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 -- W ithin 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 **MA CT 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 cy cle 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 ty**  **pe 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 A pplicable**  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 MA** **CT.** (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 cy clonic 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 phy sical or operational changes have been made that will**  **change the status of the above cy clonic 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 Sy**  **stems.** 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 Analy** 

**tical 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 7e. 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 analy tical method and QA** 

**/QC.** h. QA/QC measures associated with the collection and analysis of process or raw material **Not A pplicable.**  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 day s 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 7Notes

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. Wi ll an EPA or State prepared audit sample be **N/A** provided by the Department? c. Wi ll the Department be requesting split samples? (This **N/A** request should be made in advance of the source test.)

Notes Wi ll the Department need access to the analytical laboratory for **N/A** observation of instrument calibrations and analysis of field and audit samples?

Notes Wi ll 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 A pproved Site-Specific Test Plan** 

**Final Source Test Report An**  **aly tical Observation**  Yes/No

**Site Inspection** Yes/No Yes/No **Source Test Method A udit 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 checksidentified 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 7Notes

Is this source in compliance? **N/A**

Plan Due Date (W ithin 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 7Kohler 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

-

36 Kiln 10 Scrubber Stack

## 50

a

### HIGHER NUMBER IS FOR RECTANGULAR STACKS OR DUCTS A Disturbance



## - 36 in.

- 96 in. = 2.67

B


## Dow nstream

- 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.** 7 8 9 10 3 4 5 6 16 12

10 8 or 9 a



## DUCT DIAMETERS DOWNSTREAM FROM FLOW DISTURBANCE* (DISTANCE B)**M I** **N I** **M U** **M N** **U M** **B E** **R O** **F T** **R A** **V E** **R S** **E P** **O I** **N T** **S** 

## 40 Measurement Site



## 30

24 or 25 a



## 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

SHIPPI NG AREA UNFI NI SHED PRODUCT FINISHED PRODUCT Finished Product to Shipping Area, Defective Product to Re-Glaze and Re-Fire Shuttle Kiln #7 GREENWARE I S GLAZED I N BOOTHS, SOME I S RE-GLAZED PRIOR TO REFIRE WARE TRANSPORTED TO CASTI NG FLOOR TO BE GLAZED PLACE PRODUCT I

NTO 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 CASTI

NG PUMP SLURRY MATERI AL TO PLASTER MOLDS

12/04/2006 EPA-HQ-OAR-2013-0290-DRAFT-0069, Process Flow Diagram