CERTIFIED MAIL – Return Receipt Requested

# 7004 2510 0003 4788 0137

July 28, 2005

United States Environmental Protection Agency Dallas Regional Office

1445 Ross Avenue Dallas, Texas 75202-2733

Attn: John Hepola

RE: MACT Semi-Annual Reporting for Period January 1, 2005 through June 30, 2005

Dear Mr. Hepola,

This report includes three separate reports as requ ired by 40 CFR 63 Subparts A and NNN. The first report summarizes periods of startu p, shutdown, and malfunction where actions taken were inconsistent with the plan in ac cordance 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 63.138 6(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 CF R 63.1386(e) if monitored parameters deviate more than 1% of the total operat ing time. Each report is labeled appropriately and is for the period January 1, 2005 through June 30, 2005.

As the responsible official, I certify to the accur acy of this report. If you have any questions regarding this information, please contac t our Facility Environmental Leader, Gary Chastain at (972) 923-4330.

Sincerely,

David Randolph Plant Manager Owens Corning – Waxahachie Plant Waxahachie, TX

attachmentReport: Periods of Startup, Shutdown, and Malfuncti on Where Actions Taken were

Inconsistent with SSM Plan 40 CFR 63 Subpart NNN

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

Owens Corning – Waxahachie Plant 3700 North Interstate Highway 35E Waxahachie, TX 75165

The following instances are being reported as a dev iation of procedures outlined in the facility OMM/SSM Plans:

None

All instances of startup, shutdown and malfunction were dealt with in accordance with the facility Startup, Shutdown, and Malfunction Pla n

.

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

Print Name: David Randolph

Signature:

Title Plant ManagerSummary Report – Gaseous and Opacity Excess Emissio n and Continuous

Monitoring System Performance 40CFR63 Subpart NNN

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

Owens Corning – Waxahachie Plant 3700 North Interstate Highway 35E Waxahachie, TX 75165

HAP’s Monitored : The Wool Fiberglass MACT focuses on two surrogat e 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 produc ed 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 gla ss. The molten glass is passed through a rotary spin (RS) forming process where a fine, gl ass fiber is produced. Binder is applied to the fiber as it forms a “pack” on the su rface of a foraminous conveyor. Once collected, the pack passes through a curing and coo ling process followed by final fabrication and packaging. Tables 1 through 3 defi ne the manufacturing sources at this facility, including individual processes, control d evices, and monitored parameters.

TABLE 1

Process Control

Device Monitored Parameter

V1

Furnace Glass Melting DEP 1 st Field – Operating Status

2 nd Field – Operating Status

3 rd Field – Secondary Voltage

3 rd Field – Secondary Current Glass Melting Molten Glass Throughput

Line Forming Premix Formulation

LOI Resin Free Formaldehyde Molten Glass Throughput Curing Incinerator TemperatureTABLE 2

Process Control

Device Monitored Parameter

V2

Furnace Glass Melting Batch Wetting Water Flow

Glass Melting Molten Glass Throughput

Line Forming Premix Formulation

LOI Resin Free Formaldehyde Molten Glass Throughput Curing Incinerator Temperature

TABLE 3

Process Control

Device Monitored Parameter

V3

Furnace Glass Melting Batch Wetting Water Flow

Glass Melting Molten Glass Throughput

Line Forming Premix Formulation

LOI Resin Free Formaldehyde Molten Glass Throughput Curing Incinerator Temperature

Emission Data Summary / Operating Hours for Facilit y

For the period January 1, 2005 through June 30, 200 5 the operating hours are:

V1 Furnace – 4343

V1 Line – 4126

V2 Furnace – 4343

V2 Line – 4032

V3 Furnace – 4343

V3 Line – 4188Deviations :

V-1 DEP 2 nd Field Operating Status 1.03 hrs 0.02% deviation V-1 Furnace DEP Bypass 16.45 hrs 0.38% deviation

V-2 Furnace Batch Wetting 10.52 hrs 0.24% deviati on V-3 Furnace Batch Wetting 81.33 hrs 1.87% deviati on

V-1 Incinerator 15.75 hrs 0.38% deviation

V-2 Incinerator 24.0 hrs 0.60% deviation

V-3 Incinerator 11.0 hrs 0.26% deviation

V-2 Lost Furnace Crust 108.5 hrs 2.50% deviation

V-1 LOI Check Frequency 0.08 hrs 0.00% deviation V-2 LOI Check Frequency 0.80 hrs 0.02% deviation V-3 LOI Check Frequency 0.26 hrs 0.01% deviation

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

exceedance time:

V3 Furnace Batch Wetting 81.33 hrs 1.87% deviation

V-2 Lost Furnace Crust 108.5 hrs 2.50% deviation

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

follows.

Overcoat of V2 furnace was performed during January 2005. During an overcoat period no batch is fed to and no glass is pulled from the furnace. Records of this period indicate that no batch wetting occurred, however this was no t counted as a deviation since batch was not being fed to the furnace.

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

Print Name: David Randolph

Signature:

Title Plant ManagerGaseous and Opacity Excess Emission and Continuous Monitoring System

Performance 40CFR63 Subpart NNN

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

Owens Corning – Waxahachie Plant 3700 North Interstate Highway 35E Waxahachie, TX 75165

The following instances are being reported as a dev iation of a monitored parameter due to malfunction or startup/shutdown:

V3 Furnace Batch Wetting – See Appendix A for detai ls

V2 Lost Furnace Crust - See Appendix B for details

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

Print Name: David Randolph

Signature:

Title Plant Manager

## APPENDIX A

V3 Batch Wetting DeviationsGaseous and Opacity Excess Emission and Continuous Monitoring System

Performance 40CFR63 Subpart NNN

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

Owens Corning – Waxahachie Plant 3700 North Interstate Highway 35E Waxahachie, TX 75165

V3 Batch Wetting Deviations :

During the reporting period, there were 81 hours 31 minutes where the Batch Wetting

water flow fell below the minimum rate. Most of ba tch wetting deviations were a result of two separate instances concerning the fogger spr ay assembly. In January 2005 the west side fogger is believed to have fallen into th e melter due to support bracket failure. In June 2005 the charge boom hit the fogger spray a ssembly and knocked it into the melter. Both situations were corrected by maintena nce.

The table below summarizes the V3 Batch Wetting Dev iations:

V-3

Date Duration

d:hh:mm Hours

1/8/2005 1:00:00 24.000

1/9/2005 1:00:00 24.000

1/10/2005 0:03:00 3.000

6/6/2005 0:13:00 13.000

6/7/2005 0:06:50 6.833

Total 2:22:50 70.833

## APPENDIX B

V2 Lost Furnace CrustGaseous and Opacity Excess Emission and Continuous Monitoring System

Performance 40CFR63 Subpart NNN

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

Owens Corning – Waxahachie Plant 3700 North Interstate Highway 35E Waxahachie, TX 75165

V2 Lost Furnace Crust :

During the reporting period, there were 108 hours 3 0 minutes where an overcoat of refractory was added to the V2 furnace. The furnac e is taken off-line during this period, batch is not added and glass is not pulled from the furnace, however the glass in the

furnace remains hot and in a molten state.

The table below summarizes the V2 Lost Furnace Crus t Deviations:

V2 Lost Furnace Crust Deviations Owens Corning Waxahachie, TX January 1, 2005 to June 30, 2005

Deviation Start Time Deviation End Time Total Devia tion (hrs)

1/9/05 at 22:00 1/14/05 at 10:30 108.5January 31, 2006

United States Environmental Protection Agency Dallas Regional Office

1445 Ross Avenue Dallas, Texas 75202-2733

Attn: John Hepola

RE: MACT Semi-Annual Reporting for Period July 1, 2005 through December 31, 2005

Dear Mr. Hepola,

This report includes three separate reports as requ ired by 40 CFR 63 Subparts A and NNN. The first report summarizes periods of startu p, shutdown, and malfunction where actions taken were inconsistent with the plan in ac cordance 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 63.138 6(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 CF R 63.1386(e) if monitored parameters deviate more than 1% of the total operat ing time. Each report is labeled appropriately and is for the period July 1, 2005 th rough December 31, 2005.

As the responsible official, I certify to the accur acy of this report. If you have any questions regarding this information, please contac t our Facility Environmental Leader, Gary Chastain at (972) 923-4330.

Sincerely,

David Randolph Plant Manager Owens Corning – Waxahachie Plant Waxahachie, TX

attachmentReport: Periods of Startup, Shutdown, and Malfuncti on Where Actions Taken were

Inconsistent with SSM Plan 40 CFR 63 Subpart NNN

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

Owens Corning – Waxahachie Plant 3700 North Interstate Highway 35E Waxahachie, TX 75165

The following instances are being reported as a dev iation of procedures outlined in the facility SSM/OMM Plans:

None

All instances of startup, shutdown and malfunction were dealt with in accordance with the facility Startup, Shutdown, and Malfunction Pla n

.

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

Print Name: David Randolph

Signature:

Title Plant ManagerSummary Report – Gaseous and Opacity Excess Emissio n and Continuous

Monitoring System Performance 40CFR63 Subpart NNN

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

Owens Corning – Waxahachie Plant 3700 North Interstate Highway 35E Waxahachie, TX 75165

HAP’s Monitored : The Wool Fiberglass MACT focuses on two surrogat e 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 produc ed 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 gla ss. The molten glass is passed through a rotary spin (RS) forming process where a fine, gl ass fiber is produced. Binder is applied to the fiber as it forms a “pack” on the su rface of a foraminous conveyor. Once collected, the pack passes through a curing and coo ling process followed by final fabrication and packaging. Tables 1 through 3 defi ne the manufacturing sources at this facility, including individual processes, control d evices, and monitored parameters.

TABLE 1

Process Control

Device Monitored Parameter

V1

Furnace Glass Melting DEP 1 st Field – Operating Status

2 nd Field – Operating Status

3 rd Field – Secondary Voltage

3 rd Field – Secondary Current Glass Melting Molten Glass Throughput

Line Forming Premix Formulation

LOI Resin Free Formaldehyde Molten Glass Throughput Curing Incinerator TemperatureTABLE 2

Process Control

Device Monitored Parameter

V2

Furnace Glass Melting Batch Wetting Water Flow

Glass Melting Molten Glass Throughput

Line Forming Premix Formulation

LOI Resin Free Formaldehyde Molten Glass Throughput Curing Incinerator Temperature

TABLE 3

Process Control

Device Monitored Parameter

V3

Furnace Glass Melting Batch Wetting Water Flow

Glass Melting Molten Glass Throughput

Line Forming Premix Formulation

LOI Resin Free Formaldehyde Molten Glass Throughput Curing Incinerator Temperature

Emission Data Summary / Operating Hours for Facilit y

For the period July 1, 2005 through December 31, 20 05 the operating hours are:

V1 Furnace – 4416

V1 Line – 4112

V2 Furnace – 4416

V2 Line – 4221

V3 Furnace – 4416

V3 Line – 4092Deviations :

V-1 DEP SIR 1 Operating Status 54.83 hrs 1.24% dev iation

V-1 Furnace DEP Bypass 17.12 hrs 0.39% deviation

V-2 Furnace Batch Wetting 7.58 hrs 0.17% deviati on V-3 Furnace Batch Wetting 62.28 hrs 1.41% deviati on

V-1 Incinerator 6.25 hrs 0.15% deviation

V-2 Incinerator 4.75 hrs 0.11% deviation

V-3 Incinerator 7.00 hrs 0.17% deviation

V-1 LOI Check Frequency 5.16 hrs 0.13% deviation V-2 LOI Check Frequency 1.27 hrs 0.03% deviatio n V-3 LOI Check Frequency 7.07 hrs 0.17% deviation

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

exceedance time:

V-1 DEP SIR 1 Operating Status 54.83 hrs 1.24% dev iation

V-3 Furnace Batch Wetting 62.28 hrs 1.41% deviati on

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

follows.

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

Print Name: David Randolph

Signature:

Title Plant ManagerGaseous and Opacity Excess Emission and Continuous Monitoring System

Performance 40CFR63 Subpart NNN

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

Owens Corning – Waxahachie Plant 3700 North Interstate Highway 35E Waxahachie, TX 75165

The following instances are being reported as a dev iation of a monitored parameter due to malfunction or startup/shutdown:

V-1 DEP SIR 1 Operating Status – See Appendix A for details

V-3 Furnace Batch Wetting - See Appendix B for deta ils

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

Print Name: David Randolph

Signature:

Title Plant Manager

## APPENDIX A

V-1 DEP SIR 1 Operating StatusGaseous and Opacity Excess Emission and Continuous Monitoring System

Performance 40CFR63 Subpart NNN

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

Owens Corning – Waxahachie Plant 3700 North Interstate Highway 35E Waxahachie, TX 75165

V-1 DEP SIR 1 Operating Status Deviations :

During the reporting period, there were 54 hours 50 minutes where the V-1 DEP SIR 1 was not operating. Forty-seven hours and 42 minute s of the total deviation was due to

failure of a controller board which had to be order ed and delivered from the equipment

manufacturer. The table below summarizes the V-1 DE P SIR 1 Operating Status

Deviations:

V-1 DEP SIR 1 Operating Status Deviations
Owens Corning - Waxahachie, TX
July 1, 2005 to December 31, 2005

Beginning

Date & Time Ending

Date & Time Minutes

Duration

27-AUG-05 19:53:02.0 29-AUG-05 19:33:02.0 2862

19-SEP-05 20:54:02.0 20-SEP-05 04:01:02.0 429

TOTAL Minutes 3291

TOTAL Hours 54.83

## APPENDIX B

V-3 Furnace Batch WettingGaseous and Opacity Excess Emission and Continuous Monitoring System

Performance 40CFR63 Subpart NNN

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

Owens Corning – Waxahachie Plant 3700 North Interstate Highway 35E Waxahachie, TX 75165

V-3 Furnace Batch Wetting

During the reporting period, there were 62 hours 17 minutes where the V3 Batch Wetting system was not working properly. Of the total devi ation time the Batch Wetting system was not operating at or above its minimum flow rate for 26 hours and 45 minutes and the Overhead Batch Filling systems was operated for 35 hours and 32 minutes.

The table below summarizes the V3 Furnace Batch Wet ting Deviation:V-3 Batch Wetting Deviations
Owens Corning - Waxahachie, TX
July 1, 2005 to December 31, 2005

Beginning

Date & Time Ending

Date & Time Minutes

Duration

Batch Wetting

08-AUG-05 7:00:02.1 08-AUG-05 20:00:02.2 780

12-AUG-05 12:35:02.0 12-AUG-05 13:35:02.0 60

15-AUG-05 07:00:02.1 15-AUG-05 17:45:02.1 645

17-NOV-05 01:15:02.0 17-NOV-05 03:15:02.0 120

Total Minutes 1605

Total Hours 26.75

Overhead Fill System

07-JUL-05 04:05:02.0 07-JUL-05 07:00:02.0 175

18-JUL-05 16:00:02.0 18-JUL-05 18:30:02.0 150

29-JUL-05 17:30:02.2 29-JUL-05 19:00:02.2 90

29-JUL-05 19:00:02.1 29-JUL-05 20:00:02.1 60

13-AUG-05 4:30:02.1 13-AUG-05 6:00:02.2 90

24-AUG-05 19:00:02.0 24-AUG-05 22:30:02.0 210

26-AUG-05 08:30:02.1 26-AUG-05 08:37:02.1 7

17-SEP-05 23:00:02.0 18-SEP-05 15:00:02.0 960

28-SEP-05 02:30:02.0 28-SEP-05 07:00:02.0 270

16-OCT-05 09:00:02.0 16-OCT-05 11:00:02.0 120

Total Minutes 2132

Total Hours 35.53

TOTAL Minutes 3737

TOTAL Hour 62.28OWENS CORNING WAXAHACHIE PLANT

3700 NORTH IH 35 EAST WAXAHACHIE, TEXAS 75165

972.937.1340 FAX: 972.937.7360

INSULATING SYSTEMS BUSINESS

CERTIFIED MAIL - RETURN RECEIPT REQUESTED

# 7006 0100 0001 8216 0006

October 18, 2006

United States Environmental Protection Agency Dallas Regional Office

1445 Ross Avenue Dallas, Texas 75202-2733

Attn: John Hepola

RE: AMMENDED MACT Semi-Annual Reporting for Period January 1, 2006 through June 30, 2006

Dear Mr. Hepola:

Enclosed please find the amended MACT Semi-Annual r eport for January 1, 2006 through June 30, 2006. This report is a correction for two reports submitted on July 28, 2006: “Summary Report – Gaseous and Opacity Excess Emission and Continuous Monitoring System Performance” and “Gaseous and Opa city Excess Emission and Continuous Monitoring System Performance Report” if monitored parameters deviate more than 1% of the total operating time.

The original report did not include 2.15 hours of V -1 DEP Bypass time that occurred during the deviation reporting period. The 2.15 V- 1 DEP bypass hours were inadvertently included in the “V-1 DEP 3 rd Field Not Operating” deviation time. The corrected total is 30.17 bypass hours and 212.3 hours for “3rd Field Not Operating”.

The corrections are noted in the attached amended r eports. The V-1 DEP bypass occurrences were reported to all required agencies at the time of the malfunctions.

As the responsible official, I certify to the accur acy of this report. If you have any questions regarding this information, please contac t our Facility Environmental Leader, Gary Chastain at (972) 923-4330.

Sincerely,

David Randolph

Plant Leader Owens Corning – Waxahachie Plant Waxahachie, TXcc: Tony Walker – Air Section Manager - Region IV - TCEQ

attachmentSummary Report – Gaseous and Opacity Excess Emissi on and Continuous

Monitoring System Performance 40CFR63 Subpart NNN

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

Owens Corning – Waxahachie Plant 3700 North Interstate Highway 35E Waxahachie, TX 75165

HAP’s Monitored : The Wool Fiberglass MACT focuses on two surrogat e 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 produc ed 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 gla ss. The molten glass is passed through a rotary spin (RS) forming process where a fine, gl ass fiber is produced. Binder is applied to the fiber as it forms a “pack” on the su rface of a foraminous conveyor. Once collected, the pack passes through a curing and coo ling process followed by final fabrication and packaging. Tables 1 through 3 defi ne the manufacturing sources at this facility, including individual processes, control d evices, and monitored parameters.

TABLE 1

Process Control

Device Monitored Parameter

V1

Furnace Glass Melting DEP 1 st Field – Operating Status

2 nd Field – Operating Status

3 rd Field – Secondary Voltage

3 rd Field – Secondary Current Glass Melting Molten Glass Throughput

Line Forming Premix Formulation

LOI Resin Free Formaldehyde Molten Glass Throughput Curing Incinerator TemperatureTABLE 2

Process Control

Device Monitored Parameter

V2

Furnace Glass Melting Batch Wetting Water Flow

Glass Melting Molten Glass Throughput

Line Forming Premix Formulation

LOI Resin Free Formaldehyde Molten Glass Throughput Curing Incinerator Temperature

TABLE 3

Process Control

Device Monitored Parameter

V3

Furnace Glass Melting Batch Wetting Water Flow

Glass Melting Molten Glass Throughput

Line Forming Premix Formulation

LOI Resin Free Formaldehyde Molten Glass Throughput Curing Incinerator Temperature

Emission Data Summary / Operating Hours for Facilit y

For the period January 1, 2006 through June 30, 200 6 the operating hours are:

V1 Furnace – 4343

V1 Line – 4030

V2 Furnace – 3545

V2 Line – 3444

V3 Furnace – 4343

V3 Line – 4176Deviations :

V-1 DEP 2 nd Field Operating Status 249.28 hrs 5.74% deviation

V-1 DEP 3 rd Field Not Operating (corrected) 212.13 hrs 4.88% deviation V-1 Furnace DEP Bypass (corrected) 30.07 hrs 0.69% deviation

V-2 Furnace Batch Wetting 13.90 hrs 0.39% devia tion V-3 Furnace Batch Wetting 33.88 hrs 0.78% devia tion

V-1 Incinerator Temperature 6.00 hrs 0.15% dev iation V-2 Incinerator Temperature 1.50 hrs 0.04% dev iation V-3 Incinerator Temperature 0.50 hrs 0.01% dev iation

V-3 Lost Furnace Crust 1.03 hrs 0.02% deviatio n

V-1 High LOI 5.00 hrs 0.12% deviation

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

exceedance time:

V-1 DEP 2 nd Field Operating Status 249.28 hrs 5.74% deviation

V-1 DEP 3 rd Field Not Operating 214.28 hrs 4.93% deviation

Based on these percentages of deviations, the follo wing monitoring parameters were over 5% exceedance time, thus warranting a Quality Impro vement Plan (QIP) per 63.1382(b)(2)(ii) and 63.10(e)(3)(viii):

V-1 DEP 2 nd Field Operating Status 249.28 hrs 5.74% deviation

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

follows.

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

Print Name: David Randolph

Signature:

Title Plant LeaderGaseous and Opacity Excess Emission and Continuous Monitoring System

Performance 40CFR63 Subpart NNN

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

Owens Corning – Waxahachie Plant 3700 North Interstate Highway 35E Waxahachie, TX 75165

The following instances are being reported as a dev iation of a monitored parameter due to malfunction or startup/shutdown:

V-1 DEP 2 nd Field Operating Status – See Appendix A for Detail s V-1 DEP 3 rd Field Not Operating – See Appendix B for Details

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

Print Name: David Randolph

Signature:

Title Plant Leader

## APPENDIX A

Appendix A of the original report is unchanged and is not

resubmitted.

## APPENDIX B

V-1 DEP 3 rd 

## Field Not OperatingGaseous and Opacity Excess Emission and Continuous Monitoring System

Performance 40CFR63 Subpart NNN

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

Owens Corning – Waxahachie Plant 3700 North Interstate Highway 35E Waxahachie, TX 75165

V-1 DEP 3 rd Field Not Operating:

During the reporting period, there were 212 hours 8 minutes where the V-1 DEP 3 rd Field was not operating. Due to the 3 rd field not operating during this time period, the t wo monitoring parameters, secondary voltage and curren t were combined under this one

item.

The 3 rd Field SIR controller failed causing the field to s hutdown on March 30, 2006. Owens Corning personnel contacted the equipment man ufacture on 3/30/2006 following unsuccessful restart attempts. An OEM service tech nician arrived on sight on 3/31/2006 to troubleshoot and attempt repair. Additional equ ipment parts were needed and immediately ordered from the equipment-manufacturin g site in Sweden. These parts were received on 4/6/2006 and installed by OEM serv ice technician on 4/7/2006. These new parts failed to resolve the failure. It was de termined that the new parts were defective as received. Additional replacement equi pment parts were received on

4/8/2006. The OEM Service Technician installed the se parts on 4/8/2006 and the #3 Field was brought back on line.

The table below summarizes the period that the V-1 DEP 3 rd Field was not operating:

V-1 DEP 3 rd Field Not Operating Owens Corning Waxahachie, TX January 1, 2006 to June 30, 2006

Deviation Start Time Deviation End Time Total Devia tion (hrs)

3/30/2006 @12:08 4/8/2006 @ 10:25 212.13 hoursJuly 28, 2006

United States Environmental Protection Agency Dallas Regional Office

1445 Ross Avenue Dallas, Texas 75202-2733

Attn: John Hepola

RE: MACT Semi-Annual Reporting for Period January 1, 2006 through June 30, 2006

Dear Mr. Hepola:

This report includes three separate reports as requ ired by 40 CFR 63 Subparts A and NNN. The first report summarizes periods of startu p, shutdown, and malfunction where actions taken were inconsistent with the plan in ac cordance 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 63.138 6(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 CF R 63.1386(e) if monitored parameters deviate more than 1% of the total operat ing 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 accur acy of this report. If you have any questions regarding this information, please contac t our Facility Environmental Leader, Gary Chastain at (972) 923-4330.

Sincerely,

David Randolph

Plant Leader Owens Corning – Waxahachie Plant Waxahachie, TX

attachmentReport : Periods of Startup, Shutdown, and Malfunction Whe re Actions Taken were

Inconsistent with SSM Plan 40 CFR 63 Subpart NNN

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

Owens Corning – Waxahachie Plant 3700 North Interstate Highway 35E Waxahachie, TX 75165

All instances of startup, shutdown and malfunction were dealt with in accordance with the facility Startup, Shutdown and Malfunction Plan

.

Report : Periods of Deviation form the Operations, Mainten ance and Monitoring (OMM)

Plan 40 CFR 63 Subpart NNN

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

OMM Plan.

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

Print Name: David Randolph

Signature:

Title Plant LeaderSummary Report – Gaseous and Opacity Excess Emissio n and Continuous

Monitoring System Performance 40CFR63 Subpart NNN

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

Owens Corning – Waxahachie Plant 3700 North Interstate Highway 35E Waxahachie, TX 75165

HAP’s Monitored : The Wool Fiberglass MACT focuses on two surrogat e 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 produc ed 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 gla ss. The molten glass is passed through a rotary spin (RS) forming process where a fine, gl ass fiber is produced. Binder is applied to the fiber as it forms a “pack” on the su rface of a foraminous conveyor. Once collected, the pack passes through a curing and coo ling process followed by final fabrication and packaging. Tables 1 through 3 defi ne the manufacturing sources at this facility, including individual processes, control d evices, and monitored parameters.

TABLE 1

Process Control

Device Monitored Parameter

V1

Furnace Glass Melting DEP 1 st Field – Operating Status

2 nd Field – Operating Status

3 rd Field – Secondary Voltage

3 rd Field – Secondary Current Glass Melting Molten Glass Throughput

Line Forming Premix Formulation

LOI Resin Free Formaldehyde Molten Glass Throughput Curing Incinerator TemperatureTABLE 2

Process Control

Device Monitored Parameter

V2

Furnace Glass Melting Batch Wetting Water Flow

Glass Melting Molten Glass Throughput

Line Forming Premix Formulation

LOI Resin Free Formaldehyde Molten Glass Throughput Curing Incinerator Temperature

TABLE 3

Process Control

Device Monitored Parameter

V3

Furnace Glass Melting Batch Wetting Water Flow

Glass Melting Molten Glass Throughput

Line Forming Premix Formulation

LOI Resin Free Formaldehyde Molten Glass Throughput Curing Incinerator Temperature

Emission Data Summary / Operating Hours for Facilit y

For the period January 1, 2006 through June 30, 200 6 the operating hours are:

V1 Furnace – 4343

V1 Line – 4030

V2 Furnace – 3545

V2 Line – 3444

V3 Furnace – 4343

V3 Line – 4176Deviations :

V-1 DEP 2 nd Field Operating Status 249.28 hrs 5.74% deviation

V-1 DEP 3 rd Field Not Operating 214.28 hrs 4.93% deviation V-1 Furnace DEP Bypass 27.92 hrs 0.64% deviatio n

V-2 Furnace Batch Wetting 13.90 hrs 0.39% devia tion V-3 Furnace Batch Wetting 33.88 hrs 0.78% devia tion

V-1 Incinerator Temperature 6.00 hrs 0.15% dev iation V-2 Incinerator Temperature 1.50 hrs 0.04% dev iation V-3 Incinerator Temperature 0.50 hrs 0.01% dev iation

V-3 Lost Furnace Crust 1.03 hrs 0.02% deviatio n

V-1 High LOI 5.00 hrs 0.12% deviation

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

exceedance time:

V-1 DEP 2 nd Field Operating Status 249.28 hrs 5.74% deviation

V-1 DEP 3 rd Field Not Operating 214.28 hrs 4.93% deviation

Based on these percentages of deviations, the follo wing monitoring parameters were over 5% exceedance time, thus warranting a Quality Impro vement Plan (QIP) per 63.1382(b)(2)(ii) and 63.10(e)(3)(viii):

V-1 DEP 2 nd Field Operating Status 249.28 hrs 5.74% deviation

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

follows.

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

Print Name: David Randolph

Signature:

Title Plant LeaderGaseous and Opacity Excess Emission and Continuous Monitoring System

Performance 40CFR63 Subpart NNN

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

Owens Corning – Waxahachie Plant 3700 North Interstate Highway 35E Waxahachie, TX 75165

The following instances are being reported as a dev iation of a monitored parameter due to malfunction or startup/shutdown:

V-1 DEP 2 nd Field Operating Status – See Appendix A for Detail s V-1 DEP 3 rd Field Not Operating – See Appendix B for Details

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

Print Name: David Randolph

Signature:

Title Plant Leader

## APPENDIX A

V-1 DEP 2 nd 

## Field Operating StatusGaseous and Opacity Excess Emission and Continuous Monitoring System

Performance 40CFR63 Subpart NNN

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

Owens Corning – Waxahachie Plant 3700 North Interstate Highway 35E Waxahachie, TX 75165

V-1 DEP 2 nd Field Operating Status:

During the reporting period, there were 249 hours 1 7 minutes where the V-1 DEP 2 nd
Field was not operating. Of this total time, 244.2 5 hours were due to the #2 SIR failure on 6/6/2006. Troubleshooting procedures began with Owens Corning plant engineers in consultation with the DEP equipment manufacture. Fa ilure could not be resolved and an internal inspection by an OEM service technician wa s conducted on 6/8/2006. Based on this inspection, several possible components causin g the failure were ordered from the equipment manufacturer. On 6/13/2006, replacement of a controller did not resolve the failure issue. It was determined that the complete High Voltage Unit would require replacement. The replacement High Voltage Unit was received on 6/15/2006 and the service technician to returned to install the repla cement High Voltage Unit. The #2 field was brought back on line on 6/17/2006.

The table below summarizes the V-1 DEP 2 nd Field Operating Status Deviations:V-1 DEP 2 nd Field Operating Status Owens Corning Waxahachie, TX January 1, 2006 to June 30, 2006

Deviation Start Time Deviation End Time Total Devia tion (hrs)

4/8/2006 @ 10:00 4/8/2006 @ 14:00 4.0 hours

5/11/2006 @ 10:02 5/11/2006 @ 11:05 1.03 hours

6/6/2006 @ 15:00 6/17/2006 @ 8:28 244.25 hours

Note: During the deviation period of 6/6/2006 throu gh 7/17/2006 the DEP was offline for

13 hours 17 minutes. This time was deducted from th e deviation period to yield 244.25

hours.

## APPENDIX B

V-1 DEP 3 rd 

## Field Not OperatingGaseous and Opacity Excess Emission and Continuous Monitoring System

Performance 40CFR63 Subpart NNN

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

Owens Corning – Waxahachie Plant 3700 North Interstate Highway 35E Waxahachie, TX 75165

V-1 DEP 3 rd Field Not Operating:

During the reporting period, there were 214 hours 1 7 minutes where the V-1 DEP 3 rd
Field was not operating. Due to the 3 rd field not operating during this time period, the two monitoring parameters, secondary voltage and cu rrent were combined under this one

item.

The 3 rd Field SIR controller failed causing the field to s hutdown on March 30, 2006. Owens Corning personnel contacted the equipment man ufacture on 3/30/2006 following unsuccessful restart attempts. An OEM service tech nician arrived on sight on 3/31/2006 to troubleshoot and attempt repair. Additional equ ipment parts were needed and immediately ordered from the equipment-manufacturin g site in Sweden. These parts were received on 4/6/2006 and installed by OEM serv ice technician on 4/7/2006. These new parts failed to resolve the failure. It was de termined that the new parts were defective as received. Additional replacement equi pment parts were received on

4/8/2006. The OEM Service Technician installed the se parts on 4/8/2006 and the #3 Field was brought back on line.

The table below summarizes the period that the V-1 DEP 3 rd Field was not operating:

V-1 DEP 3 rd Field Not Operating Owens Corning Waxahachie, TX January 1, 2006 to June 30, 2006

Deviation Start Time Deviation End Time Total Devia tion (hrs)

3/30/2006 @12:08 4/8/2006 @ 10:25 214.28 hoursCERTIFIED MAIL – Return Receipt Requested

# 7006 0100 0001 8217 5109

January 26, 2007

United States Environmental Protection Agency Dallas Regional Office

1445 Ross Avenue Dallas, Texas 75202-2733

Attn: David Garcia

RE: MACT Semi-Annual Reporting for Period July 1, 2006 through December 31, 2006

Dear Mr. Garcia:

This report includes three separate reports as requ ired by 40 CFR 63 Subparts A and NNN. The first report summarizes periods of startu p, shutdown, and malfunction where actions taken were inconsistent with the plan in ac cordance 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 63.138 6(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 CF R 63.1386(e) if monitored parameters deviate more than 1% of the total operat ing time. Each report is labeled appropriately and is for the period July 1, 2006 th rough December 31, 2006.

As the responsible official, I certify to the accur acy of this report. If you have any questions regarding this information, please contac t our Facility Environmental Leader, Gary Chastain at (972) 923-4330.

Sincerely,

Glenn E. Haley

Plant Leader Owens Corning – Waxahachie Plant Waxahachie, TX

cc: Tony Walker, TCEQ Region IV – Certified Mail # 7006 0100 8217 5116

attachmentReport : Periods of Startup, Shutdown, and Malfunction Whe re Actions Taken were

Inconsistent with SSM Plan 40 CFR 63 Subpart NNN

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

Owens Corning – Waxahachie Plant 3700 North Interstate Highway 35E Waxahachie, TX 75165

All instances of startup, shutdown and malfunction were dealt with in accordance with the facility Startup, Shutdown and Malfunction Plan

.

Report : Periods of Deviation form the Operations, Mainten ance and Monitoring (OMM)

Plan 40 CFR 63 Subpart NNN

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

OMM Plan.

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

Print Name: Glenn E. Haley

Signature:

Title Plant LeaderSummary Report – Gaseous and Opacity Excess Emissio n and Continuous

Monitoring System Performance 40CFR63 Subpart NNN

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

Owens Corning – Waxahachie Plant 3700 North Interstate Highway 35E Waxahachie, TX 75165

HAP’s Monitored : The Wool Fiberglass MACT focuses on two surrogat e 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 produc ed 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 gla ss. The molten glass is passed through a rotary spin (RS) forming process where a fine, gl ass fiber is produced. Binder is applied to the fiber as it forms a “pack” on the su rface of a foraminous conveyor. Once collected, the pack passes through a curing and coo ling process followed by final fabrication and packaging. Tables 1 through 3 defi ne the manufacturing sources at this facility, including individual processes, control d evices, and monitored parameters.

TABLE 1

Process Control

Device Monitored Parameter

V1

Furnace Glass Melting DEP 1 st Field – Operating Status

2 nd Field – Operating Status

3 rd Field – Secondary Voltage

3 rd Field – Secondary Current Glass Melting Molten Glass Throughput

Line Forming Premix Formulation

LOI Resin Free Formaldehyde Molten Glass Throughput Curing Incinerator TemperatureTABLE 2

Process Control

Device Monitored Parameter

V2

Furnace Glass Melting Batch Wetting Water Flow

Glass Melting Molten Glass Throughput

Line Forming Premix Formulation

LOI Resin Free Formaldehyde Molten Glass Throughput Curing Incinerator Temperature

TABLE 3

Process Control

Device Monitored Parameter

V3

Furnace Glass Melting Batch Wetting Water Flow

Glass Melting Molten Glass Throughput

Line Forming Premix Formulation

LOI Resin Free Formaldehyde Molten Glass Throughput Curing Incinerator Temperature

Emission Data Summary / Operating Hours for Facilit y

For the period July 1, 2006 through December 31, 20 06 the operating hours are:

V1 Furnace – 4417

V1 Line – 3984

V2 Furnace – 4417

V2 Line – 4133

V3 Furnace – 4417

V3 Line – 4137Deviations :

V-1 DEP 1 st Field Operating Status 9.43 hrs 0.21% deviation

V-1 DEP 2 nd Field Operating Status 50.68 hrs 1.15% deviation V-1 Furnace DEP Bypass 11.98 hrs 0.27% deviatio n

V-2 Furnace Batch Wetting 24.05 hrs 0.54% devia tion V-3 Furnace Batch Wetting 11.05 hrs 0.25% devia tion

V-1 Incinerator Temperature 9.75 hrs 0.24% dev iation V-2 Incinerator Temperature 7.25 hrs 0.18% dev iation V-3 Incinerator Temperature 10.00 hrs 0.24% dev iation

V-2 Lost Furnace Crust 2.00 hrs 0.05% deviatio n V-3 Lost Furnace Crust 21.02 hrs 0.48% deviation

V-3 High LOI 0.45 hrs 0.01% deviation

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

exceedance time:

V-1 DEP 2 nd Field Operating Status 50.68 hrs 1.15% deviation

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

follows.

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

Print Name: Glenn E. Haley

Signature:

Title Plant LeaderGaseous and Opacity Excess Emission and Continuous Monitoring System

Performance 40CFR63 Subpart NNN

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

Owens Corning – Waxahachie Plant 3700 North Interstate Highway 35E Waxahachie, TX 75165

The following instances are being reported as a dev iation of a monitored parameter due to malfunction or startup/shutdown:

V-1 DEP 2 nd Field Operating Status – See Appendix A for Detail s

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

Print Name: Glenn E. Haley

Signature:

Title Plant Leader

## APPENDIX A

V-1 DEP 2 nd 

## Field Operating StatusGaseous and Opacity Excess Emission and Continuous Monitoring System

Performance 40CFR63 Subpart NNN

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

Owens Corning – Waxahachie Plant 3700 North Interstate Highway 35E Waxahachie, TX 75165

V-1 DEP 2 nd Field Operating Status:

During the reporting period, there were 50 hours 41 minutes where the V-1 DEP 2 nd Field was not operating. This total time was due to the #2 SIR failure on 12/5/2006. Troubleshooting procedures began with Owens Corning plant engineers in consultation with the DEP equipment manufacture. It was determin ed that an electrical short circuit on

the SIR main controller board had melted one of the electrical connectors. A replacement

controller board and connector were received from t he OEM vendor on 12/7/2006. The #2 field was brought back on line on 12/7/2006.

The table below summarizes the V-1 DEP 2 nd Field Operating Status Deviations:

V-1 DEP 2 nd Field Operating Status

Owens Corning Waxahachie, TX July 1, 2006 through December 31, 2006

Deviation Start Time Deviation End Time Total Devia tion (hrs)

12/5/2006 @ 10:42 12/7/2006 @ 13:25 50.683 hoursCERTIFIED MAIL – Return Receipt Requested

# 7006 0100 0001 8217 5307

July 30, 2007

United States Environmental Protection Agency Dallas Regional Office

1445 Ross Avenue Dallas, Texas 75202-2733

Attn: David Garcia

RE: MACT Semi-Annual Reporting for Period January 1, 2007 through June 30, 2007

Dear Mr. Garcia:

This report includes three separate reports as requ ired by 40 CFR 63 Subparts A and NNN. The first report summarizes periods of startu p, shutdown, and malfunction where actions taken were inconsistent with the plan in ac cordance 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 63.138 6(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 CF R 63.1386(e) if monitored parameters deviate more than 1% of the total operat ing 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 accur acy of this report. If you have any questions regarding this information, please contac t our Facility Environmental Leader, Gary Chastain at (972) 923-4330.

Sincerely,

Glenn E. Haley

Plant Leader Owens Corning – Waxahachie Plant Waxahachie, TX

cc: Tony Walker, TCEQ Region IV – Certified Mail # 7006 0100 8217 5289

attachmentReport : Periods of Startup, Shutdown, and Malfunction Whe re Actions Taken were

Inconsistent with SSM Plan 40 CFR 63 Subpart NNN

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

Owens Corning – Waxahachie Plant 3700 North Interstate Highway 35E Waxahachie, TX 75165

All instances of startup, shutdown and malfunction were dealt with in accordance with the facility Startup, Shutdown and Malfunction Plan

.

Report : Periods of Deviation form the Operations, Mainten ance and Monitoring (OMM)

Plan 40 CFR 63 Subpart NNN

Based on the requirements within the Operations, Ma intenance, and Monitoring Plan, an LOI is required at least once every 8 hours. There was one incident where the duration between LOI testing exceeded eight hours.

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

Print Name: Glenn E. Haley

Signature:

Title Plant LeaderSummary Report – Gaseous and Opacity Excess Emissio n and Continuous

Monitoring System Performance 40CFR63 Subpart NNN

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

Owens Corning – Waxahachie Plant 3700 North Interstate Highway 35E Waxahachie, TX 75165

HAP’s Monitored : The Wool Fiberglass MACT focuses on two surrogat e 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 produc ed 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 gla ss. The molten glass is passed through a rotary spin (RS) forming process where a fine, gl ass fiber is produced. Binder is applied to the fiber as it forms a “pack” on the su rface of a foraminous conveyor. Once collected, the pack passes through a curing and coo ling process followed by final fabrication and packaging. Tables 1 through 3 defi ne the manufacturing sources at this facility, including individual processes, control d evices, and monitored parameters.

TABLE 1

Process Control

Device Monitored Parameter

V1

Furnace Glass Melting DEP 1 st Field – Operating Status

2 nd Field – Operating Status

3 rd Field – Secondary Voltage

3 rd Field – Secondary Current Glass Melting Molten Glass Throughput

Line Forming Premix Formulation

LOI Resin Free Formaldehyde Molten Glass Throughput Curing Incinerator TemperatureTABLE 2

Process Control

Device Monitored Parameter

V2

Furnace Glass Melting Batch Wetting Water Flow

Glass Melting Molten Glass Throughput

Line Forming Premix Formulation

LOI Resin Free Formaldehyde Molten Glass Throughput Curing Incinerator Temperature

TABLE 3

Process Control

Device Monitored Parameter

V3

Furnace Glass Melting Batch Wetting Water Flow

Glass Melting Molten Glass Throughput

Line Forming Premix Formulation

LOI Resin Free Formaldehyde Molten Glass Throughput Curing Incinerator Temperature

Emission Data Summary / Operating Hours for Facilit y

For the period January 1, 2007 through June 30, 200 7 the operating hours are:

V1 Furnace – 4343

V1 Line – 3839

V2 Furnace – 4343

V2 Line – 4147

V3 Furnace – 2504

V3 Line – 2305Deviations :

V-1 DEP 1 st Field Operating Status 0.150 hrs 0.003% deviati on V-1 DEP 2 nd Field Operating Status 0.717 hrs 0.02% deviatio n V-1 DEP 3 rd Field Secondary 5.633 Hrs. 0.13% deviation Voltage & Current V-1 Furnace DEP Bypass 31.117 hrs 0.72% deviati on

V-2 Furnace Batch Wetting 25.45 hrs 0.59% devia tion V-3 Furnace Batch Wetting 12.82 hrs 0.51% devia tion

V-1 Incinerator Temperature 13.00 hrs 0.34% de viation V-2 Incinerator Temperature 8.00 hrs 0.19% dev iation V-3 Incinerator Temperature 6.50 hrs 0.28% dev iation

V-3 Lost Furnace Crust 124.00 hrs 4.95% deviatio n

V-2 High LOI 1.27 hrs 0.031% deviation

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

exceedance time:

V-3 Lost Furnace Crust Loss 124.00 hrs 4.95% dev iation

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

follows.

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

Print Name: Glenn E. Haley

Signature:

Title Plant LeaderGaseous and Opacity Excess Emission and Continuous Monitoring System

Performance 40CFR63 Subpart NNN

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

Owens Corning – Waxahachie Plant 3700 North Interstate Highway 35E Waxahachie, TX 75165

The following instances are being reported as a dev iation of a monitored parameter due to malfunction or startup/shutdown:

V-3 Lost Furnace Crust – See Appendix A for Details

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

Print Name: Glenn E. Haley

Signature:

Title Plant Leader

## APPENDIX A

V-3 Lost Furnace CrustGaseous and Opacity Excess Emission and Continuous Monitoring System

Performance 40CFR63 Subpart NNN

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

Owens Corning – Waxahachie Plant 3700 North Interstate Highway 35E Waxahachie, TX 75165

V-3 Lost Furnace Crust:

During the reporting period, there were 124 hours w here the V-3 Furnace was operated in a Hot Top or no batch crust condition. Of these to tal hours, 64 were attributed to the shut down and start up of a routine furnace rebuild. Col d top electric melters are routinely rebuilt every five to six years. Sixteen hours of t he Hot Top deviation occurred due to the glass drain process which occurs immediately prior to the furnace reconditioning process. Forty-eight hours of the remaining hot Top deviatio n occurred during the furnace restart procedure. This represents the last portion of the furnace reheat process during which cullet is added to the melter to bring the molten g lass to the proper operating level. The final step in the re-heat process is to add a batch blanket over the molten glass and return to normal batch charging operation. The additional sixty hours occurred due to a refractory cover block, located in the conditioning channel, breaking into two pieces and falling into the glass conditioning channel. Normal batch operation needed to be suspended to recover the failed refractory pieces f rom the conditioning channel and to replace the cover with new refractory. After repair s were complete, normal batch operations were commenced.

The table below summarizes the V-3 Lost Furnace Cru st Deviations:

V-1 DEP 2 nd Field Operating Status

Owens Corning Waxahachie, TX July 1, 2006 through December 31, 2006

Deviation Start Time Deviation End Time Total Devia tion (hrs)

3/30/2007 @ 05:00 3/30/2007 @ 17:00 16.0 Hours

6/12/2007 @ 10:00 6/14/2007 @ 10:00 48.0 hours

6/14/2007 @ 20:00 6/17/2007 @ 08:00 60.0 hoursCERTIFIED MAIL – Return Receipt Requested

# 7006 0100 0001 8217 5055

January 30, 2008

United States Environmental Protection Agency Dallas Regional Office

1445 Ross Avenue Dallas, Texas 75202-2733

Attn: David Garcia

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

Dear Mr. Garcia:

This report includes three separate reports as requ ired by 40 CFR 63 Subparts A and NNN. The first report summarizes periods of startu p, shutdown, and malfunction where actions taken were inconsistent with the plan in ac cordance 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 63.138 6(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 CF R 63.1386(e) if monitored parameters deviate more than 1% of the total operat ing time. Each report is labeled appropriately and is for the period July 1, 2007 th rough December 31, 2007.

As the responsible official, I certify to the accur acy of this report. If you have any questions regarding this information, please contac t our Facility Environmental Leader, Gary Chastain at (972) 923-4330.

Sincerely,

Glenn E. Haley

Plant Leader Owens Corning Insulating System LLC – Waxahachie Pl ant Waxahachie, TX

cc: Tony Walker, TCEQ Region IV – Certified Mail # 7006 0100 0001 8217 5062

AttachmentReport : Periods of Startup, Shutdown, and Malfunction Whe re Actions Taken were

Inconsistent with SSM Plan 40 CFR 63 Subpart NNN

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

Owens Corning Insulating System LLC– Waxahachie Pla nt 3700 North Interstate Highway 35E Waxahachie, TX 75165

All instances of startup, shutdown and malfunction were dealt with in accordance with the facility Startup, Shutdown and Malfunction Plan

.

Report : Periods of Deviation form the Operations, Mainten ance and Monitoring (OMM)

Plan 40 CFR 63 Subpart NNN

Based on the requirements within the Operations, Ma intenance, and Monitoring Plan, an LOI is required at least once every 8 hours. There were three incidents where the duration between LOI testing exceeded eight hours.

Based on the requirements within the Operations, Ma intenance, and Monitoring Plan, monitoring of the operating status and operating pa rameters of the Dry Electrostatic Precipitator are required at least once every 8 hou rs. All zones were in operation during this time period, however monitoring capability was lost due to failure of the network

communication circuit for the SIR controllers from 12/5/2007 through the end of the reporting period.

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

Print Name: Glenn E. Haley

Signature:

Title Plant LeaderSummary Report – Gaseous and Opacity Excess Emissio n and Continuous

Monitoring System Performance 40CFR63 Subpart NNN

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

Owens Corning Insulating System LLC– Waxahachie Pla nt 3700 North Interstate Highway 35E Waxahachie, TX 75165

HAP’s Monitored : The Wool Fiberglass MACT focuses on two surrogat e 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 produc ed 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 gla ss. The molten glass is passed through a rotary spin (RS) forming process where a fine, gl ass fiber is produced. Binder is applied to the fiber as it forms a “pack” on the su rface of a foraminous conveyor. Once collected, the pack passes through a curing and coo ling process followed by final fabrication and packaging. Tables 1 through 3 defi ne the manufacturing sources at this facility, including individual processes, control d evices, and monitored parameters.

TABLE 1

Process Control

Device Monitored Parameter

V1

Furnace Glass Melting DEP 1 st Field – Operating Status

2 nd Field – Operating Status

3 rd Field – Secondary Voltage

3 rd Field – Secondary Current Glass Melting Molten Glass Throughput

Line Forming Premix Formulation

LOI Resin Free Formaldehyde Molten Glass Throughput Curing Incinerator TemperatureTABLE 2

Process Control

Device Monitored Parameter

V2

Furnace Glass Melting Batch Wetting Water Flow

Glass Melting Molten Glass Throughput

Line Forming Premix Formulation

LOI Resin Free Formaldehyde Molten Glass Throughput Curing Incinerator Temperature

TABLE 3

Process Control

Device Monitored Parameter

V3

Furnace Glass Melting Batch Wetting Water Flow

Glass Melting Molten Glass Throughput

Line Forming Premix Formulation

LOI Resin Free Formaldehyde Molten Glass Throughput Curing Incinerator Temperature

Emission Data Summary / Operating Hours for Facilit y

For the period July 1, 2007 through December 31, 20 07 the operating hours are:

V1 Furnace – 4417

V1 Line – 4009

V2 Furnace – 4417

V2 Line – 3957

V3 Furnace – 4417

V3 Line – 3981Deviations :

V-1 DEP 2 nd Field Operating Status 270.17 hrs 6.12% deviati on V-1 DEP 3 rd Field Secondary 36.80 Hrs. 0.83% deviation Voltage & Current V-1 Furnace DEP Bypass 18.12 hrs 0.41% deviatio n

V-2 Furnace Batch Wetting 8.58 hrs 0.19% deviat ion V-3 Furnace Batch Wetting 38.38 hrs 0.17% devia tion

V-1 Incinerator Temperature 27.25 hrs 0.68% de viation V-2 Incinerator Temperature 0.50 hrs 0.01% dev iation V-3 Incinerator Temperature 1.00 hrs 0.03% dev iation

V-2 Lost Furnace Crust 175.00 hrs 3.96% deviatio n V-3 Lost Furnace Crust 70.00 hrs 1.58% deviati on

V-2 High LOI 1.45 hrs 0.037% deviation V-2 High LOI 7.00 hrs 0.176% deviation

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

exceedance time:

V-1 DEP 2 nd Field Operating Status 270.17 hrs 6.12% deviation

V-2 Lost Furnace Crust 175.00 hrs 3.96% deviatio n V-3 Lost Furnace Crust 70.00 hrs 1.58% deviati on

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

follows.

Based on these percentages of deviations, the follo wing monitoring parameters were over 5% exceedence time, thus warranting a Quality Impro vement Plan (QIP) per 63.1382(b)(2)(ii) and 63.10(e)(3)(viii):

V-1 DEP 2 nd Field Operating Status 270.17 hrs 6.12% deviation

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

Print Name: Glenn E. Haley

Signature:

Title Plant LeaderGaseous and Opacity Excess Emission and Continuous Monitoring System

Performance 40CFR63 Subpart NNN

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

Owens Corning Insulating System LLC – Waxahachie Pl ant 3700 North Interstate Highway 35E Waxahachie, TX 75165

The following instances are being reported as a dev iation of a monitored parameter due to malfunction or startup/shutdown:

V-1 DEP 2 nd Field Operating Status – See Appendix A for Detail s V-2 Lost Furnace Crust – See Appendix B for Details V-3 Lost Furnace Crust – See Appendix C for Details

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

Print Name: Glenn E. Haley

Signature:

Title Plant Leader

## APPENDIX A

V-1 DEP 2 nd 

## Field Operating StatusGaseous and Opacity Excess Emission and Continuous Monitoring System

Performance 40CFR63 Subpart NNN

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

Owens Corning – Waxahachie Plant 3700 North Interstate Highway 35E Waxahachie, TX 75165

V-1 DEP 2 nd Field Operating Status:

During the reporting period, there were 270 hours a nd 10 minutes where the V-1 DEP 2 nd
Field was not operating. Of that total time, 266 h ours and 14 minutes were due to the #2 SIR Processor Controller. A power surge during rain storm caused failure of #2 SIR Processor Controller board for the V-1 Dry Electros tatic Precipitator at 9:45 PM on 7/1/2007. A replacement SIR-A was not available fr om the equipment manufacturer so a "used" SIR-E controller unit was supplied; however with the different controller, retro-fit modifications would be necessary for proper operati on. The supplied SIR-E controller unit was installed and placed in service on 7/13/20 07 at 2:15 PM. An additional 3 hours and 50 minutes outage for SIR # 2 was necessary to complete retro-fit modifications for

the SIR–E unit on 7/30/2007.

The table below summarizes the V-1 DEP 2 nd Field Operating Status Deviations:

V-1 DEP 2 nd Field Operating Status

Owens Corning Waxahachie, TX July 1, 2007 through December 31, 2007

Deviation Start Time Deviation End Time Total Devia tion (hrs)

7/1/2007 @ 5:18 PM 7/12/2007 @ 7:33 PM 266.233 hour s 7/30/2007 @ 12:24 PM 7/30/2007 @ 7:27 PM 3.833 hour s 8/5/2007 @ 1:01 PM 8/5/2007 @ 1:06 PM 5 minutes

8/6/2007 @ 9:11 AM 8/6/2007 @ 9:12 AM 1 minute

## APPENDIX B

V-2 Lost Furnace CrustGaseous and Opacity Excess Emission and Continuous Monitoring System

Performance 40CFR63 Subpart NNN

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

Owens Corning Insulating System LLC – Waxahachie Pl ant 3700 North Interstate Highway 35E Waxahachie, TX 75165

V-2 Lost Furnace Crust:

During the reporting period, there were 175 hours w here the V-2 Furnace was operated in a Hot Top or no batch crust condition. The total a mount of hours was due V-2 production being curtailed from Nov. 21, 2007 throu gh November 28, 2007. In order to secure the melter in a “Hot Idle” condition during the curtailment period, the melter batch feeding slot was bricked up and gas fired burners u tilized to maintain temperature beginning on 11/21/2007 @ 7:00 AM. A batch blanket was established @ 2:00 PM on

7/28/2007. The table below summarizes the V-2 Lost Furnace Crust Deviation:

V-2 Lost Furnace Crust Owens Corning Waxahachie, TX July 1, 2007 through December 31, 2007

Deviation Start Time Deviation End Time Total Devia tion (hrs)

11/21/2007 @ 07:00 AM 11/28/2007 @ 8:00 AM 275.0 Ho urs

## APPENDIX C

V-3 Lost Furnace CrustGaseous and Opacity Excess Emission and Continuous Monitoring System

Performance 40CFR63 Subpart NNN

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

Owens Corning Insulating System LLC – Waxahachie Pl ant 3700 North Interstate Highway 35E Waxahachie, TX 75165

V-3 Lost Furnace Crust:

During the reporting period, there were 70 hours wh ere the V-3 Furnace was operated in a “Hot Top” or no batch crust condition. The entir e 70 hours are attributed to a single

occurrence. Batch for the melter is delivered to th e melter from the batch mixing area via a pneumatic transporter. On 12/17/2007 a failure of the batch transporter resulted in loss

of batch to the V-3 melter. Loss of batch material necessitated bricking up the melter batch feed slot and securing the melter in a “Hot I dle” condition. Loss of the melter batch blanket occurred at 9:00PM. The transporter was rep aired and returned to service on

12/20/2007. Batch blanket was established at 7:00PM

.

The table below summarizes the V-3 Lost Furnace Cru st Deviations:

V-3 Lost Furnace Crust Owens Corning Waxahachie, TX July 1, 2006 through December 31, 2006

Deviation Start Time Deviation End Time Total Devia tion (hrs)

12/17/2007 @ 09:00 PM 12/20/2007 @ 7:00 PM 70.0 Ho ursCERTIFIED MAIL – Return Receipt Requested

# 7006 0100 0001 8217 5949

July 30, 2008

United States Environmental Protection Agency Dallas Regional Office

1445 Ross Avenue Dallas, Texas 75202-2733

Attn: David Garcia

RE: MACT Semi-Annual Reporting for Period January 1, 2008 through June 30, 2008

Dear Mr. Garcia:

This report includes three separate reports as requ ired by 40 CFR 63 Subparts A and NNN. The first report summarizes periods of startu p, shutdown, and malfunction where actions taken were inconsistent with the plan in ac cordance 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 63.138 6(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 CF R 63.1386(e) if monitored parameters deviate more than 1% of the total operat ing 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 accur acy of this report. If you have any questions regarding this information, please contac t our Facility Environmental Leader, Gary Chastain at (972) 923-4330.

Sincerely,

Glenn E. Haley

Plant Leader Owens Corning Insulating System LLC – Waxahachie Pl ant Waxahachie, TX

cc: Tony Walker, TCEQ Region IV – Certified Mail # 7006 0100 0001 8217 5946

AttachmentReport : Periods of Startup, Shutdown, and Malfunction Whe re Actions Taken were

Inconsistent with SSM Plan 40 CFR 63 Subpart NNN

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

Owens Corning Insulating System LLC– Waxahachie Pla nt 3700 North Interstate Highway 35E Waxahachie, TX 75165

All instances of startup, shutdown and malfunction were dealt with in accordance with the facility Startup, Shutdown and Malfunction Plan

.

Report : Periods of Deviation form the Operations, Mainten ance and Monitoring (OMM)

Plan 40 CFR 63 Subpart NNN

Based on the requirements within the Operations, Ma intenance, and Monitoring Plan, an LOI is required at least once every 8 hours. There were two incidents where the duration between LOI testing exceeded eight hours. Total dev iation time was three hours or 0.09% of the reporting period.

Based on the requirements within the Operations, Ma intenance, and Monitoring Plan, monitoring of the operating status and operating pa rameters of the Dry Electrostatic Precipitator are required at least once every 8 hou rs. All zones were in operation during this time period, however monitoring capability was lost due to failure of the electronic

communication circuit for the SIR controllers from the beginning of the reporting period through 1/28/2008.

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

Print Name: Glenn E. Haley

Signature:

Title Plant LeaderSummary Report – Gaseous and Opacity Excess Emissio n and Continuous

Monitoring System Performance 40CFR63 Subpart NNN

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

Owens Corning Insulating System LLC– Waxahachie Pla nt 3700 North Interstate Highway 35E Waxahachie, TX 75165

HAP’s Monitored : The Wool Fiberglass MACT focuses on two surrogat e 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 produc ed 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 gla ss. The molten glass is passed through a rotary spin (RS) forming process where a fine, gl ass fiber is produced. Binder is applied to the fiber as it forms a “pack” on the su rface of a foraminous conveyor. Once collected, the pack passes through a curing and coo ling process followed by final fabrication and packaging. Tables 1 through 3 defi ne the manufacturing sources at this facility, including individual processes, control d evices, and monitored parameters.

TABLE 1

Process Control

Device Monitored Parameter

V1

Furnace Glass Melting DEP 1 st Field – Operating Status

2 nd Field – Operating Status

3 rd Field – Secondary Voltage

3 rd Field – Secondary Current Glass Melting Molten Glass Throughput

Line Forming Premix Formulation

LOI Resin Free Formaldehyde Molten Glass Throughput Curing Incinerator TemperatureTABLE 2

Process Control

Device Monitored Parameter

V2

Furnace Glass Melting Batch Wetting Water Flow

Glass Melting Molten Glass Throughput

Line Forming Premix Formulation

LOI Resin Free Formaldehyde Molten Glass Throughput Curing Incinerator Temperature

TABLE 3

Process Control

Device Monitored Parameter

V3

Furnace Glass Melting Batch Wetting Water Flow

Glass Melting Molten Glass Throughput

Line Forming Premix Formulation

LOI Resin Free Formaldehyde Molten Glass Throughput Curing Incinerator Temperature

Emission Data Summary / Operating Hours for Facilit y

For the period January 1, 2008 through June 30, 200 8 the operating hours are:

V1 Furnace – 4387

V1 Line – 3196

V2 Furnace – 3089

V2 Line – 2952

V3 Furnace – 3575

V3 Line – 3413Deviations :

V-1 DEP 1 st Field Operating Status 0.15 hrs 0.003% deviat ion

V-1 DEP 3 rd Field Secondary 8.08 hrs. 0.18% deviation Voltage & Current V-1 Furnace DEP Bypass 1.52 hrs 0.03% deviati on

V-2 Furnace Batch Wetting 4.52 hrs 0.15% devi ation V-3 Furnace Batch Wetting 5.33 hrs 0.15% devi ation

V-1 Incinerator Temperature 1.50 hrs 0.05% de viation V-2 Incinerator Temperature 2.00 hrs 0.07% de viation V-3 Incinerator Temperature 0.25 hrs 0.01% de viation

V-2 Lost Furnace Crust 96.00 hrs 3.11% deviati on

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

exceedence time:

V-2 Lost Furnace Crust 96.00 hrs 3.11% deviation

This instance will be described in more detail in t he Parameter Exceedence Report that

follows.

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

Print Name: Glenn E. Haley

Signature:

Title Plant LeaderGaseous and Opacity Excess Emission and Continuous Monitoring System

Performance 40CFR63 Subpart NNN

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

Owens Corning Insulating System LLC – Waxahachie Pl ant 3700 North Interstate Highway 35E Waxahachie, TX 75165

The following instances are being reported as a dev iation of a monitored parameter due to malfunction or startup/shutdown:

V-2 Lost Furnace Crust – See Appendix A for Details

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

Print Name: Glenn E. Haley

Signature:

Title Plant Leader

## APPENDIX A

V-2 Lost Furnace CrustGaseous and Opacity Excess Emission and Continuous Monitoring System

Performance 40CFR63 Subpart NNN

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

Owens Corning Insulating System LLC – Waxahachie Pl ant 3700 North Interstate Highway 35E Waxahachie, TX 75165

V-2 Lost Furnace Crust:

During the reporting period, there were 96 hours wh ere the V-2 Furnace was operated in a Hot Top or no batch crust condition. The total a mount of hours was due V-2 production being curtailed from March 3, 2008 throu gh April 25, 2008. The melter was secured in a “cold” shutdown state during the curta ilment period. In order to reheat the melter following the curtailment period, the melter batch feeding slot was bricked up and gas fired burners utilized to re-establish operatin g temperature beginning @ 7:00 AM on 4/16/2008. The cold solidified glass reached a mol ten state on 4/18/08 at approximately

3:00 PM. A batch blanket was established @ 3:00 PM on 4/22/2008. The table below

summarizes the V-2 Lost Furnace Crust Deviation:

V-2 Lost Furnace Crust Owens Corning Waxahachie, TX

January 1, 2008 through June 30, 2008

Deviation Start Time Deviation End Time Total Devia tion (hrs)

4/18/2008 @ 03:00 PM 4/22/2008 @ 3:00 PM 96.0 HoursOWENS CORNING INSULATING SYSTEMS, LLC - Waxahachie 3700 North Interstate Highway 35E Waxahachie, Texas 75165

CERTIFIED MAIL – Return Receipt Requested

# 7008 1300 0002 4858 7573

January 30, 2009

United States Environmental Protection Agency Dallas Regional Office

1445 Ross Avenue Dallas, Texas 75202-2733

Attn: David Garcia

RE: MACT Semi-Annual Reporting for Period July 1, 2008 through December 31, 200 8

Dear Mr. Garcia:

This report includes three separate reports as requ ired by 40 CFR 63 Subparts A and NNN. The first report summarizes periods of startu p, shutdown, and malfunction where actions taken were inconsistent with the plan in ac cordance 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 63.138 6(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 CF R 63.1386(e) if monitored parameters deviate more than 1% of the total operat ing time. Each report is labeled appropriately and is for the period July 1, 2008 th rough December 31, 2008.

As the responsible official, I certify to the accur acy of this report. If you have any questions regarding this information, please contac t our Facility Environmental Leader, Gary Chastain at (972) 923-4330.

Sincerely,

Glenn E. Haley

Plant Leader Owens Corning Insulating System LLC – Waxahachie Pl ant Waxahachie, TX

cc: Tony Walker, TCEQ Region IV – Certified Mail # 7008 1300 0002 4858 7580

AttachmentReport : Periods of Startup, Shutdown, and Malfunction Whe re Actions Taken were

Inconsistent with SSM Plan 40 CFR 63 Subpart NNN

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

Owens Corning Insulating System LLC– Waxahachie Pla nt 3700 North Interstate Highway 35E Waxahachie, TX 75165

All instances of startup, shutdown and malfunction were dealt with in accordance with the facility Startup, Shutdown and Malfunction Plan

.

Report : Periods of Deviation form the Operations, Mainten ance and Monitoring (OMM)

Plan 40 CFR 63 Subpart NNN

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

OMM Plan.

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

Print Name: Glenn E. Haley

Signature:

Title Plant LeaderSummary Report – Gaseous and Opacity Excess Emissio n and Continuous

Monitoring System Performance 40CFR63 Subpart NNN

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

Owens Corning Insulating System LLC– Waxahachie Pla nt 3700 North Interstate Highway 35E Waxahachie, TX 75165

HAP’s Monitored : The Wool Fiberglass MACT focuses on two surrogat e 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 produc ed 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 gla ss. The molten glass is passed through a rotary spin (RS) forming process where a fine, gl ass fiber is produced. Binder is applied to the fiber as it forms a “pack” on the su rface of a foraminous conveyor. Once collected, the pack passes through a curing and coo ling process followed by final fabrication and packaging. Tables 1 through 3 defi ne the manufacturing sources at this facility, including individual processes, control d evices, and monitored parameters.

TABLE 1

Process Control

Device Monitored Parameter

V1

Furnace Glass Melting DEP 1 st Field – Operating Status

2 nd Field – Operating Status

3 rd Field – Secondary Voltage

3 rd Field – Secondary Current Glass Melting Molten Glass Throughput

Line Forming Premix Formulation

LOI Resin Free Formaldehyde Molten Glass Throughput Curing Incinerator TemperatureTABLE 2

Process Control

Device Monitored Parameter

V2

Furnace Glass Melting Batch Wetting Water Flow

Glass Melting Molten Glass Throughput

Line Forming Premix Formulation

LOI Resin Free Formaldehyde Molten Glass Throughput Curing Incinerator Temperature

TABLE 3

Process Control

Device Monitored Parameter

V3

Furnace Glass Melting Batch Wetting Water Flow

Glass Melting Molten Glass Throughput

Line Forming Premix Formulation

LOI Resin Free Formaldehyde Molten Glass Throughput Curing Incinerator Temperature

Emission Data Summary / Operating Hours for Facilit y

For the period July 1, 2008 through December 31, 20 08 the operating hours are:

V1 Furnace – 4417

V1 Line – 3672

V2 Furnace – 4417

V2 Line – 3977

V3 Furnace – 0

V3 Line – 0Deviations :

V-1 DEP 2 nd Field Operating Status 11.53 hrs 0.26% deviat ion

V-1 DEP 3 rd Field Secondary 10.617 hrs. 0.24% deviation Voltage & Current V-1 Furnace DEP Bypass 24.883 hrs 0.56% devia tion

V-2 Furnace Batch Wetting 10.05 hrs 0.23% dev iation

V-1 Incinerator Temperature 0.75 hrs 0.02% de viation V-2 Incinerator Temperature 4.50 hrs 0.11% de viation

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 wil l be provided in this report.

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

Print Name: Glenn E. Haley

Signature:

Title Plant LeaderGaseous and Opacity Excess Emission and Continuous Monitoring System

Performance 40CFR63 Subpart NNN

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

Owens Corning Insulating System LLC – Waxahachie Pl ant 3700 North Interstate Highway 35E Waxahachie, TX 75165

The following instances are being reported as a dev iation of a monitoring 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 con tent of this report is accurate.

Print Name: Glenn E. Haley

Signature:

Title Plant LeaderOWENS CORNING INSULATING SYSTEMS, LLC - Waxahachie 3700 North Interstate Highway 35E Waxahachie, Texas 75165

CERTIFIED MAIL – Return Receipt Requested

# 7006 0100 0001 8217 5598

July 28, 2009

United States Environmental Protection Agency Dallas Regional Office

1445 Ross Avenue Dallas, Texas 75202-2733

Attn: David Garcia

RE: MACT Semi-Annual Reporting for Period January 1, 2009 through June 30, 2009

Dear Mr. Garcia:

This report includes three separate reports as requ ired by 40 CFR 63 Subparts A and NNN. The first report summarizes periods of startu p, shutdown, and malfunction where actions taken were inconsistent with the plan in ac cordance 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 63.138 6(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 CF R 63.1386(e) if monitored parameters deviate more than 1% of the total operat ing time. Each report is labeled appropriately and is for the period January 1, 2009 through June 30, 2009.

As the responsible official, I certify to the accur acy of this report. If you have any questions regarding this information, please contac t our Facility Environmental Leader, Gary Chastain at (972) 923-4330.

Sincerely,

Glenn E. Haley

Plant Leader Owens Corning Insulating System LLC – Waxahachie Pl ant Waxahachie, TX

cc: Tony Walker, TCEQ Region IV – Certified Mail # 7006 0100 0001 8217 5604

AttachmentReport : Periods of Startup, Shutdown, and Malfunction Whe re Actions Taken were

Inconsistent with SSM Plan 40 CFR 63 Subpart NNN

Reporting Period : January 1, 2009 through June 30, 2009

Owens Corning Insulating System LLC– Waxahachie Pla nt 3700 North Interstate Highway 35E Waxahachie, TX 75165

All instances of startup, shutdown and malfunction were dealt with in accordance with the facility Startup, Shutdown and Malfunction Plan

.

Report : Periods of Deviation form the Operations, Mainten ance and Monitoring (OMM)

Plan 40 CFR 63 Subpart NNN

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

OMM Plan.

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

Print Name: Glenn E. Haley

Signature:

Title Plant LeaderSummary Report – Gaseous and Opacity Excess Emissio n and Continuous

Monitoring System Performance 40CFR63 Subpart NNN

Reporting Period : January 1, 2009 through June 30, 2009

Owens Corning Insulating System LLC– Waxahachie Pla nt 3700 North Interstate Highway 35E Waxahachie, TX 75165

HAP’s Monitored : The Wool Fiberglass MACT focuses on two surrogat e 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 produc ed 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 gla ss. The molten glass is passed through a rotary spin (RS) forming process where a fine, gl ass fiber is produced. Binder is applied to the fiber as it forms a “pack” on the su rface of a foraminous conveyor. Once collected, the pack passes through a curing and coo ling process followed by final fabrication and packaging. Tables 1 through 3 defi ne the manufacturing sources at this facility, including individual processes, control d evices, and monitored parameters.

TABLE 1

Process Control

Device Monitored Parameter

V1

Furnace Glass Melting DEP 1 st Field – Operating Status

2 nd Field – Operating Status

3 rd Field – Secondary Voltage

3 rd Field – Secondary Current Glass Melting Molten Glass Throughput

Line Forming Premix Formulation

LOI Resin Free Formaldehyde Molten Glass Throughput Curing Incinerator TemperatureTABLE 2

Process Control

Device Monitored Parameter

V2

Furnace Glass Melting Batch Wetting Water Flow

Glass Melting Molten Glass Throughput

Line Forming Premix Formulation

LOI Resin Free Formaldehyde Molten Glass Throughput Curing Incinerator Temperature

TABLE 3

Process Control

Device Monitored Parameter

V3

Furnace Glass Melting Batch Wetting Water Flow

Glass Melting Molten Glass Throughput

Line Forming Premix Formulation

LOI Resin Free Formaldehyde Molten Glass Throughput Curing Incinerator Temperature

Emission Data Summary / Operating Hours for Facilit y

For the period January 1, 2009 through June 30, 200 9 the operating hours are:

V1 Furnace – 4344

V1 Line – 3169

V2 Furnace – 4344

V2 Line – 3809

V3 Furnace – 0

V3 Line – 0Deviations :

V-1 Furnace DEP Bypass 15.80 hrs 0.36% deviat ion

V-2 Furnace Batch Wetting 4.52 hrs 0.15% devi ation

V-2 Incinerator Temperature 8.03 hrs 0.18% de viation

V-2 Lost Furnace Crust 168.00 hrs 3.87% deviat ion

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

exceedence time:

V-2 Lost Furnace Crust 168.00 hrs 3.87% deviation

This instance will be described in more detail in t he Parameter Exceedence Report that

follows.

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

Print Name: Glenn E. Haley

Signature:

Title Plant LeaderGaseous and Opacity Excess Emission and Continuous Monitoring System

Performance 40CFR63 Subpart NNN

Reporting Period : January 1, 2009 through June 30, 2009

Owens Corning Insulating System LLC – Waxahachie Pl ant 3700 North Interstate Highway 35E Waxahachie, TX 75165

The following instances are being reported as a dev iation of a monitored parameter due to malfunction or startup/shutdown:

V-2 Lost Furnace Crust – See Appendix A for Details

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

Print Name: Glenn E. Haley

Signature:

Title Plant Leader

## APPENDIX A

V-2 Lost Furnace CrustGaseous and Opacity Excess Emission and Continuous Monitoring System

Performance 40CFR63 Subpart NNN

Reporting Period : January 1, 2009 through June 30, 2009

Owens Corning Insulating System LLC – Waxahachie Pl ant 3700 North Interstate Highway 35E Waxahachie, TX 75165

V-2 Lost Furnace Crust:

During the reporting period, there were 168 hours w here the V-2 Furnace was operated in a Hot Top or no batch crust condition. The total a mount of hours was due to production being curtailed from March 16, 2009 through March 2 9, 2009. The melter was secured in a “hot idle” with zero pull state from 3/20/2009 7: 00 AM until 3/27/2009 7:00 AM during the curtailment period. A batch blanket was established @ 8:30 AM on

3/27/2009. The table below summarizes the V-2 Lost Furnace Crust Deviation:

V-2 Lost Furnace Crust Owens Corning Waxahachie, TX

January 1, 2009 through June 30, 2009

Deviation Start Time Deviation End Time Total Devia tion (hrs)

3/20/2009 @ 07:00 AM 3/27/2009 @ 7:00 AM 168.0 Hour sOWENS CORNING INSULATING SYSTEMS, LLC - Waxahachie 3700 North Interstate Highway 35E Waxahachie, Texas 75165

CERTIFIED MAIL – Return Receipt Requested

# 7009 1410 0002 2393 0610

January 29, 2010

United States Environmental Protection Agency Dallas Regional Office

1445 Ross Avenue Dallas, Texas 75202-2733

Attn: David Garcia

RE: MACT Semi-Annual Reporting for Period July 1, 2009 through December 31, 200 9

Dear Mr. Garcia:

This report includes three separate reports as requ ired by 40 CFR 63 Subparts A and NNN. The first report summarizes periods of startu p, shutdown, and malfunction where actions taken were inconsistent with the plan in ac cordance 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 63.138 6(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 CF R 63.1386(e) if monitored parameters deviate more than 1% of the total operat ing time. Each report is labeled appropriately and is for the period July 1, 2009 th rough December 31, 2009.

As the responsible official, I certify to the accur acy of this report. If you have any questions regarding this information, please contac t our Facility Environmental Leader, Gary Chastain at (972) 923-4330.

Sincerely,

Glenn E. Haley

Plant Leader Owens Corning Insulating System LLC – Waxahachie Pl ant Waxahachie, TX

cc: Tony Walker, TCEQ Region IV – Certified Mail # 7009 1410 0002 2393 0627

AttachmentReport : Periods of Startup, Shutdown, and Malfunction Whe re Actions Taken were

Inconsistent with SSM Plan 40 CFR 63 Subpart NNN

Reporting Period : July 1, 2009 through December 31, 2009

Owens Corning Insulating System LLC– Waxahachie Pla nt 3700 North Interstate Highway 35E Waxahachie, TX 75165

All instances of startup, shutdown and malfunction were dealt with in accordance with the facility Startup, Shutdown and Malfunction Plan

.

Report : Periods of Deviation form the Operations, Mainten ance and Monitoring (OMM)

Plan 40 CFR 63 Subpart NNN

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

OMM Plan.

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

Print Name: Glenn E. Haley

Signature:

Title Plant LeaderSummary Report – Gaseous and Opacity Excess Emissio n and Continuous

Monitoring System Performance 40CFR63 Subpart NNN

Reporting Period : July 1, 2009 through December 31, 2009

Owens Corning Insulating System LLC– Waxahachie Pla nt 3700 North Interstate Highway 35E Waxahachie, TX 75165

HAP’s Monitored : The Wool Fiberglass MACT focuses on two surrogat e 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 produc ed 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 gla ss. The molten glass is passed through a rotary spin (RS) forming process where a fine, gl ass fiber is produced. Binder is applied to the fiber as it forms a “pack” on the su rface of a foraminous conveyor. Once collected, the pack passes through a curing and coo ling process followed by final fabrication and packaging. Tables 1 through 3 defi ne the manufacturing sources at this facility, including individual processes, control d evices, and monitored parameters.

TABLE 1

Process Control

Device Monitored Parameter

V1

Furnace Glass Melting DEP 1 st Field – Operating Status

2 nd Field – Operating Status

3 rd Field – Secondary Voltage

3 rd Field – Secondary Current Glass Melting Molten Glass Throughput

Line Forming Premix Formulation

LOI Resin Free Formaldehyde Molten Glass Throughput Curing Incinerator TemperatureTABLE 2

Process Control

Device Monitored Parameter

V2

Furnace Glass Melting Batch Wetting Water Flow

Glass Melting Molten Glass Throughput

Line Forming Premix Formulation

LOI Resin Free Formaldehyde Molten Glass Throughput Curing Incinerator Temperature

TABLE 3

Process Control

Device Monitored Parameter

V3

Furnace Glass Melting Batch Wetting Water Flow

Glass Melting Molten Glass Throughput

Line Forming Premix Formulation

LOI Resin Free Formaldehyde Molten Glass Throughput Curing Incinerator Temperature

Emission Data Summary / Operating Hours for Facilit y

For the period July 1, 2009 through December 31, 20 09 the operating hours are:

V1 Furnace – 4417

V1 Line – 3967

V2 Furnace – 4417

V2 Line – 3903

V3 Furnace – 0

V3 Line – 0Deviations :

V-1 Furnace DEP Bypass 30.567 hrs 0.69% deviat ion

V-2 Furnace Batch Wetting 26.13 hrs 0.59% dev iation

V-1 Incinerator Temperature 16.50 hrs 0.42% d eviation V-2 Incinerator Temperature 2.75 hrs 0.07% deviation

V-2 Lost Furnace Crust 30.48 hrs 0.69% deviation

Based on these operating hours and known deviations , there were no monitoring parameters over the 1% exceedence time. Since the total exceedence time for each parameter is less than 1%, no additional detail wil l be provided in this report.

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

Print Name: Glenn E. Haley

Signature:

Title Plant LeaderGaseous and Opacity Excess Emission and Continuous Monitoring System

Performance 40CFR63 Subpart NNN

Reporting Period : July 1, 2009 through December 31, 2009

Owens Corning Insulating System LLC – Waxahachie Pl ant 3700 North Interstate Highway 35E Waxahachie, TX 75165

The following instances are being reported as a dev iation of a monitoring 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 con tent of this report is accurate.

Print Name: Glenn E. Haley

Signature:

Title Plant Leader