January 27, 2006 

Compliance and Enforcement Division

Bay Area Air Quality Management District

939 Ellis Street

San Francisco, California 94109

Attn: Mr. James Guthrie - Director 

RE: MACT Semi-Annual Reporting for 

Period July 1, 2005 through December 31, 2005 

Dear Mr. Guthrie, 

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

NNN. The first report summarizes periods of startup, shutdown, and malfunction where 

actions taken were inconsistent with the plan in accordance with MACT requirements, 40 

CFR 63.10(d)(5) and 40 CFR 63.1386(c). The second report is the “Summary Report – 

Gaseous and Opacity Excess Emission and Continuous Monitoring System Performance” 

as required in 40 CFR 63.10(e)(3) and 40 CFR 63.1386(e). The third report is the 

“Gaseous and Opacity Excess Emission and Continuous Monitoring System Performance 

Report” as required in 40 CFR 63.10(e)(3) and 40 CFR 63.1386(e) if monitored 

parameters deviate more than 1% of the total operating time. Each report is labeled 

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

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

questions regarding this information, please contact our Facility Environmental Leader, 

Monte Schenken at (408) 235-1358. 

Sincerely, 

Pete Koska 

Plant Manager 

Owens Corning 

Santa Clara, California 

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

Inconsistent with SSM Plan

40 CFR 63 Subpart NNN

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

Owens Corning – Santa Clara Plant 

960 Central Expressway 

Santa Clara, CA 95050 

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

the facility Startup, Shutdown, and Malfunction Plan. 

Report: Periods of Deviation Startup, Shutdown, and Malfunction Where Actions 

Taken were Inconsistent with SSM Plan

40 CFR 63 Subpart NNN

Beginning October 14, 2005 at 14:30 and continuing until October 20, 2005 at 

17:30 the plant experienced an equipment malfunction that resulted in the plant 

not being able to electronically monitor the air temperature 18 to 24 inches above 

the glass crust temperature in the O-line Furnace. The crust conditions were 

monitored visually at least once per shift during this period, however the 

observations were not consistently documented. There were no crust loss events 

during this period. 

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

Print Name: Pete Koska 

Signature: 

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

Monitoring System Performance

40CFR63 Subpart NNN

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

Owens Corning – Santa Clara Plant 

960 Central Expressway 

Santa Clara, CA 95050 

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

control of HAP’s from the Fiberglass manufacturing process. Particulate matter is 

limited to 0.5 lb PM per ton of molten glass produced from the glass melting process and 

formaldehyde is limited to 1.2 lb per ton of molten glass produced during fiber forming 

and curing. 

Process Units: In general the fiberglass manufacturing process is composed of a glassmelting furnace that melts batch materials into glass. The molten glass is passed through 

a rotary spin (RS) forming process where a fine, glass fiber is produced. Binder is 

applied to the fiber as it forms a “pack” on the surface of a foraminous conveyor. Once 

collected, the pack passes through a curing and cooling process followed by final 

fabrication and packaging. Tables 1 and 2 define the manufacturing sources at this 

facility, including individual processes, control devices, and monitored parameters. 

<TABLE 1> 

 Process Control Device Monitored Parameter 

O 

Furnace Glass Melting Batch Wetting Water Flow 

Glass Melting Molten Glass Throughput 

Glass Melting Temperature above molten glass 

 

Line Forming Premix Formulation 

LOI 

Resin Free Formaldehyde 

Molten Glass Throughput 

Curing Incinerator Temperature 

 
<TABLE 2> 

 Process Control Device Monitored Parameter 

M 

Furnace Glass Melting Batch Wetting Water Flow 

Glass Melting Molten Glass Throughput 

Glass Melting Temperature above molten glass 

 

Line Forming Premix Formulation 

LOI 

Resin Free Formaldehyde 

Molten Glass Throughput 

Curing Charge 

Incinerator 

Discharge 

Incinerator 

Temperature 

 

Emission Data Summary / Operating Hours for Facility

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

M Furnace – 4416 hours 

M Line – 4191 hours 

O Furnace – 4416 hours 

O Line – 4328 hours 

Deviations: 

 Hours Deviation % Deviation

M Line Incinerator 1.57 0.04 

O Line High LOI 5.67 0.13 

O Line Batch Wetting 8.00 0.18 

Based on these operating hours and known deviations, there were no monitoring 

parameters over the 1% exceedance time. 
As the responsible official, I certify that the content of this report is accurate. 

Print Name: Pete Koska 

Signature: 

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

Performance 

40 CFR 63 Subpart NNN

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

Owens Corning – Santa Clara Plant 

960 Central Expressway 

Santa Clara, CA 95050 

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

malfunction or startup/shutdown: 

No instances of monitored parameter deviations were determined to be 

beyond the 1% trigger level for this report. 

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

Print Name: Pete Koska 

Signature: 

Title: Plant Leader 
July 19, 2006 

Compliance and Enforcement Division

Bay Area Air Quality Management District

939 Ellis Street

San Francisco, California 94109

Attn: Mr. James Guthrie - Director 

RE: MACT Semi-Annual Reporting for 

Period January 1, 2006 through June 30, 2006 

Dear Mr. Guthrie, 

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

NNN. The first report summarizes periods of startup, shutdown, and malfunction where 

actions taken were inconsistent with the plan in accordance with MACT requirements, 40 

CFR 63.10(d)(5) and 40 CFR 63.1386(c). The second report is the “Summary Report – 

Gaseous and Opacity Excess Emission and Continuous Monitoring System Performance” 

as required in 40 CFR 63.10(e)(3) and 40 CFR 63.1386(e). The third report is the 

“Gaseous and Opacity Excess Emission and Continuous Monitoring System Performance 

Report” as required in 40 CFR 63.10(e)(3) and 40 CFR 63.1386(e) if monitored 

parameters deviate more than 1% of the total operating time. Each report is labeled 

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

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

questions regarding this information, please contact our Facility Environmental Leader, 

Monte Schenken at (408) 235-1358. 

Sincerely, 

Pete Koska 

Plant Manager 

Owens Corning 

Santa Clara, California 

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

Inconsistent with SSM Plan

40 CFR 63 Subpart NNN

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

Owens Corning – Santa Clara Plant 

960 Central Expressway 

Santa Clara, CA 95050 

Based on requirements within the Startup, Shutdown, and Malfunction Plan, 

if the incinerator temperature falls below 13400 F for more than 15 minutes, the line 

production must be suspended. On 3/4/06, one of the M-line incinerators temperature 

dropped below 13400 F, the low temperature alarm failed, and for a period of 39 minutes 

line production continued. A breakdown report, # 04T11 was submitted to the 

BAAQMD along with the 10 day and 30 day reports. 

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

Plan

40 CFR 63 Subpart NNN

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

OMM Plan. 

 

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

Print Name: Pete Koska 

Signature: 

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

Monitoring System Performance

40CFR63 Subpart NNN

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

Owens Corning – Santa Clara Plant 

960 Central Expressway 

Santa Clara, CA 95050 

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

control of HAP’s from the Fiberglass manufacturing process. Particulate matter is 

limited to 0.5 lb PM per ton of molten glass produced from the glass melting process and 

formaldehyde is limited to 1.2 lb per ton of molten glass produced during fiber forming 

and curing. 

Process Units: In general the fiberglass manufacturing process is composed of a glassmelting furnace that melts batch materials into glass. The molten glass is passed through 

a rotary spin (RS) forming process where a fine, glass fiber is produced. Binder is 

applied to the fiber as it forms a “pack” on the surface of a foraminous conveyor. Once 

collected, the pack passes through a curing and cooling process followed by final 

fabrication and packaging. Tables 1 and 2 define the manufacturing sources at this 

facility, including individual processes, control devices, and monitored parameters. 

TABLE 1 

 Process Control Device Monitored Parameter 

O 

Furnace Glass Melting Batch Wetting Water Flow 

Glass Melting Molten Glass Throughput 

Glass Melting Temperature above molten glass 

 

Line Forming Premix Formulation 

LOI 

Resin Free Formaldehyde 

Molten Glass Throughput 

Curing Incinerator Temperature 

 
TABLE 2 

 Process Control Device Monitored Parameter 

M 

Furnace Glass Melting Batch Wetting Water Flow 

Glass Melting Molten Glass Throughput 

Glass Melting Temperature above molten glass 

 

Line Forming Premix Formulation 

LOI 

Resin Free Formaldehyde 

Molten Glass Throughput 

Curing Charge 

Incinerator 

Discharge 

Incinerator 

Temperature 

 

Emission Data Summary / Operating Hours for Facility

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

M Furnace – 4344 hours 

M Line – 4145 hours 

O Furnace – 4344 hours 

O Line – 4253 hours 

Deviations: 

 Hours Deviation % Deviation

M Line Incinerator 0.65 0.02 

Based on these operating hours and known deviations, there were no monitoring 

parameters over the 1% exceedance time. 

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

Print Name: Pete Koska 

Signature: 

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

Performance 

40 CFR 63 Subpart NNN

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

Owens Corning – Santa Clara Plant 

960 Central Expressway 

Santa Clara, CA 95050 

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

malfunction or startup/shutdown: 

No instances of monitored parameter deviations were determined to be 

beyond the 1% trigger level for this report. 

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

Print Name: Pete Koska 

Signature: 

Title: Plant Leader 
January 22, 2007 

Compliance and Enforcement Division

Bay Area Air Quality Management District

939 Ellis Street

San Francisco, California 94109

Attn: Mr. James Guthrie - Director 

RE: MACT Semi-Annual Reporting for 

Period July 1, 2006 through December 31, 2006 

Dear Mr. Guthrie, 

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

NNN. The first report summarizes periods of startup, shutdown, and malfunction where 

actions taken were inconsistent with the plan in accordance with MACT requirements, 40 

CFR 63.10(d)(5) and 40 CFR 63.1386(c). The second report is the “Summary Report – 

Gaseous and Opacity Excess Emission and Continuous Monitoring System Performance” 

as required in 40 CFR 63.10(e)(3) and 40 CFR 63.1386(e). The third report is the 

“Gaseous and Opacity Excess Emission and Continuous Monitoring System Performance 

Report” as required in 40 CFR 63.10(e)(3) and 40 CFR 63.1386(e) if monitored 

parameters deviate more than 1% of the total operating time. Each report is labeled 

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

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

questions regarding this information, please contact our Facility Environmental Leader, 

Monte Schenken at (408) 235-1358. 

Sincerely, 

Dan Cochran 

Plant Leader 

Owens Corning 

Santa Clara, California 

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

Inconsistent with SSM Plan

40 CFR 63 Subpart NNN

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

Owens Corning – Santa Clara Plant 

960 Central Expressway 

Santa Clara, CA 95050 

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

the facility Startup, Shutdown, and Malfunction Plan. 

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

(OMM) Plan.

40 CFR 63 Subpart NNN

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

OMM Plan. 

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

Print Name: Dan Cochran 

Signature: 

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

Monitoring System Performance

40CFR63 Subpart NNN

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

Owens Corning – Santa Clara Plant 

960 Central Expressway 

Santa Clara, CA 95050 

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

control of HAP’s from the Fiberglass manufacturing process. Particulate matter is 

limited to 0.5 lb PM per ton of molten glass produced from the glass melting process and 

formaldehyde is limited to 1.2 lb per ton of molten glass produced during fiber forming 

and curing. 

Process Units: In general the fiberglass manufacturing process is composed of a glassmelting furnace that melts batch materials into glass. The molten glass is passed through 

a rotary spin (RS) forming process where a fine, glass fiber is produced. Binder is 

applied to the fiber as it forms a “pack” on the surface of a foraminous conveyor. Once 

collected, the pack passes through a curing and cooling process followed by final 

fabrication and packaging. Tables 1 and 2 define the manufacturing sources at this 

facility, including individual processes, control devices, and monitored parameters. 

TABLE 1 

 Process Control Device Monitored Parameter 

O 

Furnace Glass Melting Batch Wetting Water Flow 

Glass Melting Molten Glass Throughput 

Glass Melting Temperature above molten glass 

 

Line Forming Premix Formulation 

LOI 

Resin Free Formaldehyde 

Molten Glass Throughput 

Curing Incinerator Temperature 

 
TABLE 2 

 Process Control Device Monitored Parameter 

M 

Furnace Glass Melting Batch Wetting Water Flow 

Glass Melting Molten Glass Throughput 

Glass Melting Temperature above molten glass 

 

Line Forming Premix Formulation 

LOI 

Resin Free Formaldehyde 

Molten Glass Throughput 

Curing Charge 

Incinerator 

Discharge 

Incinerator 

Temperature 

 

Emission Data Summary / Operating Hours for Facility

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

M Furnace – 4416 hours 

M Line – 4063.8 hours 

O Furnace – 4416 hours 

O Line – 4136.2 hours 

Deviations:

M-Line 

• High LOI 4.0 hours 0.10% 

Based on these operating hours and known deviations, there were no monitoring 

parameters over the 1% exceedance time. Since the total exceedance time for each 

parameter is less than 1%, no additional detail will be provided in this report. 

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

Print Name: Dan Cochran 

Signature: 

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

Performance 

40 CFR 63 Subpart NNN

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

Owens Corning – Santa Clara Plant 

960 Central Expressway 

Santa Clara, CA 95050 

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

malfunction or startup/shutdown: 

No instances of monitored parameter deviations were determined to be 

beyond the 1% trigger level for this report. 

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

Print Name: Dan Cohran 

Signature: 

Title: Plant Leader 
OWENS CORNING INSULATING SYSTEMS, LLC – SANTA CLARA 

960 CENTRAL EXPRESSWAY 

SANTA CLARA, CALIFORNIA 95050

 

July 23, 2007 

Compliance and Enforcement Division

Bay Area Air Quality Management District

939 Ellis Street

San Francisco, California 94109

Attn: Mr. James Guthrie - Director 

RE: MACT Semi-Annual Reporting for 

Period January 1, 2007 through June 30, 2007 

Dear Mr. Guthrie, 

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

NNN. The first report summarizes periods of startup, shutdown, and malfunction where 

actions taken were inconsistent with the plan in accordance with MACT requirements, 40 

CFR 63.10(d)(5) and 40 CFR 63.1386(c). The second report is the “Summary Report – 

Gaseous and Opacity Excess Emission and Continuous Monitoring System Performance” 

as required in 40 CFR 63.10(e)(3) and 40 CFR 63.1386(e). The third report is the 

“Gaseous and Opacity Excess Emission and Continuous Monitoring System Performance 

Report” as required in 40 CFR 63.10(e)(3) and 40 CFR 63.1386(e) if monitored 

parameters deviate more than 1% of the total operating time. Each report is labeled 

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

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

questions regarding this information, please contact our Facility Environmental Leader, 

Monte Schenken at (408) 235-1358. 

Sincerely, 

James Gerodimos 

Plant Leader 

Owens Corning Insulating Systems, LLC 

Santa Clara, California 

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

Inconsistent with SSM Plan

40 CFR 63 Subpart NNN

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

Owens Corning Insulating Systems, LLC – Santa Clara

960 Central Expressway 

Santa Clara, CA 95050 

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

actions taken were consistent with the SSM Plan. 

Report: Periods of Deviation from the Operations, maintenance and Monitoring 

(OMM) Plan

40 CFR 63 Subpart NNN

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

OMM Plan. 

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

Print Name: James Gerodimos 

Signature: 

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

Monitoring System Performance

40CFR63 Subpart NNN

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

Owens Corning Insulating Systems, LLC – Santa Clara

960 Central Expressway 

Santa Clara, CA 95050 

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

control of HAP’s from the Fiberglass manufacturing process. Particulate matter is 

limited to 0.5 lb PM per ton of molten glass produced from the glass melting process and 

formaldehyde is limited to 1.2 lb per ton of molten glass produced during fiber forming 

and curing. 

Process Units: In general the fiberglass manufacturing process is composed of a glassmelting furnace that melts batch materials into glass. The molten glass is passed through 

a rotary spin (RS) forming process where a fine, glass fiber is produced. Binder is 

applied to the fiber as it forms a “pack” on the surface of a foraminous conveyor. Once 

collected, the pack passes through a curing and cooling process followed by final 

fabrication and packaging. Tables 1 and 2 define the manufacturing sources at this 

facility, including individual processes, control devices, and monitored parameters. 

TABLE 1 

 Process Control Device Monitored Parameter 

O 

Furnace Glass Melting Batch Wetting Water Flow 

Glass Melting Molten Glass Throughput 

Glass Melting Temperature above molten glass 

 

Line Forming Premix Formulation 

LOI 

Resin Free Formaldehyde 

Molten Glass Throughput 

Curing Incinerator Temperature 

 
TABLE 2 

 Process Control Device Monitored Parameter 

M 

Furnace Glass Melting Batch Wetting Water Flow 

Glass Melting Molten Glass Throughput 

Glass Melting Temperature above molten glass 

 

Line Forming Premix Formulation 

LOI 

Resin Free Formaldehyde 

Molten Glass Throughput 

Curing Charge 

Incinerator 

Discharge 

Incinerator 

Temperature 

 

Emission Data Summary / Operating Hours for Facility

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

M Furnace – 4344 hours 

M Line – 3644 hours 

O Furnace – 4344 hours 

O Line – 3833 hours 

Deviations:

M-Line 

• High LOI 1 hour 0.03% 

Based on these operating hours and known deviations, there were no monitoring 

parameters over the 1% exceedance time. Since the total exceedance time for each 

parameter is less than 1%, no additional detail will be provided in this report. 

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

Print Name: James Gerodimos 

Signature: 

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

Performance 

40 CFR 63 Subpart NNN

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

Owens Corning Insulating Systems, LLC – Santa Clara

960 Central Expressway 

Santa Clara, CA 95050 

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

malfunction or startup/shutdown: 

No instances of monitored parameter deviations were determined to be 

beyond the 1% trigger level for this report. 

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

Print Name: James Gerodimos 

Signature: 

Title: Plant Leader 
OWENS CORNING INSULATING SYSTEMS, LLC – SANTA CLARA 

960 CENTRAL EXPRESSWAY 

SANTA CLARA, CALIFORNIA 95050

 

January 30, 2008 

Compliance and Enforcement Division

Bay Area Air Quality Management District

939 Ellis Street

San Francisco, California 94109

Attn: Mr. James Guthrie - Director 

RE: MACT Semi-Annual Reporting - July 1 through December 31, 2007 

Dear Mr. Guthrie, 

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

NNN. The first report summarizes periods of startup, shutdown, and malfunction where 

actions taken were inconsistent with the plan in accordance with MACT requirements, 40 

CFR 63.10(d)(5) and 40 CFR 63.1386(c). The second report is the “Summary Report – 

Gaseous and Opacity Excess Emission and Continuous Monitoring System Performance” 

as required in 40 CFR 63.10(e)(3) and 40 CFR 63.1386(e). The third report is the 

“Gaseous and Opacity Excess Emission and Continuous Monitoring System Performance 

Report” as required in 40 CFR 63.10(e)(3) and 40 CFR 63.1386(e) if monitored 

parameters deviate more than 1% of the total operating time. Each report is labeled 

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

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

questions regarding this information, please contact our Facility Environmental Leader, 

Monte Schenken at (408) 235-1358. 

Sincerely, 

James Gerodimos 

Plant Leader 

Owens Corning Insulating Systems, LLC – Santa Clara

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

Inconsistent with SSM Plan

40 CFR 63 Subpart NNN

Reporting Period: July 1 through December 31, 2007 

Owens Corning Insulating Systems, LLC – Santa Clara

960 Central Expressway 

Santa Clara, CA 95050 

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

actions taken were consistent with the SSM Plan. 

Report: Periods of Deviation from the Operations, maintenance and Monitoring 

(OMM) Plan

40 CFR 63 Subpart NNN

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

OMM Plan. 

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

Print Name: James Gerodimos 

Signature: 

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

Monitoring System Performance

40CFR63 Subpart NNN

Reporting Period: July 1 through December 31, 2007 

Owens Corning Insulating Systems, LLC – Santa Clara

960 Central Expressway 

Santa Clara, CA 95050 

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

control of HAP’s from the Fiberglass manufacturing process. Particulate matter is 

limited to 0.5 lb PM per ton of molten glass produced from the glass melting process and 

formaldehyde is limited to 1.2 lb per ton of molten glass produced during fiber forming 

and curing. 

Process Units: In general the fiberglass manufacturing process is composed of a glassmelting furnace that melts batch materials into glass. The molten glass is passed through 

a rotary spin (RS) forming process where a fine, glass fiber is produced. Binder is 

applied to the fiber as it forms a “pack” on the surface of a foraminous conveyor. Once 

collected, the pack passes through a curing and cooling process followed by final 

fabrication and packaging. Tables 1 and 2 define the manufacturing sources at this 

facility, including individual processes, control devices, and monitored parameters. 

TABLE 1 

 Process Control Device Monitored Parameter 

O 

Furnace Glass Melting Batch Wetting Water Flow 

Glass Melting Molten Glass Throughput 

Glass Melting Temperature above molten glass 

 

Line Forming Premix Formulation 

LOI 

Resin Free Formaldehyde 

Molten Glass Throughput 

Curing Incinerator Temperature 

 
TABLE 2 

 Process Control Device Monitored Parameter 

M 

Furnace Glass Melting Batch Wetting Water Flow 

Glass Melting Molten Glass Throughput 

Glass Melting Temperature above molten glass 

 

Line Forming Premix Formulation 

LOI 

Resin Free Formaldehyde 

Molten Glass Throughput 

Curing Charge 

Incinerator 

Discharge 

Incinerator 

Temperature 

 

Emission Data Summary / Operating Hours for Facility

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

M Furnace – 4416 hours 

M Line – 3894 hours 

O Furnace – 4416 hours 

O Line – 4036 hours 

Deviations:

M-Line 

• High LOI 0.33 hours 0.01% 

Based on these operating hours and known deviations, there were no monitoring 

parameters over the 1% exceedance time. Since the total exceedance time for each 

parameter is less than 1%, no additional detail will be provided in this report. 

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

Print Name: James Gerodimos 

Signature: 

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

Performance 

40 CFR 63 Subpart NNN

Reporting Period: July 1 through December 31, 2007 

Owens Corning Insulating Systems, LLC – Santa Clara

960 Central Expressway 

Santa Clara, CA 95050 

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

malfunction or startup/shutdown: 

No instances of monitored parameter deviations were determined to be 

beyond the 1% trigger level for this report. 

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

Print Name: James Gerodimos 

Signature: 

Title: Plant Leader 
OWENS CORNING INSULATING SYSTEMS, LLC – SANTA CLARA 

960 CENTRAL EXPRESSWAY 

SANTA CLARA, CALIFORNIA 95050

 

July 10, 2008 

Compliance and Enforcement Division

Bay Area Air Quality Management District

939 Ellis Street

San Francisco, California 94109

Attn: Mr. James Guthrie - Director 

RE: MACT Semi-Annual Reporting for 

Period January 1, 2008 through June 30, 2008 

Dear Mr. Guthrie, 

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

NNN. The first report summarizes periods of startup, shutdown, and malfunction where 

actions taken were inconsistent with the plan in accordance with MACT requirements, 40 

CFR 63.10(d)(5) and 40 CFR 63.1386(c). The second report is the “Summary Report – 

Gaseous and Opacity Excess Emission and Continuous Monitoring System Performance” 

as required in 40 CFR 63.10(e)(3) and 40 CFR 63.1386(e). The third report is the 

“Gaseous and Opacity Excess Emission and Continuous Monitoring System Performance 

Report” as required in 40 CFR 63.10(e)(3) and 40 CFR 63.1386(e) if monitored 

parameters deviate more than 1% of the total operating time. Each report is labeled 

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

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

questions regarding this information, please contact our Facility Environmental Leader, 

Monte Schenken at (408) 235-1358. 

Sincerely, 

James Gerodimos 

Plant Leader 

Owens Corning Insulating System, LLC 

Santa Clara, California 

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

Inconsistent with SSM Plan

40 CFR 63 Subpart NNN

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

Owens Corning Insulating Systems, LLC – Santa Clara

960 Central Expressway 

Santa Clara, CA 95050 

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

actions taken were consistent with the SSM Plan. 

Report: Periods of Deviation from the Operations, maintenance and Monitoring 

(OMM) Plan

40 CFR 63 Subpart NNN

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

OMM Plan. 

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

Print Name: James Gerodimos_________

Signature: 

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

Monitoring System Performance

40CFR63 Subpart NNN

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

Owens Corning Insulating Systems, LLC – Santa Clara

960 Central Expressway 

Santa Clara, CA 95050 

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

control of HAP’s from the Fiberglass manufacturing process. Particulate matter is 

limited to 0.5 lb PM per ton of molten glass produced from the glass melting process and 

formaldehyde is limited to 1.2 lb per ton of molten glass produced during fiber forming 

and curing. 

Process Units: In general the fiberglass manufacturing process is composed of a glassmelting furnace that melts batch materials into glass. The molten glass is passed through 

a rotary spin (RS) forming process where a fine, glass fiber is produced. Binder is 

applied to the fiber as it forms a “pack” on the surface of a foraminous conveyor. Once 

collected, the pack passes through a curing and cooling process followed by final 

fabrication and packaging. Tables 1 and 2 define the manufacturing sources at this 

facility, including individual processes, control devices, and monitored parameters. 

TABLE 1 

 Process Control Device Monitored Parameter 

O 

Furnace Glass Melting Batch Wetting Water Flow 

Glass Melting Molten Glass Throughput 

Glass Melting Temperature above molten glass 

 

Line Forming Premix Formulation 

LOI 

Resin Free Formaldehyde 

Molten Glass Throughput 

Curing Incinerator Temperature 

 
TABLE 2 

 Process Control Device Monitored Parameter 

M 

Furnace Glass Melting Batch Wetting Water Flow 

Glass Melting Molten Glass Throughput 

Glass Melting Temperature above molten glass 

 

Line Forming Premix Formulation 

LOI 

Resin Free Formaldehyde 

Molten Glass Throughput 

Curing Charge 

Incinerator 

Discharge 

Incinerator 

Temperature 

 

Emission Data Summary / Operating Hours for Facility

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

M Furnace – 4344 hours 

M Line – 2981 hours 

O Furnace – 4344 hours 

O Line – 2990 hours 

Deviations:

No deviation of a monitored parameter occurred during this reporting period. 

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

Print Name: James Gerodimos__ 

Signature: 

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

Performance 

40 CFR 63 Subpart NNN

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

Owens Corning Insulating Systems, LLC – Santa Clara

960 Central Expressway 

Santa Clara, CA 95050 

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

malfunction or startup/shutdown: 

No instances of monitored parameter deviations were determined for this 

reporting period. 

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

Print Name: James Gerodimos 

Signature: 

Title: Plant Leader 
OWENS CORNING INSULATING SYSTEMS, LLC – SANTA CLARA 

960 CENTRAL EXPRESSWAY 

SANTA CLARA, CALIFORNIA 95050

 

January 23, 2009 

Compliance and Enforcement Division

Bay Area Air Quality Management District

939 Ellis Street

San Francisco, California 94109

Attn: Mr. James Guthrie - Director 

RE: MACT Semi-Annual Reporting - July 1 through December 31, 2008 

Dear Mr. Guthrie, 

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

NNN. The first report summarizes periods of startup, shutdown, and malfunction where 

actions taken were inconsistent with the plan in accordance with MACT requirements, 40 

CFR 63.10(d)(5) and 40 CFR 63.1386(c). The second report is the “Summary Report – 

Gaseous and Opacity Excess Emission and Continuous Monitoring System Performance” 

as required in 40 CFR 63.10(e)(3) and 40 CFR 63.1386(e). The third report is the 

“Gaseous and Opacity Excess Emission and Continuous Monitoring System Performance 

Report” as required in 40 CFR 63.10(e)(3) and 40 CFR 63.1386(e) if monitored 

parameters deviate more than 1% of the total operating time. Each report is labeled 

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

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

questions regarding this information, please contact our Facility Environmental Leader, 

Monte Schenken at (408) 235-1358. 

Sincerely, 

James Gerodimos 

Plant Leader 

Owens Corning Insulating Systems, LLC – Santa Clara

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

Inconsistent with SSM Plan

40 CFR 63 Subpart NNN

Reporting Period: July 1 through December 31, 2008 

Owens Corning Insulating Systems, LLC – Santa Clara

960 Central Expressway 

Santa Clara, CA 95050 

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

actions taken were consistent with the SSM Plan. 

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

(OMM) Plan

40 CFR 63 Subpart NNN

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

OMM Plan. 

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

Print Name: James Gerodimos 

Signature: 

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

Monitoring System Performance

40CFR63 Subpart NNN

Reporting Period: July 1 through December 31, 2008 

Owens Corning Insulating Systems, LLC – Santa Clara

960 Central Expressway 

Santa Clara, CA 95050 

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

control of HAP’s from the Fiberglass manufacturing process. Particulate matter is 

limited to 0.5 lb PM per ton of molten glass produced from the glass melting process and 

formaldehyde is limited to 1.2 lb per ton of molten glass produced during fiber forming 

and curing. 

Process Units: In general the fiberglass manufacturing process is composed of a glassmelting furnace that melts batch materials into glass. The molten glass is passed through 

a rotary spin (RS) forming process where a fine, glass fiber is produced. Binder is 

applied to the fiber as it forms a “pack” on the surface of a foraminous conveyor. Once 

collected, the pack passes through a curing and cooling process followed by final 

fabrication and packaging. Tables 1 and 2 define the manufacturing sources at this 

facility, including individual processes, control devices, and monitored parameters. 

TABLE 1 

 Process Control Device Monitored Parameter 

O 

Furnace Glass Melting Batch Wetting Water Flow 

Glass Melting Molten Glass Throughput 

Glass Melting Temperature above molten glass 

 

Line Forming Premix Formulation 

LOI 

Resin Free Formaldehyde 

Molten Glass Throughput 

Curing Incinerator Temperature 

 
TABLE 2 

 Process Control Device Monitored Parameter 

M 

Furnace Glass Melting Batch Wetting Water Flow 

Glass Melting Molten Glass Throughput 

Glass Melting Temperature above molten glass 

 

Line Forming Premix Formulation 

LOI 

Resin Free Formaldehyde 

Molten Glass Throughput 

Curing Charge 

Incinerator 

Discharge 

Incinerator 

Temperature 

 

Emission Data Summary / Operating Hours for Facility

For the period July 1 through December 31, 2008 the operating hours are: 

M Furnace – 4416 hours 

M Line – 3438.7 hours 

O Furnace – 4416 hours 

O Line – 4009.3 hours 

Deviations:

O-Line 

• High LOI 2.0 hours 0.05% 

Based on these operating hours and known deviations, there were no monitoring 

parameters over the 1% exceedance time. Since the total exceedance time for each 

parameter is less than 1%, no additional detail will be provided in this report. 

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

Print Name: James Gerodimos 

Signature: 

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

Performance 

40 CFR 63 Subpart NNN

Reporting Period: July 1 through December 31, 2008 

Owens Corning Insulating Systems, LLC – Santa Clara

960 Central Expressway 

Santa Clara, CA 95050 

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

malfunction or startup/shutdown: 

No instances of monitored parameter deviations were determined to be 

beyond the 1% trigger level for this report. 

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

Print Name: James Gerodimos 

Signature: 

Title: Plant Leader 





OWENS CORNING INSULATING SYSTEMS, LLC – SANTA CLARA 

960 CENTRAL EXPRESSWAY 

SANTA CLARA, CALIFORNIA 95050

 

January 18, 2010 

Compliance and Enforcement Division

Bay Area Air Quality Management District

939 Ellis Street

San Francisco, California 94109

Attn: Mr. James Guthrie - Director 

RE: MACT Semi-Annual Reporting - July 1 through December 31, 2009 

Dear Mr. Guthrie, 

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

NNN. The first report summarizes periods of startup, shutdown, and malfunction where 

actions taken were inconsistent with the plan in accordance with MACT requirements, 40 

CFR 63.10(d)(5) and 40 CFR 63.1386(c). The second report is the “Summary Report – 

Gaseous and Opacity Excess Emission and Continuous Monitoring System Performance” 

as required in 40 CFR 63.10(e)(3) and 40 CFR 63.1386(e). The third report is the 

“Gaseous and Opacity Excess Emission and Continuous Monitoring System Performance 

Report” as required in 40 CFR 63.10(e)(3) and 40 CFR 63.1386(e) if monitored 

parameters deviate more than 1% of the total operating time. Each report is labeled 

appropriately and is for the period July 1 through December 31, 2009. 

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

questions regarding this information, please contact our Facility Environmental Leader, 

Monte Schenken at (408) 235-1358. 

Sincerely, 

James Gerodimos 

Plant Leader 

Owens Corning Insulating Systems, LLC – Santa Clara

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

Inconsistent with SSM Plan

40 CFR 63 Subpart NNN

Reporting Period: July 1 through December 31, 2009 

Owens Corning Insulating Systems, LLC – Santa Clara

960 Central Expressway 

Santa Clara, CA 95050 

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

actions taken were consistent with the SSM Plan. 

Report: Periods of Deviation from the Operations, maintenance and Monitoring 

(OMM) Plan

40 CFR 63 Subpart NNN

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

OMM Plan. 

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

Print Name: James Gerodimos 

Signature: 

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

Monitoring System Performance

40CFR63 Subpart NNN

Reporting Period: July 1 through December 31, 2009 

Owens Corning Insulating Systems, LLC – Santa Clara

960 Central Expressway 

Santa Clara, CA 95050 

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

control of HAP’s from the Fiberglass manufacturing process. Particulate matter is 

limited to 0.5 lb PM per ton of molten glass produced from the glass melting process and 

formaldehyde is limited to 1.2 lb per ton of molten glass produced during fiber forming 

and curing. 

Process Units: In general the fiberglass manufacturing process is composed of a glassmelting furnace that melts batch materials into glass. The molten glass is passed through 

a rotary spin (RS) forming process where a fine, glass fiber is produced. Binder is 

applied to the fiber as it forms a “pack” on the surface of a foraminous conveyor. Once 

collected, the pack passes through a curing and cooling process followed by final 

fabrication and packaging. Tables 1 and 2 define the manufacturing sources at this 

facility, including individual processes, control devices, and monitored parameters. 

TABLE 1 

 Process Control Device Monitored Parameter 

O 

Furnace Glass Melting Batch Wetting Water Flow 

Glass Melting Molten Glass Throughput 

Glass Melting Temperature above molten glass 

 

Line Forming Premix Formulation 

LOI 

Resin Free Formaldehyde 

Molten Glass Throughput 

Curing Incinerator Temperature 

 
TABLE 2 

 Process Control Device Monitored Parameter 

M 

Furnace Glass Melting Batch Wetting Water Flow 

Glass Melting Molten Glass Throughput 

Glass Melting Temperature above molten glass 

 

Line Forming Premix Formulation 

LOI 

Resin Free Formaldehyde 

Molten Glass Throughput 

Curing Charge 

Incinerator 

Discharge 

Incinerator 

Temperature 

 

Emission Data Summary / Operating Hours for Facility

For the period July 1 through December 31, 2009 the operating hours are: 

M Furnace – 4284 hours 

M Line – 2633.2 hours 

O Furnace – 4416 hours 

O Line – 4291.7 hours 

Deviations:

O-Line 

• High LOI 2.25 hours 0.05% 

Based on these operating hours and known deviations, there were no monitoring 

parameters over the 1% exceedance time. Since the total exceedance time for each 

parameter is less than 1%, no additional detail will be provided in this report. 

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

Print Name: James Gerodimos 

Signature: 

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

Performance 

40 CFR 63 Subpart NNN

Reporting Period: July 1 through December 31, 2009 

Owens Corning Insulating Systems, LLC – Santa Clara

960 Central Expressway 

Santa Clara, CA 95050 

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

malfunction or startup/shutdown: 

No instances of monitored parameter deviations were determined to be 

beyond the 1% trigger level for this report. 

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

Print Name: James Gerodimos 

Signature: 

Title: Plant Leader