Johns Manville Corporation 

 925 Carpenter Road 

 Defiance, OH 43512 

419 784-7916 

419 784-7995 Fax 

October 20, 2009 

Ms. Elissa Hartfield 

Division of Air Pollution Control 

Northwest District Office, Ohio EPA 

347 North Dunbridge Road 

Bowling Green, Ohio 43402 

Subject: Johns Manville (JM) 

 Defiance Plant #08 (Facility ID: 03-20-01-0005) 

 3rd Quarter Deviation Report 

CERTIFIED MAIL 7005 1820 0004 7975 6122 

Dear Ms. Hartfield: 

This report is being submitted to satisfy the reporting requirements as contained in the Final Permit to Install 

No. 03-16294 issued on July 6, 2006. The sources covered by this Title V Permit are located at Johns 

Manville Plant 8 in Defiance, Ohio. 

This report covers the 3rd quarter reporting period beginning July 1, 2009 and ending September 30, 2009. 

This report satisfies reporting requirements in accordance with OAC rule 3745-77-07(A)(3)(c) for deviations 

of the emission limitations, operational restrictions, and control device operating parameter limitations, 

except as may otherwise be required in the terms and conditions for a specific emissions unit. 

We are reporting one (1) quarterly deviation for this reporting period. This report is based on the best 

information available at the time; the statements and information provided in this report are true, accurate, 

and complete to the best of our knowledge. 

If you have any questions regarding this report or if you require additional information, please contact the 

Johns Manville Defiance Environmental Manager, Jim Smargiassi at (419) 784-7963. 

Best Regards, 

Matt Brown 

Defiance Complex Manager 

Johns Manville 
Ohio Environmental Protection Agency 

Deviation Reporting Form 2009 - 3rd Quater Deviation Report Pipe.doc

FACILITY NAME: JOHNS MANVILLE DEFIANCE PLANT 8 FACILITY ID: (PREMISE NUMBER) 03-20-01-0005 FACILITY ADDRESS: 925 CARPENTER ROAD, DEFIANCE OH 43512 Issuance or most recent modification date: PTI 03-16294, Modification date: July 06, 2006 QUARTERLY Reporting Period SEMIANNUAL Report

fields if this report does 

From: 07/01/09 To: 09/30/09 From: NA Total pages in report, including this one (signature page and sections I, II, and III) 

9 

Please list any supporting attachments: Malfunction Report Reporting deadline: 10/31/09 

NOTE: The deviation reporting period shall be stated in the following format: 

Axx/xx/xx through zz/zz/zz

@ where xx/xx/xx and zz/zz/z

respectively.

SIGNATURE FOR STATEMENT This statement shall be signed by the responsible official as defined in OAC rule 3745-77-01(GG). Making of any faa violation of ORC 3704.05(H), and subjects the responsible party signing this statement to civil and/or criminal pe

CERTIFICATION Based on information and belief formed after reasonable inquiry, I hereby affirm, as stated in OAC rule 3745-77-03Title V report are true, accurate and complete to the best of my knowledge. Authorized Signature _______________________________Date _______________ Name (Please Print) _Matt Brown______________________________ Title _Defiance Complex Manager______
Ohio Environmental Protection Agency 

Deviation Reporting 

FACILITY NAME JOHNS MANVILLE DEFIANCE PLANT 8 FACILITY ID (PREMISE NUMBER) 03-20-01-0005 FACILITY ADDRESS 925 CARPENTER ROAD Issuance or most recent modification date: PTI 03-16294, Modification date: July 06, 2006 QUARTERLY Reporting Period SEMIANNUAL Reporting Peri

fields if this report does includ

From: 07/01/08 To: 9/30/08 From: NA Reporting deadline: 10/31/09 

2009 - 3rd Quater Deviation Report Pipe.doc SECTION I - PART I General Terms and Conditions (Permit Requirement Reporting) (Table1)

Mark the following box with an 

>

X= if no General Terms and Conditions deviations occurred

X THERE WERE NO DEVIATIONS OF ANY OF THE TERMS AND CONDITIONS OF PART I OF THE TITLE V PERMIT 

 Add rows as necessary to the following table for reported deviations (one for each General Term as applicab

Reporting Requirement 

(choose one) 

DEVIATION 

INFORMATION 

DEVIATION 

DURATION 

TITLE V PERMIT 

TERM 

 NO./Description 

Quarterly SemiAnnual 

ACTUAL METHOD USED TO 

DETERMINE COMPLIANCE 

DATE / TIME START 

DATE / TIME END 

DESCRIPTION 

OF THE 
Ohio Environmental Protection Agency 

Deviation Reporting 

FACILITY NAME JOHNS MANVILLE DEFIANCE PLANT 8 FACILITY ID (PREMISE NUMBER) 03-20-01-0005 FACILITY ADDRESS 925 CARPENTER ROAD Issuance or most recent modification date: PTI 03-16294, Modification date: July 06, 2006 QUARTERLY Reporting Period SEMIANNUAL Reporting Peri

fields if this report does includ

From: 07/01/09 To: 09/30/09 From: NA Reporting deadline: 10/31/09 

2009 - 3rd Quater Deviation Report Pipe.doc Section II - Part II Facility-wide Permit Requirement ReportingInsignificant Emissions Unit Negative Declarations (Table1)List each insignificant emissions unit where no deviations of any PTI terms or applicable requirements for the lideviation reporting table (see next page) for reported deviations (one for each term as applicable; see detaile

THERE WERE NO DEVIATIONS OF ANY PTI TERMS OR APPLICABLE REQUIREMENTS FOR THE FOLLOWING L

THE TITLE V PERMIT:

None listed in PTI 03-16294 P097 – Pipe Emergency Generator; P110 – Pipe Resin Tanks; P111 – Pipe Liquid Urea Tanks; P112 – Pipe Silicone Tanks; P115 – Pips Caustic Tank; P116 – Pipe Process Area Heaters; P117 – Pipe Ammonia Tank
Ohio Environmental Protection Agency 

Deviation Reporting 

FACILITY NAME JOHNS MANVILLE DEFIANCE PLANT 8 FACILITY ID (PREMISE NUMBER) 03-20-01-0005 FACILITY ADDRESS 925 CARPENTER ROAD Issuance or most recent modification date: PTI 03-16294, Modification date: July 06, 2006 QUARTERLY Reporting Period SEMIANNUAL Reporting Peri

fields if this report does includ

From: 07/01/09 To: 09/30/09 From: NA Reporting deadline: 10/31/09 

2009 - 3rd Quater Deviation Report Pipe.doc Facility-wide Permit Requirements Terms and Conditions (Permit Requirement Reporting) - Negative 

X THERE WERE NO DEVIATIONS OF ANY OF THE TERMS AND CONDITIONS OF PART II OF THE TITLE V PERM

Section II - Part II Facility-wide and/or IEU permit requirement (Permit Requirement Reporting) - DeviaAdd rows as necessary to the following table for reported deviations (one for each Term as applicable; see de

Reporting 

Requirement 

(choose one) 

or both 

DEVIATION 

INFORMATION 

DEVIATION 

DURATION 

TITLE V or IEU 

PERMIT 

TERM 

 NO./Description 

or PTI terms for 

IEUs 

Quarterly SemiAnnual 

ACTUAL METHOD 

USED TO 

DETERMINE 

COMPLIANCE 

DATE / TIME START 

DATE / TIME END 

DESCRIPTION AND 

MAGNITUDE OF THE 

DEVIATION 

PROBABLE 

CAUSE FOR THE 

DEVIATION 

M
Ohio Environmental Protection Agency 

Deviation Reporting 

FACILITY NAME JOHNS MANVILLE DEFIANCE PLANT 8 FACILITY ID (PREMISE NUMBER) 03-20-01-0005 FACILITY ADDRESS 925 CARPENTER ROAD Issuance or most recent modification date: PTI 03-16294, Modification date: July 06, 2006 QUARTERLY Reporting Period SEMIANNUAL Reporting Peri

fields if this report does includ

From: 07/01/09 To: 09/30/09 From: NA Reporting deadline: 10/31/09 

2009 - 3rd Quater Deviation Report Pipe.doc Section III - Part III Emissions Unit Terms and Conditions (Permit Requirement Reporting) - Negative DList each emissions unit where no deviations of any terms for the listed emissions unit occurred, or add rows a

deviations (one for each term as applicable; see detailed instructions for more information) 

THERE WERE NO DEVIATIONS OF ANY OF THE TERMS AND CONDITIONS OF PART III OF THE TITLE V PERMIT FOR TH

Emissions Unit ID Please place an 

>

X

= below if there were no Qu

Deviations - If an 

>

X

= is not indicated, the devia

must be identified in Table2 below 

P060 – BATCH RECEIVING X P061 – ELECTRIC MELTER 1 X P062 – ELECTRIC MELTER 2 X P063 – ELECTRIC MELTER 3 P064 – FORMING AND COLLECTION UNIT 801 X P065 – SEAR ROLL AND CURING OVEN UNIT 801 X 
Ohio Environmental Protection Agency 

Deviation Reporting 

FACILITY NAME JOHNS MANVILLE DEFIANCE PLANT 8 FACILITY ID (PREMISE NUMBER) 03-20-01-0005 FACILITY ADDRESS 925 CARPENTER ROAD Issuance or most recent modification date: PTI 03-16294, Modification date: July 06, 2006 QUARTERLY Reporting Period SEMIANNUAL Reporting Peri

fields if this report does includ

From: 07/01/09 To: 09/30/09 From: NA Reporting deadline: 10/31/09 

2009 - 3rd Quater Deviation Report Pipe.doc 

P066 – PRODUCT FINISHING UNIT 801 X P067 – FORMING AND COLLECTION UNIT 802 X P068 – SEAR ROLL AND CURING OVEN UNIT 802 X P069 – PRODUCT FINISHING UNIT 802 X P070 – FORMING AND COLLECTION UNIT 803 X P071 – SEAR ROLL AND CURING OVEN UNIT 803 X P072 – PRODUCT FINISHING UNIT 803 X P073 – FORMING AND COLLECTION UNIT 804 X P074 – SEAR ROLL AND CURING OVEN UNIT 804 X 
Ohio Environmental Protection Agency 

Deviation Reporting 

FACILITY NAME JOHNS MANVILLE DEFIANCE PLANT 8 FACILITY ID (PREMISE NUMBER) 03-20-01-0005 FACILITY ADDRESS 925 CARPENTER ROAD Issuance or most recent modification date: PTI 03-16294, Modification date: July 06, 2006 QUARTERLY Reporting Period SEMIANNUAL Reporting Peri

fields if this report does includ

From: 07/01/09 To: 09/30/09 From: NA Reporting deadline: 10/31/09 

2009 - 3rd Quater Deviation Report Pipe.doc 

P075 – PRODUCT FINISHING UNIT 804 X P076 – FORMING AND COLLECTION UNIT 805 X P077 – SEAR ROLL AND CURING OVEN UNIT 805 X P078 – PRODUCT FINISHING UNIT 805 X P079 – FORMING AND COLLECTION UNIT 806 X P080 – SEAR ROLL AND CURING OVEN UNIT 806 X P081 – PRODUCT FINISHING UNIT 806 X P082 – FORMING AND COLLECTION UNIT 807 X P083 – SEAR ROLL AND CURING OVEN UNIT 807 X P084 – PRODUCT FINISHING UNIT 807 X 
Ohio Environmental Protection Agency 

Deviation Reporting 

FACILITY NAME JOHNS MANVILLE DEFIANCE PLANT 8 FACILITY ID (PREMISE NUMBER) 03-20-01-0005 FACILITY ADDRESS 925 CARPENTER ROAD Issuance or most recent modification date: PTI 03-16294, Modification date: July 06, 2006 QUARTERLY Reporting Period SEMIANNUAL Reporting Peri

fields if this report does includ

From: 07/01/09 To: 09/30/09 From: NA Reporting deadline: 10/31/09 

2009 - 3rd Quater Deviation Report Pipe.doc 

P085 – OFFLINE SEAR ROLL AND CURING OVEN X P086 – OFFLINE PRODUCT FINISHING UNIT X P087 – RECLAIM REFEED SYSTEM X 
Ohio Environmental Protection Agency 

Deviation Reporting 

FACILITY NAME JOHNS MANVILLE DEFIANCE PLANT 8 FACILITY ID (PREMISE NUMBER) 03-20-01-0005 FACILITY ADDRESS 925 CARPENTER ROAD Issuance or most recent modification date: PTI 03-16294, Modification date: July 06, 2006 QUARTERLY Reporting Period SEMIANNUAL Reporting Peri

fields if this report does includ

From: 07/01/09 To: 09/30/09 From: NA Reporting deadline: 10/31/09 

2009 - 3rd Quater Deviation Report Pipe.doc Section III - Part III Emissions Unit Terms and Conditions (Permit Requirement Reporting) - Deviation 

Add rows as necessary to the following table for reported deviations (one for each Term as applicable; see detai

for each emissions unit that has deviations of multiple terms. 

Reporting 

Requirement 

(choose one) 

or both 

DEVIATION 

INFORMATION 

DEVIATION 

DURATION 

EMISSIONS 

UNIT (EU) 

NO./Description 

(See below) 

TITLE V 

PERMIT 

TERM 

 NO & Description 

Quarterly SemiAnnual 

ACTUAL 

METHOD 

USED TO 

DETERMINE 

COMPLIANCE 

DATE / TIME START 

DATE / TIME END 

DESCRIPTION AND 

MAGNITUDE OF THE 

DEVIATION 

PROBAB

CAUSE F

THE 

DEVIATIO

P063 – 

ELECTRIC 

GLASS 

MELTER 3 

PTI 03-16294 

Part III.A.III.2 Part III.A.III.5 

X 

CMS 

(continuous 

monitoring 

system) 

7/8/09 

02:30 AM 

7/8/09 

06:50 AM 

Emissions from melter 

bypassed the baghouse 

for the duration of the 

malfunction 

Insufficie

temperatur

Melter up

startup cau

headspace 

overpressu

Notes: See page 3 of the instructions SECTION III ADDITIONAL DETAILED INSTRUCTIONS FOR COMPLETING A 
From: Smargiassi, Jim 

Sent: Wednesday, July 08, 2009 8:13 PM 

To: 'Elissa Hartfield' 

Cc: Brueckner, Nick; Brown, Matt; McKibben, Craig; Hudson, Ron; Ponce, Fred; Tarde, Jeff 

Subject: OAC 3745-15-06(B) Malfunction of equipment; scheduled maintenance; reporting 

Importance: High 

Elissa,

The malfunction occurred at the following facility;

Johns Manville Plant #08

925 Carpenter Rd

Defiance, Ohio 43512

Facility ID: 03-20-01-0005

The following sources were involved;

P063 Electric Glass Melter 3 

Date and Duration of malfunction ;

July 8, 2009 2:30 AM – 8:30 AM (6.00 hours)

APCD involved and cause of malfunction;

On 7/8/09 at 2:30 AM a block covering the vent at the top of our electric glass melter 3 was removed to relieve a 

pressure buildup in the headspace of the melter chamber due to an insufficient melting temperature upon startup. This is standard operating procedure when other pressure relief procedures have failed. Removing this block 

allows emissions from the melter to exhaust directly to the atmosphere, bypassing the dust collector. It is 

important to note that during the entire event, glass batch material was not being added to the melter; the 

batching process accounts for the majority of the particulate emissions off the melter. 

Corrective Action/Alternative control measures;

Following depressurization of the melter headspace, the refractory block was moved back into place returning the 

unit to normal exhaust operation.

Reason why impractical to shutdown;

The pressure build up was most likely due to the melter not attaining sufficient melting temperature during start-up 

resulting in too much batch being held in the melter. This elevated batch level began clogging the exhaust vent 

causing pressure to build in the melter headspace. Shutting down the unit would not have resolved the venting 

issue quickly enough and the pressurization could have resulted in serious damage occurring to the melter. 

Venting of the melter provided the time necessary for the unit to reach sufficient temperature and melt enough 

batch to bring the level of batch down, unclogging the exhaust vent to the dust collector.

Estimation of emissions;

Emission factors used in the estimates below are from the performance stack testing completed on January, 8 

2008 and from our best engineering estimates. Below is a table estimating emissions resulting from the 

malfunction incident.

Thank you,

P063 (Electric Glass Melter 3)

Air Contaminant Emission Rate (lb/hr)

PM 15.00

NOx 0.021

VOC 0.155

SO2 0.394

CO 0.778

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file://V:\Complex Environmental\SMARGIASSI\Air\Reporting and Deviations\APCD M... 10/19/2009
Jim Smargiassi EIT | Environmental Manager 

Johns Manville | 925 Carpenter Rd. | Defiance, OH 43512 

ph: 419.784.7963 | fx: 419.784.7996 | cell: 419.439.1724 

 

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file://V:\Complex Environmental\SMARGIASSI\Air\Reporting and Deviations\APCD M... 10/19/2009