Facility Name: Location:

Facility Permit Number:

Source Identification Number:

Date Plan Received:

Date Plan Approved: Date Plan Denied:

Date Additional Information Requested:

Proposed Test Date:

Test Plan Reviewed By:

** Remember -- Within 30 days of site-specific test plan receipt, the Department will notify the owner or operator of site-specific

test plan approval or denial or will request additional information.

1. Facility Information Notes:

a. Facility name, address, and Kohler Co. - Vitreous Plant Mike Cassidy

telephone number, and name of P.O. Box 1987, Camp Croft (920) 457-4441

facility contact. 4000 South Pine St. ext. 77263

Spartanburg, SC 29304

b. Facility permit number and Facility Permit # - TV-2060-0361

source identification number. Tunnel Kiln 10 - Unit ID #38

c. Name, address, and telephone Environmental Source Samplers (ESS)

number of the company 18631-H Northline Drive

contracted to perform the source Cornelius, NC 28031

test. Tel: (704) 892-4405; Fax.: (704) 892-8127

d. Name, address, and Subcontracted through ESS

telephone number of the Element One, Inc.

laboratory contracted to perform 5022-C Wrightsville Ave.

the analytical analysis of the Wilmington, NC 28403

source test samples. (910) 793-0128, Ken Smith

2. Test Objectives Notes:

a. Description and overall MACT Performance Test for Tunnel Kiln 10 and associated wet

purpose of the tests (for scrubber.

example, to demonstrate

compliance, to establish 

emission factors, etc.).

b. Citation of any applicable Clay Ceramics Manufacturing NESHAP 

State or Federal regulation or (40 CFR §63.8555, Part 63, Subpart KKKKK)

permit condition requiring the &

tests. Operation Permit # TV-2060-0361-CG, 6.0, B,6

Site-Specific Test Plan / Final Report Checklist

Kohler Co. - Vitreous Plant Spartanburg, SC

TV-2060-0361

(Kohler Co. Revision 02 - 01/10/2007)

Minimum Requirements for a Site-Specific Test Plan

Acceptable?

Acceptable?

Wednesday, February 07, 2007

N/A

1 of 7
3. Process Descriptions Notes:

a. Description of the process See the "Source Description" portion of the Notification of Intent

including a description of each to Conduct a Performance Test, dated December 7, 2006, that was 

phase of batch or cyclic mailed to the department.

processes, and the time required The operation of a tunnel kiln is a continuous process. 

to complete each phase. Kiln car cycle time - 6 to 12 hours.

b. Process design rates and Max. - 4000 lbs ware/hr

normal operating rates. Avg. - 2000 lbs ware/hr

c. Proposed operating rate and Maximum production level (63.8595(d)).

conditions for the source test.

d. Methods including proposed Every ware piece has a bar code that is scanned to track ware.

calculations, equations, and Operating rate is determined by logging the type and number for 

other related information that ware and using standard weights for each ware model to estimate

will be used to demonstrate and throughput.

verify the operating rate during

the source test.

e. Description of any air Orifice Plate Wet Scrubber

pollution control equipment.

f. Description of any stack gas Not Applicable

or opacity monitoring systems.

g. A description of all air Pressure Drop

pollution control monitors (for Liquid PH

example, pressure guages, flow

indicators, cleaning cycle timers,

electrostatic precipitator voltage

meters, etc.) when applicable.

h. A list of process and air Ware Throughput

pollution control operating Pressure drop across scrubber

parameters that will be recorded Scrubber liquid PH

during the tests, the responsible

party who will record these Scrubber chemical feed rate - 6 liters per minute. When pump is

readings, and the frequency at actuated.

which readings will be recorded.

4. Safety Considerations Notes

a. Identification of any risks The sampling location is on the rooftop by the edge of the building.

associated with sampling The parapet wall is approximately 4 ft. high which would 

location and accessibility, toxic reasonably prevent the risk of falling. 

releases, electrical hazards, or

any other unsafe conditions, and There are no other "out of the ordinary" risks other than those 

a plan of action to correct or associated with stack testing.

abate these hazards.

b. List of all necessary or Safety glasses, steel toes, hearing protection.

required safety equipment

including respirators, safety

glasses, hard hats, safety shoes,

hearing protection, and other

protective equipment.

Minimum Requirements for a Site-Specific Test Plan

Acceptable?

Acceptable?

2 of 7
5. Notes

a. Description of sampling US EPA Methods 1 through 4 and Method 26A. Particulate sampling

methods to be used. will be performed in conjunction with Method 26A.

(1) Is the method appropriate? Methods required by MACT.

(2) Is it a reference method? Yes

(3) If not a reference method, N/A

is validation included?

(4) Is validation acceptable? N/A

b. Description of analytical See US EPA Method 26A.

methods to be used.

c. Number of tests to be 1 - One

conducted.

d. Number of runs comprising a 3 - Three

test.

e. Duration of each test run. At least one hour.

f. Description of minimum

sampling volumes for each test 30 DSCF

run.

g. Location where samples will Nozzle & Probe - Sample recovery will be performed on rooftop.

be recovered. Imp. Trains & Filters - Tranported back to laboratory and recovered.

h. Explanation of how blank 

and recovery check results and Blanks will be handled as specified in Method 5 and Method 26A.

analytical non-detects will be 

used in the final emission Non-detects will be reported as less than values.

calculations.

i. Maximum amount of time a

sample will be held after As per method, 4 week sample stability. 

collection prior to analysis.

j. Method of storing and Samples will be stored/tranported according to section 8.2.7 of

transporting samples. Method 26A.

6. Notes

a. Schematics of sampling sites See the "Traverse Point Location" attachment on the Notification of 

(include stack dimensions and Intent to Conduct a Performance Test, dated December 7, 2006, that 

distances upstream and was mailed to the department.

downstream from disturbances).

b. A description of all emission The only emission point from Tunnel Kiln 10 is the exhaust from

points, including fugitive the wet scrubber. There are no fugitive emissions.

emissions, associated with the

process to be tested, and when

applicable, the method that will

be used to measure or include 

these emissions during the

source test.

c. Procedure for verifying Verification of the absence of cyclonic flow was conducted on the 

absence of cyclonic or non- stack in accordance with section 2.4 of EPA Method 1.

parallel stack gas flow. (Performed by ESS on 11/17/2006).

No physical or operational changes have been made that will 

change the status of the above cyclonic flow check.

7. Notes

a. Citation of the QA/QC ESS has a QA/QC program in place for their sampling personnel.

procedures specified in the EPA All ESS sampling personnel are equipped with applicable 

Reference Methods and the EPA regulations (40 CFR Part 60), job specific checklist, and detailed

Quality Assurance Handbook policies and sampling procedures, as documented in the EPA

for Air Pollution Measurement Quality Assurance Handbook for Air Pollution Measurement

Systems, Volume III. Systems, Volume III, (EPA/600/R-94/038c).

b. Chain-of-custody procedures ESS sample custody procedures are based upon EPA recommended

and copies of chain-of-custody procedures presented in the individual test methods, and in the 

forms. Quality Assurance Handbook for Air Pollution Measurement Systems.

c. Procedure for conditioning PM filters will be handled according to US EPA Method 5.

particulate matter filters (before

and after source testing).

d. Procedure for conducting Leak checks will be conducted according to the requirements in

leak checks on vacuum lines, US EPA methods 1 through 5 and 26A.

pitot tubes, flexible bags, orsats,

etc.

Minimum Requirements for a Site-Specific Test Plan

Sampling and Analytical 

Procedures

Sampling Locations and 

Documentation

Internal Quality Assurance 

/Quality Control (QA/QC) 

Measures. For each proposed 

test method when applicable.

Acceptable?

Acceptable?

Acceptable?

3 of 7
e. Equipment calibration All equipment will be calibrated according to the requirements

frequencies, ranges, and in the applicable reference test methods.

acceptable limits.

f. Minimum detection limits of The detection limits will meet or exceed those specified in US EPA

analytical instrumentation. Method 26A.

g. Names, addresses, and Subcontracted through ESS

responsible persons of all sub- Element One, Inc.

contracting laboratories and a 5022-C Wrightsville Ave.

description of analytical Wilmington, NC 28403

methods to be used, chain-of- Ken Smith

custody procedures and QA/QC

measures. See US EPA Method 26A for analytical method and QA/QC.

h. QA/QC measures associated

with the collection and analysis

of process or raw material Not Applicable.

samples and the frequency at

which these samples will be 

collected.

i. Methods for interference and

matrix effects checks, and Will be performed in accordance with the applicable section

number of replicate analyses. of the reference method.

j. Methods and concentrations

for internal standards (standards Will be performed in accordance with the applicable section

additions prior to extraction). of the reference method.

k. Methods and concentrations

for surrogate standards Will be performed in accordance with the applicable section

(standards additions to of the reference method.

collection media prior to

sampling).

l. Methods for recovery checks,

field blanks, lab blanks, reagent Will be performed in accordance with the applicable section

blanks, proof rinse blanks, and of the reference method.

analytical blanks.

m. Proposed range of recoveries

for data acceptability and Will be performed in accordance with the applicable section

method of data interpretation if of the reference method.

sample recovery is not within

the proposed range.

8. Final Test Report Content Notes

a. Final Report Outline N/A

b. Example calculations when

using alternative test methods or N/A

for calculation of process

operating rates.

c. Proposed report submission According to §63.8630(e)(1) of the MACT standard, the performance

date if more than 30 days after test results must be submitted within 60 calendar days following 

the source test will be needed to the completion of the performance test.

complete the report.

Minimum Requirements for a Site-Specific Test Plan

Acceptable?

4 of 7
Notes

a. Is an EPA audit sample As per the MACT General Provisions, audit samples were requested.

available? See Notification of Intent to Conduct Performance Test.

b. Will an EPA or State

prepared audit sample be N/A

provided by the Department?

c. Will the Department be 

requesting split samples? (This N/A

request should be made in 

advance of the source test.)

Notes

Will the Department need access

to the analytical laboratory for N/A

observation of instrument

calibrations and analysis of field

and audit samples?

Notes

Will a site inspection be

necessary prior to approval of N/A

the site-specific test plan?

Date Due Date Received Final Report Extension Requested? Extension

Reviewed By Reason? Due Date

Field Modifications to the Approved Site-Specific Test Plan

Final Source Test Report

Analytical Observation

Yes/No

Site Inspection

Yes/No

Yes/No

Source Test Method Audit Program

5 of 7
Contents (When applicable) Notes:

a. Summary of the results. N/A for Site-Specific Test Plan Submittal

b. Emission calculations and

emission rates in units of the 

applicable standard, permit

limit, etc.

c. Allowable emission rates in the 

units of the applicable standard,

permit limit, etc.

d. Source compliance status.

e. Process operating rates.

f. Methods including actual 

calculations, equations, and

other related information that

were used to demonstrate and

verify the operating rate during

the source test.

g. Chain of custody records.

h. Certification of all reference

standards used.

i. Signature of a responsible

facility representative who can

verify process operating rates

and prameters.

j. Legible copies of all raw

laboratory data (for example,

filter tare and final weights,

titrations, chromatograms,

spectrograms, analyzer

measurements, etc.)

k. Legible copies of all raw

field data (for example, strip

charts, field data forms, field

calibration forms, etc.).

l. Legible copies of all applicable

stack gas or opacity monitoring

system readings indentified in the 

approved site-specific test plan.

m. Legible copies of all

applicable process and air

pollution control operating

parameter readings identified in 

the approved site-specific test

plan.

n. Results of all calibrations and 

QA/QC measures and checks

identified in the approved sitespecific test plan.

o. Results of performance audits

pursuant to paragraph E.

p. Description of any deviations

from the proposed process

operations as approved in the

site-specific test plan during

testing.

q. Description of any deviations

from approved sampling 

methods/procedures.

r. Description of any deviations

from approved analytical

procedures.

s. Description of any problems

encountered during sampling

and analysis, and explanation of

how each was resolved.

Final Source Test Report Requirements

Acceptable?

6 of 7
Notes

Is this source in compliance? N/A

Plan Due Date (Within 15 days Plan Submittal Date Is the plan acceptable? (Yes/No)

of submission of a test report

indicating non-compliance).

Minimum Content of the Plan Included? Notes

a. Interim actions being taken to

minimize emissions pending N/A

demonstration of compliance.

b. Corrective actions that have 

been taken or that are proposed

to return the source to

compliance.

c. Method that will be used to 

demonstrate the source has

returned to compliance (for

example, retest and proposed

date).

Compliance Status

Yes/No

Non-Compliant Results

7 of 7
Kohler Co. Plant Date

Test No. Duct No. Duct 

Diameter 

(inches)

Duct Area 

(ft2)

Coupling 

Length 

(inches)

No. Points 

Across 

Diameter

 Disturbance

Measurement

Site

Disturbance

NORTH

TRAVERSE 

POINT NO. 

ON A 

DIAMETER 2 4 6 8 10 12 14 16 18 20 22 24

1 14.6 6.7 4.4 3.2 2.6 2.1 1.8 1.6 1.4 1.3 1.1 1.1

2 85.4 25.0 14.6 10.5 8.2 6.7 5.7 4.9 4.4 3.9 3.5 3.2

3 75.0 29.6 19.4 14.6 11.8 9.9 8.5 7.5 6.7 6.0 5.5

4 93.3 70.4 32.3 22.6 17.7 14.6 12.5 10.9 9.7 8.7 7.9

5 85.4 67.7 34.2 25.0 20.1 16.9 14.6 12.9 11.6 10.5

6 95.6 80.6 65.8 35.6 26.9 22.0 18.8 16.5 14.6 13.2

7 89.5 77.4 64.4 36.6 28.3 23.6 20.4 18.0 16.1

8 96.8 85.4 75.0 63.4 37.5 29.6 25.0 21.8 19.4

9 91.8 82.3 73.1 62.5 38.2 30.6 26.2 23.0

10 97.4 88.2 79.9 71.7 61.8 38.8 31.5 27.2

11 93.3 85.4 78.0 70.4 61.2 39.3 32.3

12 97.9 90.1 83.1 76.4 69.4 60.7 39.8

13 94.3 87.5 81.2 75.0 68.5 60.2

14 98.2 91.5 85.4 79.6 73.8 67.7

15 95.1 89.1 83.5 78.2 72.8

16 98.4 92.5 87.1 82.0 77.0

17 95.6 90.3 85.4 80.6

18 98.6 93.3 88.4 83.9

19 96.1 91.3 86.8

20 98.7 94.0 89.5

21 96.5 92.1

22 98.9 94.5

23 96.8

24 98.9

Point 

Locations 

(coupling 

included) 2 4 6 8 10 12 14 16 18 20 22 24

1 5.8

2 7.4

3 9.2

4 11.4

5 14.0

6 17.8

7 28.2

8 32.0

9 34.6

10 36.8

11 38.6

12 40.2

13

14

15

16

17

18

19

20

21

22

23

24

All

14' (4.7 dia.)

8' (2.7 dia.)

7.069 5 12

Spartanburg - Vitreous Plant -

Kiln 10 Scrubber Stack 36
50

aHIGHER NUMBER IS FOR

RECTANGULAR STACKS OR DUCTS

A

Disturbance

- 36 in.

- 96 in. = 2.67

B

Downstream - 168 in. = 4.67 Disturbance

STACK DIAMETER > 0.61 m (24 in.)

* FROM POINT OF ANY TYPE OF

DISTURBANCE (BEND, EXPANSION, CONTRACTION, ETC.)

STACK DIAMETER = 0.30 TO 0.61 m (12-24 in.)

0

2

diameters

Upstream 

Diameter

diameters

Figure 1-1. Minimum number of traverse points for particulate traverses.

3 4 5 6 7 8 9 10

16

12

10

8 or 9a

DUCT DIAMETERS DOWNSTREAM FROM FLOW DISTURBANCE* (DISTANCE B)

MINIM

U

M

N

U

M

B

E

R

O

F

T

RA

V

E

R

S

E

P

OIN

T

S

40

Measurement 

Site

30

24 or 25a

20 20

DUCT DIAMETERS UPSTREAM FROM FLOW DISTURBANCE* (DISTANCE A)

0.5 1.0 1.5 2.0 2.5
50

10

10

40

30

20

2.5
OR

Tunnel Kiln #4

OR

Shuttle Kiln #6, #7, and #9

SHIPPING AREA

UNFINISHED PRODUCT FINISHED PRODUCT

Finished Product to Shipping Area, Defective Product to Re-Glaze and Re-Fire

Shuttle Kiln #7

GREENWARE IS GLAZED IN BOOTHS, 

SOME IS RE-GLAZED PRIOR TO REFIRE

WARE TRANSPORTED TO CASTING FLOOR TO BE GLAZED

PLACE PRODUCT INTO WARE DRYER

First Fire Ware

Tunnel Kilns #1,#2,#3,#8, and #10

Re-Fire Ware 

Tunnel Kiln #10 (TKE-10)

KOHLER COMPANY

Spartanburg, South Carolina

Process Flow Diagram

PRODUCTION CASTING

PUMP SLURRY MATERIAL TO PLASTER MOLDS

 12/04/2006

EPA-HQ-OAR-2013-0290-DRAFT-0069, Process Flow Diagram