# 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 sati sfy the reporting requirements as contai ned in the Final Permit to Install

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

Manville Plant 8 in Defiance, Ohio.

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

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

of the emission limitations, operatio nal 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 in formation 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 y ou 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 ManvilleOhio Environmental Protection Agency Signature PageDeviation Reporting Form2009 - 3rd Quater Deviation Report Pipe.docFACILITY NAME: JOHNS MANVILLE DEFIANCE PLANT 8FACILITY ID: (PREMISE NUMBER) 03-20-01-0005FACILITY ADDRESS: 925 CARPENTER ROAD, DEFIANCE OH 43512Issuance or most recent modification date: PTI 03-16294, Modification date: July06, 2006QUARTERLYReporting PeriodSEMIANNUALReporting Period (please indicate “N/A” below in the “From” and “To”fields if this report does include semiannual deviation reporting)From: 07/01/09To: 09/30/09From: NATo: NATotal pages in report, including this one (signature page and sections I, II, and III)9Please list any supporting attachments: Malfunction ReportReporting deadline: 10/31/09NOTE: 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/zz are the beginning and end dates for the deviation reporting periodrespectively.SIGNATURE FOR STATEMENTThis statement shall be signed by the responsible official asdefined in OAC rule 3745-77-01(GG). Making of any false materialstatement, representation or certification constitutesa violation of ORC 3704.05(H), and subjects the responsible partysigning this statement to civil and/or criminal penalties asprovided in ORC 3704.06(C) and ORC 3704.CERTIFICATIONBased on information and belief formed after reasonable inquiry, Ihereby affirm, as stated in OAC rule 3745-77-03(D), that thestatements and information as transmitted in thisTitle 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 Section I- Page 1Deviation ReportingFACILITY NAME JOHNS MANVILLE DEFIANCE PLANT 8FACILITY ID (PREMISE NUMBER) 03-20-01-0005FACILITY ADDRESS 925 CARPENTER ROADIssuance or most recent modification date: PTI 03-16294,Modification date: July 06, 2006QUARTERLYReporting PeriodSEMIANNUALReporting Period (please indicate“N/A” below in the “From” and “To”fields if this report does include semiannual deviation reporting)From: 07/01/08To: 9/30/08From: NATo: NAReporting deadline: 10/31/092009 - 3rd Quater Deviation Report Pipe.docSECTION 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 occurredXTHERE WERE NO DEVIATIONS OF ANY OF THE TERMS AND CONDITIONSOF PART I OF THE TITLE V PERMIT DURING THE REPORTING PERIODAdd rows as necessary to the following table for reported deviations (one for each General Term as applicable; see detailed instructions for more information)(Table2)Reporting Requirement(choose one)DEVIATIONINFORMATIONDEVIATIONDURATIONTITLE V PERMITTERMNO./DescriptionQuarterlySemiAnnualACTUAL METHOD USED TODETERMINE COMPLIANCEDATE / TIMESTARTDATE / TIMEENDDESCRIPTION AND MAGNITUDEOF THE DEVIATIONPROBABLE CAUSE FORTHE DEVIATIONCORRECTIVE ACTIONS /PREVENTATIVE MEASURES TAKENOhio Environmental Protection Agency Section II- Page1Deviation ReportingFACILITY NAME JOHNS MANVILLE DEFIANCE PLANT 8FACILITY ID (PREMISE NUMBER) 03-20-01-0005FACILITY ADDRESS 925 CARPENTER ROADIssuance or most recent modification date: PTI 03-16294,Modification date: July 06, 2006QUARTERLYReporting PeriodSEMIANNUALReporting Period (please indicate“N/A” below in the “From” and “To”fields if this report does include semiannual deviation reporting)From: 07/01/09To: 09/30/09From: NATo: NAReporting deadline: 10/31/092009 - 3rd Quater Deviation Report Pipe.docSection 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 listed emissionsunit occurred, oradd rows as necessary to thedeviation reporting table (see next page) for reported deviations(one for each term as applicable; see detailed instructions for more information)THERE WERE NO DEVIATIONS OF ANYPTI TERMS OR APPLICABLE REQUIREMENTSFOR THE FOLLOWING LISTED INSIGNIFICANT EMISSIONS UNITS IDENTIFIED IN PART II.A OFTHE TITLE V PERMIT:None listed in PTI 03-16294P097 – Pipe Emergency Generator; P110 – Pipe Resin Tanks; P111 –Pipe Liquid Urea Tanks; P112 – Pipe Prereact Tanks; P113 – Pipe Silane Tanks; P114 – PipeSilicone Tanks; P115 – Pips Caustic Tank; P116 – Pipe Process Area Heaters; P117 – Pipe Ammonia Tank; P124 – Pipe T95 Resin TanksOhio Environmental Protection Agency Section II- Page2Deviation ReportingFACILITY NAME JOHNS MANVILLE DEFIANCE PLANT 8FACILITY ID (PREMISE NUMBER) 03-20-01-0005FACILITY ADDRESS 925 CARPENTER ROADIssuance or most recent modification date: PTI 03-16294,Modification date: July 06, 2006QUARTERLYReporting PeriodSEMIANNUALReporting Period (please indicate“N/A” below in the “From” and “To”fields if this report does include semiannual deviation reporting)From: 07/01/09To: 09/30/09From: NATo: NAReporting deadline: 10/31/092009 - 3rd Quater Deviation Report Pipe.docFacility-wide Permit Requirements Terms and Conditions (Permit Requirement Reporting) - Negative Declarations(mark with an>X=if applicable)(Table 2)XTHERE WERE NO DEVIATIONS OF ANY OF THE TERMS AND CONDITIONS OFPART II OF THE TITLE V PERMIT DURING THE REPORTING PERIOD SPECIFIED IN THIS REPORTSection II - Part II Facility-wide and/or IEU permit requirement (Permit Requirement Reporting) - Deviation Reporting(Table 3)Add rows as necessary to the following table for reported deviations (one for each Term as applicable; see detailed instructions for more information)ReportingRequirement(choose one)or bothDEVIATIONINFORMATIONDEVIATIONDURATIONTITLE V or IEUPERMITTERMNO./Descriptionor PTI terms forIEUsQuarterlySemiAnnualACTUAL METHODUSED TODETERMINECOMPLIANCEDATE /TIMESTARTDATE / TIMEENDDESCRIPTION ANDMAGNITUDE OF THEDEVIATIONPROBABLECAUSE FOR THEDEVIATIONCORRECTIVEACTIONS /PREVENTATIVEMEASURES TAKENWAS THISDEVIATIONATTRIBUTABLETO AMALFUNCTION? (Yes or No - IfYes, continue tothe next column)MALFUNCTIONVERBALREPORT(S)DATE(S)(If no reports were made,stateANO REPORTS@inthe space below)MALFUNCTIONWRITTENREPORT(S)DATE(S)(If no reports weremade, stateANOREPORTS@in thespace below)Ohio Environmental Protection Agency Section II- Page1Deviation ReportingFACILITY NAME JOHNS MANVILLE DEFIANCE PLANT 8FACILITY ID (PREMISE NUMBER) 03-20-01-0005FACILITY ADDRESS 925 CARPENTER ROADIssuance or most recent modification date: PTI 03-16294,Modification date: July 06, 2006QUARTERLYReporting PeriodSEMIANNUALReporting Period (please indicate“N/A” below in the “From” and “To”fields if this report does include semiannual deviation reporting)From: 07/01/09To: 09/30/09From: NATo: NAReporting deadline: 10/31/092009 - 3rd Quater Deviation Report Pipe.docSection III - Part III Emissions Unit Terms and Conditions(Permit Requirement Reporting) - Negative Declarations(Table 1)List each emissions unit where nodeviations of any terms for the listed emissions unit occurred, oradd rows as necessary to the second table (see next page) for reporteddeviations(one for each term as applicable; see detailed instructions for more information)THERE WERE NO DEVIATIONS OF ANYOF THE TERMS AND CONDITIONS OF PART III OF THE TITLEV PERMIT FOR THE FOLLOWING LISTED EMISSIONS UNITS:Emissions Unit IDPlease place an>X=below if there were no QuarterlyDeviations - If an>X=is not indicated, the deviation(s)must be identified in Table2 belowIf applicable, please place an>X=below if there wereno Semiannual Deviations - If an>X=is not indicated,the deviation(s) must be identified in Table2 belowP060 – BATCH RECEIVINGXP061 – ELECTRIC MELTER 1XP062 – ELECTRIC MELTER 2XP063 – ELECTRIC MELTER 3P064 – FORMING AND COLLECTION UNIT 801XP065 – SEAR ROLL AND CURING OVEN UNIT 801XOhio Environmental Protection Agency Section II- Page2Deviation ReportingFACILITY NAME JOHNS MANVILLE DEFIANCE PLANT 8FACILITY ID (PREMISE NUMBER) 03-20-01-0005FACILITY ADDRESS 925 CARPENTER ROADIssuance or most recent modification date: PTI 03-16294,Modification date: July 06, 2006QUARTERLYReporting PeriodSEMIANNUALReporting Period (please indicate“N/A” below in the “From” and “To”fields if this report does include semiannual deviation reporting)From: 07/01/09To: 09/30/09From: NATo: NAReporting deadline: 10/31/092009 - 3rd Quater Deviation Report Pipe.docP066 – PRODUCT FINISHING UNIT 801XP067 – FORMING AND COLLECTION UNIT 802XP068 – SEAR ROLL AND CURING OVEN UNIT 802XP069 – PRODUCT FINISHING UNIT 802XP070 – FORMING AND COLLECTION UNIT 803XP071 – SEAR ROLL AND CURING OVEN UNIT 803XP072 – PRODUCT FINISHING UNIT 803XP073 – FORMING AND COLLECTION UNIT 804XP074 – SEAR ROLL AND CURING OVEN UNIT 804XOhio Environmental Protection Agency Section II- Page3Deviation ReportingFACILITY NAME JOHNS MANVILLE DEFIANCE PLANT 8FACILITY ID (PREMISE NUMBER) 03-20-01-0005FACILITY ADDRESS 925 CARPENTER ROADIssuance or most recent modification date: PTI 03-16294,Modification date: July 06, 2006QUARTERLYReporting PeriodSEMIANNUALReporting Period (please indicate“N/A” below in the “From” and “To”fields if this report does include semiannual deviation reporting)From: 07/01/09To: 09/30/09From: NATo: NAReporting deadline: 10/31/092009 - 3rd Quater Deviation Report Pipe.docP075 – PRODUCT FINISHING UNIT 804XP076 – FORMING AND COLLECTION UNIT 805XP077 – SEAR ROLL AND CURING OVEN UNIT 805XP078 – PRODUCT FINISHING UNIT 805XP079 – FORMING AND COLLECTION UNIT 806XP080 – SEAR ROLL AND CURING OVEN UNIT 806XP081 – PRODUCT FINISHING UNIT 806XP082 – FORMING AND COLLECTION UNIT 807XP083 – SEAR ROLL AND CURING OVEN UNIT 807XP084 – PRODUCT FINISHING UNIT 807XOhio Environmental Protection Agency Section II- Page4Deviation ReportingFACILITY NAME JOHNS MANVILLE DEFIANCE PLANT 8FACILITY ID (PREMISE NUMBER) 03-20-01-0005FACILITY ADDRESS 925 CARPENTER ROADIssuance or most recent modification date: PTI 03-16294,Modification date: July 06, 2006QUARTERLYReporting PeriodSEMIANNUALReporting Period (please indicate“N/A” below in the “From” and “To”fields if this report does include semiannual deviation reporting)From: 07/01/09To: 09/30/09From: NATo: NAReporting deadline: 10/31/092009 - 3rd Quater Deviation Report Pipe.docP085 – OFFLINE SEAR ROLL AND CURING OVENXP086 – OFFLINE PRODUCT FINISHING UNITXP087 – RECLAIM REFEED SYSTEMXOhio Environmental Protection Agency Section II- Page5Deviation ReportingFACILITY NAME JOHNS MANVILLE DEFIANCE PLANT 8FACILITY ID (PREMISE NUMBER) 03-20-01-0005FACILITY ADDRESS 925 CARPENTER ROADIssuance or most recent modification date: PTI 03-16294,Modification date: July 06, 2006QUARTERLYReporting PeriodSEMIANNUALReporting Period (please indicate“N/A” below in the “From” and “To”fields if this report does include semiannual deviation reporting)From: 07/01/09To: 09/30/09From: NATo: NAReporting deadline: 10/31/092009 - 3rd Quater Deviation Report Pipe.docSection III - Part III Emissions Unit Terms and Conditions(Permit Requirement Reporting) - Deviation Reporting(Table2)Add rows as necessary to the following table for reported deviations (one for each Term as applicable; see detailed instructions for more information) - Please group deviationsfor each emissions unit that has deviations of multiple terms.ReportingRequirement(choose one)or bothDEVIATIONINFORMATIONDEVIATIONDURATIONEMISSIONSUNIT (EU)NO./Description(See below)TITLE VPERMITTERMNO & DescriptionQuarterlySemiAnnualACTUALMETHODUSED TODETERMINECOMPLIANCEDATE /TIMESTARTDATE /TIME ENDDESCRIPTION ANDMAGNITUDE OF THEDEVIATIONPROBABLECAUSE FORTHEDEVIATIONCORRECTIVE ACTIONS /PREVENTATIVEMEASURES TAKENWAS THISDEVIATIONATTRIBUTABLETO AMALFUNCTION ?(Yes or No - IfYes, continue tothe next column)MALFUNCTIONVERBALREPORT(S)DATE(S)(If no reportswere made,stateANOREPORTS@inthe space below)MALFUNCTIONWRITTENREPORT(S)DATE(S)(If no reportswere made, stateANO REPORTS@in the spacebelow)P063 –ELECTRICGLASSMELTER 3PTI 03-16294Part III.A.III.2Part III.A.III.5XCMS(continuousmonitoringsystem)7/8/0902:30 AM7/8/0906:50 AMEmissions from melterbypassed the baghousefor the duration of themalfunctionInsufficienttemperature inMelter uponstartup causedheadspace tooverpressurizeFurnace chiefs made awareof conditions that led toover-pressurization. Startuptemperature written intoSOP for melter startupYES 07/08/2009 07/08/2009Notes:See page 3 of the instructionsSECTION III ADDITIONAL DETAILED INSTRUCTIONS FOR COMPLETING A DEVIATION REPORTING TABLEfor guidance on this table.

# From: Smargiassi, Jim

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

To: 'Elissa Hartfield'

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

Subject: OAC 3745-15-06(B) Malfunction of equipmen t; 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 th e vent at the top of our electric gl ass melter 3 was re moved to relieve a

pressure buildup in the headspace of the melter cham ber due to an insufficient melting temperature upon startup. This is standard operating procedure when other pres sure relief procedures have fail ed. Removing this block

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

important to note that during the en tire 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 re fractory 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 no t attaining sufficient meltin g 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. Sh utting down the unit would not have resolved the venting

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

Venting of the melter provided the ti me necessary for the unit to reach su fficient temperature and melt enough

batch to bring the level of batch down, uncl ogging 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 emis sions 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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# Jim Smargiassi EIT | Environmental Manager

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

ph: 419.784.7963 | fx: 419.78 4.7996 | cell: 419.439.1724 

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