure, and the date of the change in service. ii. The owner or operator shall either maintain monthly records, including calculations, from either monthly usage records or ratioed annual emissions from the previous year that show the total VOC emissions during each calendar month and consecutive 12-month period for this emission unit. Page 51 of 130 03-31-2011

### PermitNo: 245-09-C (R1) PlantID: 0072 b. TAC 

### The owner or operator shall keep arecord ofthe Material SafetyData Sheet (MSDS) for each TAC-containingmaterial inthis emission unit. S4. Reporting 

### (Regulation 2.16, section 4.1.9.3)
a. VOC 

### See General PermitReportingRequirements. b. TAC 

### The owner or operator shall submit a plant-wide 

### emissions-based EA Demonstration to the District showing compliance with theplant-wide 

### EA goals of7.5 new and existing, 3.8 for all new combined, and 1for each process when a change occurs that increases emissions above De minimus or previously modeled values. U008 Comment 

### 1. EmissionpointsE08M, E08N and E08P are not subjectto 40 CFR 60 subpartKb because this subpart does not apply to storage vessels with a capacity greater than or equal to 151 m3 

### (39,890 gallons) storing a 

### liquid with a maximum true vapor pressure less than 3.5 kilopascals (kPa) (0.51 psi) or with a capacity greater than or equal to 75 m3 

### (19,813 gallons) but less than 151 m 3 

### (39,890 gallons) storing a liquid with a maximum true vaporpressure less than 15.0 kPa (2.18 psi).

SCH Page 52 of 130 03-31-2011PermitNo: 245-09-C (R1) Plant ID: 0072 Emission UnitU009: Glass Installation U009 Applicable Regulations : FederallyEnforceable Regulations Regulation Title Applicable Sections 1.05 Compliance with Emission Standards and 1, 3, 4 and 5 Maintenance Requirements Standards of Performance for New 7.59 Miscellaneous Metal Parts and Products Surface 1through 7 Coating Operations 40 CPR 63 General Provisions 60.1 through 60.18 SubpartA 40 CPR 63 NationalEmission Standards for Hazardous Air Subpart IIII Pollutants: Surface Coating ofAutomobiles and 1, 2, 3, 4, 7, and 8 Light-DutyTrucks
District OnlyEnforceableRegulations Regulation Title Applicable Sections 1.18 Rule Effectiveness 1through 3 5.01 General Provisions 1through 4 5.02 Adoption ofNational Emission Standards for 1, 3,4 and 5 Hazardous AirPollutants 5.14 Hazardous AirPollutants and Source Categories 1and 2 5.21 Environmental Acceptabilityfor Toxic Air 1through 5 Contaminants Procedures for Determiningthe Maximum 5.22 AmbientConcentration ofa Toxic Air 1through 5 Contaminant 5.23 Categories ofToxic Air Contaminants 1through 6

SCH Page 53 of 130 03-31-2011

### PermitNo: 245-09-C (R1) U009 Emission Points:

ID Description Glass, E09A Windshield, and BackLights Installation PlantID: 0072

U009 Emission Points Applicable AllowableEmission/ Control Stack Requirement EquipmentStandard Device ID 5.21 3.5 lb/gal, less water and N/A S-400 exempt VOCs, as applied 7.59 U009 ControlDevices: Thereareno controldevices associated with Emission Unit U009.

SCH Page 54 of 130 03-31-2011PermitNo: 245-09-C (R1) PlantID: 0072 U009 Specific Conditions Sl. Standards (Regulation 2.16, section4.1.1)
a. VOC 

### i. The owner or operator shall not cause or allow the emission ofVOC from any affected facility resulting from the coating of metallic surfaces in excess of0.42 kg ofVOC/1 (3.5 lb VOC/gal) ofcoating, excluding water and exempt solvents, as applied for extreme performance coatings. (Regulation 7.59, section 3.1.3)
11. See Louisville Assembly Plant, Ford Motor Company Plant-wide ApplicabilityLimit (PAL). b. TAC The owner or operator shall not allow any TAC emissiOns to exceed environmentally acceptable levels whether specifically established bymodeling or derived from default de minimis levels. (Regulation 5.01, section 3.)
c. HAP See LAP MACT Standards Section. S2. Monitoring (Regulation 2.16, section4.1.9.1)

SCH a. VOC The owner or operator shall maintain the following monthly records to demonstrate ongoing compliance with the VOC content limit and with Regulation 1.05, section 4:
1. Calculations ofVOC emissions from each facility based on the recorded parameters. Calculations of daily usage and VOC emissions from each facility based on the recorded parameters by prorating monthly net usage based on dailyvehicle production.
11. Determine daily usage ofeach material and VOC emissions by prorating monthlyconsumptionbased on dailyvehicles produced. b. TAC See Specific Condition S3.b.
c. HAP Page 55 of 130 03-31-2011PermitNo: 245-09-C (R1) Plant ID: 0072 See LAP MACTMonitoring Section. S3. Record Keeping (Regulation 2.16, section4.1.9.2)

SCH The owner or operator shall maintain the required records for a minimum of5 years and make the records readily available to the District upon request.
a. VOC 

### i. An owner or operator ofan affected facility subjectto this regulation shall maintain records that include, but not be limited to, the following: (Regulation 7.59, section 6.1) 1) The regulation and section number applicable to the affected facility for which the records are being maintained, 2) The application method and substrate type (metal, plastic, etc.), 3) The amount and type of coatings (including catalyst and reducer for multicomponent coatings) and solvent (including exempt compounds) used at each point ofapplication during the averaging period. The District may specifically authorize the usage record to reflect a period longer than the compliance averaging period, with the usage prorated for each compliance averaging period by a method approved by the District. In this case, the usage record period shall not exceed 1 calendarmonth, 4) The VOC content as applied in each coating and solvent, 5) The date, or usage record period, for each application of coating and solvent, 6) The amount of surface preparation, clean-up, wash-up of solvent (including exempt compounds) used and the VOC content ofeach material used during the averaging period. The District may specifically authorize the usage record to reflect a period longer than the compliance averaging period, with the usage prorated for each compliance averaging period by a method approved by the District. In this case, the usage record period shall not exceed 1 calendarmonth.
11. The owner or operator shall maintain monthly records, including calculations, that show the total plant-wide VOC emissions during each calendar month and consecutive 12-monthperiod. Page 56 of 130 03-31-2011PermitNo: 245-09-C (R1) PlantID: 0072 iii. The owner or operator shall maintain a copy ofthe Material Safety Data Sheet (MSDS) for each VOC containingmaterial used atthis plant b. TAC The owneroroperator shall keep a record ofthe Material SafetyData Sheet (MSDS) for each TAC-containingmaterial inthis emission unit.
c. HAP See LAP MACTRecordkeeping Section. S4. Reporting (Regulation 2.16, section. 4.1.9.3)

SCH a. VOC See General PermitReporting Requirements. b. TAC The owner or operator shall submit a plant-wide emissions-based EA Demonstration to the District showing compliance with theplant-wide EA goals of7.5 new and existing, 3.8 for all new combined, and 1 for each process when a change occurs that increases emissions above De minimus orpreviously modeled values.
c. HAP See LAPMACTReportingRequirements.

Page 57 of 130 03-31-2011PermitNo: 245-09-C (R1) Plant ID: 0072 UOlO Emission UnitDescription: E-Coat Operation UOlO Applicable Regulations: FederallyEnforceableRegulations Regulation Title Applicable Sections 1.05 Compliance with Emission Standards and 1, 3, 4 and 5 Maintenance Requirements 7.01 General Provisions 7.2 7.08 Standards ofPerformance forNewProcess 1through 3 Operations 40 CFR 60 General Provisions 60.1 through 60.18 SubpartA 40 CFR60 NationalEmission Standards ofPerformance for SubpartMM Automobile and LightDutyTruck Surface 60.390 through 60.397 Coating Operations 40 CFR 63 General Provisions 63.1 through 63.16 SubpartA 40 CFR 63 NationalEmission Standards for Hazardous Air SubpartIIII Pollutants: Surface Coating ofAutomobiles and 1, 2, 3 ,4, 7 and 8 Light-DutyTrucks

District Only Enforceable Regulations Regulation Subject Applicable Sections 1.18 Rule Effectiveness 1through 3 5.01 General Provisions 1through 4 5.02 Adoption ofNationalEmission Standards for 1, 3, 4 and 5 Hazardous AirPollutants 5.14 Hazardous Air Pollutants and Source Categories 1 and2 5.21 Environmental Acceptabilityfor Toxic Air 1through 5 Contaminants 5.22 Procedures for Determiningthe Maximum Ambient 1through 5 Concentration ofa Toxic Air Contaminant 5.23 Categories ofToxic Air Contaminants 1through 6 7.02 FederalNew Source Performance Standards 1.50, 2 , 3, 4 and 5 IncorporatedbyReference SCH Page 58 of 130 03-31-2011PermitNo: 245-09-C (R1) U010 Emission Points:

ID Description

E10A E-CoatDip Tank

EIOB E-Coat Oven

SCH Plant ID: 0072

U010 Emission Points Applicable AllowableEmission/Equipment Control Requirement Standard Device (RT) is :2: 0.16, not exceed 1.4 lbs/gal 40 CFR 60 (0.17 kg/!) SubpartMM RT is :2: 0.04 and< 0.16, not exceed the weight per gallon limit calculated as follows: 0.17 x 350(0 160

-\)kg ofVOC per liter of applied coating solids 6.17 and 7.01 RT is<0.040, not be subject to an N/A emission limit a. 0.6 lbs HAP/GACS Or b. 1.1 lbs HAPs/GACS 40 CFR 63 (the above limits are applicable to a SubpartIIII group ofemissions sources and are different depending upon whether compliance is demonstrated with (a) or without (b) E-coat) 40 CFR 60 SubpartMM See Specific Condition S1.a 6.17 and 7.01 a. 0.6 lbs HAP/GACS Or C10A b. 1.1 lbs HAPs/GACS 40 CFR 63 (the above limits are applicable to a SubpartIIII group ofemissions sources and are different depending upon whether compliance is demonstrated with (a) or without (b) E-coat) 7.08 

### < 300ppm

Page 59 of 130 03-31-2011PermitNo: 245-09-C (R1) Plant ID: 0072 

### UOlO Emission Points ID Description Applicable Allowable Emission/Equipment Control Requirement Standard Device

40 CPR 60 SubpartMM See Specific Condition S1.a 6.17 and 7.01

40 CPR 63 a. 0.6 lbs HAP/GACS SubpartIIII Or ElOC E-Coat Oven b. 1.1 lbs HAPs/GACS C10B (3rd Pass) (the above limits are applicable to a group ofemissions sources and are different depending upon whether compliance is demonstrated with (a) or without (b) E-coat) 7.08 < 300ppm 40 CPR 60 SubpartMM See Specific Condition S1.a 6.17 and 7.01 E-Coat a. 0.6 lbs HAP/GACS E10D DumpMetal Or NIA AST b. 1.1 lbs HAPs/GACS 40 CPR 63 (the above limits are applicableto a SubpartIIII group ofemissions sources and are different depending upon whether compliance is demonstrated with (a) or without (b)E-coat) E-Coat Scuff <20% E17A Booth 7.08 C17A 2.34lb/hr UOlO Control Devices: ID Description Performance Stack ID Indicator C10A One (1) Regenerative Thermal Temperature S-041, S-043, S-045 Oxidizer (RTO) C10B One (1) Regenerative Thermal Temperature S-020 to S-022, S-050 Oxidizer (RTO) C17A DryPanelFilter N/A S-047, S-048

SCH Page 60 of 130 03-31-2011PermitNo: 245-09-C (R1) PlantID: 0072 

### UOlO Specific Conditions S1. Standards (Regulation 2.16, section 4.1.1)

SCH 

### a. VOC i. The owner or operator shall be subjectto the following emission limits ( 40 CFR 60.392, Regulation 7.01 section 7.2 andRegulation 6.17, section 3): 1) When the solids turnover ratio (RT) is ;::: 0.16, not exceed 1.4 lbs/gal (0.17 kg/1) ofapplied coating solids. 2) Whenthe RT is;:::: 0.04 and< 0.16, not exceed the weightper gallon limit calculated as follows: 0.17 x 350<0

·160

-RT) kg ofVOC per liter ofapplied coating solids. 3) When the RT is < 0.040, not be subject to an emission limit establishedpursuantto this regulation.
11. See Louisville Assembly Plant, Ford Motor Company Plant-wide ApplicabilityLimit (PAL). b. PM
1. See Louisville Assembly Plant, Ford Motor Company Plant-wide ApplicabilityLimit (PAL). ii. The owner or operator shall not allow PM emissions to exceed 2.34 lb/hr. (Regulation 7.08, section 3.1.2) (See Comment 1)
111. The owner or operator shall not operate the scuff booth unless the particulate filters are installed and operating properly. The owner or operator shall follow good operatingpractices forthe particulate filters.
c. Opacity The owner or operator shall not allowvisible emissions to equal or exceed 20% opacity. (Regulation 7.08, section 3.1.1) 

### d. HAP See LAP FordMotor CompanyMACT Standards Section.


### e. NOx Page 61 of 130 03-31-2011PermitNo: 245-09-C (R1) PlantID: 0072 The owner or operator shall not cause to be discharged into the atmosphere from any affected facility or from any air pollution control equipment installed on any affected facility any NOx fumes in excess of 300 ppm by volume expressed as N02• (Regulation 7.08, section 4) (See Comment 2) 

### f. TAC
1. The owner or operator shall not allow any TAC emissions to exceed environmentally acceptable levels whether specifically established by modeling or derived from default de minimis levels. (Regulation 5.01, section 3.)
11. The owner or operator shall utilize the control devices at all times the surface coating operations are in operation and shall, maintain and operate any affected facility including associated air pollution control equipment in a manner consistent with good air pollution control practice for minimizing emissions. (Regulation 5.21, section4.7) S2. Monitoring (Regulation 2.16, section 4.1.9.1.2)

SCH 

### a. VOC
1. Monitor ongoing compliance by calculating monthly, the daily volumeweighted average VOC content ofthe coatings (including resin, pigment, and flow control additive) used. Procedures used for this determination may be those provided in the "Protocol for Determining Daily Volatile Organic Compound Emission Rate ofAutomobile and Light-Duty Truck Topcoat Operations," EPA-450/3-88-018 (Docket ID No. OAR-2002- 0093 and Docket IDNo. A-2001-22).
n. The owner or operator shall during operation of any coating operation(s) for which emission reductions due to the use ofadd-on control equipment are relied upon to demonstrate compliance with the emission limits above, maintain the afterburners combustion chamber temperature at;:::: 760° Cor othertemperature, as determined during the latest stacktest, based upon a three hour average, and maintain a combustion chambertemperature ofno more than 28°C (50°F) below the average combustion temperature. In addition, the afterburners shall have a minimum residence time of 0.5 seconds. The temperature shall be recorded using a recorder, which shall be calibrated and maintained according to the manufacturer's specifications. Temperature measurements of the thermal oxidizer combustion chamber shall be made at least once every 15 minutes and recorded during operation ofthe associated coating operations.
111. If necessary for purposes of compliance, this line shall not be operated unless all control devices are beingproperly operated. Page 62 of 130 03-31-2011PermitNo: 245-09-C (Rl) Plant ID: 0072

SCH IV. Use EPAMethod 24to determine the amount ofVOC in the coating. The following equation may be used as an alternate method to demonstrate compliance:

Where: n 

### V C. 

## voc =

# s _l_l w 

# v i=l I

VOCw 

### = the weighted average coatingVOC content, as applied; and less water and exempt solvents, expressed in pounds of VOC per gallon ofcoating.
n 

### = number ofdifferent coatings used on a coatingline a given month. V1 

### = the volume ofeach coating used on a coating line, as applied and less water and exempt solvents, a given month. C1 the VOC content ofeach coating used on a coating line, as applied and less water and exempt solvents, a given month. Vt 

### = total volume ofall coatings applied each month on a coating line, lesswater and exempt solvents.
v. Meet the standards specified in 40 CPR 60.392, as calculated using the prescribed transfer efficiency of 40 CPR 60.393(c)(1)(i)(C) for the monthly weighted average mass ofVOC emitted per volume of applied coating solids. b. PM The owner or operator shall include monthly inspection routine maintenance as recommendedbythe manufacturer, and promptrepair ofany defects.
c. Opacity See Specific Condition S2.b. d. HAP See LAP FordMotor CompanyMACTMonitoring Section.
e. 

### NOx Page 63 of 130 03-31-2011PermitNo: 245-09-C (R1) Plant ID: 0072 There are no monitoringrequirements for NOx compliance. (See Comment 2) 

### f. TAC
1. See Specific Condition S2.a.ii and iii. ii. See Specific Condition S3.f. S3. Record Keeping (Regulation 2.16, section4.1.9.2)

SCH a. VOC Performrecordkeepingfor VOCs for 40 CFR 60.395 and 1.05, Section 4: i. Record monthly the quantity ofresin, pigment, and flow control additive addedto the electrocoat system.
11. Determine and recordmonthlyusage ofeachmaterial. iii. Calculations shall incorporate control efficiency where being relied upon for compliance purposes and shall include downtime adjustments to account for increased emissions during the period the afterburners were not operating. If used for compliance, the owner or operator shall also maintain records ofcontrol device downtimes and bypasses, including the date and duration ofeach occurrence. iv. The owner or operator shall continuously record the incinerator combustiontemperature during coating operations for thermal incineration or the gas temperature upstream and downstream of the incinerator catalystbed during coating operations for catalytic incineration.
v. The owner or operator shall maintain monthly records, including calculations that show the total plant-wide VOC emissions during each calendarmonth and consecutive 12-monthperiod.
VI. Record the afterburner combustion chamber temperature and temperature recording frequency from Specific Condition S2.a.ii. b. 

### PM i. The owner or operator shall keep a recordthat shows the date and the name ofthepersonwho inspectedthe filters and iffilters were replaced. ii. Proper operation of the fabric filter shall be ensured by maintaining records ofinspections and routine maintenance activities and shall make these records available to the District upon request. A demonstration that Page 64 of 130 03-31-2011PermitNo: 245-09-C (Rl) PlantID: 0072 proper operation ofthe fabric filter has occurred satisfies this compliance requirement for the standard specified inSl.b.ii. above.
c. Opacity See Specific Condition S3.b. d. HAP See LAP FordMotor CompanyMACTRecordkeeping Section.
e. 

### NOx There are no record keepingrequirements for NOx compliance. (See Comment 2) f. TAC i. The owner or operator shall keep a record of the Material Safety Data Sheet (MSDS) for eachTAC-containingmaterial in this emissionunit.
11. The owner or operator shall maintain records that identify all periods of bypassing the control devices while the surface coating operations are in operation for a given day. The records shall include the date, duration (including start and stop time) ofeach bypass event, identification ofthe control device and process equipment in operation, and the total lb/hr emissions ofeach TAC from each piece ofequipment during each bypass event, if that control equipment is required to meet the EA goals. (See Comment 3)
m. See Specific Conditions S3.a.iii. S4. Reporting (Regulation 2.16, section 4.1.9.2)

SCH 

### a. VOC i. See General PermitReporting Requirements.
11. For the control devices, the owner or operator shall clearly identify all deviations from permit requirements. If no deviations occur in that reporting period then the owner or operator shall report a negative declaration includingthe following information: 1) EmissionUnitnumber and Control ID number; 2) The beginning and ending date ofthe reportingperiod; 3) Identification ofthe operatingparameters beingmonitored; 4) Number, duration, and cause ofall exceedances ofthe parameters; Page 65 of 130 03-31-2011PermitNo: 245-09-C (Rl) PlantID: 0072

SCH and 5) Description ofthe corrective action taken for each exceedance.
111. Perform reporting for VOCs for 40 CFR60.395 and 1.05, Section 4:

b. PM 1) The owner or operator shall report the volume weighted average mass of VOC per volume of applied coating solids for each affected facility. 2) For thermal incinerators, every three-hour period shall be reported during which the average temperature measured is more than 28 

## oc less thanthe average temperature during the most recent control device performance test. 3) For catalytic incinerators, everythree-hour period shall be reported during which the average temperature immediately before the catalyst bed, when the coating system is operational, is more than 28 

## oc less than the average temperature immediately before the catalyst bed during the most recent control device performance test at which destruction efficiency was determined. In addition, every three-hour period shall be reported each quarter during which the average temperature difference across the catalyst bed when the coating system is operational is less than 80 percent ofthe average temperature difference ofthe device during the most recent control device performance test at which destruction efficiency was determined. 4) For thermal and catalytic incinerators, ifno suchperiods occur, the owner oroperator shall submit a negative report. 5) The owner or operator shall notify the Administrator 30 days in advance ofanytestbyMethod 25.
Any deviation from the requirementto performmonthlyvisible inspections ofthe scuffbooth PMfilter system.
c. Opacity See Specific Condition S4.b. d. HAP See LAP Ford MotorCompanyMACTReporting Requirements.
e. 

### NOx There are no reporting requirements for NOx compliance. (See Comment2) Page 66 of 130 03-31-2011

### PermitNo: 245-09-C (R1) Plant ID: 0072 f. TAC 

### i. The owner or operator shall submit a plant-wide 

### emissions-based EA Demonstration to the District showing compliance with theplant-wide 

### EA goals of7.5 new and existing, 3.8 for all new combined, and 1 for each process when a change occurs that increases emissions above De minimus orpreviouslymodeled values.
n. 

### Identification of all periods of bypassing the control devices while the surface coating operations were in operation during a reporting period. The report shall include the date, duration (including start and stop time) ofeach bypass event, and the totallb/hr emissions ofeach TAC from each piece ofequipment during each bypass event, ifthat control equipment is requiredto meetthe EA goals. (See Comment 3) iii. See Specific Conditions S4.a.ii. DOlO Comments 

### 1. Compliance with this requirement is demonstrated through a mass balance approach or engineering estimate. 2. The District has performed a one-time NOx compliance demonstration using AP-42 emission factors and combusting natural gas, and the emission standard cannot be exceeded. Therefore, there are no monitoring, record keeping, and reporting requirements with respectto NOx emission limits. 3. The reported total lb/hr emissions of each TAC from each piece of equipment during each bypass event will be used only to determine if each TAC claimed as de minimis pursuant to Regulation 5.01 Section 1.6 in Ford Motor Company Louisville Assembly Plant's current plant-wide emissions-based EA demonstration continue to meet the de minimis criteria specified in Section 1.6.4. Should emissions during a bypass event for a TAC claimed to be de minimis exceed the de minimis criteria, Ford Motor Company Louisville Assembly Plant shall submit an updated plant-wide emission-based EA Demonstration to the District showing compliance with the plant-wide EA goals of7.5 new and existing, 3.8 for all new combined, and 1 for each process where the TAC emissions increase above de minimis values.

SCH Page 67 of 130 03-31-2011PermitNo: 245-09-C (R1) PlantID: 0072 U011 Emission UnitDescription: Guidecoat Operation U011 Applicable Regulations: Federally Enforceable Regulations Regulation Title Applicable Sections 1.05 Compliance with Emission Standards and 1, 3, 4 and 5 Maintenance Requirements 7.01 General Provisions 7.2 7.08 Standards ofPerformance forNewProcess 1through 3 Operations Standards ofPerformance forNew 7.59 Miscellaneous Metal PartsProducts Surface 1through 7 Coating Operation 40 CFR 60 General Provisions 60.1 through 60.18 SubpartA 40 CFR 60 NationalEmission Standards ofPerformance for SubpartMM Automobile and LightDutyTruck Surface 60.390 through 60.397 Coating Operations 40 CFR 63 GeneralProvisions 63.1 through 63.16 SubpartA 40 CFR 63 NationalEmission Standards for Hazardous Air Subpart IIII Pollutants: Surface Coating ofAutomobiles and 1, 2, 3 ,4, 7 and 8 Light-DutyTrucks

SCH Page 68 of 130 03-31-2011PermitNo: 245-09-C (R1) Plant ID: 0072

District Only Enforceable Regulations Regulation Title Applicable Sections 1.18 Rule Effectiveness 1through 3 5.01 General Provisions 1through 4 5.02 Adoption ofNationalEmission Standards for 1, 3, 4 and 5 HazardousAirPollutants 5.14 Hazardous AirPollutants and Source Categories 1and 2 5.21 EnvironmentalAcceptability for Toxic Air 1through 5 Contaminants Procedures for Determiningthe Maximum 5.22 Ambient Concentration ofa Toxic Air 1through 5 Contaminant 5.23 Categories ofToxic Air Contaminants 1through 6 7.02 FederalNew Source Performance Standards 1.50, 2, 3, 4 and 5 IncorporatedbyReference

SCH Page 69 of 130 03-31-2011PermitNo: 245-09-C (R1) U011 Emission Points:

ID Description

GuidecoatPaint EllA SprayBooth andAir Supply House

Touchup and EllB BlackoutBooth

EllC Guidecoat Oven (1st and 2nd Pass)

SCH PlantID: 0072
U011 Emission Points Applicable AllowableEmission/ Control Requirement Equipment Standard Device

40 CPR 60 SubpartMM See Specific Condition S1.a 6.17 and 7.01
a. 0.6 lbs HAP/GACS Or CllA b. 1.1 lbs HAPs/GACS 40 CPR 63 (the above limits are applicable to a Subpart IIII group ofemissions sources and are different depending uponwhether compliance is demonstrated with

(a) orwithout (b) Guidecoat) <20% C10B 7.08 2.34lb/hr 7.59 3.5 lbs VOC/gal 40 CPR 60 SubpartMM See Specific Condition S1.a 6.17 and 7.01 a. 0.6 lbs HAP/GACS Or b. 1.1 lbs HAPs/GACS CllC 40 CPR 63 (the above limits are applicableto a Subpart IIII group ofemissions sources and are different depending upon whether compliance is demonstrated with

(a) orwithout (b) Guidecoat) 7.08 < 300 ppm

Page 70 of 130 03-31-2011PermitNo: 245-09-C (Rl) Plant ID: 0072 UOll Emission Points ID Description Applicable Allowable Emission/ Control Requirement Equipment Standard Device

40 CPR 60 SubpartMM See Specific Condition Sl.a 6.17 and 7.01

40 CPR 63 a. 0.6 lbs HAP/GACS Guidecoat Oven (3rd SubpartIIII Or EllD b. 1.1 lbs HAPs/GACS C10B Pass) (the above limits are applicableto a group ofemissions sources and are different depending upon whether compliance is demonstrated with

(a) orwithout (b) Guidecoat) 7.08 < 300ppm EllE/ Guidecoat/Topcoat 1.05 Same as for 7.59 N/A E12G Paint Kitchen 40 CPR 60.3092 See Specific Condition S1.a Guidecoat (Prime) <20% E18A 7.08 C18A ScuffBooth 2.34lb/hr UOll ControlDevices: UOll Control Devices Performance ID Description Indicator StackiD C11A WaterWash N/A S-080 to S090 CIOB One (1) Regenerative Temperature S-179 to S182 and S-098, S099, Thermal Oxidizer (RTO) S050 CllC One (1) Regenerative Temperature S-091 to S-092, S-097 Thermal Oxidizer (RTO) C18A DryPanelFilter N/A S-175 to S-178

SCH Page 71 of 130 03-31-2011PermitNo: 245-09-C (R1) PlantID: 0072 UOll Specific Conditions S1. Standards (Regulation 2.16, section 4.1.1)

SCH a. VOC
1. The owner or operator shall be subjectto the limit of 1.40 kg VOC/1 (11.7 lb VOC/gal) ofapplied coating solids, less water and exempt solvents. (40 CFR60.392)
11. The owner or operator shall be subject to the limit of 1.8 kg VOC/1 (15.1 lb VOC/gal) of applied coating solids, less water and exempt solvents. (Regulation 7.01 section 7.2 and Regulation 6.17, section 3.2) (See Comment 3) iii. For Emission Point E11B, the owner or operator shall not cause or allow the emission ofVOC from any affected facility resulting from the coating ofmetallic surfaces in excess of0.42 kg ofVOC/1 (3.5 lb ofVOC/gal) of coating, excluding water and exempt solvents, as applied for extreme performance coatings. (Regulation7.59, section 3.1.3) iv. See Louisville Assembly Plant, Ford Motor Company Plant-wide Applicability Limit (PAL). b. PM i. See Louisville Assembly Plant, Ford Motor Company Plant-wide Applicability Limit (PAL). ii. The owner or operator shall not allow PM emissions to exceed 2.34 lb/hr. (Regulation 7.08, section 3.1.2) (See Comment 1)
111. The owner or operator shall not operate the scuff booth unless the particulate filters are installed and operating properly. The owner or operator shall follow good operatingpractices for the particulate filters.
c. Opacity The owner or operator shall not allowvisible emissions to equal orexceed 20% opacity. (Regulation 7.08, section 3.1.1) d. HAP See LAP FordMotor CompanyMACT Standards Section.
e. NOx Page 72 of 130 03-31-2011

### PermitNo: 245-09-C (R1) PlantID: 0072 The owneror operator shall not cause to be discharged into the atmosphere from any affected facility or from any airpollution control equipment installed on any affected facility anyNOx fumes in excess of300 ppm by volume expressed as N02. (Regulation 7.08, section 4) (See Comment 2) 

### f. TAC
1. 

### The owner or operator shall not allow any TAC emissions to exceed environmentally acceptable levels whether specifically established by modeling or derived from default de minimis levels. (Regulation 5.01, section 3.)
11. 

### The owner or operator shall utilize the control devices at all times the surface coating operations are in operation and shall, maintain and operate any affected facility including associated air pollution control equipment in a manner consistent with good air pollution control practice for minimizing emissions. (Regulation 5.21, section 4.7) S2. Monitoring 

### (Regulation 2.16, section 4.1.9.1)

SCH a. VOC
1. 

### For Emission Point E11B, record monthly usage. Determine daily usage of each material by prorating monthly consumption based on daily vehicles produced. Record the amount of surface preparation, clean up, wash-up of solvent (including exempt compounds) used and the VOC content of each material used during the averaging period. (Regulation 7.59, section 3.1.4 and 6.1.6, and 2.16, section 4.1.9.1.2)
11. 

### The owner or operator shall during operation ofany coating operation(s) for which emission reductions due to the use ofadd-on control equipment are relied upon to demonstrate compliance with the emission limits above, maintain the afterburners combustion chambertemperature at;::: 760° Cor other temperature, as determined during the latest stack test, based upon a three hour average, and maintain a combustion chambertemperature ofno more than 28°C (50°F) below the average combustion temperature. In addition, the afterburners shall have a minimum residence time of 0.5 seconds. The temperature shall be recorded using a recorder, which shall be calibrated and maintained according to the manufacturer's specifications. Temperature measurements of the thermal oxidizer combustion chamber shall be made at least once every 15 minutes and recorded during operation ofthe associated coating operations.
111. 

### The line shall not be operatedunless all control devices are beingproperly operated. Page 73 of 130 03-31-2011PermitNo: 245-09-C (Rl) PlantID: 0072

SCH IV. Measure capture efficiencypursuant to Regulation 1.05, Section 3, except that EPA Method 204F, Volatile Organic Compounds Content in Liquid Input Stream (Distillation Approach), shall be used to determine VOC input.
v. Use EPA Method 24 to determine the amount ofVOC in the coating. The following equation may be used as an alternate method to demonstrate compliance:

b. PM Where: n

### ---¥yCi**i,J;~i** VOCw = the daily weighted average coating VOC content, as applied; and less water and exempt solvents, expressed in pounds of VOC per gallon ofcoating.
n 

### = number ofdifferent coatings used on a coating line a given day. V1 = the volume ofeach coating used on a coating line, as applied and less water and exempt solvents, a given day. C1 the VOC content ofeach coating used on a coating line, as applied and less water and exempt solvents, a given day. 

### Vt = total volume ofall coatings applied each day on a coating line, less water and exempt solvents.

The owner or operator shall include monthly inspection routine maintenance as recommended bythe manufacturer, and promptrepair ofany defects.
c. Opacity See Specific Condition S2.b. d. HAP See LAPFord Motor CompanyMACTMonitoring Section.
e. 

### NOx There are no monitoringrequirements forNOx compliance. (See Comment 2) Page 74 of 130 03-31-2011

### PermitNo: 245-09-C (Rl) f. 

### TAC Plant ID: 

### 0072

1. 

### See Specific Condition S2.a.iii and iv.
11. 

### See Specific Condition S3.f. S3. Record Keeping 

### (Regulation 2.16, section 4.1.9.2)

SCH a. VOC 

### i. For Emission Point E11B, the owner or operator of an affected facility subject to this regulation shall maintain records that include, but not be limitedto, the following: (Regulation 7.59, section 6.1) 1) 

### The regulation and section number applicable to the affected facility for which the records are being maintained, 2) The application method and substrate type (metal, plastic, etc.), 3) The amount and type of coatings (including catalyst and reducer for multi-component coatings) and solvent (including exempt compounds) used at each point ofapplication during the averaging period. The District may specifically authorize the usage record to reflect a period longer than the compliance averaging period, with the usage prorated for each compliance averaging period by a method approved by the District. In this case, the usage record period shall not exceed 1calendarmonth, 4) The VOC content as applied in each coating and solvent, 5) The date, or usage record period, for each application of coating and solvent, 6) The amount of surface preparation, clean-up, wash-up of solvent (including exempt compounds) used and the VOC content ofeach material used during the averaging period. The District may specifically authorize the usage record to reflect a period longer than the compliance averaging period, with the usage prorated for each compliance averaging period by a method approved by the District. In this case, the usage record period shall not exceed 1 calendarmonth. ii. The owner or operator shall maintain the following records: (40 CPR 60.395 and 1.05, Section 4) 1) Record dailythe quantity ofpaint and dilution solvent added to the Page 75 ofl30 03-31-2011

### PermitNo: 245-09-C (R1) PlantID: 0072

SCH guidecoat (primer surfacer). 2) The owner or operator shall monitor ongoing compliance by calculating monthly, a daily volume-weighted average of the coatings used. 3) Combine daily pour records with monthly tank level readings to determine monthlypaintusage. 4) Determine daily paint usage of each material by prorating consumptionbased on daily surface area coated. 5) Determine daily usage and emissions by using calculation procedures in Protocol for Determiningthe Daily Volatile Organic Compound Emission Rate ofAutomobile and Light Truck Topcoat Operations, EPA-450/3-88-018. 6) Calculations shall incorporate control efficiency and shall include downtime adjustments to account for increased emissions during the period the afterburners were not operating. The owner or operator shall also maintain records ofcontrol devices downtimes and bypasses, includingthe date and duration ofeach occurrence. 7) Report all instances ofnon-compliance to the District no later than (15) days afterthe occurrence has been confirmed, notwithstanding Regulation 1.07. 8) Meet the standards specified in 40 CPR 60.392, as calculated, using the prescribed transfer efficiency of 40 CPR 60.393 (c)(1)(i)(C) for the monthly weighted average mass of VOC emitted pervolume ofapplied coating solids.
111. 

### Record the temperature and frequency from Specific Condition S2.a.ii. b. PM i. The owner or operator shall keep arecordthat shows the date and the name oftheperson who inspected the filters and iffilters were replaced. ii. Proper operation of the fabric filter shall be ensured by maintaining records of inspections and routine maintenance activities and shall make these records available to the District upon request. A demonstration that proper operation ofthe fabric filter has occurred satisfies this compliance requirement for the standard specified in S1.b.ii. above.
Page 76 of 130 03-31-2011PermitNo: 245-09-C (R1) PlantID: 0072 

### c. Opacity See Specific Condition S3.b. 

### d. HAP See LAP FordMotor CompanyMACTRecordkeeping Section.
e. 

### NOx There are no record keepingrequirements for NOx compliance. (See Comment 2) f. TAC i. The owner or operator shall keep a record of the Material Safety Data Sheet (MSDS) for each TAC-containingmaterial inthis emission unit. ii. The owner or operator shall maintain records that identify all periods of bypassing the control devices while the surface coating operations are in operation for a given day. The records shall include the date, duration (including start and stop time) ofeach bypass event, identification ofthe control device and process equipment in operation, and the total lb/hr emissions ofeach TAC from each piece ofequipment during each bypass event, if that control equipment is required to meet the EA goals. (See Comment4)
111. See Specific Conditions S3.a.ii.(5) S4. 

### Reporting (Regulation 2.16, section. 4.1.9.3)

SCH a. VOC
1. See General PermitReportingRequirements.
11. For the control devices, the owner or operator shall clearly identify all deviations from permit requirements. If no deviations occur in that reporting period then the owner or operator shall report a negative declaration for the following category: 1) EmissionUnit number and Control 

### ID number; 2) The beginning and ending date ofthe reportingperiod; 3) Identification ofthe operatingparameters beingmonitored; 4) Number, duration, and cause ofall exceedances oftheparameters; and 5) Description ofthe corrective action taken for each exceedance. Page 77 of 130 03-31-2011PermitNo: 245-09-C (Rl) PlantID: 0072

SCH 111. Performrecordkeeping for VOCs for 40 CFR60.395 and 1.05, Section 4:

b. PM 1) The owner or operator shall report the volume weighted average mass of VOC per volume of applied coating solids for each affected facility. 2) The owner or operator shall continuously record the incinerator combustion temperature during coating operations for thermal incineration or the gas temperature upstream and downstream of the incinerator catalyst bed during coating operations for catalytic incineration. 3) Forthermal incinerators, every three-hour period shall be reported during which the average temperature measured is more than 28 

## oc less than the average temperature duringthe mostrecent control deviceperformancetest. 4) For catalytic incinerators, everythree-hourperiod shall be reported during which the average temperature immediately before the catalyst bed, when the coating system is operational, is more than 28 

## oc less than the average temperature immediately before the catalyst bed during the mostrecent control device performance test at which destruction efficiency was determined. In addition, every three-hour period shall be reported each quarter during which the average temperature difference across the catalyst bed when the coating system is operational is less than 80 percent ofthe average temperature difference ofthe device during the mostrecent control device performance test at which destruction efficiency was determined. 5) Forthermal and catalytic incinerators, ifno suchperiods occur, the owner oroperator shall submit a negative report. 6) The owner or operator shall notify the Administrator 30 days in advance ofanytestbyMethod 25.
Any deviation from the requirementto perform monthlyvisible insp·ections ofthe scuffboothPMfilter system.
c. Opacity See Specific Condition S4.b. d. HAP See LAP Ford Motor CompanyMACT Reporting Requirements.
e. 

### NOx Page 78 of 130 03-31-2011

### PermitNo: 245-09-C (R1) PlantID: 0072 There are no reporting requirements for NOx compliance. (See Comment 2) 

### f. TAC 

### i. The owner or operator shall submit a plant-wide 

### emissions-based EA Demonstration to the District showing compliance with theplant-wide 

### EA goals of 7.5 new and existing, 3.8 for all new combined, and 1 for each process when a change occurs that increases emissions above De minimus orpreviously modeledvalues. ii. Identification ofall periods ofbypassing the control devices while the surface coating operations were in operation during a reporting period. The report shall include the date, duration (including start and stop time) ofeach bypass event, and the totallb/hr emissions ofeach TAC from each piece ofequipment during each bypass event, ifthat control equipment is required to meetthe EA goals. (See Comment4) iii. See Specific Conditions S4.a.ii. U011 Comments 

### 1. Compliance with this requirement is demonstrated through a mass balance approach or engineering estimate. 2. The District has performed a one-time NOx compliance demonstration using AP-42 emission factors and combusting natural gas, and the emission standard cannot be exceeded. Therefore, there are no monitoring, record keeping, and reportingrequirements withrespectto NOx emissionlimits. 3. IfFord is in compliance with the 40 CPR 60 Subpart MM 

### 60.3092 VOC limitthanthey are in compliance with Regulation 6.17, section 3.3 VOC limit. 4. The reported total lb/hr emissions of each TAC from each piece of equipment during each bypass event will be used only to detennine if each TAC claimed as de minimis pursuant to Regulation 5.01 Section 1.6 in Ford Motor Company Louisville Assembly Plant's current plant-wide emissions-based EA demonstration continue to meet the de minimis criteria specified in Section 1.6.4. Should emissions during a bypass event for a TAC claimed to be de minimis exceed the de minimis criteria, Ford Motor Company Louisville Assembly Plant shall submit an updated plant-wide emission-based EA Demonstration to the District showing compliance with the plant-wide EA goals of7.5 new and existing, 3.8 for all new combined, and 1 for each process where the TAC emissions increase above de minimis values.

SCH Page 79 of 130 03-31-2011PermitNo: 245-09-C (R1) PlantID: 0072 U012 Emission UnitDescription: Topcoat Operation U012 Applicable Regulations: FederallyEnforceable Regulations Regulation Title Applicable Sections 1.05 Compliance with Emission Standards and 1,3,4and5 Maintenance Requirements 7.08 Standards ofPerformance forNewProcess 1through 3 Operations 7.01 General Provisions 7.2 40 CPR 60 General Provisions 60.1 through 60.18 SubpartA 40 CPR 60 National Emission Standards ofPerformance for SubpartMM Automobile and LightDutyTruck Surface 60.390 through 60.397 Coating Operations 40 CPR 63 General Provisions 63.1 through 63.16 SubpartA 40 CPR 63 National Emission Standards for Hazardous Air SubpartIIII Pollutants: Surface Coating ofAutomobiles and 1, 2, 3 ,4, 7 and 8 Light-DutyTrucks

SCH Page 80 of 130 03-31-2011PermitNo: 245-09-C (R1) Plant ID: 0072
District Only EnforceableRegulations Regulation Subject Applicable Sections 1.18 Rule Effectiveness 1through 3 5.01 General Provisions 1through 4 5.02 Adoption ofNationalEmission Standards for 1,3,4and5 Hazardous AirPollutants 5.14 Hazardous AirPollutants and Source Categories 1and 2 5.21 Environmental Acceptabilityfor Toxic Air 1through 5 Contaminants 5.22 Procedures for Determiningthe Maximum Ambient 1through 5 Concentration ofa Toxic Air Contaminant 5.23 Categories ofToxicAirContaminants 1through 6 7.02 Federal New Source Performance Standards 1.50, 2 , 3, 4 and 5 IncorporatedbyReference

SCH Page 81 of 130 03-31-2011PermitNo: 245-09-C (R1) U012 Emission Points: U012 Emission Points Description Applicable AllowableEmission/ Requirement Equipment Standard

40 CFR 60 SubpartMM See Specific Condition S1.a. 6.17 and 7.01 <20% 7.08 E12ANorth Main 2.34lb/hr Enamel Booth and a. 0.6 lbs HAP/GACS Air Supply Or b. 1.1 lbs HAPs/GACS 40 CFR 63 (the above limits are applicable to a SubpartIIII group ofemissions sources and are different depending upon whether compliance is demonstrated with (a) orwithout (b) Topcoat) 40 CFR 60 SubpartMM See Specific Condition S1.a. 6.17 and 7.01 <20% 7.08 E12B NorthMain < 300ppm Enamel Oven c. 0.6 lbs HAP/GACS Or d. 1.1 lbs HAPs/GACS 40 CFR63 (the above limits are applicable to a SubpartIIII group ofemissions sources and are different depending upon whether compliance is demonstrated with (a) or without (b) Topcoat)

SCH Page 82 of 130 PlantID: 0072

Control Device

C12A, C12B Cl2C, C12H and C12G

Cl2D

03-31-2011PermitNo: 245-09-C (Rl) PlantID: 0072 U012 Emission Points Description Applicable Allowable Emission/ Control Requirement Equipment Standard Device

40 CPR 60 SubpartMM See Specific Condition Sl.a. 6.17 and 7.01 <20% 7.08 E12C SouthMain 2.34lb/hr Cl2C, C12E, Enamel Booth and Air a. 0.6 lbs HAP/GACS C12H and C12G Supply House Or b. 1.1 lbs HAPs/GACS 40 CPR 63 (the above limits are applicable to a SubpartIIII group ofemissions sources and are different depending uponwhether compliance is demonstrated with (a) orwithout (b) Topcoat) 40 CPR60 SubpartMM See Specific Condition S1.a. 6.17 and 7.01 <20% 7.08 E12D South Main < 300 ppm C12D Enamel Oven c. 0.6 lbs HAP/GACS Or d. 1.1 lbs HAPs/GACS 40 CPR 63 (the above limits are applicable to a SubpartIIII group ofemissions sources and are different depending upon whether compliance is demonstrated with (a) orwithout (b) Topcoat)

SCH Page 83 of 130 03-31-2011PermitNo: 245-09-C (R1) PlantID: 0072 U012 Emission Points Description Applicable AllowableEmission/ Control Requirement Equipment Standard Device

40 CFR 60 SubpartMM See Specific Condition S1.a. 6.17 and 7.01 <20% 7.08 E12E TuTone/Repair 2.34lb/hr TopcoatBooth and Air a. 0.6 lbs HAP/GACS Cl2F SupplyHouse Or b. 1.1 lbs HAPs/GACS 40 CFR 63 (the above limits are applicable to a Subpart IIII group ofemissions sources and are different depending upon whether compliance is demonstrated with (a) orwithout (b) Topcoat) 40 CFR 60 SubpartMM See Specific Condition Sl.a. 6.17 and 7.01 <20% 7.08 E12F Tutone/Repair < 300 ppm Topcoat Oven c. 0.6 lbs HAP/GACS C12D Or d. 1.1 lbs HAPs/GACS 40 CFR 63 (the above limits are applicable to a Subpart IIII group ofemissions sources and are different depending upon whether compliance is demonstrated with (a) orwithout (b) Topcoat)

SCH Page 84 of 130 03-31-2011PermitNo: 245-09-C (R1) Plant ID: 0072 U012 Emission Points Description Applicable Allowable Emission/ Control Requirement Equipment Standard Device

40 CFR 60 SubpartMM See Specific Condition S1.a. 6.17 and 7.01 E11E/E12G a. 0.6 lbs HAP/GACS Guidecoat/Topcoat Or N/A Kitchen b. 1.1 Ibs HAPs/GACS 40 CFR 63 (the above limits are applicableto a Subpart IIII group ofemissions sources and are different depending upon whether compliance is demonstrated with (a) or without (b) Topcoat) E12HTopcoat Scuff <20% 7.08 C19A Booth 2.34lb/hr E12ITuTone/Repair <20% 7.08 C20A ScuffBooth 2.34lb/hr
U12 Control Devices: Description Performance ID Indicator StackiD C12A, C12B WaterWash, two (2) Carbon Adsorber and two (2) C12C, C12H Regenerative Thermal Oxidizer Temperature S- to S090

and C12G (RTO) Cl2C, C12E, Two (2) Regenerative Thermal S-150 to S-174, S- Oxidizer (RTO) ,WaterWash and Temperature C12H and C12G CarbonAdsorber 193, S-194 and S-203 Regenerative Thermal Oxidizer Temperature S-404, S-408, S-409 C12D (RTO) and S-215 C12F WaterWash N/A S-110 to S124 and S410 C19A DryPanel Filter N/A S-183 and S-184 C20A DryPanel Filter N/A S-185 and S-186

SCH Page 85 of 130 03-31-2011PermitNo: 245-09-C (R1) Plant ID: 0072 U012 Specific Conditions S1. Standards (Regulation 2.16, section 4.1.1)

SCH a. VOC

b. 1. The owner or operator shall be subject to the limit of 1.47 kg VOC/1 (12.3 lb VOC/gal) ofapplied coating solids, less water and exempt solvents. ( 40 CFR 60.392) (See Comment 3)
11. The owner or operator shall be subject to the limit of 11.3 lb VOC/gal of applied coating solids, less water and exempt solvents. (Regulation 7.01 section 7.2 and Regulation 6.17, section 3.3) iii. See Louisville Assembly Plant, Ford Motor Comgany Plant-wide AgplicabilityLimit CPAL). PM
1. See Louisville Assembly Plant, Ford Motor Company Plant-wide ApplicabilityLimit CPAL). ii. The owner or operator shall not allow PM emissions to exceed 2.34 lb/hr. (Regulation 7.08, section 3.1.2) (See Comment 1)
111. The owner oroperator shall not operate the booths unless theparticulate filters are installed and operatingproperly.
c. Opacity The owner or operator shall not allowvisible emissions to equal or exceed 20% opacity. (Regulation 7.08, section 3.1.1) d. HAP See LAP Ford Motor ComganyMACT Standards Section.
e. NOx The owner oroperator shall not cause to be discharged into the atmosphere from any affected facility orfrom any airpollution control equipment installed on any affected facility anyNOx fumes in excess of300 ppmbyvolume expressed as N02• (Regulation 7.08, section 4) (See Comment 2) 

### f. TAC Page 86 of 130 03-31-2011

### PermitNo: 245-09-C (R1) PlantID: 0072 1. 

### The owner or operator shall not allow any TAC emissions to exceed environmentally acceptable levels whether specifically established by modeling or derived from default de minimis levels. (Regulation 5.01, section 3.)
11. 

### The owner or operator shall utilize the control devices at all times the surface coating operations are in operation ifthe control device reductions were used to demonstrate compliance and shall, maintain and operate any affected facility including associated air pollution control equipment in a manner consistent with good air pollution control practice for minimizing emissions. (Regulation 5.21, section 4.7) S2. Monitoring 

### (Regulation 2.16, section 4.1.9.1.2)

SCH a. VOC
1. 

### Monitor ongoing compliance by calculating monthly, a daily volumeweighted average of the coatings used. Procedures used for this determination shall be those of "Protocol for Determining Daily Volatile Organic Compound Emission Rate ofAutomobile and Light-Duty Truck Topcoat Operations," EPA-450/3-88-018 (Docket ID No. OAR-2002- 0093 and Docket ID 

### No. A-2001-22). ii. The owner or operator shall during operation ofany coating operation(s) for which emission reductions due to the use ofadd-on control equipment are relied upon to demonstrate compliance with the emission limits above, maintain the afterburners combustion chamber temperature at;:::: 760° Cor other temperature, as determined during the latest stack test, based upon a three hour average, and maintain a combustion chamber temperature ofno more than 28°C (50°F) below the average combustion temperature. In addition, the afterburners shall have a minimum residence time of 0.5 seconds. The temperature shall be recorded using a recorder, which shall be calibrated and maintained according to the manufacturer's specifications. Temperature measurements of the thermal oxidizer combustion chamber shall be made at least once every 15 minutes and recorded during operation ofthe associated coating operations.
111. 

### If necessary for purposes of compliance, this line shall not be operated unless all control devices are beingproperly operated. iv. Use EPA Method 24 to determine the amount ofVOC in the Coating. The following equation may be used as an alternate method to demonstrate compliance:
Page 87 of 130 03-31-2011PermitNo: 245-09-C (Rl) PlantID: 0072

SCH Where: n 

### V C. 

# voc = 

# s _l_l w 

## v i=l I

VOCw 

### = the daily weighted average coating VOC content, as applied; and less water and exempt solvents, expressed in pounds of VOC per gallon ofcoating.
n 

### = number ofdifferent coatings used on a coating line a given day. V1 

### = the volume ofeach coating used on a coating line, as applied and less water and exempt solvents, a given day. C1 the VOC content ofeach coating used on a coating line, as applied and less water and exempt solvents, a given day. 

### Vt 

### = total volume ofall coatings applied each day on a coating line, less water and exempt solvents.
v. Meet the standards specified in 40 CPR 60.392, as calculated, using the prescribed transfer efficiency of 40 CPR 60.393(c)(l)(i)(C) for the monthly weighted average mass of VOC emitted per volume of applied coating solids. 

### b. PM The owner or operator shall follow good operating practices for the particulate filers, including monthly inspection, routine maintenance as recommended by the manufacturer, and promptrepair ofany defects.
c. Opacity See Specific Condition S2.b. d. HAP See LAP FordMotor CompanyMACTMonitoring Section.
e. 

### NOx There are no monitoringrequirements for NOx compliance. (See Comment 2) 

### f. TAC Page 88 of 130 03-31-2011PermitNo: 245-09-C (R1) Plant ID: 0072 i. See Specific Condition S2.a.ii and iii. ii. See Specific Condition S3.f. S3. Record Keeping (Regulation 2.16, section4.1.9.2)

SCH a. VOC
1. The owner or operator shall maintain the following records: (40 CFR 60.395 and 1.05, Section 4) 1) Record daily the quantity and type of paint withdrawn from the topcoat paint circulation system for use in the final repair operation. 2) Determine daily VOC emissions based on the topcoat and final repairrecords. 3) As an alternative to daily material usage records, the owner or operator may utilize material usage factor of 0.5% of topcoat usage. 4) Calculations shall incorporate control efficiency and shall include downtime adjustments to account for increased emissions during the period the afterburners were not operating. The owner or operator shall also maintain records ofcontrol devices downtimes and bypasses, includingthe date and duration ofeach occurrence. ii. The owner or operator shall continuously record the incinerator combustiontemperature during coating operations forthermal incineration or the gas temperature upstream and downstream of the incinerator catalystbed during coating operations for catalytic incineration
111. Record the temperature and frequency during operation of any coating operation specified in Specific Condition S2.a.ii. b. PM
1. The owner or operator shall keep a record that shows the date and the name oftheperson who inspected the filters and iffilters were replaced. ii. Proper operation of the fabric filter shall be ensured by maintaining records of inspections and routine maintenance activities and shall make these records available to the District upon request. A demonstration that proper operation ofthe fabric filter has occurred satisfies this compliance requirement for the standard specified inS1.b.ii. above. Page 89 of 130 03-31-2011PermitNo: 245-09-C (Rl) PlantID: 0072

c. Opacity See Specific Condition S3.b. 

### d. HAP See LAPFordMotor CompanyMACTRecordkeeping Section.
e. 

### NOx There are no record keepingrequirements for NOx compliance. (See Comment2) 

### f. TAC i. The owner or operator shall keep a record of the Material Safety Data Sheet (MSDS) for each TAC-containingmaterial inthis emission unit.
11. The owner or operator shall maintain records that identify all periods of bypassing the control devices while the surface coating operations are in operation for a given day. The records shall include the date, duration (including start and stop time) ofeach bypass event, identification ofthe control device and process equipment in operation, and the total lb/hr emissions ofeach TAC from each piece ofequipment during each bypass event, if that control equipment is required to meet the EA goals. (See Comment4) iii. See Specific Conditions S3.a.i.(4) S4. Reporting (Regulation 2.16, section. 4.1.9.3)

SCH a. VOC
1. See General PermitReporting Requirements.
11. For the control devices, the owner or operator shall clearly identify all deviations from permit requirements. If no deviations occur in that reporting period then the owner or operator shall report a negative declaration includingthe following information: 1) Emission Unit number and Control 

### ID number; 2) The beginning and ending date ofthe reporting period; 3) Identification ofthe operatingparameters beingmonitored; 4) Number, duration, and cause ofall exceedances ofthe parameters; and 5) Description ofthe corrective action taken for each exceedance. Page 90 of 130 03-31-2011PermitNo: 245-09-C (R1) Plant ID: 0072

SCH 111. Perform reporting for VOCs for 40 CPR 60.395 and 1.05, Section 4: 1) The owner or operator shall report the volume weighted average mass of VOC per volume of applied coating solids for each affected facility. 2) For thermal incinerators, every three-hour period shall be reported during which the average temperature measured is more than 28 

## oc less than the average temperature duringthe mostrecent control deviceperformance test. 3) For catalytic incinerators, everythree-hourperiod shall be reported during which the average temperature immediately before the catalyst bed, when the coating system is operational, is more than 28 

## oc less than the average temperature immediately before the catalyst bed during the mostrecent control device performance test at which destruction efficiency was determined. In addition, every three-hour period shall be reported each quarter during which the average temperature difference across the catalyst bed when the coating system is operational is less than 80 percent ofthe average temperature difference ofthe device during the most recent control device performance test at which destruction efficiency was determined. 4) Forthermal and catalytic incinerators, ifno suchperiods occur, the owner or operator shall submit a negative report. 5) The owner or operator shall notify the Administrator 30 days in advance ofanytestbyMethod 25.
IV. Report all instances ofnon-complianceto the Districtno laterthan (15) days afterthe occurrence has been confirmed, notwithstanding Regulation 1.07. b. PM Any deviation from the requirement to perform monthlyvisible inspections ofthe scuffboothPMfilter system.
c. Opacity See Specific Condition S4.b. d. HAP See LAP Ford Motor Company MACTReporting Requirements.
e. 

### NOx Page 91 of 130 03-31-2011

### PermitNo: 245-09-C (R1) Plant ID: 0072 There are no reporting requirements forNOx compliance. (See Comment 2) f. TAC 

### i. The owner or operator shall submit a plant-wide 

### emissions-based EA Demonstration to the District showing compliance with theplant-wide 

### EA goals of7.5 new and existing, 3.8 for all new combined, and 1 for each process when a change occurs that increases emissions above De minimus orpreviously modeled values.
11. 

### Identification of all periods of bypassing the control devices while the surface coating operations were in operation during a reporting period. The report shall include the date, duration (including start and stop time) ofeach bypass event, and the totallb/hr emissions ofeach TAC from each piece ofequipment during each bypass event, ifthat control equipment is required to meet the EA goals. (See Comment 4)
111. 

### See Specific Conditions S4.a.ii. U012 Comments 

### 1. Compliance with this requirement is demonstrated through a mass balance approach or engineering estimate. 2. The District has performed a one-time NOx compliance demonstration using AP-42 emission factors and combusting natural gas, and the emission standard cannot be exceeded. Therefore, there are no monitoring, record keeping, and reporting requirements with respectto NOx emission limits. 3. IfFord is in compliance with Regulation 6.17, section 3.3 VOC limitthanthey are in compliance with the 40 CFR 60 SubpartMM 60.3092 VOC limit. 4. The reported total lb/hr emissions of each TAC from each piece of equipment during each bypass event will be used onlyto determine if each TAC claimed as de minimis pursuant to Regulation 5.01 Section 1.6 in Ford Motor Company Louisville Assembly Plant's current plant-wide emissions-based EA demonstration continue to meet the de minimis criteria specified in Section 1.6.4. Should emissions during a bypass event for a TAC claimed to be de minimis exceed the de minimis criteria, Ford Motor Company Louisville Assembly Plant shall submit an updated plant-wide emission-based EA Demonstration to the District showing compliance with the plant-wide EA goals of7.5 new and existing, 3.8 for all new combined, and 1 

### for each process where the T

### AC emissions increase above de minimis values.

SCH Page 92 

### of 130 03-31-2011PermitNo: 245-09-C (R1) PlantID: 0072 U013 Emission UnitDescription: Plant-wide Gasoline Fueling FederallyEnforceable Regulations Regulation Title Applicable Sections 1.05 Compliancewith Emission Standards and 1, 3, 4 and 5 MaintenanceRequirements 7.15 Standards ofPerformance forNewProcess 1through 6 Operations U013 Applicable Regulations: District OnlyEnforceable Regulations Regulation Title Applicable Sections 1.18 RuleEffectiveness 1through 3 5.01 General Provisions 1through 4 5.14 Hazardous AirPollutants and Source Categories 1and 2 Methodologyfor DeterminingBenchmark 5.20 Ambient Concentration ofa Toxic Air 1through 6 Contaminant 5.21 Environmental Acceptabilityfor Toxic Air 1through 5 Contaminants Procedures for Determiningthe Maximum 5.22 AmbientConcentration ofa Toxic Air 1through 5 Contaminant 5.23 Categories ofToxic Air Contaminants 1through 6

SCH Page 93 of 130 03-31-2011PermitNo: 245-09-C (Rl) U013 Emissions Points:

ID Description

El3A Gasoline Tank#1 El3B Gasoline Tank#2 El3C Gasoline Tank#3 El3D Two (2) Fueling Stations PlantID: 0072

U013 Emission Points Applicable Allowable Emission/ Control Requirement Equipment Standard Device 7.15 Stage I vaporrecovery system N/A 7.15 Stage I vaporrecovery system N/A 7.15 Stage I vaporrecovery system N/A See Comment2 ORVREquipped Vehicles N/A and 3 U013 ControlEquipment: There are no control devices associated with Emission UnitU013.

SCH Page 94 of 130 03-31-2011

### PermitNo: 245-09-C (Rl) Plant ID: 0072 U013 Specific Conditions: 

### Sl. Standards 

### (Regulation 2.16, section 4.1.1)
a. VOC 

### i. Storage tanks, Emission Points E13A through E13C, shall be equipped with the following: (Regulation 7.15, section 3.1)

b. TAC 

### a) A submerged fill pipe; (Regulation 7.15, section 3.1.1) b) Ifthe gasoline storage tank is equipped with a separate gauge well, a gauge well drop tube shall be installed which extends to within six inches of the bottom of the tank; (Regulation 7.15, section 3.1.2) c) Vent line restrictions on the affected facility; and (Regulation 7.15, section 3.1.3) d) Vapor balance systemandvapor tight connections on the liquid fill and vapor return hoses. The cross-sectional area ofthe vaporreturn hose and any other vapor return passages in the circuit connecting the vapor space in the service station tank to that ofthe truck tank must be at least 50% ofthe liquid fill hose cross-sectional area for each tank and free of flow restrictions to achieve acceptable recovery. The vapor balance equipment must be maintained according to the manufacturer's specifications. The type, size and design ofthe vapor balance system are subject to the approval of the District. (Regulation 7.15, section 3.1.4)

The owner or operator shall not allow any TAC emissiOns to exceed environmentally acceptable levels whether specifically established by modeling or derived from default de minimis levels. (Regulation 5.01, section 3.) (See Comment 1) S2. Monitoring 

### (Regulation 2.16, section 4.1.9.1.2)

SCH a. VOC 

### Storage tanks: To demonstrate ongoing compliance with Regulation 1.05, Section 4, the owner or operator shall monitor the quantity of gasoline used to fuel vehicles. a) The owner or operator shall monthly: Page 95 of 130 03-31-2011PermitNo: 245-09-C (Rl) PlantID: 0072 1) Checkthe storage tankfill points for tightness; 2) 

### If a two point vapor recovery system on the storage tank, check rubber gaskets for tears, verify spring loaded valves properly operate and tankrefill caps have rubber gaskets in good condition; replace any damagedparts; and b) The owner oroperator shall annually: Verifypressure vacuum valve on ventpipe is operatingproperly annually and replace anydamaged part. c) The owneror operatormust complete all repairs within 5 working days. b. TAC See Comment 1. S3. Record Keeping (Regulation 2.16, section 4.1.9.2)
a. VOC
1. The owner or operator shall record total monthly gasoline throughput and make theserecords available to the Districtuponrequest.
11. The owner or operator shall maintain records ofthe monthly and annual inspections. These records shall contain the date and time of the inspection; who performed the inspection; and the results of the inspection. b. TAC The owner oroperator shallkeep a record ofthe Material Safety Data Sheet (MSDS) for each TAC-containing material inthis emissionunit. (See Comment 1) S4. Reporting (Regulation 2.16, section. 4.1.9.3)
a. VOC See General PermitReporting Requirements. 

### b. TAC There are no routine reporting requirements for this equipment. (See Comment 1) SCH Page 96 of 130 03-31-2011PermitNo: 245-09-C (R1) PlantID: 0072 U013 Comments 1. The emissions from a motor vehicle fueling or refuelingprocess and process equipment for gasoline and otherliquid fuels are de minimis under STAR. (Regulation 5.01, section 1.6.6.) 2. The District reviewed a letter dated January 18,2007regardingthe current applicability of Stage IIVaporRecovery. EPA has provided guidance thatvehicleproductionplants doing initial fueling ofvehicle comply with vaporrecoveryrequirements bymeans of ORVRrequirements for compliant vehicles. TheDistrict concurs thatthe external vapor recovery system as required bythe applicable Title V operatingpermitfor LAP is not required for fueling vehicles with ORVR. 3. Regulation 6.40 does not applyto the initial fueling ofnewmotorvehicles at amotor vehicle assembly facility per section 2.1.2.

SCH Page 97 of 130 03-31-2011PermitNo: 245-09-C (R1) PlantID: 0072 U014 and U022 Emission UnitDescription: PaintEquipment Cleaning Operations U014 and U022 Applicable Regulations: FederallyEnforceable Regulations Regulation Title Applicable Sections 1.05 Compliance with Emission Standards and 1, 3, 4 and 5 MaintenanceRequirements 6.18 Standards ofPerformance for SolventMetal 1though 4 CleaningEquipment 7.25 Standards ofPerformance forNew Source Using 1through 5 Volatile Organic Compounds 40 CPR 63 General Provisions 63.1 through 63.16 SubpartA 40 CPR 63 NationalEmission Standards for Hazardous Air SubpartIIII Pollutants: Surface Coating ofAutomobiles and 1,2,3,4,7and8 Light-DutyTrucks
District OnlyEnforceable Regulations Regulation Title Applicable Sections 1.18 Rule Effectiveness 1through 3 5.01 General Provisions 1through 4 5.14 Hazardous AirPollutants and Source Categories 1and 2 Methodologyfor DeterminingBenchmark 5.20 Ambient Concentration ofa Toxic Air 1through 6 Contaminant 5.21· Environmental Acceptabilityfor Toxic Air 1through 5 Contaminants Procedures for Determiningthe Maximum 5.22 Ambient Concentration ofa Toxic Air 1through 5 Contaminant 5.23 Categories ofToxic Air Contaminants 1through 6

SCH Page 98 of 130 03-31-2011PermitNo: 245-09-C (R1) PlantID: 0072 U014 and U022 Emission Points: U014 and U022 Emission Points ID Description Applicable Allowable Emission/ Control Requirement Equipment Standard Device
PaintEquipment 7.25 See Specific Conditions S1.a. E14A N/A Cleaning Booth 40 CPR 63 SubpartIIII Section 63.3094 PaintEquipment 7.25 See Specific Conditions Sl.a. E22A Purging and Plant N/A Cleaning 40 CPR 63 SubpartIIII Section 63.3094 SolventMetal See Specific Conditions S1.a.iii N/A Cleaning 6.18 N/A Equipment U014 and U022 ControlDevices: There are no control devices associated withEmissionUnit UO 14 and U022.

SCH Page 99 of 130 03-31-2011PermitNo: 245-09-C (Rl) Plant ID: 0072 U014 and U022 Specific Conditions
S1. Standards (Regulation 2.16, section 4.1.1)

SCH a. VOC
1. ApplicatorPaintPurging: The automatic spray applicators will incorporate a purge paint and solvent recovery system that will collect the purged materials.
11. The owner or operator of a cold cleaner to clean non-paint or non-sealer related equipment using volatile organic compounds (VOC) shall, install, maintain, and operatethe control equipment as follows: The cold cleaner shall be equipped with a tightly fitting cover that is free ofcracks, holes, or other defects. Ifthe solvent is agitated orheated, then the cover shall be designed so that it can be easily operated with 1 hand. (Regulation 6.18, section 4.1.1) The cold cleaner shall be equipped with a drainage facility that is designed so that the solvent that drains off parts removed from the cleaner will return to the cold cleaner. The drainage facility may be external if the District determines that an internal type cannot fit into the cleaning system. (Regulation 6.18, section 4.1.2) A permanent, conspicuous label summarizing the operating requirements specified in Specific Condition SI.b. shall be installed on or near the cold cleaner. (Regulation 6.18, section 4.1.3) Ifused, the solvent spray shall be a fluid stream, not a fine, atomized, or shower type spray, at a pressure that does not cause excessive splashing. Flushing ofparts using a flexible hose or other flushing device shall be performed only within the freeboard area ofthe cold cleaner. Solvent flow shall be directed downwardto avoidturbulence at the air-solvent interface and to prevent solvent from splashing outside of the cold cleaner. (Regulation 6.18, section4.1.4) Work area fans shall be located and positioned so that they do not blow across the opening ofthe cold cleaner. (Regulation 6.18, section 4.1.6) The solvent-containing portion of the cold cleaner shall be free of all liquid leaks. Auxiliary cold cleaner equipment such as pumps, water separators, steam traps, or distillation units shall not have any visible liquid leaks, visibletears, or cracks. (Regulation 6.18, section 4.1.8) The owner or operator shall observe at all times the following operating Page 100ofl30 03-31-2011PermitNo: 245-09-C (R1) Plant ID: 0072

SCH b. 

### TAC requirements: (Regulation 6.18, section 4.2) Waste solvent shall neither be disposed ofnor transferred to another party in a manner such that more than 20% by weight ofthe waste solvent can evaporate. Waste solvent shall be stored only in a covered container. A covered container may contain a device that allows pressure relief, but does not allow liquid solventto drain from the container. (Regulation 6.18, section 4.2.1) The solvent level in the cold cleaner shall not exceed the fill line. (Regulation 6.18, section4.2.2) The cold cleaner cover shall be closed whenever a part is not being handled in the cold cleaner. (Regulation 6.18, section4.2.3) Parts to be cleaned shall be racked or placed into the cold cleaner in a mannerthatwill minimize drag-out losses. (Regulation 6.18, section 4.2.4) Cleaned patis shall be drained for at least 15 seconds or until dripping ceases, whichever is longer. Parts having cavities or blind holes shall be tipped or rotated while the part is draining. Duringthe draining, tipping, or rotating, the parts shall be positioned so that the solvent drains directly backto the cold cleaner. (Regulation 6.18, section 4.2.5) A spill during solvent transfer shall be cleaned immediately, and the wipe rags or other sorbent material shall be immediately stored in a covered container for disposal or recycling, unless enclosed storage ofthese items is not allowed by fire protection authorities. (Regulation 6.18, section 4.2.6) Sponges, fabric, wood, leather, paper products, and other absorbent material shall not be cleaned in a cold cleaner. (Regulation 6.18, section 4.2.7) The owner or operator shall not operate a cold cleaner used to clean nonpaint or non-sealer related equipment using a solvent with a vapor pressure that exceeds 1.0 mm Hg (0.019 psi) measured at 20°C (68°F). (Regulation 6.18, section 4.3.2)

The owner or operator shall not allow any TAC emissiOns to exceed environmentally acceptable levels whether specifically established by modeling or derived from default de minimis levels. (Regulation 5.01, section 3.)
c. HAP
Page 101 of 130 03-31-2011PermitNo: 245-09-C (Rl) PlantID: 0072 1. The owner oroperator shall follow the workpractices specified in 40 CFR 63 Subpart IIII, Specific Condition Sl.b and c. to minimize VOC emissions from purge and cleaning operations. ii. See LAP FordMotor CompanyMACT Standards Section. S2. Monitoring (Regulation 2.16, section 4.1.9.1.2)
a. VOC See Specific Condition Sl.a. b. TAC See Specific Condition S3.b.
c. HAP See LAP Ford Motor CompanyMACTMonitoring Section. S3. Record Keeping (Regulation 2.16, section 4.1.9.2)
a. VOC
1. See Specific Condition Sl.a.
11. The owner oroperator shall maintainrecords that include the following for eachpurchase: (Regulation 6.18, section4.4.2)

b. TAC 1) The name and address ofthe solvent supplier, 2) The date ofthepurchase, 3) The type ofthe solvent, and 4) The vaporpressure ofthe solventmeasured in mm Hg at 20oC (68°F).

The owner or operator shall keep a record ofthe Material Safety Data Sheet (MSDS) for each TAC-containingmaterial in this emissionunit.
c. HAP SeeLAP FordMotorCompanyMACTRecordkeeping Section. S4. Reporting (Regulation 2.16, section4.1.9.2) SCH Page 102 of 130 03-31-2011PermitNo: 245-09-C (R1) PlantID: 0072 a. VOC See General PermitReportingRequirements. b. TAC The owner or operator shall submit a plant-wide emissions-based EA Demonstration to the District showing compliance with theplant-wide EA goals of7.5 new and existing, 3.8 for all new combined, and 1for each process when a change occurs that increases emissions above De minimus or previously modeled values.
c. HAP See LAPFordMotor CompanyMACTReporting Requirements. U014 and U022 Comments 1. Specific Conditions involving work practice standards only have no monitoring, record keeping and reportingrequirements, as such wouldbe impractical. 2. The aqueous cold cleaners that contain no VOCs are not subjectto Regulation 6.18.

SCH Page 103 of 130 03-31-2011PermitNo: 245-09-C (R1) PlantID: 0072 U015 Emission Unit Description: SealerDeck U015 Applicable Regulations: FederallyEnforceable Regulations Regulation Title Applicable Sections 1.05 Compliance with Emission Standards and 1, 3, 4 and 5 Maintenance Requirements 7.59 Standards ofPerformanceforNew Source Using 1through 5 Volatile Organic Compounds 40 CFR 63 General Provisions 63.1 through 63.16 SubpartA 40 CFR 63 National Emission Standards for Hazardous Air SubpartIIII Pollutants: Surface Coating ofAutomobiles and 1, 2, 3, 4, 7 and 8 Light-DutyTrucks
District Only Enforceable Regulations Regulation Title Applicable Sections 1.18 Rule Effectiveness 1through 3 5.01 General Provisions 1through 4 5.02 Adoption ofNationalEmission Standards for 1, 3, 4 and 5 Hazardous AirPollutants 5.14 Hazardous AirPollutants and Source Categories 1and 2 Methodology for DeterminingBenchmark 5.20 Ambient Concentration ofa Toxic Air 1through 6 Contaminant 5.21 EnvironmentalAcceptabilityfor Toxic Air 1through 5 Contaminants Procedures for Determiningthe Maximum 5.22 Ambient Concentration ofa Toxic Air 1through 5 Contaminant 5.23 Categories ofToxic Air Contaminants 1through 6

SCH Page 104 of 130 03-31-2011PermitNo: 245-09-C (R1) U015 Emission Points:

ID Description

ElSA SealerApplication
N/A Sealers and Deadeners (otherthan glass bonding) PlantID: 0072

U015 Emission Points Applicable Allowable Emission/ Control Requirement Equipment Standard Device 7.59 3.5 lbs/gal N/A Section 40 CFR 63.3090 (c) 40 CFR 63 or 63.3091 (c) N/A Subpart IIII 0.01 lb VOC per lb of adhesive and sealermaterial U015 Control Devices: There are no control devices associated withEmission Unit U015.

SCH Page 105 of 130 03-31-2011PermitNo: 245-09-C (R1) Plant ID: 0072 U015 Specific Conditions
S1. Standards (Regulation 2.16, section 4.1.1)
a. VOC
1. The owner or operator shall not cause or allow the emission ofVOC from any affected facility resulting from the coating of metallic surfaces in excess of3.5 lb VOC/gal ofcoating, excluding water and exempt solvents, as applied for extreme performance coatings. (Regulation 7.59, section 3.1.3)
n. See Louisville Assembly Plant, Ford Motor Company Plant-wide ApplicabilityLimit (PAL). b. TAC The owner or operator shall not allow any TAC em1sswns to exceed environmentally acceptable levels whether specifically establishedbymodeling or derivedfrom default de minimis levels. (Regulation 5.01, section 3.)
c. HAP See LAP FordMotor CompanyMACT Standards Section. S2. Monitoring (Regulation 2.16, section 4.1.9.1.2)
a. VOC See Specific Condition S3.a. b. TAC See Specific Condition S3.b.
c. HAP See LAP FordMotor CompanyMACTMonitoring Section. S3. Record Keeping (Regulation 2.16, section 4.1.9.2)

SCH a. VOC
1. The owner or operator of an affected facility subject to this regulation shall maintain records that include, but not be limited to, the following: Page 106of130 03-31-2011PermitNo: 245-09-C (Rl) PlantID: 0072

b. TAC (Regulation 7.59, section 6.1) 1) The regulation and section number applicable to the affected facility for whichthe records are beingmaintained, 2) The application method and substrate type (metal, plastic, etc.), 3) The amount and type of coatings (including catalyst and reducer for multi-component coatings) and solvent (including exempt compounds) used at eachpoint ofapplication during the averaging period. The District may specifically authorize the usage record to reflect a period longer than the compliance averaging period, with the usage prorated for each compliance averaging period by a method approved by the District. In this case, the usage record period shall not exceed 1calendarmonth, 4) The VOC content as applied in each coating and solvent, 5) The date, or usage record period, for each application of coating and solvent, 6) The amount of surface preparation, clean-up, wash-up of solvent (including exempt compounds) used and the VOC content ofeach material used during the averaging period. The District may specifically authorize the usage record to reflect a period longer than the compliance averaging period, with the usage prorated for each compliance averaging period by a method approved by the District. In this case, the usage record period shall not exceed 1 calendarmonth.

The owner or operator shall keep a record ofthe Material SafetyData Sheet (MSDS) for each TAC-containingmaterial in this emission unit.
c. HAP See LAP FordMotorCompanyMACTRecordkeeping Section. S4. Reporting (Regulation 2.16, section4.1.9.3)
a. VOC See General PermitReportingRequirements. b. TAC SCH Page 107 of 130 03-31-2011

### PermitNo: 245-09-C (R1) PlantID: 0072

SCH The owner or operator shall submit a plant-wide 

### emissions-based EA Demonstration to the District showing compliance with the plant-wide 

### EA goals of7.5 new and existing, 3.8 for all new combined, and 1 for each process when a change occurs that increases emissions above De minimus or previously modeled values.
c. 

### HAP See LAP Ford Motor CompanyMACTReportingRequirements.

Page 108 of 130 03-31-2011PermitNo: 245-09-C (Rl) PlantID: 0072 U016 Emission Unit Description: Final Repair Spray Booth; infrared curing, and spotrepair bays for repairing coating on vehicles U016 Applicable Regulations: Federally EnforceableRegulations Regulation Title .Applicable Sections 1.05 Compliance with Emission Standards and 1,3,4and5 Maintenance Requirements 7.01 General Provisions 7.2 7.08 Standards ofPerformance forNewProcess Operations 1through 3 40 CFR 60 General Provisions 63.1 through 63.16 SubpartA 40 CFR60 National Emission Standards ofPerformance for SubpartMM Automobile and LightDutyTruck Surface 60.390 through 60.397 Coating Operations 40 CFR 63 General Provisions 63.1 through 63.16 Subpart A 40 CFR 63 NationalEmission Standards for Hazardous Air SubpartIIII Pollutants: Surface Coating ofAutomobiles and 1, 2, 3 ,4, 7 and 8 Light-DutyTrucks

SCH Page 109 of 130 03-31-2011PermitNo: 245-09-C (R1) PlantID: 0072 District Only EnforceableRegulations Regulation Title Applicable Sections 1.18 Rule Effectiveness 1through 3 5.01 General Provisions 1through 4 5.02 Adoption ofNationalEmission Standards for 1, 3, 4 and 5 Hazardous AirPollutants 5.14 Hazardous AirPollutants and Source Categories 1and 2 Methodology for DeterminingBenchmark 5.20 Ambient Concentration ofa Toxic Air 1through 6 Contaminant 5.21 Environmental Acceptabilityfor Toxic Air 1through 5 Contaminants Procedures for Determiningthe Maximum 5.22 Ambient Concentration ofa Toxic Air 1through 5 Contaminant 5.23 Categories ofToxic Air Contaminants 1through 6

SCH Page 110 of 130 03-31-2011PermitNo: 245-09-C (Rl) U016 Emission Points:

ID Description

E16A FinalRepair Booth

E16B Final Repair Oven

SCH Plant ID: 0072

U016 Emission Points Applicable Allowable Emission/ Control Requirement Equipment Standard Device 40 CPR 60 Subpart MM See Specific Conditions Sl.a. 6.17 and 7.01 <20% 7.08 2.34lb/hr a. 0.6 lbs HAP/GACS C16A Or b. 1.1 lbs HAPs/GACS 40 CPR 63 Subpart IIII (the above limits are applicableto a group ofemissions sources and are different depending uponwhether compliance is demonstrated with

(a) orwithout (b) final repair) 40 CPR 60 Subpart MM 6.17 and 7.01 See Specific Conditions Sl.a. <20% 7.08 < 300ppm a. 0.6 lbs HAP/GACS N/A Or b. 1.1 lbs HAPs/GACS 40 CPR 63 Subpart IIII (the above limits are applicableto a group ofemissions sources and are different depending upon whether compliance is demonstrated with

(a) orwithout (b) final repair)

Page 111 of130 03-31-2011PermitNo: 245-09-C (R1) PlantID: 0072 U016 Emission Points ID Description Applicable Allowable Emission/ Control Requirement EquipmentStandard Device 40 CFR 60 SubpartMM See Specific Conditions S1.a 6.17and7.01 <20% 7.08 2.34lb/hr E16C FinalRepair a. 0.6 lbs HAP/GACS N/A SpotPaint Or b. 1.1 lbs HAPs/GACS 40 CFR 63 SubpartIIII (the above limits are applicable to a group ofemissions sources and are different depending upon whether compliance is demonstrated with

(a) orwithout (b) final repair) U016 ControlDevices: ID Description Performance StackiD Indicator C16A Fabric Filter N/A S187 and S188

SCH Page 112 of 130 03-31-2011PermitNo: 245-09-C (Rl) PlantID: 0072 U016 Specific Conditions
1. Standards (Regulation 2.16, section4.1.1)

SCH a. VOC
1. The owner or operator shall be subject to the emission limit of 4.8 lbs VOC/gal (0.58 kg/1) of coating, less water and exempt solvents. (40 CFR60.3092, Regulation 7.01 section 7.2 and Regulation 6.1, section 3.4)
11. See Louisville Assembly Plant, Ford Motor Company Plant-wide ApplicabilityLimit (PAL). b. PM 

### i. See Louisville Assembly Plant, Ford Motor Company Plant-wide ApplicabilityLimit (PAL).
11. The owner or operator shall not allow PM emissions to exceed 2.34 lb/hr. (Regulation 7.08, section 3.1.2) (See Comment 1)
111. The owner or operator shall not operate the Final RepairBooth unless the particulate filters are installed and operatingproperly.
c. Opacity The owner or operator shall not allow visible emissions to equal or exceed 20% opacity. (Regulation 7.08, section 3.1.1) d. HAP See LAP FordMotor CompanyMACT Standards Section.
e. NOx The owner or operator shall not cause to be discharged into the atmosphere from any affected facility orfrom any airpollution control equipment installed on any affected facility anyNOx fumes in excess of300ppmby volume expressed as N02. (Regulation 7.08, section 4) (See Comment 2) 

### f. TAC The owner or operator shall not allow any TAC emtsswns to exceed environmentally acceptable levels whether specifically established by modeling or derived from default de minimis levels. (Regulation 5.01, section 3.) Page 113 of 130 03-31-2011PermitNo: 245-09-C (R1) Plant ID: 0072 S2. Monitoring (Regulation 2.16, section 4.1.9.1.2)

SCH a. VOC
1.

ii.

Where:Monitor ongoing compliance by calculatingmonthly, a daily a volume weighted average ofthe coatings used. Procedures used for this determinationshall be those of''Protocolfor DeterminingDailyVolatile Organic CompoundEmission Rate ofAutomobile and Light-DutyTruck Topcoat Operations,'' EPA-450/3-88-018 (DocketID No. OAR-2002 -0093 and DocketID No. A-2001-22) UseEPAMethod 24 to determine the amount ofVOC in the Coating. The following equation may be used as an alternate methodto demonstrate compliance:

n 

### V. C. 

# voc =**s-~ -~**  w 

# v i=l t VOCw = the daily weighted average coating VOC content, as applied; and less water and exempt solvents, expressed in pounds ofVOC per gallon of coating.
n = number ofdifferent coatings used on a coating line a given day. V1 

### = the volume of each coating used on a coating line, as applied and less waterand exempt solvents, a given day. C1 the VOC content of each coating used on a coating line, as applied and less water and exempt solvents, a given day. 

### Vt 

### = total volume ofall coatings applied each day on a coating line, less water and exempt solvents.
111. Meetthe standards specified in 40 CFR 60.392, as calculated, using the prescribedtransfer efficiency of40 CFR60.393(c)(1)(i)(C) for the monthlyweighted average mass ofVOC emittedpervolume ofapplied coating solids. b. PM The owner or operator shall follow good operating practices for the particulate filters, including monthly inspection, routine maintenance as recommended bythe manufacturer, andpromptrepair ofany defects. Page 114 of 130 03-31-2011PermitNo: 245-09-C (R1) PlantID: 0072 c. Opacity See Specific Condition S2.b. d. HAP See LAP FordMotor CompanyMACTMonitoring Section.
e. 

### NOx There are no monitoringrequirements forNOx compliance. (See Comment 2) 

### f. TAC See Specific Condition S3.f. S3. Record Keeping (Regulation 2.16, section 4.1.9.2)

SCH a. VOC Performrecord keepingfor VOCs for 40 CPR 60.395 and 1.05, Section 4: 1) Record monthlythe daily quantity andtype ofpaintwithdrawn from the topcoatpaintcirculation system for use in the final repair operation using the methodology specified in S2.a. 2) Monthly, determine the daily VOC emissions based onthe topcoat and final repairrecords. 3) As an alternative to daily material usage records, the owner or operator mayutilize an appropriate materialusage factor determinedto be acceptable bythe District. (See Comment 3) 4) The owner or operator shall continuously record the incinerator combustiontemperature during coating operations for thermal incineration or the gas temperature upstream and downstream of the incinerator catalystbed during coating operations for catalytic incineration. b. PM
1. The owner oroperator shall keep a recordthat showsthe date and the name ofthe personwho inspectedthe filters and iffilters were replaced. ii. Proper operation of the fabric filter shall be ensured by maintaining records of inspections and routine maintenance activities and shall make these records available to the District upon request. A demonstration that Page 115 of 130 03-31-2011PermitNo: 245-09-C (Rl) PlantID: 0072 proper operation ofthe fabric filter has occurred satisfies this compliance requirement for the standard specified in Sl.b.ii. above.


### c. Opacity See Specific Condition S3.b. 

### d. HAP See LAPFord Motor CompanyMACT Recordkeeping Section.
e. 

### NOx There are no recordkeeping requirements for NOx compliance. (See Comment2) 

### f. TAC The owner or operator shallkeep arecord ofthe Material Safety Data Sheet (MSDS) for eachTAC-containingmaterial in this emissionunit. S4. Reporting (Regulation 2.16, section4.1.9.2)

SCH a. VOC i. See General PermitReporting Requirements. ii. Forthe control devices, the owneror operator shall clearly identify all deviations from permitrequirements. Ifno deviations occurinthat reporting periodthen the owner oroperator shall report a negative declaration with the following information: 1) EmissionUnitnumber and Control 

### ID number; 2) The beginning and endingdate ofthereportingperiod; 3) Identification ofthe operatingparameters being monitored; 4) Number, duration, and cause ofall exceedances ofthe parameters; and 5) Description ofthe corrective actiontaken for each exceedance. iii. Perform reporting for VOCs for 40 CFR60.395 and 1.05, Section 4: 1) The owner or operator shall report the volume weighted average mass of VOC per volume of applied coating solids for each affected facility. 2) The owner or operator shall notify the Administrator 30 days in advance ofanytest byMethod 25. Page 116 of 130 03-31-2011PermitNo: 245-09-C (R1) PlantID: 0072 b. PM 

### i. Any deviation from the requirement to perform monthly visible inspections ofthe booth PMfilter system;
11. The dates that filters were replaced or a declaration that there were no filters replaced duringthe reportingperiod; and
111. See General PermitReportingRequirements.
c. Opacity See Specific Condition S4.b. d. HAP See LAP Ford Motor CompanyMACTReporting Requirements.
e. 

### NOx There are no reporting requirements for NOx compliance. (See Comment 2) 

### f. TAC The owner or operator shall submit a plant-wide emissions-based EA Demonstration to the District showing compliance with theplant-wide EA goals of7.5 new and existing, 3.8 for all new combined, and 1 for each process when a change occurs that increases emissions above De minimus or previously modeled values. U016 Comment 1. Compliance with this requirement is demonstrated through a mass balance approach or engineering estimate. 2. The District has performed a one-time NOx compliance demonstration using AP-42 emission factors and combusting natural gas, and the emission standard cannot be exceeded. Therefore, there are no monitoring, record keeping, and reporting requirements withrespectto NOx emission limits. 3. The District has deemed 0.5% as an appropriate material usage factor for Emission Unit U016.

SCH Page 117 of 130 03-31-2011PermitNo: 245-09-C (R1) PlantID: 0072 U023 Emission UnitDescription: Phosphate Operation U023 Applicable Regulations: District OnlyEnforceableRegulations Regulation Title Applicable Sections 5.01 General Provisions 1through 4 5.14 Hazardous AirPollutants and Source Categories 1and 2 Methodology for DeterminingBenchmark 5.20 Ambient Concentration ofa Toxic Air 1through 6 Contaminant 5.21 Environmental Acceptabilityfor ToxicAir 1through 5 Contaminants Procedures for Determiningthe Maximum 5.22 Ambient Concentration ofa Toxic Air 1through 5 Contaminant 5.23 Categories ofToxic Air Contaminants 1through 6 U023 Emission Points: U023 Emission Points ID Description Applicable Allowable Emission/ Control Requirement Equipment Standard E1000 Phosphate 5.01 See Specific Conditions S3. E1001 Phosphate Dump 5.01 See Specific Conditions S3. Tanlc U023 ControlDevices: There are no control devices associated with EmissionUnit U023.

SCH Page 118of130 Device N/A N/A

03-31-2011PermitNo: 245-09-C (R1) Plant ID: 0072 U023 Specific Conditions S1. Standards (Regulation 2.16, section 4.1.1) TAC The owner or operator shall not allow any TAC emissions to exceed environmentally acceptable levels whether specifically established by modeling or derived from default de minimis levels. (Regulation 5.01, section 3.) S2. Monitoring (Regulation 2.16, section 4.1.9.1.2) TAC See Specific Condition S3. S3. Record Keeping (Regulation 2.16, section 4.1.9.2) TAC The owner oroperator shall keep arecord ofthe Material SafetyData Sheet (MSDS) for each TAC-containingmaterial in this emission unit. S4. Reporting (Regulation 2.16, section 4.1.9.2)

SCH TAC The owner or operator shall submit aplant-wide emissions-based EA Demonstration to the District showing compliance with theplant-wide EA goals of7.5 new and existing, 3.8 for all new combined, and 1 for each process when a change occurs that increases emissions above Deminimus orpreviouslymodeled values.

Page 119 of 130 03-31-2011PermitNo: 245-09-C (R1) Plant ID: 0072 U025 Emission UnitDescription: Twelve (12) DirectHeatExchangers U025 Applicable Regulations: FEDERALLY ENFORCEABLE REGULATIONS Regulation Title Applicable Sections 7.08 Standards ofPerformance forNewIndirect Heat 1through 4 Exchangers Reasonable Available ControlTechnology 6.42 Requirements for Major Volatile Organic 1.2, and 2 through 5 Compound
District Only Enforceable Regulations Regulation Title Applicable Sections 5.01 General Provisions 1through 4 Methodology for DeterminingBenchmark 5.20 Ambient Concentration ofa Toxic Air 1through 6 Contaminant 5.21 Environmental Acceptabilityfor ToxicAir 1through 5 Contaminants Procedures for Determiningthe Maximum 5.22 Ambient Concentration ofa Toxic Air 1through 5 Contaminant 5.23 Categories ofToxic Air Contaminants 1through 6 U025 Emission Points: U025 Emission Points ID Description Applicable Regulation Control Device 5.21 E25 DirectHeatExchangers 6.42 N/A 7.08 U025 ControlDevices: There are no control devices associatedwith Emission Unit U025.

SCH Page 120 of 130 03-31-2011PermitNo: 245-09-C (Rl) PlantID: 0072 U025 Specific Conditions Sl. Standards (Regulation 2.03, section 5.1)
a. PM The owner or operator shall not allow PM em1ss10ns to exceed 2.34 lb/hr. (Regulation 7.08, section 3.1.2) (See Comment 1) b. Opacity The owner or operator shall not allow visible emissions to equal or exceed 20% opacity. (Regulation 7.08, section 3.1.1)
c. NOx
1. The owner or operator shall not allow or cause the plant-wide NOx emissions to exceed 99 tons during any consecutive 12-month period in orderto stay belowNOx RACT applicabilitythresholds. 

### ii. The owner or operator shall not allow NOx emissions to exceed 300 ppm by volume expresses as N02• (Regulation 7.08, section 4.1.) (See Comment 4) d. TAC The owner or operator shall not allow any TAC em1sswns to exceed environmentally acceptable levels whether specifically established by modeling or derived from default de minimis levels. (Regulation 5.01, section 3.) S2. Monitoring (Regulation 2.03, section 5.1)
a. PM There are no monitoringrequirements for PMcompliance. (See Comment 1) b. Opacity See Comment2.


### c. NOx See Specific Condition S3.c. d. TAC
SCH Page 121 of 130 03-31-2011PermitNo: 245-09-C (R1) Plant ID: 0072 See Comment 3. S3. Record Keeping (Regulation 2.03, section 5.1) The owner or operator shall maintain the required records for a minimum of5 years and make the records readily available to the Districtupon request.
a. PM There are no record keeping requirements for PM compliance for this equipment. (See Comment 1) b. Opacity There are no record keeping requirements for Opacity compliance for this equipment. (See Comment2)
c. NOx
1. The owner or operator shall calculate and record the monthly and 12 consecutive monthplant-wideNOx emissions for each month in the report period. ii. See Comment4. d. TAC See Comment 3. S4. Reporting (Regulation 2.03, section 5.1)

SCH a. PM See Comment 1. b. Opacity See Comment2.
c. NOx
1. The owner or operator shall report the monthly and 12 consecutive month plant-wideNOx emissions for eachmonth inthe reportperiod.
11. See PALReporting Requirements. Page 122 of 130 03-31-2011

### PermitNo: 245-09-C (R1) Plant ID: 0072 d. TAC 

### The owner or operator shall submit a plant-wide 

### emissions-based EA Demonstration to the District showing compliance with the plant-wide 

### EA goals of7.5 new and existing, 3.8 for all new combined, and 1for each process when a change occurs that increases emissions above De minimus or previously modeled values. U025 Comments 

### 1. The District has performed a one-time PM compliance demonstration for the space heater, using AP-42 emission factors and combusting natural gas, and the emission standards cannot be exceeded. Therefore, there are no monitoring, record keeping, and reporting requirements for this space heaterwithrespectto PM emission limits. 2. The District has determined that using a natural gas fired boiler will inherently meet the 20% opacity standard. Therefore, the company is not required to perform periodic monitoring to demonstrate compliance withthe opacity standard. 3. STAR Regulation 5.01, section 1.6.7 states the TACs from natural combustion are De Minimis. 4. The District performed a onetime compliance demonstration for NOx and the 300 ppm standard cannotbe exceeded uncontrolled.

SCH Page 123 of 130 03-31-2011

### PermitNo: 245-09-C (R1) PlantID: 0072 

### Ford LAP Plant-wide Permit Shield 

### The owner or operator is hereby granted a permit shield that shall apply as long as the owner or operator demonstrates ongoing compliance with all conditions ofthis permit. Compliance with the conditions ofthis permit shall be deemed compliance with all applicable requirements ofthe regulations cited in this permit as ofthe date of issuance, pursuant to Regulation 2.16, section 4.6.1. Off-permitDocuments Document 

### Rule Effectiveness Plan 10 April1995
Alternative Operating Scenarios 

### The owner or operator did not request to operate under any alternative operating scenarios in its Title Vpermit application. InsignificantActivities Description Quantity Basis Internal combustion Various Regulation 2.02, Section 2.2 engines fixed ormobile Presses extruding Various Regulation 2.02, Section 2.3.1 metal/mineral/wood Brazing, soldering or Various Regulation 2.02, Section 2.3.4 welding equipment Woodworking, except for conveying, hogging, or Various Regulation 2.02, Section 2.3.5 burning wood/sawdust Lab venting and exhaust systems (non radioactive Various Regulation 2.02, Section 2.3.11 materials) Ventilation systems
- Various Regulation 2.02, Section 2.3.12 bakeries & restaurants Washing or drying fabricated metal or glass; Various Regulation 2.02, Section 2.3.15 non VOC use; no oil or solid fuel Residential/domestic Various Regulation 2.02, Section 2.3.12 equipment Portable diesel or gasoline Various Regulation 2.02, Section 2.3.23 storage tanks 

### SCH Page 124 of 130 03-31-2011PermitNo: 245-09-C (R1) PlantID: 0072 InsignificantActivities Description Quantity Basis Diesel fuel storage tanks Various Regulation 2.02, Section 2.3 .25 (emergency use only) Closed pressure storage 2 Regulation 2.02, Section 2.3.26 vessels Portabletote tanks for raw Tote tanks are kept closed when not in use. Emissions from tanks material shipment of Various solvent

- based coatings are negligible, and are accounted for byprocess material balance. Backup generators for emergency power.(< 500 2 Generators normal use is very low andHP <500 HP. hrs/year) WastewaterPretreatment 1 Emissions insignificant system. FluidFill (hydraulic fluids, Emissions insignificant due to lowvapor pressure ofmaterials oil, anti-freeze) and Various Lubricating operations. used. Miscellaneous maintenance procedures including lubrication, grinding, Various Negligible emissions cleaning, woodworking, etc. Directheat exchangers <1 Various Regulation 2.02, Section 2.1.1 MMBtu/hr

a. Insignificant Activities are only those activities or processes falling into the general categories defined in District Regulation 2.02, Section 2, and not associated with a specific operation or process for which there is a specific regulation. Equipment associated with a specific operation or process (Emission Unit) shall be listed with the specific process even though there may be no applicable requirements. Information contained in the permit and permit summary shall clearly indicate that those items identified with negligible emissions have no applicable requirements.

SCH b. Activities identified in District Regulation 2.02, Section 2, may not require a permit and may be insignificant with regard to application disclosure requirements butmay still have generally applicable requirements that continue to applyto the source.
c. For all insignificant activities that emit regulated air pollutants for which the company has accepted a plant-wide synthetic minor limit, the company shall maintain sufficient records to calculate the emissions and report those emissions inthe quarterly compliance reports and the annual emissions inventoryreport. d. The Insignificant Activities table is correct as ofthe date the permitwas proposed for review by the USEP A, Region 4. The company shall submit an updated list of

Page 125 of 130 03-31-2011PermitNo: 245-09-C (R1) PlantID: 0072

SCH insignificant activities annually withthe Title V compliance certificationpursuant to DistrictRegulation 2.16, section4.3.5 .3.6.
e. In lieu ofrecording annual throughputs for each Insignificant Activity, the owner or operator may elect to report the Potential To Emit quantity listed in the Insignificant Activities table as the annual emission for each piece ofequipment, since the emissions from the source's InsignificantActivities are minor.

Page 126 of 130 03-31-2011

### PermitNo: 245-09-C (R1) 

### Ford Louisville AssemblyPlant Compliance Assurance Monitoring (CAM) Plan PROCESS/OPERATIONAL RESTRICTION(S) 

### PlantID: 0072

1. 

### The thermal oxidizer used to control VOC emissions from the coating operations shall be operated to maintain a combustion chamber temperature of no more than 50 degrees Fahrenheit below the average combustion temperature during the most recent acceptable performance test and shall have a minimum design retention time of 0.5 seconds. The minimum temperature requirement may be based upon a 3 hour average. (64.6(c)(1)(i),(ii)) 

### 2. The carbon adsorber used to control VOC emissions from the coating operations shall be operated to maintain a desorption gas inlet temperature of no more than 15 degrees Fahrenheit below the average desorption gas inlet temperature during the most recent acceptable performance test. The minimum temperature requirement may be based upon a 3hour average. (64.6(c)(1)(i),(ii)) 

### 3. When relying on add-on control devices to demonstrate compliance with the emission requirements ofthis permit (i.e., control efficiency credit), the permittee may use nonzero control efficiencies for any period of time in which a deviation or excursion (including a deviation during startup, shutdown, or malfunction) from an operating limit occurs. Ifcompliance withthe emission limits is achieved, then no enforceable deviation or excursionwill have occurred. (64.6(b))
MONITORING/RECORDKEEPING 

### Records shall be maintained on file for aperiod offive years. 1. 

### Temperature measurements ofthe thermal oxidizer combustion chamber shall be made at least once every 15 minutes and recorded during operation of the associated coating operations. (64.6(c)(1)(i),(ii)) 

### 2. Temperature measurements ofthe concentrator desorption gas inlet shall be made and recorded at least once every 15 minutes during operation of the associated coating operations. (64.6(c)(1)(i),(ii)) 

### 3. Ifcoating operations can continue operating during a control device bypass, the bypass shall be monitored such that the valve or closure method cannot be opened without creating an alarm condition for which arecord shall be made. Records ofthe bypass line that was open and the length of time the bypass was open during operation of the associated coating operations shall be kept on file. (64.3(a)(2)) 

### 4. The CAM O&M plan shall be updated as necessaryto reflect any necessary changes. All records and activities associated with the O&M plan shall be kept on file for a period of SCH Page 127 of 130 03-31-2011PermitNo: 245-09-C (R1) PlantID: 0072 at least five years. (64.6(c)(l)(i),(ii), 64.7(e)) REPORTING 1. Each quarterly report for monitoring and deviations shall identify the number, duration and cause of any excursions ofthese requirements and the corrective actions taken. If there were no excursions in the reporting period, thenthis report shall include a statement thatthere were no excursions. (40 CFR64.9(a)(2)(i)) OTHERREQUIREMENT(S) For the purposes of Compliance Assurance Monitoring (CAM), excursiOns will be defined as follows: (64.6(c)(2))
a. A temperature excursion is defined as a confirmedthree-hourperiod during which the average fails to meetthe specifiedtemperature requirements. b. A monitoring excursion is defined as a failure to properlymonitor as required. c. A monitoring excursion can also be defined as failure to properly implement and/ormaintain the O&Mplan.
Elements ofan O&Mplan

- CAM General- Keep records ofmaintenance inspections which include the dates ofthe inspections andthe dates and reasons for repairs ifmade. The following items shall be addressed in an O&M Plan for each respective control device used to demonstrate compliance with applicable VOC emissions limits.
RTO's • Validation ofoperation ofeach thermocouple a minimum ofonce every 12 months or thermocouple replacement. • *Perform a heat exchange/heattransfer media inspection aminimum ofonce every 18 months, or • *Perform an inspection ofthe valve seals condition once every 18 months and verify valve timing/synchronizationthrough visual observation (orthrough an alarm system) once every 18 months. Carbon Adsorbor • Validation ofoperation ofeach thermocouple aminimum ofonce every 12 months or thermocouple replacement. • Perform semi-annual observationsto confirm that the carbon adsorbor is rotating (ifa rotary carbon adsorbor) and thatthe desorption fan is operating. • *Perform internal observation ofadsorbentmaterials for contamination and erosion a minimum ofonce every 18 months. SCH Page 128 of 130 03-31-2011PermitNo: 245-09-C (R1) PlantID: 0072 • Observe and record the pressure drop across the carbon adsorbor a minimum ofonce every calendar quarter. 

## *This requirement is satisfied ifaperformancetest (i.e., stacktest) has beenperformed.

SCH Page 129 of 130 03-31-2011

### PermitNo: 245-09-C (R1) Plant ID: 0072 

### Attachment A: Processes Added/Removed/Modified from Compliance Ford Motor CompanyLouisville Assembly Plant This sheet covers the period from
_______to ______ _ Emission Point (Note 1) Equipment Description

(Note 1) Change Category (Note 1) Equipment Action (Note 2) Date ofAction (Note 3)

Note 1:

Note 2: Note 3:

SCH Description of equipment being added/removed/modified including em1ss10n point identification and category of change. This log shall include any equipment/process that is added or removed from the calculation of annual emissions. Any equipment being added, removed, or modified form the emissions must be listed. Ifequipmentis being added, list date ofcommencementofoperation (including startup). Ifequipment is being removed, list date ofremoval from installation. Page 130of130 03-31-2011

## LouisvilleMetroAirPollution ControlDistrict 850 BarretAve., Louisville, Kentucky 40204 March 31, 2011 

## PAL Construction StatementofBasis Company: FordMotor Company-Louisville AssemblyPlant PlantLocation: 2000 FernValleyRoad, Louisville, Kentucky 40213 DateApplication Received: 07 August 2008 Application Number: 11042 DateofDraftPermit: 03/31/2011 DistrictEngineer: Shannon Clemons Hosey PermitNo: 245-09-C (R1) PlantID: 0072 SIC Code: 3711 NAICS: 336112 AFS: 00072 Introduction: This permit will be issued pursuant to: (1) Regulation 2.16, (2) Title 40 ofthe Code ofFederal Regulations Part 70, and (3) Title V ofthe Clean Air Act Amendments of 1990. Its purpose is to identify and consolidate existingDistrict and Federal air requirements and to provide methods of determining continued compliance withthese requirements. Jefferson County is classified as an attainment area for lead (Pb), sulfur dioxide (S02), nitrogen dioxide (N02), carbon monoxide (CO), 1hr and 8 hr ozone (03), and particulate matter less than 10 microns (PM 10); and is a non-attainment area for particulate matter less than 2.5 microns (PM2.s). Application Type/PermitActivity: [ ] Initial Issuance [ ] PermitRevision [ ]Administrative [ ] Minor [ ] Significant [ ] PermitRenewal [X] Construction Compliance Summary: [X] Compliance certification signed [ ] Source is out ofcompliance [ ] Compliance schedule included [X] Source is operating in compliance

### PermitNo. 245-09-C (R1) PlantID 0072 I. SourceInformation

SCH 

### 1. ProductDescription: Manufacture ofautomobiles. 2. Process Description: Vehicle bodies are assembled andprimed in the body shop. A variety ofsealers are applied to the bodies which are thenpainted. Wax is applied to certain bodyparts. Next, windshields and backlights are installed, then a structural adhesive is usedto bond glass to the bodies. 3. Site Determination: There are no other facilities that are contiguous or adjacent and under commoncontrol. 4. Emission Unit Summary: Emission Unit EquipmentDescription U002-U004 Five (5) Boilers 

## uoos Volatile Organic Liquid Storage Tanks U009 Glass Installation U010 E-Coat Operation UOll Guidecoat Operation U012 Topcoat Operation U013 Plant-wide ProductFueling U014/U022 PaintEquipment Cleaning Operation U015 Sealer Deck U016 Final Repair SprayBooth U023 Phosphate Operation U025 Twelve (12) DirectHeatExchangers 5. Fugitive Sources: There are no fugitive emissions. 6. PermitRevisions:

Page 2 of34 03-31-2011

### PermitNo. 245-09-C (R1) PlantID 0072
Revision Issue Public Attachment No. Date NoticeDate Type No./Page No. Description NA 7/30/2010 6111/2010 Initial Entire Permit PAL, STAR TAC

R1

SCH requirements, RO change, DRE forE-coat control device change and 112(J) Part 1 & 

### 2 applications. 3/31/2011 NA Admin Pages 43 and Revision to include Revision 50 permit 229-96-0 and correct Methanol Tank Vapor Pressure 7. Emission Summary: Pollutantthattriggered ActualEmissions (tpy) MajorSource Status Pollutant 2008 Data (based on PTE) 

# co 32.02 Yes NOx 38.11 Yes 

# so2 0.23 No PM 3.77 No 

# voc 273.0 Yes SingleHAP> 1tpy Methanol 2.43 Yes

Xylene 9.1 Yes Toluene 1.93 Yes Ethylbenzene 1.84 Yes

TotalHAPs 21.78 Yes 8. ApplicableRequirements: [X] PSD [ ] NSR [X] NSPS [ ] NESHAPS [X] SIP [X] District-Origin [X] MACT [ ] Other 9. Future MACT Requirements: The federal regulation 40 CPR 63, Subpart DDDDD has been vacated since June 8, 2007, therefore the boiler MACT requirements will 

### notbe included in this permit.
Page 3 of34 03-31-2011

### PermitNo. 245-09-C (R1) PlantID 0072 

### 10. Referenced Federal Regulations in Permit: 40 CFR 63 Subpart IIII

40 CFR 63 SubpartDe

40 CFR 63 SubpartEEEE 40 CFR 60 SubpartMM

40 CFR 63 SubpartZZZZ National Emission Standards for Hazardous AirPollutants- Surface Coating of Automobile and LightDutyTrucks Standards ofPerformance for Small Industrial-Commercial-Institutional Steam Generating Units Organic Liquids Distribution Operations National Emission Standards of Performance for Automobile and LightDuty Truck Surface Coating Operations National Emissions Standards for Hazardous AirPollutants for Stationary Reciprocating Internal CombustionEngines 

### II. RegulatoryAnalysis

SCH 

### 1. Acid Rain Requirements: The source is not subjectto the AcidRainProgram. 

### 2. Stratospheric Ozone Protection Requirements: Title VI ofthe CAAA regulates ozone depleting substances and requires aphase-out oftheir use. This rule applies to any facility that manufactures, sells, distributes, or otherwise uses any ofthe listed chemicals. This source does not manufacture, sell, or distribute any ofthe listed chemicals. The source's use oflisted chemicals is that in fire extinguishers, chillers, air conditioners and otherHV AC equipment. 

### 3. Prevention of Accidental Releases 112(r): The source does not manufacture, process, use, store, or otherwise handle one or more ofthe regulated substances listed in 40 CFR Part 68, Subpart F, and District Regulation 5.15, 

### Chemical Accident Prevention Provisions, in a quantity in excess of the corresponding specified threshold amount. 

### 4. Basis ofRegulation Applicability
a. Plant-wide The source is subject to a 

### plant-wide PAL limit of 1316 tons of VOC during any consecutive 12-monthperiod. The source is subject to a

### plant-wide PAL limit of21.2 tons ofPMduring any consecutive 12-monthperiod.
Page 4 of34 03-31-2011

### PermitNo. 245-09-C (Rl) Plant ID 0072

SCH The source is subject to a plant-wide 

### PAL limit of 21.2 tons of PM10 

### during any consecutive 12-monthperiod. The source is subject to a plant-wide 

### PAL limit of 17.2 tons of PM2.s during any consecutive 12-monthperiod. The source is subject to aplant-wide 

### PAL limit of99 tons ofNOx during any consecutive 12-monthperiod. The source is subject to a plant-wide 

### PAL limit of 39.33 tons of S02 during any consecutive 12-monthperiod. The source is subject to a plant-wide 

### PAL limit of 151.4 tons of CO during any consecutive 12-monthperiod. Regulations 5.01, 5.21, and 5.23 (STAR Program) establishes requirements for environmental acceptability of toxic air contaminants (TACs) and the requirement to comply with all applicable emission standards. The owner or operator shall not allow any TAC emissions to exceed environmentally acceptable levels whether specifically established by modeling or derived from default de minimis levels. (Regulation 5.01, section 3.) The TAC emissions from the combustion ofnatural gas are considered to be "de minimis emissions" by the District. This includes all of the emissions from a process or process equipment for which the only emissions are the products ofcombustion ofnatural gas, such as from a natural gas-fired boiler orturbine, but does not include the other emissions from a process or process equipment that are not the products of the combustion ofnatural gas. (Regulation 5.01, section 1.6.7) b. Emission Unit U002-U004- Five Boilers
1. 

### Equipment:



### Page 5 of34 03-31-2011PermitNo. 245-09-C (R1) PlantID 0072

PIPE
E02A

E04A

E04B

E05

SCH Installation Applicable Capacity Date Regulation Basis forApplicability 7.06 Boiler less than 6.42 100 MMBtu/hr 40 CFR60 Boilers with heat generating capacities greater than 1mmbtu/hr, modified after April 9,1972, are SubpartDC subject to Regulation 7.06 for PM and S02. 7.06 6.42 Boilers emitting large amounts ofNOxare 63.6 MMBtu!hr 1995 subjectto Regulation 6.42 for majornitrogen 40 CFR60 SubpartDC oxides emitting facilities. 7.06 Standards ofPerformance for Small Industrial6.42 Commercial-Institutional Steam Generating 63.6 MMBtu!hr 1995 Units 40 CFR60 Subpart DC Boilers with heat generating capacities greater 7.06 than 1mmbtu/hr, modified after April 9,1972, are subject to Regulation 7.06 for PMand S02. 33.5 MMBtu/hr 1996 40 CFR60 Standards ofPerformance for Small IndustrialSubpart DC Commercial-Institutional Steam Generating Units
11. 

### Standards/OperatingLimits
a. 

### PM i. See Permit 245-09-C (R1) PAL limits.
11. The emission standard for PM is determined in accordance withRegulation 7.06, section 4.1.4 

### b. Opacity Regulation 7.06, section 5.1.1 establishes an opacity standard ofless than 20%.
c. 

### S02
1. See Permit245-09-C (R1) PAL limits. ii. For Emission Point E04A, E04B and E05 the emission standard for 

## so2 is determined m accordance withRegulation 7.06, section 5.1.1. iii. EmissionPoints E04A, E04B and E05 are subject to Page 6 of34 03-31-2011PermitNo. 245-09-C (R1) PlantID 0072

SCH 40 CPR 60, Subpart De. However, there is no S02 emission standard for natural gas fired boilers in Subpart De. d. NOx Regulation 6.42 requires the owner or operator shall not allow the NOx emissions to exceed 99 tons during any consecutive 12-monthperiod in orderto avoidNOxRACT. iii. Monitoring
a. 

### PM Maintain records ofmonthlynatural gas and/or otherfuel usage. b. Opacity Regulation 7.06 does not require any specific monitoring requirements for opacity, however, Regulation 2.16, section 4.1.9.1. requires sufficient monitoring to assure ongoing compliancewiththeterms and conditions ofthe permit.
c. 

### S02 Regulation 7.06 does not require any specific monitoring requirements for S02 , however, Regulation 2.16, section 4.1.9.1. requires sufficient monitoring to assure compliance withthe terms and conditions ofthe permit. d. NOx Maintain records of monthly fuel usage, and use AP-42 emission factors and/or fuel analysis data, to calculate monthlyemissions. iv. Record Keeping
a. 

### PM See PMMonitoring. b. Opacity Regulation 7.06 does not require any specific record keeping requirements for opacity, however, Regulation Page 7 of34 03-31-2011PermitNo. 245-09-C (R1) PlantID 0072

SCH 2.16, section 4.1.9.2. requires sufficient record keeping to assure compliance with the terms and conditions of the permit.
c. 

### S02 40 CFR 60, Subpart De requires records ofthe amount of fuel combusted each month. Regulation 7.06 does not require any specific record keeping requirements for S02, however, Regulation 2.16, section 4.1.9.2. requires sufficient record keeping to assure compliance with the terms and conditions ofthepermit. d. NOx The source shall calculate and record the monthly and 12 consecutive month plant-wide NOx emissions for each month inthe reportperiod.
v. Reporting
a. PM Regulation 2.16, section 4.1.9.3. requires sufficient reporting requirements to assure compliance with the terms and conditions ofthe permit. The source shall report any deviations from the permit. b. Opacity Regulation 2.16, section 4.1.9.3. requires sufficient reporting requirements to assure compliance with the terms and conditions ofthepermit.
c. 

### S02 There are no periodic compliance reporting requirements for S02. d. NOx Regulation 2.16, section 4.1.9.3. requires sufficient reporting requirements to assure compliance with the terms and conditions ofthe permit.
c. Emission UnitU008- Volatile OrganicLiquid Storage Tanks
Page 8 of34 03-31-2011PermitNo. 245-09-C (R1) PlantID 0072

PIPE E08AMethanol Tank E08G UG Solvent Tank E08M Anti-Freeze Tank E08NPower SteeringFluidTank E080BrakeFluid Tank E08P Diesel Fuel Tank

SCH Installation Applicable Capacity Date Regulation Basis for Applicability

6,000 2002 7.12 10,000 1986 7.12 20,000 1990 7.12 VOC storage tanks greaterthan 250 gallon capacity are subject to Regulation 7.12 for VOC 20,000 1990 7.12 whichwere installed after April 19, 1972. 6,000 1980 7.12 20,000 After 1972 7.12
ii. 

### Standards/OperatingLimits 

# voc 1) Regulation 7.12, section 3.3 requires submerged fill ifthe materials have an as stored vapor pressure of 1.5 psia or greater. Regulation 7.12 applies due to the size ofthe tanks, however, since the vapor pressure as stored is less than 1.5 psia there are no applicable emission or equipment standards. 2) See Permit 245-09-C (R1) PAL limits
111. 

### Monitoring 

# voc The source is required to monitor and maintain records of the material·stored in each storage vessel. Ifthe contents ofthe storage vessels are changed, a record shall be made ofthe new contents, the newvaporpressure, and the date ofthe change in service.
lV. 

### Record Keeping 

# voc The source shall maintain records of the material stored in each storage vessel. Ifthe contents ofthe storage vessels are changed, a
Page 9 of34 03-31-2011

### PermitNo. 245-09-C (R1) Plant ID 0072 record shall be made ofthe new contents, the new vapor pressure, and the date ofthe change in service.
v. Reporting 

# voc There are no Emission Unit specific compliance reporting requirements for the tanks. The source is required to report the throughput for purposes of demonstrating ongoing compliance with the plant-wide PAL VOC emission limit. d. Emission UnitU009- Glass Installation

PIPE E009 Glass, Windshield, and BackLights Installation



### SCH 1. 

### Equipment:
Installation Applicable Capacity Date Regulation Basis for Applicability The glass installation operation N/A 1994 7.59 is subjectto the VOC emission standard in Regulation 7.59 and was installed after September 1, 1976. 

### ii. Standards/OperatingLimits 

# voc 1) Regulation 7.59, section 3.1.3 requires the source shall not cause or allow the emission of VOC from any affected facility resulting from the coating of metallic surfaces in excess of 0.42 kg of VOC/1 (3.5 lb VOC/gal) of coating, excluding water and exempt solvents, as applied for extreme performance coatings. 2) See Permit 245-09-C (R1) PAL limits
111. 

### Monitoring 

# voc Regulation 2.16, section 4.1.9.1. requires sufficient monitoring to assure ongoing compliance with the terms and conditions ofthe permit. iv. Record Keeping Page 10 of34 03-31-2011PermitNo. 245-09-C (Rl) Plant ID 0072



# voc 1) Regulation 7.59, section 6.1 and Regulation 2.16, section 4.1.9.2. requires sufficient record keeping to assure compliance with the terms and conditions ofthepermit. 2) Regulation 2.16, section 4.1.9.2. requires the source to monitor the plant-wide VOC emissions during each consecutive 12-month period to assure the emissions of VOC remain belowtheplant-wide PAL limit.


### v. Reporting 

# voc Regulation 2.16, section 4.1.9.3. requires sufficient reporting requirements to assure compliance with the terms and conditions ofthe permit.


### e. Emission Unit UOlO- 

### E-Coat Operation
1. 

### Equipment
PIPE Capacity Installation Applicable Basis for Applicability Date Regulation 40 CFR63 Subpart IIII E10AE-CoatDip N/A 1996 Tank 40 CFR60 Subpart MM SubpartIIII Hazardous Air 40 CFR63 Subpart Pollutants: Surface Coating of IIII Automobiles and Light. E 1 OB E-Coat Oven N/A 1988 40 CFR 60 Subpart MM 40 CFR 63 Subpart SubpartMMestablishes standards IIII for National Emission Standards of E 1OC E-Coat Oven N/A 1996 Performance for Automobile and (3'd Pass) 40 CFR 60 Subpart Light DutyTruck Surface Coating MM Operations. 40 CFR 63 Subpart E10D E-CoatDump IIII Metal AST N/A 1996 40 CFR 60 Subpart MM

SCH Page 11 of34 03-31-2011PermitNo. 245-09-C (R1) PlantID 0072

E17A E-Coat Scuff Booth

SCH ForRegulation 7.08 the scuff N/A 1989 booth is subjectto PMemission 7.08 standard and was installed after September 1, 1976.

11. Standards/Operating Limits
a. VOC 1) The E-Coat Operation is subject is subject to 40 CPR Part 63, Subpart IIII

- Surface Coating of Automobiles and Light-Duty Trucks and 40 CPR 60, Subpart MM - National Emission Standards of Performance for Automobile and Light Duty Truck Surface Coating Operations section 60.392 emission limits. 2) See Permit245-09-C (R1) PAL limits b. PM 1) The PM limits are calculated per Regulation 7.08, section 3.1.2. The equation to calculate the emission limits is E = 3.59P0

·62
, where P is expressed in tons/hr. 2) See Permit245-09-C (R1) PALlimits
c. Opacity Regulation 7.08, section 3.1.2. establishes an opacity standard ofless than 20%. iii. Monitoring
a. VOC 40 CPR Part 63, Subpart IIII

- Surface Coating of Automobiles and Light-Duty Trucks and 40 CPR 60, Subpart MM National Emission Standards of Performance for Automobile and LightDuty Truck Surface Coating Operations sections 60.392 establishes monitoring requirements. b. PM
Page 12 of34 03-31-2011PermitNo. 245-09-C (Rl) Plant

### ID 0072

SCH Regulation 7.08 does not require any specific monitoring requirements for PM, however, Regulation 2.16, section 4.1.9.1. requires sufficient monitoring to assure ongoing compliance withthe terms and conditions ofthepermit.
c. 

### Opacity Regulation 7.08 does not require any specific monitoring requirements for opacity, however, Regulation 2.16, section 4.1.9.1. requires sufficient monitoring to assure compliance with the terms and conditions ofthepermit. iv. 

### Record Keeping
a. VOC 40 CPR Part 60, Subpart MM - National Emission Standards ofPerformance for Automobile and Light Duty Truck Surface Coating Operations sections 60.3095 and 40 CPR Part 63

- Surface Coating ofAutomobiles and Light Duty Trucks establishes record keeping requirement. Regulation 2.16, section 4.1.9.2 establishes record keeping requirements to assure ongoing compliance with the terms and conditions ofthepermit. b. PM See PMMonitoring.
c. 

### Opacity Regulation 7.08 does not require any specific record keeping requirements for opacity, however, Regulation 2.16, section 4.1.9.2. requires sufficient record keeping to assure ongoing compliance with the terms and conditions ofthe permit.


### v. Reporting


### a. VOC Regulation 2.16, section 4.1.9.3. establishes reporting requirements to assure ongoing compliance with the terms and conditions ofthe permit.

Page 13 of34 03-31-2011PermitNo. 245-09-C (R1) 

### b. PlantID 0072
PM Regulation 7.08 does not require any specific reporting requirements for PM, however, Regulation 2.16, section 4.1.9.3. requires reporting to assure compliance with the terms and conditions ofthepermit.


### c. Opacity Regulation 7.08 does notrequire any specificreporting requirements for opacity, however, Regulation 2.16, section 4.1.9.3. requires reportingto assure compliance withthe terms and conditions ofthepermit. f. 

### Emission UnitUOll- Guidecoat Operation
1. 

### Equipment:
PIPE Capacity Installation Applicable Basis for Applicability Date Regulation Subpart IIII Hazardous Air 40 CFR 63 Subpart Pollutants: Surface Coating of illi Automobiles and Light-Duty EllA Guidecoat Trucks PaintBooth and Air N/A 1988 SubpartMMNational Emission Supply Hose 40 CFR 60 Subpart Standards ofPerformance for MM Automobile and LightDutyTruck Surface Coating Operations establishes standards. ForRegulation 7.08 the scuff 7.08 booth is subjectto PMemission standard and was installed after EllB Touchup and N/A 1988 September 1, 1976. BlackoutBooth The guidecoat operation is subject 7.59 to the VOC emission standard in Regulation 7.59 and was installed after Stj)tember 1, 1976. 40 CFR63 Subpart Subpart Illi Hazardous Air IIII Pollutants: Surface Coating of E11C Guidecoat 40 CFR 60 Subpart Automobiles and Light-Duty Ovens (1st and 2nd N/A 1988 MM Trucks Pass) 7.08 SubpartMMNationalEmission Standards ofPerformance for 40 CFR63 Subpart Automobile andLightDutyTruck EliD Guidecoat N/A IIII Surface Coating Operations Oven (3 rdPass) 1988 establishes standards. 40 CFR 60 Subpart MM

SCH Page 14 of34 03-31-2011PermitNo. 245-09-C (R1) PlantID 0072

PIPE

E11E/E12G Guidecoat/Topcoat PaintKitchen

E18A Guidecoat ScuffBooth

SCH Capacity Installation Applicable Basis for Applicability Date Regulation ForRegulation 7.08 the equipment is subjectto PMemission standard 7.08 and was installed after September 1, 1976. 40 CFR63 Subpart Subpart IIII Hazardous Air IIII Pollutants: Surface Coating of Automobiles and Light-Duty Trucks N/A 1988 SubpartMMNational Emission 40 CFR 60 Subpart Standards ofPerformance for MM Automobile and LightDuty Truck Surface Coating Operations establishes standards. ForRegulation 7.08 the scuff NIA 1989 booth is subjectto PMemission 7.08 standard and was installed after September 1, 1976.

11. 

### Standards/OperatingLimits
a. VOC 1) The Guidecoat Operation is subject to 40 CFRPart 63, Subpart IIII

- Surface Coating ofAutomobiles and Light-DutyTrucks and 40 CFR 60, Subpart MM -NationalEmission Standards ofPerformance for Automobile and LightDutyTruck Surface Coating Operations section 60.392 emission limits. 2) Regulation 7.59, section 3.1.3 requires the source shall not cause or allowthe emission ofVOC from any affected facility resulting from the coating of metallic surfaces in excess of0.42kg ofVOC/1 (3.5 lb ofVOC/gal) ofcoating, excluding water and exempt solvents, as applied for extreme performance coatings. 3) See Permit245-09-C (Rl)PAL limits b. PM 1) The PM limits are calculated per Regulation 7.08, section 3.1.2. The equationto calculate the emission limits is E 

### = 3.59P0

·62
, where P is expressed in tons/hr. Page 15 of34 03-31-2011PermitNo. 245-09-C (R1) PlantID 0072

SCH 2) See Permit245-09-C (Rl)PAL limits
c. Opacity Regulation 7.08, section 3.1.2. establishes an opacity standard ofless than 20%.
111. Monitoring
a. VOC 40 CFR Part 63, Subpart IIII

- Surface Coating of Automobiles and Light-Duty Trucks and 40 CFR 60, Subpart MM National Emission Standards of Performance for Automobile and LightDutyTruck Surface Coating Operations sections 60.392 establishes monitoring requirements. b. 

### PM Regulation 7.08 does not require any specific monitoring requirements for PM, however, Regulation 2.16, section 4.1.9

### .I. requires sufficient monitoring to assure ongoing compliance withthe terms and conditions ofthepermit.
c. Opacity Regulation 7.08 does not require any specific monitoring requirements for opacity, however, Regulation 2.16, section 4.1.9

### .I. requires sufficient monitoring to assure compliance withthe terms and conditions ofthepermit.
IV. Record Keeping
a. VOC 1) 40 CFR Part 60, Subpart MM -National Emission Standards ofPerformance for Automobile and Light Duty Truck Surface Coating Operations sections 60.3095 and 40 CFR Part 63

- Surface Coating of Automobiles and Light-Duty Trucks establishes record keeping requirement. Regulation 2.16, section 4.1.9.2 establishes record keeping requirements to assure ongoing compliance withthe terms and conditions ofthepermit.
Page 16 of34 03-31-2011PermitNo. 245-09-C (R1) Plant ID 0072

SCH 2) Regulation 7.59, section 6.1 and Regulation 2.16, section 4.1.9.2. requires sufficient record keeping to assure compliance with the terms and conditions of thepermit. b. PM See PMMonitoring.
c. Opacity Regulation 7.08 does not require any specific record keeping requirements for opacity, however, Regulation 2.16, section 4.1.9.2. requires sufficient record keeping to assure ongoing compliance with the terms and conditions ofthepermit.
v. Reporting
a. VOC Regulation 2.16, section 4.1.9.3. establishes reporting requirements to assure ongoing compliance with the terms and conditions ofthe permit. b. PM Regulation 7.08 does not require any specific reporting requirements for PM, however, Regulation 2.16, section 4.1.9.3. requires reporting to assure compliance with the terms and conditions ofthe permit.
c. Opacity Regulation 7.08 does not require any specific reporting requirements for opacity, however, Regulation 2.16, section 4.1.9.3. requires reporting to assure compliance with the tenns and conditions ofthe permit. g. Emission Unit U012- Topcoat Operation

Page 17 of34 03-31-2011

### PermitNo. 245-09-C (Rl) Plant 

### ID 0072

1. Equipment:

PIPE Capacity Installation Applicable Basis for Applicability Date Regulation ForRegulation 7.08 the scuff 7.08 booth is subjectto PMemission standard and was installed after September 1, 1976. The topcoat operation is subject to 7.59 the VOC emission standard in Regulation 7.59 and was installed E12ANorth Main after September 1, 1976. Enamel Booth and N/A 1985 Subpart IIII Hazardous Air Air Supply 40 CFR 63 Subpart Pollutants: Surface Coating of IIII Automobiles andLight-Duty Trucks SubpartMMNational Emission 40 CFR 60 Subpart Standards ofPerformance for Automobile andLightDuty Truck MM Surface Coating Operations establishes standards. Subpart IIII Hazardous Air 40 CFR 63 Subpart Pollutants: Surface Coating of IIII Automobiles and Light-Duty Trucks E12B NorthMain N/A 1985 Enamel Oven SubpartMMNational Emission 40 CFR 60 Subpart Standards ofPerformance for MM Automobile andLightDuty Truck Surface Coating Operations establishes standards. ForRegulation 7.08 the scuff 7.08 booth is subjectto PMemission standard and was installed after September 1, 1976. Subpart IIII Hazardous Air E12C SouthMain 40 CFR63 Subpart Pollutants: Surface Coating of N/A 1985 IIII Automobiles and Light-Duty EnamelBooth Trucks SubpartMMNational Emission 40 CFR 60 Subpart Standards ofPerformance for Automobile andLightDutyTruck MM Surface Coating Operations establishes standards. ForRegulation 7.08 the scuff 7.08 booth is subject to PMemission standard and was installed after El2DAir Supply and September 1, 1976. Oven N/A 1985 SubpartMMestablishes standards 40 CFR60 Subpart for National Emission Standards of Performance for Automobile and MM LightDuty Truck Surface Coating Operations.
SCH 

### Page 18 of34 03-31-2011PermitNo. 245-09-C (Rl) Plant ID 0072

E12F Air Supply House and Oven

E11E/E12G Guidecoat/Topcoat Kitchen

E12HTopcoat Scuff Booth

E12I TuTone/Repair ScuffBooth

SCH ForRegulation 7.08 the scuff 7.08 booth is subjectto PMemission standard and was installed after September 1, 1976. N/A 1985 Subpart MMestablishes standards 40 CFR60 Subpart for National Emission Standards of Performance for Automobile and MM LightDutyTruck Surface Coating Operations. SubpartMMestablishes standards for National Emission Standards of N/A 1988 40 CFR60 Subpart Performance for Automobile and MM LightDuty Truck Surface Coating Operations. ForRegulation 7.08 the scuff N/A 1985 7.08 booth is subjectto PMemission standard and was installed after September 1, 1976. · ForRegulation 7.08 the scuff N/A 1985 7.08 booth is subjectto PMemission standard and was installed after September 1, 1976.

ii. Standards/Operating Limits
a. VOC 1) The Topcoat Operation is subject is subject to 40 CFR Part 63, Subpart IIII

- Surface Coating of Automobiles and Light-Duty Trucks and 40 CFR 60, Subpart MM - National Emission Standards of Performance for Automobile and Light Duty Truck Surface Coating Operations section 60.392 emission limits. 2) Regulation 7.59, section 3.1.3. requires the source shall not cause or allow the emission ofVOC from any affected facility resulting from the coating of metallic surfaces in excess of0.42 kg ofVOC/1 (3.5 lb of VOC/gal) of coating, excluding water and exempt solvents, as applied for extreme performance coatings.

Page 19 of34 03-31-2011PermitNo. 245-09-C (R1) PlantID 0072

SCH 3) See Permit245-09-C (R1) PAL limits b. PM 1) The PM limits are calculated per Regulation 7.08, section 3.1.2. The equationto calculate the emission limits is E = 3.59P062
, where P is expressed in tons/hr. 2) SeePermit245-09-C (R1) PAL limits
c. Opacity Regulation 7.08, section 3.1.2. establishes an opacity standard ofless than 20%. 

### iii. Monitoring
a. VOC 40 CFR Part 63, Subpart IIII

- Surface Coating of Automobiles and Light-Duty Trucks and 40 CFR 60, Subpart MM National Emission Standards of Performance for Automobile andLightDuty Truck Surface Coating Operations sections 60.392 establishes monitoring requirements. b. PM Regulation 7.08 does not require any specific monitoring requirements for PM, however, Regulation 2.16, section 4.1.9.1. requires sufficient monitoring to assure ongoing compliancewiththe terms and conditions ofthepermit.
c. Opacity Regulation 7.08 does not require any specific monitoring requirements for opacity, however, Regulation 2.16, section 4.1.9.1. requires sufficient monitoring to assure compliance withtheterms andconditions ofthe permit. iv. Record Keeping
a. VOC

Page 20 of34 03-31-2011PermitNo. 245-09-C (R1) 1)

2)

3)

b. PM Plant ID 0072 40 CFR Part 60, Subpart MM -National Emission Standards ofPerformance for Automobile and Light Duty Truck Surface Coating Operations sections 60.3095 and 40 CFR Part 63

- Surface Coating of Automobiles and Light-Duty Trucks establishes record keeping requirement. Regulation 2.16, section 4.1.9.2 establishes record keeping requirements to assure ongoing compliance withthe terms and conditions ofthepermit. Regulation 7.59, section 6.1 and Regulation 2.16, section 4.1.9.2. requires sufficientrecord keeping to assure compliance with the terms and conditions of thepermit. Regulation 2.16, section 4.1.9.1 requires the source to monitor the plant-wide VOC emissions during each consecutive 12-month period to assure the emissions of VOC remain below the plant-wide PAL limit.

See PMMonitoring.
c. Opacity Regulation 7.08 does not require any specific record keeping requirements for opacity, however, Regulation 2.16, section 4.1.9.2. requires sufficient record keeping to assure ongoing compliance with the terms and conditions ofthe permit.
v. Reporting

SCH a. VOC Regulation 2.16, section 4.1.9.3. establishes reporting requirements to assure ongoing compliance with the terms and conditions ofthepermit. 

### b. PM Regulation 7.08 does not require any specific reporting requirements for PM, however, Regulation 2.16, section

Page 21 of34 03-31-2011

### PermitNo. 245-09-C (R1)

SCH Plant ID 0072 4.1.9.3. requires reporting to assure compliance with the terms and conditions ofthepermit.
c. Opacity 

### Regulation 7.08 does not require any specific reporting requirements for opacity, however, Regulation 2.16, section 4.1.9.3. requires reporting to assure compliance with the terms and conditions ofthe permit.

Page 22 of34 03-31-2011PermitNo. 245-09-C (Rl) Plant ID 0072


### g. Emission UnitU013 -Plant-wideProductFueling

PIPE
El3A Gasoline Tank#1

E13B Gasoline Tank#2

El3C Gasoline Tank#3
El3DTwo Fueling Stations with Vapor Recovery

SCH Installation Applicable Capacity Date Regulation Basis for Applicability Standards ofPerformance for Gasoline Transferto New 20,000 gallons 1990 7.15 Service Station Storage Tanks (Stage I Vapor Recovery) Standards ofPerformance for Gasoline Transferto New 20,000 gallons 1990 7.15 Service Station Storage Tanks (Stage I Vapor Recovery) Standards ofPerformance for Gasoline Transferto New 20,000 gallons 1990 7.15 Service Station Storage Tanks (Stage I Vapor Recovery) N/A 1994 7.25 OR VREquipped Vehicles

11. 

### Standards/OperatingLimits 

## voc Regulation 7.15 requires that storage tanks shall be equipped with the following:
a. A submergedfill pipe; b. If the gasoline storage tank is equipped with a separate gauge well, a gauge well drop tube shall be installed which extends to within six inches ofthe bottom ofthe tank; c. Vent line restrictions on the affected facility; and d. Vapor balance system and vapor tight connections on the liquid fill and vapor return hoses. The cross-sectional area of the vapor return hose and any other vapor return passages in the circuit connecting the vapor space in the service stationtankto that ofthe truck tankmust be at least 50% of the liquid fill hose cross-sectional area for each tank and free of flow restrictions to achieve acceptable recovery. The vapor balance equipment must be maintained according to the manufacturer's specifications. The type, size and design ofthe vapor balance system are subjectto the approval ofthe District.
111. 

### Monitoring Page 23 of34 03-31-2011PermitNo. 245-09-C (R1) Plant ID 0072


# voc Regulation 7.15 does not require any specific monitoring requirements for VOC, however, Regulation 2.16, section 4.1.9.1. requires sufficient monitoring to assure ongoing compliance with theterms and conditions ofthepermit.
IV. 

### Record Keeping 

# voc Regulation 7.15 does not require any specific record keeping requirements for VOC, however, Regulation 2.16, section 4.1.9.2. requires sufficient record keeping to assure ongoing compliance with theterms and conditions ofthepermit.


### v. Reporting 

# voc Regulation 2.16, section 4.1.9.3. establishes reporting requirements to assure ongoing compliance with the terms and conditions ofthe permit. 

### h. Emission UnitU014/U022- PaintEquipment Cleaning Operation
Installation Applicable PIPE Capacity Date Regulation Basis for Applicability This regulation applies to each existing auto and truck E14 Paint manufacturing facility which Equipment N/A 1985 7.25 was in being orhad a CleaningBooth construction permit issued by the Districtbefore June 13, 1979 This regulation applies to each existing auto and truck E22APaint manufacturing facility which EquipmentPurging N/A 1976 7.25 was in being orhad a andPlant Cleaning construction permit issued by the Districtbefore June 13, 1979 Standards ofPerformance for Solvent Metal Gasoline Transferto New Cleaning N/A N/A 6.18 Service Station Storage Equipment Tanks (Stage I Vapor Recovery)

SCH Page 24 of34 03-31-2011PermitNo. 245-09-C (Rl) PlantID 0072

11. 

### Standards/OperatingLimits 

# voc 1) The source shall follow the procedure below to minimize VOC emissions from purge and cleaning operations under Regulation 7.25, section 3. 2) For all cold solvent patis washers, the source shall comply with the standards ofRegulation 6.18, sections 4.1 through 4.3.
111. 

### Monitoring 

# voc Regulation 2.16, section 4.1.9.1. requires sufficient monitoring to assure ongoing compliance with the terms and conditions ofthe permit.
IV. 

### Record Keeping 

# voc Regulation 2.16, section 4.1.9.2. requires sufficient record keeping to assure ongoing compliance with the terms and conditions ofthe permit.


### v. Reporting 

# voc Regulation 2.16, section 4.1.9.3. establishes reporting requirements to assure ongoing compliance with the terms and conditions ofthe permit. 

### i. Emission UnitU015- SealerDeck
Installation Applicable PIPE Capacity Date Regulation Basis for Applicability The sealer operation is E15A Sealer subject to the VOC emission N/A 1994 7.59 standard in Regulation 7.59 Application and was installed after September 1, 1976.

SCH Page 25 of34 03-31-2011

### PermitNo. 245-09-C (R1) Plant ID 0072

PIPE Sealers and Deadeners (other than glass bonding)



### SCH Installation Applicable Capacity Date Regulation Basis for Applicability Subpart Illiestablishes 40 CFR63 Subpart standards for Hazardous Air N/A N/A Pollutants: Surface Coating IIII ofAutomobiles and LightDuty Trucks 

### ii. Standards/OperatingLimits 

# voc 1) Regulation 7.59, section 3.1.3. requires the source shall not cause or allow the emission of VOC from any affected facility resulting from the coating of metallic surfaces in excess of 3.5 lb VOC/gal of coating, excluding water and exempt solvents, as applied for extreme performance coatings. 2) See Permit 245-09-C (R1) PAL limits iii. 

### Monitoring 

# voc Regulation 2.16, section 4.1.9.1. requires sufficient monitoring to assure ongoing compliance with the terms and conditions of the permit. 

### tv. Record Keeping 

# voc 1) Regulation 7.59, section 6.1 and Regulation 2.16, section 4.1.9.2. requires sufficient record keeping to assure compliance withthe terms and conditions ofthe permit. 2) Regulation 2.16, section 4.1.9.2. requires the source to monitor the plant-wide 

### VOC emissions during each consecutive 12-month period to assure the emissions of VOC remain below theplant-wide 

### PAL limit.
v. Reporting 

# voc

Page 26 of34 03-31-2011PermitNo. 245-09-C (R1) PlantID 0072 Regulation 2.16, section 4.1.9.3. establishes reporting requirements to assure ongoing compliance with the terms and conditions ofthe permit. j. 

### Emission UnitU016- Final Repair SprayBooth; infrared curing, and spotrepair bays for repairing coating on vehicles

PIPE

E16A Final Repair Booth

E16B Final Repair Oven

SCH Installation Applicable Capacity Date Regulation Basis for Applicability 7.08 ForRegulation 7.08 the scuff booth is subject to PM 40 CFR63 Subpart emission standard and was N/A 1982 IIII installed after September 1, 1976. 40 CFR60 Subpart MM Subpart IIII establishes 7.08 standards for Hazardous Air Pollutants: Surface Coating 40 CFR 63 Subpart ofAutomobiles and LightIIII DutyTrucks N/A 1982 SubpartMMestablishes standards for National 40 CFR60 Subpart Emission Standards of MM Performance for Automobile and Light Duty Truck Surface Coating Operations. ii. 

### Standards/OperatingLimits
a. VOC 1) TheE-Coat Operation is subjectto 40 CPRPart 60, Subpart IIII

- Surface Coating ofAutomobiles and Light-Duty Trucks. 40 CPR 60, Subpart IIII section 60.392 emission limits. 2) See Permit245-09-C (R1) PAL limits 

### b. PM 1) The PM limits are calculated per Regulation 7.08, section 3.1.2. The equationto calculate the emission limits is E 

### = 3.59P0

·62
, where P is expressed in tons/hr. 2) See Permit245-09-C (R1) PAL limits
Page 27 of34 03-31-2011PermitNo. 245-09-C (R1) Plant ID 0072

SCH c. Opacity Regulation 7.08, section 3.1.2. establishes an opacity standard ofless than 20%.
m. Monitoring
a. VOC 40 CFR Part 60, Subpart lUI

- Surface Coating of Automobiles and Light-Duty Trucks sections 60.392 establishes monitoringrequirements. b. PM Regulation 7.08 does not require any specific monitoring requirements for PM, however, Regulation 2.16, section 4.1.9.1. requires sufficient monitoring to assure ongoing compliancewiththeterms and conditions ofthepermit.
c. Opacity Regulation 7.08 does not require any specific monitoring requirements for opacity, however, Regulation 2.16, section 4.1.9.1. requires sufficient monitoringto assure compliance with theterms and conditions ofthepermit.
IV. Record Keeping
a. VOC 1) 40 CFR Part 60, Subpart IIII - Surface Coating of Automobiles and Light-Duty Trucks sections 60.395 establishes record keeping requirement. Regulation 2.16, section 4.1.9.2. establishes record keeping requirements to assure ongoing compliance withthe terms and conditions ofthe permit. 2) Regulation 2.16, section 4.1.9.2. requires the source to monitor the plant-wide VOC emissions during each consecutive 12-month period to assure the emissions of VOC remain below the plant-wide PAL limit. b. PM

Page 28 of34 03-31-2011PermitNo. 245-09-C (Rl) PlantID 0072 See PMMonitoring.


### c. Opacity Regulation 7.08 does not require any specific record keeping requirements for opacity, however, Regulation 2.16, section 4.1.9.2. requires sufficient record keeping to assure ongoing compliance with the terms and conditions ofthe permit.
v. Reporting
a. VOC Regulation 2.16, section 4.1.9.3. establishes reporting requirements to assure ongoing compliance with the terms and conditions ofthe permit. b. PM Regulation 7.08 does not require any specific reporting requirements for PM, however, Regulation 2.16, section 4.1.9.3. requires reporting to assure compliance with the terms and conditions ofthepermit.
c. Opacity Regulation 7.08 does not require any specific reporting requirements for opacity, however, Regulation 2.16, section 4.1.9.3. requires reporting to assure compliance with the terms and conditions ofthe permit. k. Emission Unit U025- Twelve (12) DirectHeat Exchangers U025 Emission Points ID Description Applicable Regulation ControlDevice 6.42 E25 DirectHeatExchangers N/A 7.08
11. Standards/Operating Limits
a. PM

SCH Page 29 of34 03-31-2011PermitNo. 245-09-C (R1) Plant ID 0072 The PM limits are calculated per Regulation 7.08, section 3.1.2. The equation to calculate the emission limits is E = 3.59P0

·62
, where P is expressed in tons/hr. The maximum throughput is less than 1,000 pounds per hour; therefore, the PM emission standard is 2.34 lb/hr. b. Opacity Regulation 7.08, section 3.1.1. establishes an opacity standard ofless than 20%.
c. NOx Per Regulation 6.42, the owner or operator shall not allow or cause theplant-wide NOx emissions to equal or exceed 100 tons during any consecutive 12-month period in order to avoidNOxRACT.
111. Monitoring

IV.

SCH a. 

### PM There are no compliance monitoring requirements for this equipment. The potential uncontrolled PM emissions are less thanthe applicable emission standard. b. Opacity Regulation 7.08 does not require any specific monitoring requirements for opacity, however, Regulation 2.16, section 4.1.9.1. requires sufficient monitoring to assure compliance withtheterms and conditions ofthe permit.
c. NOx



### a. Regulation 7.08 does not require any specific monitoring requirements for NOx, however, Regulation 2.16, section 4.1.9.1. establishes monitoring requirements to assure ongoing compliance with the terms and conditions ofthe permit. Record Keeping 

### PM

Page 30 of34 03-31-2011PermitNo. 245-09-C (R1) Plant ID 0072 There are no compliance record keeping requirements for this equipment. The potential uncontrolled PM emissions are less than the applicable emission standard. b. Opacity Regulation 7.08 does not require any specific monitoring requirements for opacity, however, Regulation 2.16, section 4.1.9.2. requires reporting to assure compliance with the terms and conditions ofthepermit.
c. NOx Regulation 7.08 does not require any specific record keeping requirements for NOx, however, Regulation 2.16, section 4.1.9.2. requires sufficient record keeping to assure ongoing compliance with the terms and conditions of the permit.


### v. Reporting
a. PM There are no routine compliance reporting requirements for this equipment. The potential uncontrolled PM emissions are less than the applicable emission standard. b. Opacity Regulation 7.08 does not require any specific reporting requirements for opacity, however, Regulation 2.16, section 4.1.9.3. requires reporting to assure compliance with the terms and conditions ofthepermit.
c. NOx Regulation 7.08 does not require any specific reporting requirements for NOx, however, Regulation 2.16, section 4.1.9.3. requires reporting to assure compliance with the terms and conditions ofthe permit. III. Other Requirements

SCH 1. Temporary Sources: The source did not request to operate any temporary facilities.

Page 31 of34 03-31-2011PermitNo. 245-09-C (Rl) Plant

### ID 0072 

### 2. ShortTermActivities: The source did not report ant shortterm activities. 

### 3. Emissions Trading: N/A 4. Alternative Operating Scenarios: The source did not request to operate under any alternative operating scenarios. 5. Compliance Status: Ford Motor Company-Louisville Assembly Plant is required to submit their annual Compliance Certification to the District on or before April 15th ofeach calendar year. As ofthe effective date ofPermit245-09-C (Rl), there are no compliance schedules in effect orprogress reports required. 6. InsignificantActivities InsignificantActivities Description Quantity Basis Internal combustion engines Various Regulation 2.02, Section 2.2 fixed ormobile Presses extruding Various Regulation 2.02, Section 2.3.1 metal/mineral/wood Brazing, soldering or Various Regulation 2.02, Section 2.3.4 welding equipment Woodworking, except for conveying, hogging, or Various Regulation 2.02, Section2.3.5 burning wood/sawdust Lab venting and exhaust systems (non radioactive Various Regulation 2.02, Section 2.3.11 materials) Ventilation systems
- Various Regulation 2.02, Section 2.3.12 bakeries & restaurants Washing or drying fabricated metal or glass; non Various Regulation 2.02, Section 2.3.15 VOC use; no oil or solid fuel Residential/domestic Various Regulation 2.02, Section 2.3.12 equipment Portable diesel orgasoline Various Regulation 2.02, Section2.3.23 storage tanks Diesel fuel storagetanks Various Regulation 2.02, Section 2.3.25 (emergency use only) Closed pressure storage 2 Regulation 2.02, Section 2.3.26 vessels
SCH Page 32 of34 03-31-2011

### PermitNo. 245-09-C (Rl) Plant ID 0072 InsignificantActivities Description Quantity Basis Portable tote tanks for raw Tote tanks are kept closedwhen not in use. Emission from tanks material shipment ofsolvent Various are negligible, and are accounted for byprocess material balance.

- based coatings Backup generators for emergency power.(< 500 2 Generators normal use is very low and HP <500 HP. hrs/year) Wastewater Pretreatment 1 Emissions insignificant system. FluidFill (hydraulic fluids, Emissions insignificant due to lowvaporpressure ofmaterials oil, anti-freeze) and Various used. Lubricating operations. Miscellaneous mainten-ance procedures includ-ing Various Negligible emissions lubrication, grinding, cleaning, woodworking, etc. Directheat exchangers <1 Various Regulation 2.02, Section 2.1.1 MMBtu/hr



### SCH a. Insignificant Activities are only those activities or processes falling into the general categories defined in District Regulation 2.02, Section 2, and not associated with a specific operation or process for which there is a specific regulation. Equipment associated with a specific operation or process (Emission Unit) shall be listed with the specific process even though there may be no applicable requirements. Information contained in the permit and permit summary shall clearly indicate that those items identified with negligible emissions have no applicable requirements. b. Activities identified in District Regulation 2.02, Section 2, may not require a permit and may be insignificant with regard to application disclosure requirements butmay still have generally applicable requirements that continue to apply to the source.
c. For all insignificant activities that emit regulated air pollutants for which the company has accepted a plant-wide synthetic minor limit, the company shall maintain sufficient records to calculate the emissions and report those emissions in the quarterly compliance reports and the annual emissions inventoryreport. d. The Insignificant Activities table is correct as ofthe date the permit was proposed for review by the USEPA, Region 4. The company shall submit an updated list of insignificant activities annually with the Title V 

### compliance certificationpursuant to DistrictRegulation 2.16, section 4.3.5.3.6. Page 33 of34 03-31-2011PermitNo. 245-09-C (R1) PlantID 0072

SCH e. In lieu ofrecording annual throughputs for each Insignificant Activity, the owner or operator may elect to report the Potential To Emit quantity listed in the Insignificant Activities table as the annual emission for each piece ofequipment, since the emissions from the source's InsignificantActivities are minor.

Page 34 of34 03-31-2011