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Startup, Shutdown and Malfunction Plan 

In Accordance with Brick and Structural Clay 

National Emission Standard for Hazardous Air Pollutants 

Bill Tudor 

For 

BORAL BRICKS 

TERRE HAUTE FACILITY 

TERRE HAUTE, INDIANA 

LAST REVISED 

February 2008 

• 

Responsible Official Signature 

Regional Production Manager Date 
Revision to SSMP: 

) Original SMMP 

Date of Revision Reason for Revision 

February 2008 

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Startup, Shutdown and Malfunction Plan 

SECTION 1.0- INTRODUCTION 

Boral Bricks 

Terre Haute Plant 

This Startup, Shutdown, and Malfunction Plan (SSMP) has been developed to meet the 

requirements found in the National Emission Standard for Hazardous Air Pollutants (NESHAP) 

codified in 40 CFR Part 63, Subpart A {§63.6(e)}, Subpart JJJJJ {§63.8420(c)}and Section 

D.3.13 of the current permit, T 167-23205-00139. This SSMP covers the tunnel kiln (EU02), 

which is the affected source in the Subpart JJJJJ, and the Hellmich dry hydrated lime injection 

baghouse system CDOl (DIFF). 

At all times, including periods of startup, shutdown, and malfunction, Boral Bricks Terre Haute 

(Boral Bricks) will operate and maintain any air pollution control equipment and monitoring 

equipment that is used to meet the standard in a manner consistent with safety and good air 

pollution control practices for minimizing emissions to the levels required by the relevant 

standards (i.e., meet the emission standard or comply with the SSMP). Determination of whether 

such operation and maintenance procedures are being used will be based on information that may 

include, but is not limited to, monitoring results, review of operation and maintenance 

procedures (e.g. the SSMP), review of operation and maintenance records, and inspection of the 

source. 

Malfunctions will be corrected as soon as practicable after their occurrence in accordance with 

this SSMP. To the extent that an unexpected event arises during a startup, shutdown, or 

malfunction, Boral Bricks will comply by minimizing emissions during such a startup, 

shutdown, and malfunction event consistent with safety and good air pollution control practices. 

The remainder of this document summarizes the procedures that will be followed during periods 

when the kiln and control device are being started, shutdown, and during malfunctions. Boral 

Bricks must record each start-up, shutdown, or malfunction period and document any additional 

information required by the regulation. Examples of forms that can be used for these instances 

have been included in this S SMP. 

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Startup, Shutdown and Malfunction Plan 

SECTION 2.0- PURPOSE 

Boral Bricks 

Terre Haute Plant 

Under 40 CFR 63.6(e), Boral Bricks is required to develop and implement for the Terre Haute 

kiln and control device a written SSMP that describes, in detail: (1) procedures for operating and 

maintaining the source during periods of startup, shutdown, and malfunction; (2) a program of 

corrective action for malfunctioning process; and (3) the air pollution control and monitoring 

equipment used to comply with the relevant standard. The purpose of the SSMP is to: 

(A) Ensure that, at all times, Boral Bricks operates and maintains air pollution control and 

monitoring equipment in a manner consistent with safety and good air pollution control practices 

for minimizing emissions to the levels required by the relevant standards; 

(B) Ensure that Boral Bricks is prepared to correct malfunctions as soon as practicable after their 

occurrence in order to minimize excess emissions of hazardous air pollutants; and 

(C) Reduce the reporting burden associated with periods of startup, shutdown, and malfunction 

(including corrective action taken to restore malfunctioning process and air pollution control 

equipment to its normal or usual manner of operation). 

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Startup, Shutdown and Malfunction Plan Boral Bricks 

Terre Haute Plant 

) SECTION 3.0- REGULATORY ANALYSIS 

) _/ 

The general regulatory requirements cited below are addressed in this plan: 

3.1 

e: §§63.6(e)(3) of Subpart A, General Provisions and 63.8420(c) of Subpart JJJJJ requires 

that Boral Bricks develop and implement a SSMP for operations used to comply with the 

Brick and Structural Clay NESHAP. This SSMP is intended to meet the requirements for 

Boral Bricks Terre Haute kiln operations. 

i'l §63.6(e)(3) of Subpart A, General Provisions, requires Boral Bricks to describe the 

corrective action that will be taken if a malfunction occurs at an affected process, air 

pollution control device or monitoring equipment. 

i'l In addition to the requirements to develop and implement a written SSMP, Boral Bricks 

is also required under §63.6(e)(3)(vii) to perform the following activities or functions: 

Keep records of any malfunction event that occurs and keep records of the actions 

taken to minimize emissions during the event. 

Submit reports if procedures taken during the event are not consistent with the 

procedures that are included in the SSMP and excess emissions occurred. 

Revise the SSMP if a malfunction occurs that has not been described within this 

SSMP or procedures for corrective action have not been adequately described. 

Update the plan if requested by EPA or the appropriate State or Local Air 

Pollution Control Authority. 

Definition of "Malfunction" 

During the course of normal operations, Boral Bricks may experience malfunction events. 

Please be aware that facilities may use a different definition of the term "malfunction" than the 

regulatory definition. The General Provisions define a "malfunction" as: 

Any sudden, infrequent, and not reasonably preventable failure of air 

pollution control and monitoring equipment, process equipment, or a 

process to operate in a normal or usual manner which causes, or has the 

potential to cause, the emission limitations in an applicable standard to 

be exceeded. (§63.2). 

As stated above, a malfunction, as defined under Part 63, must have the potential to cause an 

exceedance in the emission limitations of the standard. This plan, however, is designed to 

document all upsets and to determine whether or not they meet the definition of a "malfunction" 

under the rule. 

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Startup, Shutdown and Malfunction Plan Boral Bricks 

Terre Haute Plant 

Boral Bricks also has a separate plan for routine maintenance of the Terre Haute kiln process 

equipment and control device covered under the Brick and Structural Clay NESHAP that is 

called our Operating, Monitoring, and Maintenance Plan (OMMP). According to our OMMP, 

routine maintenance operations must be performed in accordance with the equipment 

manufacturer's specifications and recommendations, as well as the procedures specific to Boral 

Bricks that are detailed in our OMMP. 

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Startup, Shutdown and Malfunction Plan Boral Bricks 

Terre Haute Plant 

SECTION 4.0- AFFECTED SOURCES AND CONTROL DEVICES 

This plan covers the following devices: 

General Description: 

Affected Source: 

Capture/Control/Monitoring Device ID: 

Brief Description of System: 

Terre Haute Tunnel Kiln Controlled by Dry 

Hydrated Lime Injection Baghouse 

Terre Haute Tunnel Kiln (EU02) 

Dry Hydrated Lime Injection Baghouse System 

CDOI (DIFF) 

The Terre Haute tunnel kiln is a landfill gas with natural gas backup kiln designed to produce 26 

tons of fired brick per hour. Due to the site-wide potential emissions ofHF, HCl and total HAP, 

the Boral Bricks complex is a major source of HAP. 

The Terre Haute tunnel kiln was constructed after the promulgation date of July 22, 2002, and 

thus the kiln must comply with the "new source MACT requirements" that are contained in 40 

CFR Part 63, Subpart JJJJJ. The existing source MACT requirements require the kiln to meet 

the following limits: 

HF- 90% control or 0.057lb/ton (0.029 kg/Mg) 

HCl - 85% control or 0.056 lb/ton (0.028 kg/Mg) 

PM- 0.12 lb/ton (O.XX kg/Mg) (Method 5 filterable PM) 

VE: No Visible Emissions per Method 22 

Boral Bricks Terre Haute elected to add a Hellmich dry injection baghouse system (DIFF) in 

order to comply with the above limits . 

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Startup, Shutdown and Malfunction Plan Boral Bricks 

Terre Haute 

5.0 PROCEDURES FOR STARTUP, SHUTDOWNS, & MALFUNCTIONS 

This section includes a description of Boral Terre Haute standard procedures for starting the 

tunnel kiln (EU02), and reagent injection baghouse system, shutting down the kiln and reagent 

injection baghouse system, and for dealing with malfunctions that occur. For the purposes of 

this plan, the malfunctions include only those incidents that have the potential to cause an 

exceedance of the emission or operating limits. These situations would include: 

o A situation that causes the emissions from Kiln 1 (EU02) to bypass the control 

device (DIFF) be vented directly to the atmosphere; and 

o A situation that causes the reagent injection baghouse system to fail, thus 

increasing emissions above the NESHAP limits. 

o An occurrence that causes the operating limits to be exceeded. 

o Failure of the electronic monitoring system. 

In general, the focus of our procedures is to protect both the integrity of the control system and 

reduce the emissions to the atmosphere. Boral believes that both are critical to ensuring the 

long-term emission reduction ability of the system. In addition, the safety of plant personnel and 

visitors is always the first priority. 

) To balance these, Boral follows the following general principles: 

• The exhaust from the kiln is vented through the control device when the stack 

temperature is within the acceptable range. Venting at too low a temperature could cause 

moisture to enter the system and cause the lime to solidify. Venting at too high a 

temperature could damage the bags which would lead to visible and gaseous emissions. 

[It should be noted that Boral uses bags appropriate for the expected temperature ranges 

to be encountered]. 

• There must be a clear path though the system for the exhaust to be vented through the 

control. Exhausting when there is no clear path (e.g., dampers closed to all cleaning 

modules) would damage the control, creating potential safety issues and potentially 

damaging the integrity of the cleaning process. 

• The lime feed into the control is continuous, unless feeding additional lime could damage 

the system. For example, the lime flow would be halted if there is not sufficient flow 

since the lime needs sufficient air flow to keep the particles suspended and to avoid 

blockages. 

All of these principles were considered when the procedures were developed. 

This plan includes three procedure for start-up, a regular shutdown procedure, an emergency 

shutdown procedure (i.e., "hard shutdown") and numerous malfunction scenarios. 

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BORAL BRICKS 

Terre Haute 

SECTION 5.1- STARTUP PROCEDURES 

This section describes the start-up procedures for the Lingl kiln and the Hellmich DIFF. The 

kiln is due to startup in February 2008. The Hellmich DIFF will be brought online initially while 

the kiln was in operation (when the temperature of the flue gas is in the right temperature range). 

The standard start-up procedure for the kiln and control device is described on the following 

page. 

This same general procedure is followed for each start-up of the control/kiln. However, some 

steps are skipped if previously completed. 

In general, there are three possible start-up scenarios that could occur: 

• Cold kiln, cold control. As stated above, this scenario has yet to occur since the control 

was started while the kiln was "hot." The procedure on the next page is based on a "cold 

kiln/cold control" start. 

• Hot kiln, cold control. The procedure on the next page was followed, except that the 

exhaust air was immediately "up to temperature." (Initial System Start) 

• Hot kiln, hot control. This would be a re-start after some event caused the control to 

switch to bypass. Other than bypasses that occur for routine maintenance, an example of 

these events would be a brief power outage that causes the system dampers to close. In 

this event, the restart procedure would still run through the system checks, but most steps 

would be shortened since both the baghouse and the exhaust would be up to the correct 

temperature. 

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Terre Haute II STARTUP- NORMAL II 

The hot and cold startup procedures for the kiln and lime injection baghouse system are outlined 

below. Boral Bricks will document each time the system undergoes startup. 

Steps for Hot Startup Notes 

1. Reset the main gas valve and restart air 

compressor if necessary. 

2. Start signal is initiated from the kiln controls. 

3. The kiln exhaust fan at the D IFF starts in 

bypass mode and goes through a purge cycle 

of the kiln for safety. 

4. The burners are ignited and the DIFF System must be at a constant 

switches immediately to the full automatic temperature of 284°F before the DIFF 

mode (full operation). The DIFF runs for one can be started. 

hour while checking to see that the exhaust In the event that the minimum 

temperature is above the minimum for proper temperature is not reached, the kiln 

operation. When the proper temperature is will normally not be hot enough for 

reached, the DIFF will be placed back into the normal resumption of processing 

automatic operation and production will ofbrick. No new product will be 

resume. introduced to the kiln and thus 

emissions will be minimized during 

this time. 

5. Heat kiln up until the temperature is 

sufficient to begin processing brick and start 

the pusher process. 

6. Check DIFF operation and insure that all 

controls are properly operating. 

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Steps for Cold Startup 

1. Reset the main gas valve and restart air 

compressor if necessary. 

2. Start signal is initiated from the kiln controls. 

3. The kiln exhaust fan at the DIFF starts in bypass 

mode and goes through a purge cycle of the kiln 

for safety. 

4. The burners are ignited. When the proper 

temperature is reached, the DIFF will be placed 

into automatic operation and production will 

commence. 

5. Heat kiln up until the temperature is sufficient 

to begin processing brick and start the pusher 

process. 

6. Check DIFF operation and insure that all 

controls are properly operating. 

Steps Taken to Minimize Emissions: 

Notes 

No new product will be introduced to the 

kiln until proper temperatures are 

reached and thus emissions will be 

minimized during this time. 

1. When there is any type of malfunction of the kiln that results in the kiln 

stoppage such as interruption of natural gas supply or electrical power, 

no new product is placed into or comes out of the kiln. 

2. No new product is processed in the kiln until a proper operational 

temperature is reached for pushing new product into the kiln. The 

minimum temperature required for the DIFF operation will be reached 

before the kiln is at a proper temperature for introduction of new 

product. With no new product being introduced to the kiln, the level of 

emissions will be continually decreasing until the pushing of new 

production resumes. 

3. In order to minimize emissions, the fresh lime metering screw should be set to the 

maximum metering performance so that the baghouses fill with lime as quickly as 

possible. Once the reaction product cellular wheel sluice is removing material, you can 

assume that there is enough recirculated material in the process. The fresh lime meter 

can now be set to the normal flowrate setting (level established during the performance 

test). 

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SECTION 5.2- SHUTDOWN PROCEDURES 

II SHUTDOWN- NORMAL 

There is generally minimal need for shutting down the control and/or the kiln. The kiln tends to 

remain in operation. If the control and/or the kiln need to be stopped, the following general 

principles impact the procedures 

• Unless a safety issue or control device integrity issue occurs, the kiln will continue to 

vent through the control device until the exhaust reaches the low temperature set point 

(284 °F). 

• Unless safety to Boral personnel and visitors or ongoing integrity of the control is 

threatened, all procedures will be aimed at minimizing avoidable emissions of HAP to the 

atmosphere. 

If the control must be taken offline for routine maintenance, the time will be documented as 

being part of the time allowed under the Routine Maintenance Bypass Allowance in Boral's 

permit. 

5.2.1 Normal Shutdown Procedures 

The normal shutdown procedures for the kiln and lime injection baghouse system are listed 

below. Boral Bricks will document each time the system is shutdown. 

Steps for Kiln Shutdown 

1. Initiate shutdown through the kiln controls. 

2. The burners are stopped at the kiln and the 

pushing of new product into the kiln is 

immediately stopped. 

Steps for DIFF Shutdown Notes 

1. Initiate shutdown through the kiln 

controls. 

2. The DIFF damper goes to the bypass 

position and the fan stops immediately. 

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Steps for Long Term DIFF Shut Down 

Following is the procedure for shutting 

the system down for a long period of time 

or if entrance inside the system is 

required. 

1. The fuel sources to the kiln will be 

stopped. Unless a safety issue or control 

device integrity issue occurs, the kiln will 

continue to vent through the control 

device until the exhaust reaches the low 

temperature set point (284 °F) 

2. When kiln exhaust temperature is 

below low temperature set point, the 

control will be placed in bypass mode. 

3. The filter bags will be cleaned to 

remove excess lime 

4. If the control is to sit for an extended 

period, the hoppers in the bottom of the 

baghouse will be emptied to the waste silo 

and the waste lime will be disposed. 

At this point the control can be shut down 

completely for maintenance. 

Steps Taken to Minimize Emissions: 

Notes 

1. The introduction of new product into the kiln is stopped at the same time 

that the burners are stopped. 

2. The kiln will continue to vent through the control device until the exhaust reaches the 

low temperature set point (284 °F). This insures that the exhaust will be cleaned as long 

as the raw gas may contain harmful emissions. 

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5 .2.2 Emergency Shutdown Procedures 

II SHUTDOWN- EMERGENCY II 

The emergency shutdown procedures for the kiln and reagent injection baghouse system are 

listed below. Boral Terre Haute will document each time there is an emergency shutdown. 

Emergency shutdown is triggered automatically by the system when it senses conditions that can 

lead to imminent danger or damage to equipment. Emergency stops buttons are also located in 

several areas of the plant. Emergency shutdown is exactly the same as is listed previously in 

section 5.2.1. 

Steps Taken to Minimize Emissions: 

• In an emergency shutdown, safety is the primary issue. Boral Terre Haute will work to 

minimize emissions to the extent practicable. 

• Maintenance will determine whether the shutdown was due to true malfunction of the 

system or due to a malfunction of a sensor. The kiln will be stopped if the shutdown is 

due to a baghouse malfunction that stops the exhaust fan or if the malfunction is a part of 

the kiln control system. If the emergency pertains to only the baghouse, only the 

baghouse will cease operation and the system will operate in bypass until the situation is 

controlled. 

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SECTION 5.3- MALFUNCTION PROCEDURES 

II MALFUNCTIONS- OVERVIEW II 

This section describes the overall approach to identifying the cause of a malfunction and 

correcting it. It should be noted that Boral-Terre Haute has a responsibility to assure worker 

safety and to comply with all NFP A safety requirements. This will often affect the approach that 

must be taken to rectify a malfunction situation. Boral-Terre Haute will work to minimize 

emissions at all times, while ensuring all other health and safety requirements are also met. 

Any malfunction of the baghouse initiates an alarm: 

Hellmich DIFF has 2 categories of alarms: 

1. WARNING ALARM: This is an audible alarm and a light will flash. The alarm devices are 

located both at the baghouse and inside the main plant facility to ensure that prompt attention 

can be given. There are a number of malfunctions that can trigger a fault within the system 

and trigger an alarm. Depending on the nature of the malfunction, the baghouse may or may 

not go to bypass immediately. Most of the faults begin as warnings of a minor malfunction 

that if not given attention will lead to a bypass of the system after a predetermined time 

period. The only malfunctions that lead to an immediate switch to bypass are loss ofl.D. fan, 

loss of compressed air or loss of power. Too high or too low temperature to the baghouse 

will also lead to a bypass if they are not corrected. The graphic display will show the nature 

of the malfunction and indicate the part of the device that needs attention. 

2. CRITICAL ALARM: An alarm that is triggered by an event that puts personnel safety or 

equipment integrity in danger. A critical alarm will immediately cause the system to go into 

bypass and shutdown. This alarm is only triggered when either personnel are in danger or 

the integrity of the system could be compromised. Protecting the integrity of the system will 

ensure a more rapid return to normal operation of the control. In general, there is at least one 

system or indication alarm that would indicate problems before they would rise to the level 

of a critical alarm. 

Boral's approach for minimizing emissions during any malfunctions are based on the following 

concepts: 

1. Minimize the amount of time the system is shut down. To minimize the amount oftime the 

kilns and the DIFF systems are shutdown, Boral will: 

a. Respond as quickly as possible to each WARNING ALARM. 

b. Maintain spare parts on hand for all components that have or are known to have the 

potential for failure, as well as any parts recommended by the Kiln manufacturer and 

Reagent Injection Fabric Filter System manufacturer. 

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Description of Equipment: 

Type of Malfunction: 

Possible Causes (not complete): 

Alarm Type: 

Steps Taken to Correct Problem: 

DIFF 

MALFUNCTION 21 

Failure of equipment to reset itself to correct operation after 

a power outage. 

Failure of Automatic Resets following a power outage 

Power failure 

Observation by Boral Staff 

1. Maintenance is contacted due to visual observation and responds immediately. 

2. Key Boral personnel will identify the cause of the problem. 

3. Boral staff and maintenance will work and trouble shoot the system until repaired. 

4. Upon resetting the equipment, the DIFF silo will be re-filled (if required) to normal levels 

with reagent. 

Steps Taken to Minimize Emissions: 

1. After a power failure, Boral personnel will confirm that all default settings have been 

reset to the correct operating order as quickly as possible. 

2. In most cases, the DIFF will continue to operate and since there is reagent in the system 

during much of the malfunction HF will continue to be removed. 

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Type of Malfunction: Acts of God 

II ACTS OF GOD 

General Steps Taken to Correct Malfunction and Reduce Emissions 

• Ensure that the situation has become stable and the hazards have been cleared before 

proceeding further. 

• Confirm the system status and note which equipment is off-line or otherwise impaired. 

• Notify appropriate maintenance or other responsible personnel (see Section 6.1). 

• Respond to correct or repair the malfunction in a safe, efficient and timely manner as 

soon as it is practicable, for example: 

o Right overturned equipment and attempt to reinstall/restart; and 

o Ensure all power and gas lines are functioning correctly and are free from defect 

• Suspend operations as soon as practicable until compliance can be assured if failure 

cannot be repaired in a timely manner. 

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Terre Haute II LOSS OF POWER/GAS II 

Type of Malfunction: Loss of Power or Gas 

General Steps Taken to Correct Malfunction and Reduce Emissions 

• Ensure that the situation has become stable and the hazards have been cleared before 

proceeding further. 

• Confirm the system status and note which equipment is off-line or otherwise impaired. 

• Notify appropriate maintenance or other responsible personnel. 

• Respond to correct or repair the malfunction in a safe, efficient and timely manner as 

soon as it is practicable, for example: 

• 

• 

Call power company if power failure seems plant-wide; if not, trace power failure 

from equipment to power source; 

o Check source of gas; 

o Trace gas line from equipment to the source and determine whether any leaks 

or breaks in line exist; and 

o Repair any breaks or leaks that are found in the utility system at the facility. 

A loss of gas pressure or a general loss of power will result in an automatic stoppage 

of the kiln operation and thus emissions will be minimized until power and or gas is 

restored to allow normal operations. If the power loss is only at the baghouse unit, 

there will be no exhaust from the kiln and the kiln will automatically stop and will not 

operate until the situation is corrected. 

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Terre Haute 

SECTION 6.0- RESPONSffiiLITIES AND POINTS OF CONTACT 

SECTION 6.1- ORGANIZATIONAL CHART 

Table of key individuals (by name or position), their contact information (phone, pager, cell, 

email), their responsibilities, back up personnel. 

Plant Manager Greg Camp 

Direct Phone: 706-421-3898 

Regional Production Manager Bill Tudor 

Direct Phone: 205-908-0593 

Environmental Manager: Neil Klein 

Cell Phone: 812-221-6421 

SECTION 6.2- RECORDKEEPING PLAN 

All data and reports demonstrating compliance with a MACT standard, as well as previous 

versions of the SSMP, must be maintained for five years. 

Location of Electronic File: All records will be kept at the plant premises for inspection on 

demand. 

SECTION 6.3- TRAINING REQUIREMENTS 

To be completed 

SECTION 6.4- SSMP VERSION CONTROL PROCEDURES 

Protocol for identifying when to update the plan, managing previous versions of the plan and 

document control procedures is included in Section 7.0. 

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SECTION 7.0- RECORDKEEPING AND REPORTING REQUIREMENTS 

SECTION 7.1- OVERVIEW OF REQUIREMENTS 

The type of records that will be retained by Boral-Terre Haute meet the requirements of Part 63. 

These records include: 

• Log of all startups and shutdowns of the machines 

• Record of each malfunction, and whether the actions taken to correct the malfunction were 

the same as the SSMP. (It may be possible that some events are not malfunctions. If it can be 

determined that an event was not a malfunction, such an event will be documented). 

The types of reports that are required to be submitted by Boral-Terre Haute vary considerably, 

depending on whether the actions taken were consistent with the SSMP. 

• 

• 

If the actions taken during the malfunction were consistent with this SSMP, Boral-Terre 

Haute will state this fact in our semiannual excess emissions report (due within 30 days 

following the end of each 6-month period) with the following information included 

(§63.1 0( d)(S)(i)): 

o Certifying signature of the owner/open~tor or other responsible official; 

o Statement that the actions taken during the malfunction were consistent with the 

Malfunction Plan; 

o The number, duration, and a brief description of malfunction that occurred during the 

reporting period (§63.10(d)(5)(i)) or a copy of a malfunction report form that 

includes this information (see Section 7.2.1 for an example form); 

o Whether any excess emissions and/or parameter monitoring exceedances are believed 

to have occurred during the malfunction (§63.1 0( d)(S)(ii)); and 

o Any additional information required by our State or permitting authority. 

If the actions taken during a malfunction were not consistent with this SSMP, because the 

plan did not address the type of malfunction that occurred and/or the actions taken were not 

included in the current SSMP, and excess emissions occurred, the Environmental Supervisor 

should report the actions taken by telephone or facsimile (FAX) transmission within two (2) 

working days after the malfunction. A letter must then be sent within seven (7) working days 

after the malfunction. The letter should include the following information (§63.10(d)(5)(ii)): 

o Name, title, and certifying signature of responsible official; 

o Explanation of the circumstances of the malfunction; 

o The reasons for not following the current SSMP; and 

o Any additional information required by our State or permitting authority. 

• If actions taken during the malfunction were not consistent with the SSMP or did not address 

the particular type of malfunction that occurred, and the Boral-Terre Haute's SSMP should 

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include these events or actions for future events. Then General Provisions also require 

((§63.6( e )(3)(viii)): 

o Revise the SSMP within 45 days after the malfunction to include procedures for 

operating and maintaining the source during similar malfunction events, with a 

program of corrective action to address the malfunctions; and 

o Report the revisions of your SSMP in the semi annual excess emissions report (within 

30 days following the end of each 6-month period). 

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SECTION 7.2- EXAMPLE REPORT FORMS 

i. Malfunction reports (internal) 

Forms to be completed for each malfunction that occurs - must include determination of whether 

SSMP was followed. 

ii. Malfunction Log 

Table listing each malfunction and whether it was included in plan or, if not, whether required 

notifications were provided 

iii. Example Notifications 

iv. 

Provide examples of: verbal/written notification required within 2 days of malfunction not 

included in SSMP; written notification required within 7 days of the end of a malfunction not 

included in SSMP; language to include in semiannual reports. 

Addresses 

INDIANA DEPARTMENT OF ENVIRONMENTAL MANAGEMENT 

Indiana Department of Environmental Management· 

Compliance Data Section, Office of Air Quality 

100 North Senate A venue 

MC61-53IGCN1003 

Indianapolis, Indiana 46204-2251 

And 

Vigo County Air Pollution Control 

103 South Third Street 

Terre Haute, Indiana 47807 

US Environmental Protection Agency 

EPA Region 5 Regional Office 

77 W. Jackson Blvd. 

Chicago, IL 60604 

Page 47 of47 Boral Terre Haute SSMP Feb 2008 

Revision 0- Feb. 2008 
APPENDIX A- RECORDS OF SSM EVENTS 

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