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 required by 40 CFR 63 Subparts A and 

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

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

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

Gaseous and Opacity Excess Emission and Continuous Monitoring System Performance” 

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

“Gaseous and Opacity Excess Emission and Continuous Monitoring System Performance 

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

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

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

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

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

Gary Chastain at (972) 923-4330.

Sincerely,

David Randolph

Plant Manager

Owens Corning – Waxahachie Plant

Waxahachie, TX 

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

Inconsistent with SSM Plan

40 CFR 63 Subpart NNN

Reporting Period: January 1, 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 deviation 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 Plan. 

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

Print Name: David Randolph 

Signature: 

Title Plant Manager 
Summary Report – Gaseous 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 

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

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

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

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

and curing. 

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

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

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

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

fabrication and packaging. Tables 1 through 3 define the manufacturing sources at this 

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

TABLE 1 

 Process Control 

Device 

Monitored Parameter 

V1 

Furnace Glass Melting DEP 1st 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 Temperature 

 
TABLE 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 Facility

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

V1 Furnace – 4343 

V1 Line – 4126 

V2 Furnace – 4343 

V2 Line – 4032 

V3 Furnace – 4343 

V3 Line – 4188 
Deviations: 

V-1 DEP 2nd 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% deviation 

V-3 Furnace Batch Wetting 81.33 hrs 1.87% deviation 

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 monitoring 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 not counted as a deviation since batch 

was not being fed to the furnace. 

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

Print Name: David Randolph 

Signature: 

Title Plant Manager 
Gaseous 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 deviation of a monitored parameter due to 

malfunction or startup/shutdown: 

V3 Furnace Batch Wetting – See Appendix A for details 

V2 Lost Furnace Crust - See Appendix B for details 

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

Print Name: David Randolph 

Signature: 

Title Plant Manager 
APPENDIX A 

V3 Batch Wetting Deviations
Gaseous 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 batch wetting deviations were a result 

of two separate instances concerning the fogger spray assembly. In January 2005 the 

west side fogger is believed to have fallen into the melter due to support bracket failure. 

In June 2005 the charge boom hit the fogger spray assembly and knocked it into the 

melter. Both situations were corrected by maintenance. 

The table below summarizes the V3 Batch Wetting Deviations: 

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 Crust
Gaseous 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 30 minutes where an overcoat of 

refractory was added to the V2 furnace. The furnace 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 Crust Deviations: 

V2 Lost Furnace Crust Deviations 

Owens Corning 

Waxahachie, TX 

January 1, 2005 to June 30, 2005 

Deviation Start Time Deviation End Time Total Deviation (hrs) 

1/9/05 at 22:00 1/14/05 at 10:30 108.5 
January 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 required by 40 CFR 63 Subparts A and 

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

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

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

Gaseous and Opacity Excess Emission and Continuous Monitoring System Performance” 

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

“Gaseous and Opacity Excess Emission and Continuous Monitoring System Performance 

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

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

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

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

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

Gary Chastain at (972) 923-4330.

Sincerely,

David Randolph

Plant Manager

Owens Corning – Waxahachie Plant

Waxahachie, TX 

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

Inconsistent with SSM Plan

40 CFR 63 Subpart NNN

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

Owens Corning – Waxahachie Plant 

3700 North Interstate Highway 35E 

Waxahachie, TX 75165 

The following instances are being reported as a deviation 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 Plan. 

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

Print Name: David Randolph 

Signature: 

Title Plant Manager 
Summary Report – Gaseous and Opacity Excess Emission and Continuous 

Monitoring System Performance

40CFR63 Subpart NNN

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

Owens Corning – Waxahachie Plant 

3700 North Interstate Highway 35E 

Waxahachie, TX 75165 

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

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

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

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

and curing. 

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

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

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

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

fabrication and packaging. Tables 1 through 3 define the manufacturing sources at this 

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

TABLE 1 

 Process Control 

Device 

Monitored Parameter 

V1 

Furnace Glass Melting DEP 1st 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 Temperature 

 
TABLE 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 Facility

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

V1 Furnace – 4416 

V1 Line – 4112 

V2 Furnace – 4416 

V2 Line – 4221 

V3 Furnace – 4416 

V3 Line – 4092 
Deviations: 

V-1 DEP SIR 1 Operating Status 54.83 hrs 1.24% deviation 

V-1 Furnace DEP Bypass 17.12 hrs 0.39% deviation 

V-2 Furnace Batch Wetting 7.58 hrs 0.17% deviation 

V-3 Furnace Batch Wetting 62.28 hrs 1.41% deviation 

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% deviation 

V-3 LOI Check Frequency 7.07 hrs 0.17% deviation

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

exceedance time: 

V-1 DEP SIR 1 Operating Status 54.83 hrs 1.24% deviation 

V-3 Furnace Batch Wetting 62.28 hrs 1.41% deviation 

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

follows. 

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

Print Name: David Randolph 

Signature: 

Title Plant Manager 
Gaseous 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 deviation 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 details 

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

Print Name: David Randolph 

Signature: 

Title Plant Manager 
APPENDIX A 

V-1 DEP SIR 1 Operating Status 
Gaseous 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 minutes of the total deviation was due to 

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

manufacturer. The table below summarizes the V-1 DEP 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 Wetting 
Gaseous 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 deviation 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 Wetting 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 62.28 
OWENS 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 report 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 Opacity 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 3rd 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 reports. 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 accuracy of this report. If you have any 

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

Gary Chastain at (972) 923-4330.

Sincerely,

David Randolph

Plant Leader

Owens Corning – Waxahachie Plant

Waxahachie, TX 
cc: Tony Walker – Air Section Manager - Region IV - TCEQ 

attachment 
 Summary Report – Gaseous and Opacity Excess Emission and Continuous 

Monitoring System Performance

40CFR63 Subpart NNN

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

Owens Corning – Waxahachie Plant 

3700 North Interstate Highway 35E 

Waxahachie, TX 75165 

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

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

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

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

and curing. 

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

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

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

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

fabrication and packaging. Tables 1 through 3 define the manufacturing sources at this 

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

TABLE 1 

 Process Control 

Device 

Monitored Parameter 

V1 

Furnace Glass Melting DEP 1st 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 Temperature 

 
TABLE 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 Facility

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

V1 Furnace – 4343 

V1 Line – 4030 

V2 Furnace – 3545 

V2 Line – 3444 

V3 Furnace – 4343 

V3 Line – 4176 
Deviations: 

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

V-1 DEP 3rd 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% deviation 

V-3 Furnace Batch Wetting 33.88 hrs 0.78% deviation 

V-1 Incinerator Temperature 6.00 hrs 0.15% deviation 

V-2 Incinerator Temperature 1.50 hrs 0.04% deviation 

V-3 Incinerator Temperature 0.50 hrs 0.01% deviation 

V-3 Lost Furnace Crust 1.03 hrs 0.02% deviation 

V-1 High LOI 5.00 hrs 0.12% deviation 

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

exceedance time: 

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

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

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

5% exceedance time, thus warranting a Quality Improvement Plan (QIP) per 

63.1382(b)(2)(ii) and 63.10(e)(3)(viii): 

V-1 DEP 2nd 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 content of this report is accurate. 

Print Name: David Randolph 

Signature: 

Title Plant Leader 

 
Gaseous and Opacity Excess Emission and Continuous Monitoring System 

Performance 

40CFR63 Subpart NNN

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

Owens Corning – Waxahachie Plant 

3700 North Interstate Highway 35E 

Waxahachie, TX 75165 

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

malfunction or startup/shutdown: 

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

V-1 DEP 3rd Field Not Operating – See Appendix B for Details 

As the responsible official, I certify that the content 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 3rd Field Not Operating 
Gaseous 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 3rd Field Not Operating:

During the reporting period, there were 212 hours 8 minutes where the V-1 DEP 3rd Field 

was not operating. Due to the 3rd field not operating during this time period, the two 

monitoring parameters, secondary voltage and current were combined under this one 

item. 

The 3rd Field SIR controller failed causing the field to shutdown on March 30, 2006. 

Owens Corning personnel contacted the equipment manufacture on 3/30/2006 following 

unsuccessful restart attempts. An OEM service technician arrived on sight on 3/31/2006 

to troubleshoot and attempt repair. Additional equipment parts were needed and 

immediately ordered from the equipment-manufacturing site in Sweden. These parts 

were received on 4/6/2006 and installed by OEM service technician on 4/7/2006. These 

new parts failed to resolve the failure. It was determined that the new parts were 

defective as received. Additional replacement equipment parts were received on 

4/8/2006. The OEM Service Technician installed these 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 3rd Field was not operating: 

V-1 DEP 3rd Field Not Operating 

Owens Corning 

Waxahachie, TX 

January 1, 2006 to June 30, 2006 

Deviation Start Time Deviation End Time Total Deviation (hrs) 

3/30/2006 @12:08 4/8/2006 @ 10:25 212.13 hours 
July 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 required by 40 CFR 63 Subparts A and 

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

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

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

Gaseous and Opacity Excess Emission and Continuous Monitoring System Performance” 

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

“Gaseous and Opacity Excess Emission and Continuous Monitoring System Performance 

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

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

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

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

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

Gary Chastain at (972) 923-4330.

Sincerely,

David Randolph

Plant Leader

Owens Corning – Waxahachie Plant

Waxahachie, TX 

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

Inconsistent with SSM Plan

40 CFR 63 Subpart NNN

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

Owens Corning – 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, Maintenance and Monitoring (OMM) 

Plan

40 CFR 63 Subpart NNN

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

OMM Plan. 

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

Print Name: David Randolph 

Signature: 

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

Monitoring System Performance

40CFR63 Subpart NNN

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

Owens Corning – Waxahachie Plant 

3700 North Interstate Highway 35E 

Waxahachie, TX 75165 

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

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

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

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

and curing. 

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

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

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

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

fabrication and packaging. Tables 1 through 3 define the manufacturing sources at this 

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

TABLE 1 

 Process Control 

Device 

Monitored Parameter 

V1 

Furnace Glass Melting DEP 1st 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 Temperature 

 
TABLE 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 Facility

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

V1 Furnace – 4343 

V1 Line – 4030 

V2 Furnace – 3545 

V2 Line – 3444 

V3 Furnace – 4343 

V3 Line – 4176 
Deviations: 

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

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

V-1 Furnace DEP Bypass 27.92 hrs 0.64% deviation 

V-2 Furnace Batch Wetting 13.90 hrs 0.39% deviation 

V-3 Furnace Batch Wetting 33.88 hrs 0.78% deviation 

V-1 Incinerator Temperature 6.00 hrs 0.15% deviation 

V-2 Incinerator Temperature 1.50 hrs 0.04% deviation 

V-3 Incinerator Temperature 0.50 hrs 0.01% deviation 

V-3 Lost Furnace Crust 1.03 hrs 0.02% deviation 

V-1 High LOI 5.00 hrs 0.12% deviation 

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

exceedance time: 

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

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

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

5% exceedance time, thus warranting a Quality Improvement Plan (QIP) per 

63.1382(b)(2)(ii) and 63.10(e)(3)(viii): 

V-1 DEP 2nd 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 content of this report is accurate. 

Print Name: David Randolph 

Signature: 

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

Performance 

40CFR63 Subpart NNN

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

Owens Corning – Waxahachie Plant 

3700 North Interstate Highway 35E 

Waxahachie, TX 75165 

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

malfunction or startup/shutdown: 

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

V-1 DEP 3rd Field Not Operating – See Appendix B for Details 

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

Print Name: David Randolph 

Signature: 

Title Plant Leader 
APPENDIX A 

V-1 DEP 2nd Field Operating Status 
Gaseous 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 2nd Field Operating Status:

During the reporting period, there were 249 hours 17 minutes where the V-1 DEP 2nd

Field was not operating. Of this total time, 244.25 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. Failure could not be resolved and an 

internal inspection by an OEM service technician was conducted on 6/8/2006. Based on 

this inspection, several possible components causing 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 replacement High Voltage Unit. The #2 field 

was brought back on line on 6/17/2006. 

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

Owens Corning 

Waxahachie, TX 

January 1, 2006 to June 30, 2006 

Deviation Start Time Deviation End Time Total Deviation (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 through 7/17/2006 the DEP was offline for 

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

hours. 
APPENDIX B 

V-1 DEP 3rd Field Not Operating 
Gaseous 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 3rd Field Not Operating:

During the reporting period, there were 214 hours 17 minutes where the V-1 DEP 3rd

Field was not operating. Due to the 3rd field not operating during this time period, the 

two monitoring parameters, secondary voltage and current were combined under this one 

item. 

The 3rd Field SIR controller failed causing the field to shutdown on March 30, 2006. 

Owens Corning personnel contacted the equipment manufacture on 3/30/2006 following 

unsuccessful restart attempts. An OEM service technician arrived on sight on 3/31/2006 

to troubleshoot and attempt repair. Additional equipment parts were needed and 

immediately ordered from the equipment-manufacturing site in Sweden. These parts 

were received on 4/6/2006 and installed by OEM service technician on 4/7/2006. These 

new parts failed to resolve the failure. It was determined that the new parts were 

defective as received. Additional replacement equipment parts were received on 

4/8/2006. The OEM Service Technician installed these 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 3rd Field was not operating: 

V-1 DEP 3rd Field Not Operating 

Owens Corning 

Waxahachie, TX 

January 1, 2006 to June 30, 2006 

Deviation Start Time Deviation End Time Total Deviation (hrs) 

3/30/2006 @12:08 4/8/2006 @ 10:25 214.28 hours 
CERTIFIED 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 required by 40 CFR 63 Subparts A and 

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

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

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

Gaseous and Opacity Excess Emission and Continuous Monitoring System Performance” 

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

“Gaseous and Opacity Excess Emission and Continuous Monitoring System Performance 

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

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

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

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

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

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 

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

Inconsistent with SSM Plan

40 CFR 63 Subpart NNN

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

Owens Corning – 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, Maintenance and Monitoring (OMM) 

Plan

40 CFR 63 Subpart NNN

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

OMM Plan. 

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

Print Name: Glenn E. Haley 

Signature: 

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

Monitoring System Performance

40CFR63 Subpart NNN

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

Owens Corning – Waxahachie Plant 

3700 North Interstate Highway 35E 

Waxahachie, TX 75165 

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

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

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

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

and curing. 

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

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

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

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

fabrication and packaging. Tables 1 through 3 define the manufacturing sources at this 

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

TABLE 1 

 Process Control 

Device 

Monitored Parameter 

V1 

Furnace Glass Melting DEP 1st 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 Temperature 

 
TABLE 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 Facility

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

V1 Furnace – 4417 

V1 Line – 3984 

V2 Furnace – 4417 

V2 Line – 4133 

V3 Furnace – 4417 

V3 Line – 4137 
Deviations: 

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

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

V-1 Furnace DEP Bypass 11.98 hrs 0.27% deviation 

V-2 Furnace Batch Wetting 24.05 hrs 0.54% deviation 

V-3 Furnace Batch Wetting 11.05 hrs 0.25% deviation 

V-1 Incinerator Temperature 9.75 hrs 0.24% deviation 

V-2 Incinerator Temperature 7.25 hrs 0.18% deviation 

V-3 Incinerator Temperature 10.00 hrs 0.24% deviation 

V-2 Lost Furnace Crust 2.00 hrs 0.05% deviation 

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 monitoring parameters were over the 1% 

exceedance time: 

V-1 DEP 2nd 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 content of this report is accurate. 

Print Name: Glenn E. Haley 

Signature: 

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

Performance 

40CFR63 Subpart NNN

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

Owens Corning – Waxahachie Plant 

3700 North Interstate Highway 35E 

Waxahachie, TX 75165 

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

malfunction or startup/shutdown: 

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

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

Print Name: Glenn E. Haley 

Signature: 

Title Plant Leader 
APPENDIX A 

V-1 DEP 2nd Field Operating Status 
Gaseous 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 2nd Field Operating Status:

During the reporting period, there were 50 hours 41 minutes where the V-1 DEP 2nd 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 determined 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 the 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 2nd Field Operating Status Deviations: 

V-1 DEP 2nd Field Operating Status 

Owens Corning 

Waxahachie, TX 

July 1, 2006 through December 31, 2006 

Deviation Start Time Deviation End Time Total Deviation (hrs) 

12/5/2006 @ 10:42 12/7/2006 @ 13:25 50.683 hours 
CERTIFIED 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 required by 40 CFR 63 Subparts A and 

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

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

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

Gaseous and Opacity Excess Emission and Continuous Monitoring System Performance” 

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

“Gaseous and Opacity Excess Emission and Continuous Monitoring System Performance 

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

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

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

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

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

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 

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

Inconsistent with SSM Plan

40 CFR 63 Subpart NNN

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

Owens Corning – 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, Maintenance and Monitoring (OMM) 

Plan 

40 CFR 63 Subpart NNN

Based on the requirements within the Operations, Maintenance, 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 content of this report is accurate. 

Print Name: Glenn E. Haley 

Signature: 

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

Monitoring System Performance

40CFR63 Subpart NNN

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

Owens Corning – Waxahachie Plant 

3700 North Interstate Highway 35E 

Waxahachie, TX 75165 

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

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

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

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

and curing. 

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

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

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

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

fabrication and packaging. Tables 1 through 3 define the manufacturing sources at this 

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

TABLE 1 

 Process Control 

Device 

Monitored Parameter 

V1 

Furnace Glass Melting DEP 1st 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 Temperature 

 
TABLE 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 Facility

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

V1 Furnace – 4343 

V1 Line – 3839 

V2 Furnace – 4343 

V2 Line – 4147 

V3 Furnace – 2504 

V3 Line – 2305 
Deviations: 

V-1 DEP 1st Field Operating Status 0.150 hrs 0.003% deviation 

V-1 DEP 2nd Field Operating Status 0.717 hrs 0.02% deviation 

V-1 DEP 3rd Field Secondary 5.633 Hrs. 0.13% deviation 

 Voltage & Current 

V-1 Furnace DEP Bypass 31.117 hrs 0.72% deviation 

V-2 Furnace Batch Wetting 25.45 hrs 0.59% deviation 

V-3 Furnace Batch Wetting 12.82 hrs 0.51% deviation 

V-1 Incinerator Temperature 13.00 hrs 0.34% deviation 

V-2 Incinerator Temperature 8.00 hrs 0.19% deviation 

V-3 Incinerator Temperature 6.50 hrs 0.28% deviation 

V-3 Lost Furnace Crust 124.00 hrs 4.95% deviation 

V-2 High LOI 1.27 hrs 0.031% deviation 

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

exceedance time: 

V-3 Lost Furnace Crust Loss 124.00 hrs 4.95% deviation 

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

follows. 

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

Print Name: Glenn E. Haley 

Signature: 

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

Performance 

40CFR63 Subpart NNN

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

Owens Corning – Waxahachie Plant 

3700 North Interstate Highway 35E 

Waxahachie, TX 75165 

The following instances are being reported as a deviation 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 content of this report is accurate. 

Print Name: Glenn E. Haley 

Signature: 

Title Plant Leader 
APPENDIX A 

V-3 Lost Furnace Crust 
Gaseous 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 where the V-3 Furnace was operated in 

a Hot Top or no batch crust condition. Of these total hours, 64 were attributed to the shut 

down and start up of a routine furnace rebuild. Cold top electric melters are routinely 

rebuilt every five to six years. Sixteen hours of the 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 deviation 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 glass 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 from the conditioning channel and to 

replace the cover with new refractory. After repairs were complete, normal batch 

operations were commenced. 

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

V-1 DEP 2nd Field Operating Status 

Owens Corning 

Waxahachie, TX 

July 1, 2006 through December 31, 2006 

Deviation Start Time Deviation End Time Total Deviation (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 hours 
CERTIFIED 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 required by 40 CFR 63 Subparts A and 

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

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

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

Gaseous and Opacity Excess Emission and Continuous Monitoring System Performance” 

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

“Gaseous and Opacity Excess Emission and Continuous Monitoring System Performance 

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

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

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

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

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

Gary Chastain at (972) 923-4330.

Sincerely,

Glenn E. Haley

Plant Leader

Owens Corning Insulating System LLC – Waxahachie Plant

Waxahachie, TX 

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

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

Inconsistent with SSM Plan

40 CFR 63 Subpart NNN

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

Owens Corning Insulating System LLC– 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, Maintenance and Monitoring (OMM) 

Plan 

40 CFR 63 Subpart NNN

Based on the requirements within the Operations, Maintenance, 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, Maintenance, and Monitoring Plan, 

monitoring of the operating status and operating parameters of the Dry Electrostatic 

Precipitator are required at least once every 8 hours. 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 content of this report is accurate. 

Print Name: Glenn E. Haley 

Signature: 

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

Monitoring System Performance

40CFR63 Subpart NNN

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

Owens Corning Insulating System LLC– Waxahachie Plant 

3700 North Interstate Highway 35E 

Waxahachie, TX 75165 

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

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

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

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

and curing. 

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

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

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

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

fabrication and packaging. Tables 1 through 3 define the manufacturing sources at this 

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

TABLE 1 

 Process Control 

Device 

Monitored Parameter 

V1 

Furnace Glass Melting DEP 1st 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 Temperature 

 
TABLE 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 Facility

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

V1 Furnace – 4417 

V1 Line – 4009 

V2 Furnace – 4417 

V2 Line – 3957 

V3 Furnace – 4417 

V3 Line – 3981 
Deviations: 

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

V-1 DEP 3rd Field Secondary 36.80 Hrs. 0.83% deviation 

 Voltage & Current 

V-1 Furnace DEP Bypass 18.12 hrs 0.41% deviation 

V-2 Furnace Batch Wetting 8.58 hrs 0.19% deviation 

V-3 Furnace Batch Wetting 38.38 hrs 0.17% deviation 

V-1 Incinerator Temperature 27.25 hrs 0.68% deviation 

V-2 Incinerator Temperature 0.50 hrs 0.01% deviation 

V-3 Incinerator Temperature 1.00 hrs 0.03% deviation 

V-2 Lost Furnace Crust 175.00 hrs 3.96% deviation 

V-3 Lost Furnace Crust 70.00 hrs 1.58% deviation 

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 monitoring parameters were over the 1% 

exceedance time: 

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

V-2 Lost Furnace Crust 175.00 hrs 3.96% deviation 

V-3 Lost Furnace Crust 70.00 hrs 1.58% deviation 

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

follows. 

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

5% exceedence time, thus warranting a Quality Improvement Plan (QIP) per 

63.1382(b)(2)(ii) and 63.10(e)(3)(viii): 

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

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

Print Name: Glenn E. Haley 

Signature: 

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

Performance 

40CFR63 Subpart NNN

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

Owens Corning Insulating System LLC – Waxahachie Plant 

3700 North Interstate Highway 35E 

Waxahachie, TX 75165 

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

malfunction or startup/shutdown: 

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

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 content of this report is accurate. 

Print Name: Glenn E. Haley 

Signature: 

Title Plant Leader 
APPENDIX A 

V-1 DEP 2nd Field Operating Status 
Gaseous 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 2nd Field Operating Status:

During the reporting period, there were 270 hours and 10 minutes where the V-1 DEP 2nd

Field was not operating. Of that total time, 266 hours 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 Electrostatic Precipitator at 9:45 PM on 

7/1/2007. A replacement SIR-A was not available from 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 operation. The supplied SIR-E controller 

unit was installed and placed in service on 7/13/2007 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 2nd Field Operating Status Deviations: 

V-1 DEP 2nd Field Operating Status 

Owens Corning 

Waxahachie, TX 

July 1, 2007 through December 31, 2007 

Deviation Start Time Deviation End Time Total Deviation (hrs) 

7/1/2007 @ 5:18 PM 7/12/2007 @ 7:33 PM 266.233 hours 

7/30/2007 @ 12:24 PM 7/30/2007 @ 7:27 PM 3.833 hours 

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 Crust 
Gaseous and Opacity Excess Emission and Continuous Monitoring System 

Performance 

40CFR63 Subpart NNN

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

Owens Corning Insulating System LLC – Waxahachie Plant 

3700 North Interstate Highway 35E 

Waxahachie, TX 75165 

V-2 Lost Furnace Crust:

During the reporting period, there were 175 hours where the V-2 Furnace was operated in 

a Hot Top or no batch crust condition. The total amount of hours was due V-2 

production being curtailed from Nov. 21, 2007 through 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 utilized 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 Deviation (hrs) 

11/21/2007 @ 07:00 AM 11/28/2007 @ 8:00 AM 275.0 Hours 
APPENDIX C 

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

Performance 

40CFR63 Subpart NNN

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

Owens Corning Insulating System LLC – Waxahachie Plant 

3700 North Interstate Highway 35E 

Waxahachie, TX 75165 

V-3 Lost Furnace Crust:

During the reporting period, there were 70 hours where the V-3 Furnace was operated in 

a “Hot Top” or no batch crust condition. The entire 70 hours are attributed to a single 

occurrence. Batch for the melter is delivered to the 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 Idle” condition. Loss of the melter batch 

blanket occurred at 9:00PM. The transporter was repaired and returned to service on 

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

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

V-3 Lost Furnace Crust 

Owens Corning 

Waxahachie, TX 

July 1, 2006 through December 31, 2006 

Deviation Start Time Deviation End Time Total Deviation (hrs) 

12/17/2007 @ 09:00 PM 12/20/2007 @ 7:00 PM 70.0 Hours 
CERTIFIED 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 required by 40 CFR 63 Subparts A and 

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

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

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

Gaseous and Opacity Excess Emission and Continuous Monitoring System Performance” 

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

“Gaseous and Opacity Excess Emission and Continuous Monitoring System Performance 

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

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

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

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

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

Gary Chastain at (972) 923-4330.

Sincerely,

Glenn E. Haley

Plant Leader

Owens Corning Insulating System LLC – Waxahachie Plant

Waxahachie, TX 

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

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

Inconsistent with SSM Plan

40 CFR 63 Subpart NNN

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

Owens Corning Insulating System LLC– 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, Maintenance and Monitoring (OMM) 

Plan 

40 CFR 63 Subpart NNN

Based on the requirements within the Operations, Maintenance, 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 deviation time was three hours or 0.09% 

of the reporting period. 

Based on the requirements within the Operations, Maintenance, and Monitoring Plan, 

monitoring of the operating status and operating parameters of the Dry Electrostatic 

Precipitator are required at least once every 8 hours. 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 content of this report is accurate. 

Print Name: Glenn E. Haley 

Signature: 

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

Monitoring System Performance

40CFR63 Subpart NNN

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

Owens Corning Insulating System LLC– Waxahachie Plant 

3700 North Interstate Highway 35E 

Waxahachie, TX 75165 

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

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

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

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

and curing. 

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

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

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

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

fabrication and packaging. Tables 1 through 3 define the manufacturing sources at this 

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

TABLE 1 

 Process Control 

Device 

Monitored Parameter 

V1 

Furnace Glass Melting DEP 1st 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 Temperature 

 
TABLE 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 Facility

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

V1 Furnace – 4387 

V1 Line – 3196 

V2 Furnace – 3089 

V2 Line – 2952 

V3 Furnace – 3575 

V3 Line – 3413 
Deviations: 

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

V-1 DEP 3rd Field Secondary 8.08 hrs. 0.18% deviation 

 Voltage & Current 

V-1 Furnace DEP Bypass 1.52 hrs 0.03% deviation 

V-2 Furnace Batch Wetting 4.52 hrs 0.15% deviation 

V-3 Furnace Batch Wetting 5.33 hrs 0.15% deviation 

V-1 Incinerator Temperature 1.50 hrs 0.05% deviation 

V-2 Incinerator Temperature 2.00 hrs 0.07% deviation 

V-3 Incinerator Temperature 0.25 hrs 0.01% deviation 

V-2 Lost Furnace Crust 96.00 hrs 3.11% deviation 

Based on these operating hours, the following monitoring 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 the Parameter Exceedence Report that 

follows. 

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

Print Name: Glenn E. Haley 

Signature: 

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

Performance 

40CFR63 Subpart NNN

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

Owens Corning Insulating System LLC – Waxahachie Plant 

3700 North Interstate Highway 35E 

Waxahachie, TX 75165 

The following instances are being reported as a deviation 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 content of this report is accurate. 

Print Name: Glenn E. Haley 

Signature: 

Title Plant Leader 
APPENDIX A 

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

Performance 

40CFR63 Subpart NNN

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

Owens Corning Insulating System LLC – Waxahachie Plant 

3700 North Interstate Highway 35E 

Waxahachie, TX 75165 

V-2 Lost Furnace Crust:

During the reporting period, there were 96 hours where the V-2 Furnace was operated in 

a Hot Top or no batch crust condition. The total amount of hours was due V-2 

production being curtailed from March 3, 2008 through April 25, 2008. The melter was 

secured in a “cold” shutdown state during the curtailment 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 operating temperature beginning @ 7:00 AM on 

4/16/2008. The cold solidified glass reached a molten 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 Deviation (hrs) 

4/18/2008 @ 03:00 PM 4/22/2008 @ 3:00 PM 96.0 Hours
OWENS 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, 2008 

Dear Mr. Garcia: 

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

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

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

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

Gaseous and Opacity Excess Emission and Continuous Monitoring System Performance” 

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

“Gaseous and Opacity Excess Emission and Continuous Monitoring System Performance 

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

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

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

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

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

Gary Chastain at (972) 923-4330.

Sincerely,

Glenn E. Haley

Plant Leader

Owens Corning Insulating System LLC – Waxahachie Plant

Waxahachie, TX 

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

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

Inconsistent with SSM Plan

40 CFR 63 Subpart NNN

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

Owens Corning Insulating System LLC– 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, Maintenance and Monitoring (OMM) 

Plan 

40 CFR 63 Subpart NNN

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

OMM Plan. 

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

Print Name: Glenn E. Haley 

Signature: 

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

Monitoring System Performance

40CFR63 Subpart NNN

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

Owens Corning Insulating System LLC– Waxahachie Plant 

3700 North Interstate Highway 35E 

Waxahachie, TX 75165 

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

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

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

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

and curing. 

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

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

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

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

fabrication and packaging. Tables 1 through 3 define the manufacturing sources at this 

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

TABLE 1 

 Process Control 

Device 

Monitored Parameter 

V1 

Furnace Glass Melting DEP 1st 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 Temperature 

 
TABLE 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 Facility

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

V1 Furnace – 4417 

V1 Line – 3672 

V2 Furnace – 4417 

V2 Line – 3977 

V3 Furnace – 0 

V3 Line – 0 
Deviations: 

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

V-1 DEP 3rd Field Secondary 10.617 hrs. 0.24% deviation 

 Voltage & Current 

V-1 Furnace DEP Bypass 24.883 hrs 0.56% deviation 

V-2 Furnace Batch Wetting 10.05 hrs 0.23% deviation 

V-1 Incinerator Temperature 0.75 hrs 0.02% deviation 

V-2 Incinerator Temperature 4.50 hrs 0.11% deviation 

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

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

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

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

Print Name: Glenn E. Haley 

Signature: 

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

Performance 

40CFR63 Subpart NNN

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

Owens Corning Insulating System LLC – Waxahachie Plant 

3700 North Interstate Highway 35E 

Waxahachie, TX 75165 

The following instances are being reported as a deviation 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 content of this report is accurate. 

Print Name: Glenn E. Haley 

Signature: 

Title Plant Leader 
OWENS 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 required by 40 CFR 63 Subparts A and 

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

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

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

Gaseous and Opacity Excess Emission and Continuous Monitoring System Performance” 

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

“Gaseous and Opacity Excess Emission and Continuous Monitoring System Performance 

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

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

appropriately and is for the period January 1, 2009 through June 30, 2009. 

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

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

Gary Chastain at (972) 923-4330.

Sincerely,

Glenn E. Haley

Plant Leader

Owens Corning Insulating System LLC – Waxahachie Plant

Waxahachie, TX 

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

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

Inconsistent with SSM Plan

40 CFR 63 Subpart NNN

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

Owens Corning Insulating System LLC– 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, Maintenance and Monitoring (OMM) 

Plan 

40 CFR 63 Subpart NNN

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

OMM Plan. 

 

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

Print Name: Glenn E. Haley 

Signature: 

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

Monitoring System Performance

40CFR63 Subpart NNN

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

Owens Corning Insulating System LLC– Waxahachie Plant 

3700 North Interstate Highway 35E 

Waxahachie, TX 75165 

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

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

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

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

and curing. 

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

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

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

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

fabrication and packaging. Tables 1 through 3 define the manufacturing sources at this 

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

TABLE 1 

 Process Control 

Device 

Monitored Parameter 

V1 

Furnace Glass Melting DEP 1st 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 Temperature 

 
TABLE 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 Facility

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

V1 Furnace – 4344 

V1 Line – 3169 

V2 Furnace – 4344 

V2 Line – 3809 

V3 Furnace – 0 

V3 Line – 0 
Deviations: 

V-1 Furnace DEP Bypass 15.80 hrs 0.36% deviation 

V-2 Furnace Batch Wetting 4.52 hrs 0.15% deviation 

V-2 Incinerator Temperature 8.03 hrs 0.18% deviation 

V-2 Lost Furnace Crust 168.00 hrs 3.87% deviation 

Based on these operating hours, the following monitoring 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 the Parameter Exceedence Report that 

follows. 

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

Print Name: Glenn E. Haley 

Signature: 

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

Performance 

40CFR63 Subpart NNN

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

Owens Corning Insulating System LLC – Waxahachie Plant 

3700 North Interstate Highway 35E 

Waxahachie, TX 75165 

The following instances are being reported as a deviation 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 content of this report is accurate. 

Print Name: Glenn E. Haley 

Signature: 

Title Plant Leader 
APPENDIX A 

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

Performance 

40CFR63 Subpart NNN

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

Owens Corning Insulating System LLC – Waxahachie Plant 

3700 North Interstate Highway 35E 

Waxahachie, TX 75165 

V-2 Lost Furnace Crust:

During the reporting period, there were 168 hours where the V-2 Furnace was operated in 

a Hot Top or no batch crust condition. The total amount of hours was due to production 

being curtailed from March 16, 2009 through March 29, 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 Deviation (hrs) 

3/20/2009 @ 07:00 AM 3/27/2009 @ 7:00 AM 168.0 Hours 
OWENS 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, 2009 

Dear Mr. Garcia: 

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

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

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

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

Gaseous and Opacity Excess Emission and Continuous Monitoring System Performance” 

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

“Gaseous and Opacity Excess Emission and Continuous Monitoring System Performance 

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

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

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

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

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

Gary Chastain at (972) 923-4330.

Sincerely,

Glenn E. Haley

Plant Leader

Owens Corning Insulating System LLC – Waxahachie Plant

Waxahachie, TX 

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

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

Inconsistent with SSM Plan

40 CFR 63 Subpart NNN

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

Owens Corning Insulating System LLC– 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, Maintenance and Monitoring (OMM) 

Plan 

40 CFR 63 Subpart NNN

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

OMM Plan. 

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

Print Name: Glenn E. Haley 

Signature: 

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

Monitoring System Performance

40CFR63 Subpart NNN

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

Owens Corning Insulating System LLC– Waxahachie Plant 

3700 North Interstate Highway 35E 

Waxahachie, TX 75165 

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

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

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

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

and curing. 

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

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

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

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

fabrication and packaging. Tables 1 through 3 define the manufacturing sources at this 

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

TABLE 1 

 Process Control 

Device 

Monitored Parameter 

V1 

Furnace Glass Melting DEP 1st 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 Temperature 

 
TABLE 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 Facility

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

V1 Furnace – 4417 

V1 Line – 3967 

V2 Furnace – 4417 

V2 Line – 3903 

V3 Furnace – 0 

V3 Line – 0 
Deviations: 

V-1 Furnace DEP Bypass 30.567 hrs 0.69% deviation 

V-2 Furnace Batch Wetting 26.13 hrs 0.59% deviation 

V-1 Incinerator Temperature 16.50 hrs 0.42% deviation 

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 will be provided in this report. 

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

Print Name: Glenn E. Haley 

Signature: 

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

Performance 

40CFR63 Subpart NNN

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

Owens Corning Insulating System LLC – Waxahachie Plant 

3700 North Interstate Highway 35E 

Waxahachie, TX 75165 

The following instances are being reported as a deviation 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 content of this report is accurate. 

Print Name: Glenn E. Haley 

Signature: 

Title Plant Leader