Fill and Sign the National Insurance Proposal Form

January 4, 2002 Mr. James Hunsicker Naval Surface Warfare Center, Crane Division Building 3260, Code 09510 300 Highway 361 Crane, Indiana 47522 Re: 101-14493 Significant Source Modification to: Part 70 permit No.: T101-7341-00005 Dear Mr. Hunsicker: Naval Surface Warfare Center, Crane Division was issued Part 70 operating permit T101-734100005 on May 15, 2001 for a military base. An application to modify the source was received on June 14, 2001. Pursuant to 326 IAC 2-7-10.5 the following emission units are approved for construction at the source: (a) One (1) contained detonation chamber, identified as P01, located in building 3339, with a maximum capacity of 7500 pounds per hour gross weight of munitions, 750 pounds per hour net explosive weight (NEW), equipped with one (1) baghouse for particulate control, and exhausting to stack S01. The following construction conditions are applicable to the proposed project: 1. General Construction Conditions The data and information supplied with the application shall be considered part of this source modification approval. Prior to any proposed change in construction which may affect the potential to emit (PTE) of the proposed project, the change must be approved by the Office of Air Management (OAM). 2. This approval to construct does not relieve the permittee of the responsibility to comply with the provisions of the Indiana Environmental Management Law (IC 13-11 through 13-20; 13-22 through 13-25; and 13-30), the Air Pollution Control Law (IC 13-17) and the rules promulgated thereunder, as well as other applicable local, state, and federal requirements. 3. Effective Date of the Permit Pursuant to IC 13-15-5-3, this approval becomes effective upon its issuance. 4. Pursuant to 326 IAC 2-1.1-9 and 326 IAC 2-7-10.5(i), the Commissioner may revoke this approval if construction is not commenced within eighteen (18) months after receipt of this approval or if construction is suspended for a continuous period of one (1) year or more. Naval Surface Warfare Center - Crane Division Crane, Indiana Page 2 of 2 SSM: 101-14493-00005 5. All requirements and conditions of this construction approval shall remain in effect unless modified in a manner consistent with procedures established pursuant to 326 IAC 2. 6. Pursuant to 326 IAC 2-7-10.5(l) the emission units constructed under this approval shall not be placed into operation prior to revision of the source’s Part 70 Operating Permit to incorporate the required operation conditions. This significant source modification authorizes construction of the new emission units. Operating conditions shall be incorporated into the Part 70 operating permit as a significant permit modification in accordance with 326 IAC 2-7-10.5(l)(2) and 326 IAC 2-7-12. Operation is not approved until the significant permit modification has been issued. Pursuant to Contract No. A305-0-00-36, IDEM, OAQ has assigned the processing of this application to Eastern Research Group, Inc., (ERG). Therefore, questions should be directed to Mike Heaney, ERG, P.O. Box 2010, Morrisville, North Carolina 27560, or call (919) 468-7870 to speak directly to Mr. Heaney. Questions may also be directed to Duane Van Laningham at IDEM, OAQ, 100 North Senate Avenue, P.O. Box 6015, Indianapolis, Indiana, 46206-6015, or call (800) 451-6027, press 0 and ask for Duane Van Laningham, or extension 3-6878, or dial (317) 233-6878. Sincerely, Original Signed by Paul Dubentzky Paul Dubenetzky, Chief Permits Branch Office of Air Quality Attachments ERG/MH cc: File - Martin County Martin County Health Department Air Compliance Section Inspector - Gene Kelso Compliance Data Section - Karen Nowak Administrative and Development - Sara Cloe Technical Support and Modeling - Michele Boner PART 70 OPERATING PERMIT OFFICE OF AIR QUALITY Naval Surface Warfare Center, Crane Division 300 Highway 361 Crane, Indiana 47522 (herein known as the Permittee) is hereby authorized to operate subject to the conditions contained herein, the source described in Section A (Source Summary) of this permit. This permit is issued in accordance with 326 IAC 2 and 40 CFR Part 70 Appendix A and contains the conditions and provisions specified in 326 IAC 2-7 as required by 42 U.S.C. 7401, et. seq. (Clean Air Act as amended by the 1990 Clean Air Act Amendments), 40 CFR Part 70.6, IC 13-15 and IC 13-17. Operation Permit No.: T101-7341-00005 Issued by: Janet G. McCabe, Assistant Commissioner Office of Air Quality Issuance Date: May 15, 2001 Significant Source Modification: 101-14493-00005 Affected Pages: All Issued by: Original Signed by Paul Dubenetzky Paul Dubenetzky, Branch Chief Office of Air Quality Issuance Date: January 4, 2002 Naval Surface Warfare Center Crane Division Crane, Indiana Permit Reviewer: Kimberly Paurazas Significant Source Modification: 101-14493-00005 Modified by: ERG/MH Page 2 of 121 101-7341-00005 TABLE OF CONTENTS SECTION A A.1 A.2 A.3 A.4 SOURCE SUMMARY General Information [326 IAC 2-7-4(c)] [326 IAC 2-7-5(15)] Emission Units and Pollution Control Equipment Summary [326 IAC 2-7-4(c)(3)] Specifically Regulated Insignificant Activities [326 IAC 2-7-1(21)] [326 IAC 2-7-4(c)] Part 70 Permit Applicability [326 IAC 2-7-2] SECTION B B.1 B.2 B.3 B.4 B.5 B.6 B.7 B.8 B.9 B.10 B.11 B.12 B.13 B.14 B.15 B.16 B.17 B.18 B.19 B.20 B.21 B.22 B.23 B.24 GENERAL CONDITIONS Definitions [326 IAC 2-7-1] Permit Term [326 IAC 2-7-5(2)] Enforceability [326 IAC 2-7-7(a)] Termination of Right to Operate [326 IAC 2-7-10] [326 IAC 2-7-4(a)] Severability [326 IAC 2-7-5(5)] Property Rights or Exclusive Privilege [326 IAC 2-7-5(6)(D)] Duty to Supplement and Provide Information [326 IAC 2-7-4(b)] [326 IAC 2-7-5(6)(E)] Compliance with Permit Conditions [326 IAC 2-7-5(6)(A)] [326 IAC 2-7-5(6)(B)] Certification [326 IAC 2-7-4(f)] [326 IAC 2-7-6(1)] Annual Compliance Certification [326 IAC 2-7-6(5)] Preventive Maintenance Plan [326 IAC 2-7-5(1),(3)and (13)][326 IAC 2-7-6(1)and(6)] Emergency Provisions [326 IAC 2-7-16] Permit Shield [326 IAC 2-7-15] Multiple Exceedances [326 IAC 2-7-5(1)(E)] Deviations from Permit Requirements and Conditions [326 IAC 2-7-5(3)(C)(ii)] Permit Modification, Reopening, Revocation and Reissuance, or Termination Permit Renewal [326 IAC 2-7-4] Permit Amendment or Modification [326 IAC 2-7-11][326 IAC 2-7-12] Permit Revision Under Economic Incentives and Other Programs Operational Flexibility [326 IAC 2-7-20] Construction Permit Requirement [326 IAC 2] Inspection and Entry [326 IAC 2-7-6(2)] Transfer of Ownership or Operation [326 IAC 2-7-11] Annual Fee Payment [326 IAC 2-7-19] [326 IAC 2-7-5(7)] SECTION C SOURCE OPERATION CONDITIONS Emission Limitations and Standards [326 IAC 2-7-5(1)] C.1 Particulate Matter Emission Limitations for Processes with Process Weight Rates Less than One Hundred [326 IAC 6-3-2(c)] C.2 Opacity [326 IAC 5-1] C.3 Open Burning [326 IAC 4-1] [IC 13-17-9] C.4 Incineration [326 IAC 4-2] [326 IAC 9-1-2] C.5 Fugitive Dust Emissions [326 IAC 6-4] C.6 Operation of Equipment [326 IAC 2-7-6(6)] C.7 Asbestos Abatement Projects [326 IAC 14-10] [326 IAC 18] [40 CFR 61.140] Testing Requirements [326 IAC 2-7-6(1)] C.8 Performance Testing [326 IAC 3-6] Compliance Monitoring Requirements [326 IAC 2-7-5(1)] [326 IAC 2-7-6(1)] C.9 Compliance Schedule [326 IAC 2-7-6(3)] C.10 Compliance Monitoring [326 IAC 2-7-5(3)] [326 IAC 2-7-6(1)] C.11 Maintenance of Monitoring Equipment [326 IAC 2-7-5(3)(A)(iii)] C.12 Maintenance of Emission Monitoring Equipment [326 IAC 2-7-5(3)(A)(iii)]\ C.13 Monitoring Methods [326 IAC 3] C.14 Pressure Gauge Specifications Naval Surface Warfare Center Crane Division Crane, Indiana Permit Reviewer: Kimberly Paurazas Significant Source Modification: 101-14493-00005 Modified by: ERG/MH Page 3 of 121 101-7341-00005 TABLE OF CONTENTS (Continued) Corrective Actions and Response Steps [326 IAC 2-7-5] [326 IAC 2-7-6] C.15 Emergency Reduction Plans [326 IAC 1-5-2] [326 IAC 1-5-3] C.16 Risk Management Plan [326 IAC 2-7-5(12)] [40 CFR 68.215] C.17 Compliance Monitoring Plan - Failure to Take Response Steps [326 IAC 2-7-5] C.18 Actions Related to Noncompliance Demonstrated by a Stack Test [326 IAC 2-7-5] [326 IAC 2-7-6] Record Keeping and Reporting Requirements [326 IAC 2-7-5(3)] [326 IAC 2-7-19] C.19 Emission Statement [326 IAC 2-7-5(3)(C)(iii)] [326 IAC 2-7-5(7)] [326 IAC 2-7-19(c)] [326 IAC 2-6] C.20 General Record Keeping Requirements [326 IAC 2-7-5(3)] [326 IAC 2-1.1-11] C.21 General Reporting Requirements [326 IAC 2-7-5(3)(C)] Stratospheric Ozone Protection C.22 Compliance with 40 CFR 82 and 326 IAC 22-1 SECTION D.1 FACILITY OPERATION CONDITIONS - Abrasive Blasting Units Emission Limitations and Standards [326 IAC 2-7-5(1)] D.1.1 Particulate Matter Emissions Limitations [326 IAC 6-3-2] D.1.2 Preventive Maintenance Plan [326 IAC 2-7-5(13)] Compliance Determination Requirements D.1.3 Particulate Matter (PM) Compliance Monitoring Requirements [326 IAC 2-7-6(1)] [326 IAC 2-7-5(1)] D.1.4 Visible Emissions Notations D.1.5 Parametric Monitoring D.1.6 Baghouse Inspections D.1.7 Filter System Inspections D.1.8 Broken Bag or Filter System Failure Detection Record Keeping and Reporting Requirements [326 IAC 2-7-5(3)] [326 IAC 2-7-19] D.1.9 Record Keeping Requirements SECTION D.2 FACILITY OPERATION CONDITIONS - Boilers Emission Limitations and Standards [326 IAC 2-7-5(1)] D.2.1 Particulate Matter Emissions Limitations [326 IAC 6-2-3] D.2.2 Particulate Matter Emissions Limitations [326 IAC 6-2-4] D.2.3 Sulfur Dioxide Emissions Limitations [326 IAC 7-1.1-2] D.2.4 Preventive Maintenance Plan [326 IAC 2-7-5(13)] Compliance Determination Requirements D.2.5 Sulfur Dioxide Emissions and Sulfur Content Compliance Monitoring Requirements [326 IAC 2-7-6(1)] [326 IAC 2-7-5(1)] D.2.6 Visible Emissions Notations Record Keeping and Reporting Requirements [326 IAC 2-7-5(3)] [326 IAC 2-7-19] D.2.7 Record Keeping Requirements D.2.8 Reporting Requirements Naval Surface Warfare Center Crane Division Crane, Indiana Permit Reviewer: Kimberly Paurazas Significant Source Modification: 101-14493-00005 Modified by: ERG/MH Page 4 of 121 101-7341-00005 TABLE OF CONTENTS (Continued) SECTION D.3 FACILITY OPERATION CONDITIONS - Carpentry Shops Emission Limitations and Standards [326 IAC 2-7-5(1)] D.3.1 Particulate Matter Emissions Limitations [326 IAC 6-3-2] D.3.2 Preventive Maintenance Plan [326 IAC 2-7-5(13)] Compliance Determination Requirements D.3.3 Particulate Matter (PM) Compliance Monitoring Requirements [326 IAC 2-7-6(1)] [326 IAC 2-7-5(1)] D.3.4 Visible Emissions Notations D.3.5 Cyclone Inspections D.3.6 Broken Cyclone or Failure Detection Record Keeping and Reporting Requirements [326 IAC 2-7-5(3)] [326 IAC 2-7-19] D.3.7 Record Keeping Requirements SECTION D.4 FACILITY OPERATION CONDITIONS - Paint Booths Emission Limitations and Standards [326 IAC 2-7-5(1)] D.4.1 Particulate Matter Limitation (PM) [326 IAC 6-3-2] D.4.2 PSD Minor Limit [326 IAC 2-2] D.4.3 General Provisions Relating to VOC Rules: Military Specifications [326 IAC 8-1-7] D.4.4 Miscellaneous Metal Coating Operations [326 IAC 8-2-9] D.4.5 Preventive Maintenance Plan [326 IAC 2-7-5(13)] Compliance Determination Requirements D.4.6 VOC D.4.7 VOC Emissions D.4.8 Particulate Matter (PM) Compliance Monitoring Requirements [326 IAC 2-7-6(1)] [326 IAC 2-7-5(1)] D.4.9 Monitoring Record Keeping and Reporting Requirements [326 IAC 2-7-5(3)] [326 IAC 2-7-19] D.4.10 Record Keeping Requirements D.4.11 Reporting Requirements SECTION D.5 FACILITY OPERATION CONDITIONS - Asphaltic Coating Operations Emission Limitations and Standards [326 IAC 2-7-5(1)] D.5.1 Particulate Matter Emissions Limitations [326 IAC 6-3-2] D.5.2 Preventive Maintenance Plan [326 IAC 2-7-5(13)] Compliance Monitoring Requirements [326 IAC 2-7-6(1)] [326 IAC 2-7-5(1)] D.5.3 Electrostatic Precipitator Operating Condition D.5.4 Preventive Inspections D.5.5 Opacity Readings Record Keeping and Reporting Requirements [326 IAC 2-7-5(3)] [326 IAC 2-7-19] D.5.6 Record Keeping Requirements Naval Surface Warfare Center Crane Division Crane, Indiana Permit Reviewer: Kimberly Paurazas Significant Source Modification: 101-14493-00005 Modified by: ERG/MH Page 5 of 121 101-7341-00005 TABLE OF CONTENTS (Continued) SECTION D.6 FACILITY OPERATION CONDITIONS -Open Burning/Open Detonation Emission Limitations and Standards [326 IAC 2-7-5(1)] D.6.1 Open Burning [326 IAC 4-1] D.6.2 RCRA Air Standards and Limitations D.6.3 Source Modification Requirements [326 IAC 2-7-10.5] Compliance Monitoring Requirements [326 IAC 2-7-6(1)] [326 IAC 2-7-5(1)] D.6.4 Air Quality Requirements [326 IAC 2-1.1-5] Record Keeping and Reporting Requirements [326 IAC 2-7-5(3)] [326 IAC 2-7-19] D.6.5 Record Keeping Requirements D.6.6 Reporting Requirements SECTION D.7 FACILITY OPERATION CONDITIONS -Chromic Acid Anodizing Tank Emission Limitations and Standards [326 IAC 2-7-5(1)] D.7.1 General Provisions Relating to HAPs [326 IAC 20-14][40 CFR 63, Subpart A] D.7.2 National Emission Standards for Chromium Emissions From Hard and Decorative Chromium Electroplating and Chromium Anodizing Tanks [326 IAC 20-8-1] [40 CFR 63, Subpart N] D.7.3 Work Practice Standards [40 CFR 63.342(f)] D.7.4 Preventive Maintenance Plan [326 IAC 2-7-5(13)] D.7.5 Operation and Maintenance Plan [40 CFR 63.342(f)(3)] Compliance Determination Requirements D.7.6 Testing Requirements [326 IAC 2-7-6(1)] [40 CFR 63.344(c)] D.7.7 Establishing Site-Specific Operating Parameter Values [40 CFR 63.343(c) and 63.344(d)] Compliance Monitoring Requirements [326 IAC 2-7-6(1)] [326 IAC 2-7-5(1)] D.7.8 Monitoring to Demonstrate Continuous Compliance [40 CFR 63.343(c)(2)] Record Keeping and Reporting Requirements [326 IAC 2-7-5(3)] [326 IAC 2-7-19] D.7.9 Record Keeping Requirements D.7.10 Reporting Requirements SECTION D.8 FACILITY OPERATION CONDITIONS - Stripping Tank (Open Top Vapor Degreaser) Emission Limitations and Standards [326 IAC 2-7-5(1)] D.8.1 General Provisions Relating to HAPs [326 IAC 20-14][40 CFR 63, Subpart A] D.8.2 National Emissions Standards for Halogenated Solvent Cleaning [326 IAC 20-14][40 CFR 63, Subpart T] D.8.3 Work Practice Standards [40 CFR 63.463(d)] D.8.4 Open Top Vapor Degreaser Operations [326 IAC 8-3-3] D.8.5 Organic Solvent Degreasing Operations: Open Top Vapor Degreaser Operation and Control Requirements [326 IAC 8-3-6] D.8.6 Preventive Maintenance Plan [326 IAC 2-7-5(13)] Compliance Determination Requirements [326 IAC 2-1.1-11] [326 IAC 2-7-6(1)] D.8.7 Testing Requirements [326 IAC 2-1.1-11] [326 IAC 2-7-6(1)] [40 CFR 63.465] Naval Surface Warfare Center Crane Division Crane, Indiana Permit Reviewer: Kimberly Paurazas Significant Source Modification: 101-14493-00005 Modified by: ERG/MH Page 6 of 121 101-7341-00005 TABLE OF CONTENTS (Continued) Compliance Monitoring Requirements [326 IAC 2-7-6(1)] [326 IAC 2-7-5(1)] D.8.8 Monitoring Procedures [326 IAC 2-7-6(1)] Record Keeping and Reporting Requirements [326 IAC 2-7-5(3)] [326 IAC 2-7-19] D.8.9 Record Keeping Requirements D.8.10 Reporting Requirements SECTION D.9 FACILITY OPERATION CONDITIONS -Vapor Degreaser Emission Limitations and Standards [326 IAC 2-7-5(1)] D.9.1 Open Top Vapor Degreaser Operations [326 IAC 8-3-3] D.9.2 Preventive Maintenance Plan [326 IAC 2-7-5(13)] Compliance Determination Requirements D.9.3 VOC Emissions SECTION D.10 FACILITY OPERATION CONDITIONS - Mixing and Pouring (Plastic-bonded Explosive Line) Emission Limitations and Standards [326 IAC 2-7-5(1)] D.10.1 Particulate Matter Emissions Limitations [326 IAC 6-3-2] D.10.2 Preventive Maintenance Plan [326 IAC 2-7-5(13)] Compliance Determination Requirements D.10.3 Particulate Matter (PM) Compliance Monitoring Requirements [326 IAC 2-7-6(1)] [326 IAC 2-7-5(1)] D.10.4 Visible Emissions Notations D.10.5 Scrubber Operation Condition Record Keeping and Reporting Requirements [326 IAC 2-7-5(3)] [326 IAC 2-7-19] D.10.6 Record Keeping Requirements SECTION D.11 FACILITY OPERATION CONDITIONS -Explosive Bomb Loading Operations Emission Limitations and Standards [326 IAC 2-7-5(1)] D.11.1 Particulate Matter Emissions Limitations [326 IAC 6-3-2] D.11.2 Preventive Maintenance Plan [326 IAC 2-7-5(13)] Compliance Determination Requirements D.11.3 Particulate Matter (PM) Compliance Monitoring Requirements [326 IAC 2-7-6(1)] [326 IAC 2-7-5(1)] D.11.4 Visible Emissions Notations D.11.5 Scrubber Operation Condition Record Keeping and Reporting Requirements [326 IAC 2-7-5(3)] [326 IAC 2-7-19] D.11.6 Record Keeping Requirements Naval Surface Warfare Center Crane Division Crane, Indiana Permit Reviewer: Kimberly Paurazas Significant Source Modification: 101-14493-00005 Modified by: ERG/MH Page 7 of 121 101-7341-00005 TABLE OF CONTENTS (Continued) SECTION D.12 FACILITY OPERATION CONDITIONS -Rotary Kiln Furnace Emission Limitations and Standards [326 IAC 2-7-5(1)] D.12.1 Particulate Matter Emissions Limitations [326 IAC 6-3-2] D.12.2 Preventive Maintenance Plan [326 IAC 2-7-5(13)] Compliance Determination Requirements D.12.3 Particulate Matter (PM) Compliance Monitoring Requirements [326 IAC 2-7-6(1)] [326 IAC 2-7-5(1)] D.12.4 Visible Emissions Notations D.12.5 Scrubber Operation Condition Record Keeping and Reporting Requirements [326 IAC 2-7-5(3)] [326 IAC 2-7-19] D.12.6 Record Keeping Requirements SECTION D.13 FACILITY OPERATION CONDITIONS -Service Station and above Ground Gasoline Storage Tanks Emission Limitations and Standards [326 IAC 2-7-5(1)] D.13.1 Gasoline Dispensing Facilities [326 IAC 8-4-6] D.13.2 Preventive Maintenance Plan [326 IAC 2-7-5(13)] Compliance Determination Requirements D.13.3 Testing Requirements [326 IAC 2-7-6(1),(6)] Record Keeping and Reporting Requirements [326 IAC 2-7-5(3)] [326 IAC 2-7-19] D.13.4 Record Keeping Requirements D.13.5 Reporting Requirements SECTION D.14 FACILITY OPERATION CONDITIONS -Testing of Fuses, Boosters and other Explosive Devices Emission Limitations and Standards [326 IAC 2-7-5(1)] D.14.1 Particulate Matter Emissions Limitations [326 IAC 6-3-2] D.14.2 Preventive Maintenance Plan [326 IAC 2-7-5(13)] Compliance Determination Requirements D.14.3 Particulate Matter (PM) Compliance Monitoring Requirements [326 IAC 2-7-6(1)] [326 IAC 2-7-5(1)] D.14.4 Visible Emissions Notations D.14.5 Parametric Monitoring D.14.6 Baghouse Inspections D.14.7 Vertical Packed-Bed Tower Inspections D.14.8 Broken Bag or Failure Detection D.14.9 Vertical Packed-Bed Tower Failure Detection Record Keeping and Reporting Requirements [326 IAC 2-7-5(3)] [326 IAC 2-7-19] D.14.10 Record Keeping Requirements Naval Surface Warfare Center Crane Division Crane, Indiana Permit Reviewer: Kimberly Paurazas Section D.15 Significant Source Modification: 101-14493-00005 Modified by: ERG/MH Page 8 of 121 101-7341-00005 TABLE OF CONTENTS (Continued) FACILITY OPERATION CONDITIONS - Autoclaves Emission Limitations and Standards [326 IAC 2-7-5(1)] D.15.1 Particulate Matter Emissions Limitations [326 IAC 6-3-2] D.15.2 Preventive Maintenance Plan [326 IAC 2-7-5(13)] Compliance Determination Requirements D.15.3 Particulate Matter (PM) Compliance Monitoring Requirements [326 IAC 2-7-6(1)] [326 IAC 2-7-5(1)] D.15.4 Visible Emissions Notations D.15.5 Scrubber Operation Condition Record Keeping and Reporting Requirements [326 IAC 2-7-5(3)] [326 IAC 2-7-19] D.15.6 Record Keeping Requirements Section D.16 FACILITY OPERATION CONDITIONS -Extruder Process Line Emission Limitations and Standards [326 IAC 2-7-5(1)] D.16.1 Particulate Matter Emission Limitations [326 IAC 6-3-2] D.16.2 Preventive Maintenance Plan [326 IAC 2-7-5(13)] Compliance Monitoring Requirements [326 IAC 2-7-6(1)] [326 IAC 2-7-5(1)] D.16.3 Visible Emissions Notations Record Keeping and Reporting Requirements [326 IAC 2-7-5(3)] [326 IAC 2-7-19] D.16.4 Record Keeping Requirements Section D.17 FACILITY OPERATION CONDITIONS -Insignificant Activities - Underground Storage Tanks Record Keeping and Reporting Requirements [326 IAC 2-7-5(3)] [326 IAC 2-7-19] D.17.1 Record Keeping Requirements Section D.18 FACILITY OPERATION CONDITIONS -Insignificant Activities-Fuel Oil Combustion Sources Emission Limitations and Standards [326 IAC 2-7-5(1)] D.18.1 Particulate Matter Emission Limitations [326 IAC 6-2-3] D.18.2 Particulate Matter Emissions Limitations [326 IAC 6-2-4] D.18.3 Preventive Maintenance Plan [326 IAC 2-7-5(13)] Record Keeping and Reporting Requirements [326 IAC 2-7-5(3)] [326 IAC 2-7-19] D.18.4 Record Keeping Requirements Section D.19 FACILITY OPERATION CONDITIONS -Insignificant Activities-Natural Gas Combustion Sources Emission Limitations and Standards [326 IAC 2-7-5(1)] D.19.1 Particulate Matter Emission Limitations [326 IAC 6-2-3] D.19.2 Particulate Matter Emissions Limitations [326 IAC 6-2-4] D.19.3 Preventive Maintenance Plan [326 IAC 2-7-5(13)] Naval Surface Warfare Center Crane Division Crane, Indiana Permit Reviewer: Kimberly Paurazas Section D.20 Significant Source Modification: 101-14493-00005 Modified by: ERG/MH Page 9 of 121 101-7341-00005 TABLE OF CONTENTS (Continued) FACILITY OPERATION CONDITIONS – Insignificant Activities – Incinerator Emission Limitations and Standards [326 IAC 2-7-5(1)] D.20.1 Incinerator Requirements [326 IAC 4-2-2] Section D.21 FACILITY OPERATION CONDITIONS - Contained Detonation Chamber Emission Limitations and Standards [326 IAC 2-7-5(1)] D.21.1 D.21.2 D.21.3 D.21.4 PSD Significant Net Emission Increase Limit [326 IAC 2-2][40 CFR 52.21] RCRA Air Standards and Limitations Particulate Matter (PM) [326 IAC 6-3-2] Preventive Maintenance Plan [326 IAC 2-7-5(13)] Compliance Determination Requirements D.21.5 Testing Requirements [326 IAC 2-7-6(1),(6)] [326 IAC 2-1.1-11] D.21.6 Particulate Matter (PM) Compliance Monitoring Requirements [326 IAC 2-7-6(1)] [326 IAC 2-7-5(1)] D.21.7 Visible Emissions Notations D.21.8 Parametric Monitoring D.21.9 Baghouse Inspections D.21.10 Broken or Failed Bag Detection Record Keeping and Reporting Requirement [326 IAC 2-7-5(3)] [326 IAC 2-7-19] D.21.11 Record Keeping Requirements D.21.12 Reporting Requirements Certification Emergency Occurrence Report Natural Gas Fired Boiler Certification Quarterly Report Quarterly Deviation and Compliance Monitoring Report Chromium Electroplating NESHAP - Ongoing Compliance Status Report Part 70 Quarterly Report - Contained Detonation Chamber Naval Surface Warfare Center Crane Division Crane, Indiana Permit Reviewer: Kimberly Paurazas SECTION A Significant Source Modification: 101-14493-00005 Modified by: ERG/MH Page 10 of 121 101-7341-00005 SOURCE SUMMARY This permit is based on information requested by the Indiana Department of Environmental Management (IDEM), Office of Air Quality (OAQ). The information in Sections A.1 through A.4 and in all Facility Description boxes in the D Sections is descriptive information and does not constitute enforceable conditions; however, the Permittee should be aware that physical changes or changes in the method of operation that may render this descriptive information obsolete or inaccurate may also trigger requirements for permits or permit modifications under 326 IAC 2. A.1 General Information [326 IAC 2-7-4(c)] [326 IAC 2-7-5(15)] The Permittee owns and operates a military base where ammunition, rockets and other military ordnance are manufactured, stored and disposed. Responsible Official: Source Address: Mailing Address: Contact Person: Phone Number: SIC Code: County Location: County Status: Source Status: A.2 Captain T. Scott Wetter 300 Highway 361, Crane, Indiana 47522-5009 Code 09510 Building 3260, 300 Highway 361, Crane, Indiana 47522 Mr. Shashi Kumar (812) 854-6156 9711, 3483 Martin Attainment for all criteria pollutants Part 70 Permit Program Major Source, under PSD Rules; Major Source, Section 112 of the Clean Air Act Emission Units and Pollution Control Equipment Summary [326 IAC 2-7-4(c)(3)] [326 IAC 2-7-5(15)] This stationary source consists of the following emission units and pollution control devices: (a) Eighteen (18) Abrasive Blasting Units: (1) CRN-0104-03-23-HH16, located in Building 104, constructed in 1983, with a maximum capacity of 1000 lbs/yr (0.5 tons per year (TPY)) abrasive used, using a filter system to control particulate matter emissions, and exhausting to stack CRN-0104-03-23-HH16-S. (2) CRN-0106-02-23-HH13, located in Building 106, constructed in 1988, with a maximum capacity of 3000 lbs/yr (1.5 TPY) abrasive used, using a baghouse to control particulate matter emissions, and exhausting to stack CRN-0106-02-23HH13-S1, S2. (3) CRN-0107-05-23-HH13, located in Building 107, constructed in 1980, with a maximum capacity of 4433 lbs/yr (2.2 TPY)abrasive used, using a baghouse to control particulate matter emissions, and exhausting to stack CRN-0107-05-23HH13-S. (4) CRN-0107-06-23-HH13, located in Building 107, constructed in 1980, with a maximum capacity of 4433 lbs/yr (2.2 TPY) abrasive used, using a baghouse to control particulate matter emissions, and exhausting to stack CRN-0107-06-23HH13-S. (5) CRN-0107-07-23-HH13, located in Building 107, constructed in 1980, with a maximum capacity of 4433 lbs/yr (2.2 TPY) abrasive used, using a baghouse to control particulate matter emissions, and exhausting to stack CRN-0107-07-23HH13-S. Naval Surface Warfare Center Crane Division Crane, Indiana Permit Reviewer: Kimberly Paurazas Significant Source Modification: 101-14493-00005 Modified by: ERG/MH Page 11 of 121 101-7341-00005 (6) CRN-2171-01-17-DD22, located in Building 2171, constructed in 1970, with a maximum capacity of 1000 lbs/yr (0.5 TPY) abrasive used, using a baghouse to control particulate matter emissions, and exhausting to stack CRN-2171-01-17DD22-S. (7) CRN-2521-07-02-J17, located in Building 2521, constructed after 1987, with a maximum capacity of 36,036 lbs/yr (18.0 TPY) abrasive used, using a filter system to control particulate matter emissions, and exhausting to stack CRN2521-07-02-J17-S. (8) CRN-2521-08-02-J17, located in Building 2521, constructed after 1987, with a maximum capacity of 36,036 lbs/yr (18.0 TPY) abrasive used, using a filter system to control particulate matter emission, and exhausting to stack CRN2521-08-02-J17-S. (9) CRN-2521-09-2-J17, located in Building 2521, constructed after 1987, with a maximum capacity of 36,036 lbs/yr (18.0 TPY) abrasive used, using a filter system to control particulate matter emissions, and exhausting to stack CRN2521-09-2-J17-S. (10) CRN-2930-06-17-V25, located in Building 2930, constructed in 1993, with a maximum capacity of 1000 lbs/yr (0.5 TPY)abrasive used, using a filter system to control particulate matter emissions, and exhausting to stack CRN-293006,07,08-17-V25-S. (11) CRN-2930-07-17-V25, located in Building 2930, constructed in 1993,with a maximum capacity of 1000 lbs/yr (0.5 TPY) abrasive used, using a filter system to control particulate matter emissions, and exhausting to stack CRN-293006,07,08-17-V25-S. (12) CRN-2930-08-17-V25, located in Building 2930, constructed in 1993, with a maximum capacity of 1000 lbs/yr (0.5 TPY) abrasive used, using a filter system to control particulate matter emissions, and exhausting to stack CRN-293006,07,08-17-V25-S. (13) CRN-3234-14-17-U26, located in Building 3234, constructed in 1993, with a maximum capacity of 36,036 lbs/yr (18.0 TPY) abrasive used, using a filter system to control particulate matter emissions, and exhausting to stack CRN3234-14-17-U26-S. (14) CRN-0107-08-23-HH13, located in Building 107, constructed in 1993, with a maximum capacity of 700 lbs/yr (0.4 TPY) abrasive used, using a baghouse to control particulate matter emissions, and exhausting to stack CRN-0107-08-23HH13-S. (15) Pangborn Rotoblaster CRN-0155-06-17-BB25, located in Building 155, constructed in 1972, with a maximum capacity of 3000 lbs/yr (1.5 TPY) abrasive used, using a baghouse to control particulate matter emissions, and exhausting to stack CRN-0155-06-17-BB25-S. (16) CRN-0227-03-23-HH12, located in Building 227, constructed before 1991, with a maximum capacity of 3000 lbs/yr (1.5 TPY) abrasive used, using baghouse to control particulate matter emissions, and exhausting to stack CRN-0227-03-23HH12-S. Naval Surface Warfare Center Crane Division Crane, Indiana Permit Reviewer: Kimberly Paurazas Significant Source Modification: 101-14493-00005 Modified by: ERG/MH Page 12 of 121 101-7341-00005 (17) (18) (b) CRN-3168-03-17-V28, located in Building 3168, constructed in 1988, with a maximum capacity of 1000 lbs/yr (0.5 TPY) abrasive used, using a filter system to control particulate matter emissions, and exhausting to stack CRN-3168-0317-V28-S. CRN-0107-09-23-HH13, located in Building 107, constructed in 1993, with a maximum capacity of 700 lbs/yr (0.35 TPY) abrasive used, using a baghouse to control emissions, and exhausting to stack CRN-0107-08-23-HH13. Thirty-three (33) boilers: (1) Cleaver Brooks natural gas-fired boiler, identified as CRN-0115-01-23-GG12, located in Building 115, constructed in 1997, with a maximum capacity of 16.75 mmBtu/hr, and exhausting to stack CRN-0115-01-23-GG12-S. (2) Cleaver Brooks natural gas and/or distillate fuel No.2-fired boiler, identified as CRN-0115-03-23-GG12, located in Building 115, constructed in 1997, with a maximum capacity of 16.75 mmBtu/hr, and exhausting to stack CRN-0115-0323-GG12-S. (3) Cleaver Brooks natural gas-fired boiler, identified as CRN-0128-01-17-W25, located in Building 128, constructed in 1997, with a maximum capacity of 16.75 mmBtu/hr, and exhausting to stack CRN-0128-01-17-W25-S. (4) Cleaver Brooks natural gas and/or distillate fuel No.2-fired boiler, identified as CRN-0128-03-17-W25, located in Building 128, constructed in 1997, with a maximum capacity of 16.75 mmBtu/hr, and exhausting to stack CRN-0128-0317-W25-S. (5) Cleaver Brooks natural gas and/or distillate fuel No.2-fired boiler, identified as CRN-0140-01-17-Y25, located in Building 140, constructed in 1982, with a maximum capacity of 6.2 mmBtu/hr, and exhausting to stack CRN-0140-01-17Y25-S. (6) Cleaver Brooks natural gas and/or distillate fuel No.2-fired boiler, identified as CRN-0140-02-17-Y25, located in Building 140, constructed in 1982, with a maximum capacity of 6.2 mmBtu/hr, and exhausting to stack CRN-0140-02-17Y25-S. (7) Cleaver Brooks natural gas and/or distillate fuel No.2-fired boiler, identified as CRN-0150-01-17-CC23, located in Building 150, constructed in 1989, with a maximum capacity of 25.2 mmBtu/hr, and exhausting to stack CRN-0150-01-17CC23-S. (8) Cleaver Brooks natural gas and/or distillate fuel No.2-fired boiler, identified as CRN-0150-02-17-CC23, located in Building 150, constructed in 1972, with a maximum capacity of 17.5 mmBtu/hr, and exhausting to stack CRN-0150-02-17CC23-S. (9) Cleaver Brooks natural gas and/or distillate fuel No.2-fired boiler, identified as CRN-0150-03-17-CC23, located in Building 150, constructed in 1989, with a maximum capacity of 25.2 mmBtu/hr, and exhausting to stack CRN-0150-03-17CC23-S. (10) Cleaver Brooks natural gas and/or distillate fuel No.2-fired boiler, identified as CRN-0199-01-23-JJ14, located in Building 199, constructed in 1978, with a Naval Surface Warfare Center Crane Division Crane, Indiana Permit Reviewer: Kimberly Paurazas Significant Source Modification: 101-14493-00005 Modified by: ERG/MH Page 13 of 121 101-7341-00005 maximum capacity of 17.5 mmBtu/hr, and exhausting to stack CRN-0199-01-23JJ14-S. (11) Cleaver Brooks natural gas and/or distillate fuel No.2-fired boiler, identified as CRN-0199-02-23-JJ14, located in Building 199, constructed in 1978, with a maximum capacity of 17.5 mmBtu/hr, and exhausting to stack CRN-0199-02-23JJ14-S. (12) Kewanee natural gas and/or distillate fuel No.2-fired boiler, identified as CRN1819-01-17-Y23, located in Building 1819, constructed in 1981, with a maximum capacity of 3.35 mmBtu/hr, and exhausting to stack CRN-1819-01-17-Y23-S. (13) Kewanee natural gas and/or distillate fuel No.2-fired boiler, identified as CRN1819-02-17-Y23, located in Building 1819, constructed in 1981, with a maximum capacity of 3.35 mmBtu/hr, and exhausting to stack CRN-1819-02-17-Y23-S. (14) Kewanee natural gas and/or distillate fuel No.2-fired boiler, identified as CRN2087-01-10-S30, located in Building 2087, constructed in 1978, with a maximum capacity of 3.35 mmBtu/hr, and exhausting to stack CRN-2087-01-10-S30-S. (15) Iron Fireman natural gas and/or distillate fuel No.2-fired boiler, identified as CRN-2692-01-17-W27, located in Building 2692, constructed in 1983, with a maximum capacity of 3.01 mmBtu/hr, and exhausting to stack CRN-2692-01-17W27-S. (16) Cleaver Brooks natural gas and/or distillate fuel No.2-fired boiler, identified as CRN-2737-01-12-M41, located in Building 2737, constructed in 1987, with a maximum capacity of 12.5 mmBtu/hr, and exhausting to stack CRN-2737-01-12M41-S. (17) Cleaver Brooks natural gas and/or distillate fuel No.2-fired boiler, identified as CRN-2737-02-12-M41, located in Building 2737, constructed in 1987, with a maximum capacity of 12.5 mmBtu/hr, and exhausting to stack CRN-2737-02-12M41-S. (18) Cleaver Brooks natural gas and/or distillate fuel No.2-fired boiler, identified as CRN-2737-03-12-M41, located in Building 2737, constructed in 1987, with a maximum capacity of 12.5 mmBtu/hr, and exhausting to stack CRN-2737-03-12M41-S. (19) Superior natural gas and/or distillate fuel No.2-fired boiler, identified as CRN3234-02-17-U26, located in Building 3234, constructed in 1992, with a maximum capacity of 8.234 mmBtu/hr, and exhausting to stack CRN-3234-02-17-U26-S. (20) Superior natural gas and/or distillate fuel No.2-fired boiler, identified as CRN3234-03-17-U26, located in Building 3234, constructed in 1992, with a maximum capacity of 8.234 mmBtu/hr, and exhausting to stack CRN-3234-03-17-U26-S. (21) Superior natural gas and/or distillate fuel No.2-fired boiler, identified as CRN0041-01-17-U26, located in Building 41, constructed in 1977, with a maximum capacity of 10.0 mmBtu/hr, and exhausting to stack CRN-0041-01-17-U26-S. (22) Johnston natural gas and/or distillate fuel No.2-fired boiler, identified as CRN0041-02-17-U26, located in Building 41, constructed in 1983, with a maximum capacity of 6.9 mmBtu/hr, and exhausting to stack CRN-0041-02-17-U26-S. Naval Surface Warfare Center Crane Division Crane, Indiana Permit Reviewer: Kimberly Paurazas Significant Source Modification: 101-14493-00005 Modified by: ERG/MH Page 14 of 121 101-7341-00005 (23) (24) Cleaver Brooks natural gas and/or distillate fuel No.2-fired boiler, identified as CRN-0115-02-23-GG12, located in Building 115, constructed in 1985, with a maximum capacity of 6.2 mmBtu/hr, and exhausting to stack CRN-0115-02-23GG12-S. (25) Cleaver Brooks natural gas and/or distillate fuel No.2-fired boiler, identified as CRN-0128-02-17-W25, located in Building 128, constructed in 1984, with a maximum capacity of 6.2 mmBtu/hr, and exhausting to stack CRN-0128-02-17W25-S. (26) Cleaver Brooks natural gas and/or distillate fuel No.2-fired boiler, identified as CRN-0149-01-10-S30, located in Building 149, constructed in 1980, with a maximum capacity of 6.7 mmBtu/hr, and exhausting to stack CRN-0149-01-10S30-S. (27) Cleaver Brooks natural gas and/or distillate fuel No.2-fired boiler, identified as CRN-0149-02-10-S30, located in Building 149, constructed in 1980, with a maximum capacity of 6.7 mmBtu/hr, and exhausting to stack CRN-0149-02-10S30-S. (28) Cleaver Brooks natural gas and/or distillate fuel No.2-fired boiler, identified as CRN-0180-01-17-W22, located in Building 180, constructed in 1999, with a maximum capacity of 4.2 mmBtu/hr, and exhausting to stack CRN-0180-01-17W22-S. (29) Cleaver Brooks natural gas and/or distillate fuel No.2-fired boiler, identified as CRN-0180-02-17-W22, located in Building 180, constructed in 1999, with a maximum capacity of 4.2 mmBtu/hr, and exhausting to stack CRN-0180-02-17W22-S. (30) Kewanee natural gas and/or distillate fuel No.2-fired boiler, identified as CRN2517-01-10-T21, located in Building 2517, constructed in 1981, with a maximum capacity of 4.85 mmBtu/hr, and exhausting to stack CRN-2517-01-10-T21-S. (31) Kewanee natural gas and/or distillate fuel No.2-fired boiler, identified as CRN2517-02-10-T21, located in Building 2517, constructed in 1981, with a maximum capacity of 4.85 mmBtu/hr, and exhausting to stack CRN-2517-02-10-T21-S. (32) Johnston natural gas and/or distillate fuel No.2-fired boiler, identified as CRN2523-01-9-K18, located in Building 2523, constructed in 1983, with a maximum capacity of 17.38 mmBtu/hr, and exhausting to stack CRN-2523-01-9-K18-S. (33) (c) Cleaver Brooks natural gas and/or distillate fuel No.2-fired boiler, identified as CRN-0064-01-10-T27, located in Building 64, constructed in 1976, with a maximum capacity of 10.0 mmBtu/hr, and exhausting to stack CRN-0064-01-10T27-S. Johnston natural gas and/or distillate fuel No.2-fired boiler, identified as CRN2523-02-9-K18, located in Building 2523, constructed in 1983, with a maximum capacity of 17.4 mmBtu/hr, and exhausting to stack CRN-2523-02-9-K18-S. Three (3) Carpentry Shops, identified as: (1) CRN-0056-04-10-T21, located in Building 56, using a wood usage of 74,880 board feet per year, with a process weight rate of 0.14 tons per hour, equipped Naval Surface Warfare Center Crane Division Crane, Indiana Permit Reviewer: Kimberly Paurazas Significant Source Modification: 101-14493-00005 Modified by: ERG/MH Page 15 of 121 101-7341-00005 with a cyclone for particulate control, and exhausting to stack CRN-0056-04-10T21-S. (2) (3) (d) CRN-0224-02-23-HH12, located in Building 224, using a wood usage of 1,000,000 board feet per year, with a process weight rate of 0.69 tons per hour, equipped with a cyclone for particulate control, and exhausting to stack CRN0224-02-23-HH12-S. CRN-2720-04-23-GG12, located in Building 2720, using a wood usage of 14,000 board feet per year, with a process weight rate of 0.25 tons per hour, equipped with a cyclone for particulate control, and exhausting to stack CRN2720-04-23-GG12-S. Thirty-two (32) paint booths: (1) CRN-0102-01-23-FF14, located in Building 102, constructed in 1993, using a dry filter to control particulate matter emissions. (2) CRN-0104-01-23-HH16, located in Building 104, constructed in 1983, using a water wall to control particulate matter emissions. (3) CRN-0104-02-23-HH16, located in Building 104, constructed in 1983, using a water wall to control particulate matter emissions. (4) CRN-0106-01-23-HH13, located in Building 106, constructed in 1960, using a water wall to control particulate matter emissions. (5) CRN-0107-01-23-HH13, located in Building 107, constructed in 1980, using a dry filter to control particulate matter emissions. (6) CRN-0107-02-23-HH13, located in Building 107, constructed in 1980, using a water wall to control particulate matter emissions. (7) CRN-0107-03-23-HH13, located in Building 107, constructed in 1980, using a dry filter to control particulate matter emissions. (8) CRN-0107-04-23-HH13, located in Building 107, constructed in 1980, using a wet wall to control particulate matter emissions. (9) CRN-0136-01-17-Z26, located in Building 136, constructed in 1963, using a dry filter to control particulate matter emissions. (10) CRN-0155-01-17-BB25, located in Building 155, constructed in 1986, using a dry filter to control particulate matter emissions. (11) CRN-0155-02-17-BB25, located in Building 155, constructed in 1986, using a dry filter to control particulate matter emissions. (12) CRN-0155-03-17-BB25, located in Building 155, constructed in 1986, using a dry filter to control particulate matter emissions. (13) CRN-0155-04-17-BB25, located in Building 155, constructed in 1986, using a dry filter to control particulate matter emissions. (14) CRN-0169-01-24-EE22, located in Building 169, constructed in 1950, using a dry filter to control particulate matter emissions. Naval Surface Warfare Center Crane Division Crane, Indiana Permit Reviewer: Kimberly Paurazas Significant Source Modification: 101-14493-00005 Modified by: ERG/MH Page 16 of 121 101-7341-00005 (15) CRN-2520-01-17-Y26, located in Building 2520, constructed in 1968, using a water wall to control particulate matter emissions. (16) Bomb Finishing Line, with a maximum capacity of thirteen (13) units per hour and Projectile Renovation Operations with a maximum capacity of 120 units per hour, consisting of the following units: (i) CRN-2728-01-12-N42, located in Building 2728, constructed in 1999, using a dry filter to control particulate matter emissions. (ii) CRN-2728-02-12-N42, located in Building 2728, constructed in 1999, using a dry filter to control particulate matter emissions. (iii) CRN-2728-03-12-N42, located in Building 2728, constructed in 1999, using a dry filter to control particulate matter emissions. (17) CRN-3234-09-17-U26, located in Building 3234, constructed in 1994, using a dry filter to control particulate matter emissions. (18) CRN-3234-10-17-U26, located in Building 3234, constructed in 1994, using a dry filter to control particulate matter emissions. (19) CRN-3234-15-17-U26, located in Building 3234, constructed in 1994, using a dry filter to control particulate matter emissions. (20) CRN-0101-01-23-FF13, located in Building 101, constructed in 1945, using a dry filter to control particulate matter emissions. (21) CRN-0109-01-23-GG14, located in Building 109, constructed in 1981, using a dry filter to control particulate matter emissions. (22) CRN-0174-01-24-FF21, located in Building 174, constructed in 1986, using a dry filter to control particulate matter emissions. (23) CRN-0198-01-23-II15, located in Building 198, constructed in 1980, using a dry filter to control particulate matter emissions. (24) CRN-0227-01-23-HH12, located in Building 227, constructed prior to 1991, using a dry filter to control particulate matter emissions. (25) CRN-0227-02-23-HH12, located in Building 227, constructed prior to 1991, using a dry filter to control particulate matter emissions. (26) CRN-2074-03-16-DD13, located in Building 2074, constructed in 1987, using a dry filter to control particulate matter emissions. (27) CRN-2517-05-10-T21, located in Building 2517, constructed in 1969, using a dry filter to control particulate matter emissions. (28) CRN-2697-01-17-W24, located in Building 2697, constructed in 1983, using a dry filter to control particulate matter emissions. (29) CRN-2713-01-17-X23, located in Building 2713, constructed in 1979, using a dry filter to control particulate matter emissions. Naval Surface Warfare Center Crane Division Crane, Indiana Permit Reviewer: Kimberly Paurazas Significant Source Modification: 101-14493-00005 Modified by: ERG/MH Page 17 of 121 101-7341-00005 (30) CRN-2805-01-23-GG19, located in Building 2805, constructed in 1969, using a dry filter to control particulate matter emissions. (31) CRN-2805-02-23-GG19, located in Building 2805, constructed in 1995, using a dry filter to control particulate matter emissions. (32) CRN-3168-02-17-V28, located in Building 3168, constructed in 1988, using a dry filter to control particulate matter emissions. (e) One (1) Asphaltic Coating Operation, identified as CRN-0155-05-17-BB25, located in Building 155, with a maximum usage of 3.64 tons per hour, using an electrostatic precipitator for PM control, and exhausting to stack CRN-0155-05-17-BB25-S. (f) Open Burning/Open Detonation: (1) Open Burning of Ordnance at the Ammunition Burning Ground, identified as CRN-ABG-01-19-DD43, with a maximum usage of 2.3 mmlb/yr (1150 tons/yr) of Dunnage; 0.64 mmlb/yr (320 tons/yr) of Explosive; 4.7 mmlb/yr (2350 tons/yr) of Propellant. (2) Open Detonation of Ordnance at the Demolition Range, identified as CRN-DR01-24-KK21, with a maximum usage of 0.13 mmlb/yr (65 tons/yr) of Dunnage; 1.6 mmlb/yr (800 tons/yr) of Explosive; 0.52 mmlb/yr (260 tons/yr) of Propellant. (3) Open Burning of Ordnance at the Old Rifle Range, identified as CRN-ORR-0124-JJ24, with a maximum usage of 0.15 mmlb/yr (75 tons/yr) of Dunnage; 0.032 mmlb/yr (16 tons/yr) of Explosive; 0.012 mmlb/yr (6 tons/yr) of Propellant. (4) Fast and Slow Cookoff at the Ordnance Test Area, identified as CRN-OTA-0129-WW18, with a maximum usage of 10,000 units of various ordnance per year. (g) One (1) Chromic Acid Anodizing Tank, identified as CRN-3234-13-17-U26, located in Building 3234, equipped with a packed-bed scrubber, and exhausting to stack CRN3234-13-17-U26-S. (h) One (1) Stripping Tank (open-top vapor degreaser), constructed in 1992, identified as CRN-3234-12-17-U26, located in Building 3234, and exhausting to stack CRN-3234-1217-U26-S. (i) One (1) Vapor Degreaser, identified as CRN-0106-03-23-HH13, located in Building 106, with a maximum Natural Orange usage of 0.5 gallons per day, equipped with cooling/condensing coils and a cover to control VOC emissions, and exhausting to stack CRN-0106-03-23-HH13-S. (j) Mixing and pouring equipment in Building 200 used as a plastic bonded explosive line, constructed in 1984, consisting of mixing and pouring operations, using a carbon adsorption system with a wet scrubber to control particulate matter emissions. (k) Explosive Bomb Loading Operation, constructed in 1987, consisting of: (1) screening and weighing aluminum powder in Building 2714, using a baghouse for particulate control; and (2) screening and weighing TNT in Building 153, using a wet scrubber for particulate control; and Naval Surface Warfare Center Crane Division Crane, Indiana Permit Reviewer: Kimberly Paurazas (3) Significant Source Modification: 101-14493-00005 Modified by: ERG/MH Page 18 of 121 101-7341-00005 melting and mixing aluminum powder and TNT in Building 152, using a wet scrubber for particulate control. (l) One natural gas-fired rotary kiln furnace in Building 69, used for white phosphorous conversion to phosphoric acid, constructed in 1983 and using a variable throat venturi scrubber to control particulate matter emissions. (m) Service Station (Gasoline/Diesel Dispensing), identified as CRN-3280-04-17-X23, located in Building 3280, with a maximum usage of 350,000 gallons of unleaded gasoline per year, and 350,000 gallons of diesel per year. (1) Two (2) Above ground vertical fixed-roof cone tanks, storing unleaded gasoline, constructed in 1995, identified as: (A) (B) (n) CRN-3280-01-17-X23, located in Building 3280, with a maximum capacity of 11,600 gallons (43.9 m3), and equipped with a vapor recovery system of 99.9+% removal efficiency; CRN-3280-02-17-X23, located in Building 3280, with a maximum capacity of 11,600 gallons (43.9 m3), and equipped with a vapor recovery system of 99.9+% removal efficiency. Testing of Fuses, Boosters, and other Explosive Devices (1) One (1) containment chamber in Building 2167, constructed in 1986, used to test burn pyrotechnic items. (2) One (1) test cell in Building 3235, constructed in 1991, used to test lithium batteries, using a vertical packed-bed tower to control particulate matter emissions. (3) One (1) containment chamber in Building 142, constructed in 1995, used to test detonation of fuses, boosters and other explosive devices, using a baghouse to control particulate matter emissions. (o) (p) One (1) C-4 extruder process line, located in Building 2172, with a maximum manufacturing capacity of forty (40) 1.2 pound C-4 blocks per minute. (q) A.3 Eighteen (18) autoclaves and one (1) belt flaker located in in Building 160, used for the demilitarization of 750 pound bombs, with a combined maximum capacity of 2,000 lbs/hr, using six (6) wet scrubbers to control particulate matter emissions. One (1) contained detonation chamber, identified as P01, located in Building 3339, with a maximum capacity of 7500 pounds per hour gross weight of munitions, 750 pounds per hour net explosive weight (NEW), equipped with one (1) baghouse for particulate control, and exhausting to stack S01. Insignificant Activities [326 IAC 2-7-1(21)] [326 IAC 2-7-4(c)] [326 IAC 2-7-5(15)] (a) This stationary source also includes the following insignificant activities: (1) Natural gas-fired combustion sources with heat input less than ten million (10,000,000) Btu per hour, identified as: (A) Natural gas-fired boilers, existing and in operation before September 21, 1983, located in the following buildings: Naval Surface Warfare Center Crane Division Crane, Indiana Permit Reviewer: Kimberly Paurazas Significant Source Modification: 101-14493-00005 Modified by: ERG/MH Page 19 of 121 101-7341-00005 (i) (ii) (B) boiler in each of the following buildings: 1, 2, 4, 12, 14, 17, 18, 38, 45, 181, 224, 300, 479, 1817, 1909, 2037, 2038, 2044, 2059, 2074, 2088, 2167, 2506, 2516, 2682, 2693, 2701, 2720, 2721, 2748, 2749, 2889, 2931, 2964, 2987, 2993, 3006 boilers in each of the following buildings: 7, 2521 Natural gas-fired boilers, constructed after September 21, 1983, located in the following buildings: (i) one boiler in each of the following buildings: 5, 8, 10, 34, 36, 37, 40, 47, 66, 77, 105, 128, 363, 365, 366, 966, 1141, 1149, 2036, 2041, 2045, 2694, 2807, 2921, 3109, 3149, 3168, 3173, 3188, 3234, 3235, 3239, 3243, 3250 (ii) two boilers in each of the following buildings: 39, 180, 364, 2035, 2674, 2906 (iii) four boilers in each of the following buildings: 3241, 3251 (2) Propane or liquified petroleum gas, or butane-fired combustion sources with heat input less than six million (6,000,000) Btu per hour. (3) Fuel oil-fired combustion sources with heat input less than two million (2,000,000) Btu per hour and firing fuel containing less than five-tenths (0.5) percent sulfur by weight. (A) 1.63 mmBtu fuel oil-fired boiler, constructed in July 1983, located in Building 74. (B) 0.275 mmBtu/hr fuel oil-fired boiler, constructed in September 1990, located in Building 2918. (C) Two (2) 1.3 mmBtu/hr natural gas/fuel oil-fired boilers, identified as Cleaver Brooks CRN-0180-01-17-W22 and CRN-0180-02-17-W22, constructed in 1999, located in Building 180. (4) Equipment powered by internal combustion engines of less than 500,000 Btu/hour capacity, except where total capacity of equipment operated by one stationary source exceeds 2,000,000 Btu/hour. (5) A gasoline fuel transfer and dispensing operation handling less than or equal to 1,300 gallons per day, such as filling of tanks, locomotives, automobiles, having a storage tank of less than 10,500 gallon capacity. (6) A petroleum fuel, other than gasoline, dispensing facility, having a storage tank of less than 10,500 gallon capacity, and dispensing less than 230,000 gallons per month. (7) Storage tanks less than one thousand (1,000) gallons in capacity with annual throughputs less than twelve thousand (12,000) gallons. (8) Application of oils, greases, lubricants or other nonvolatile materials applied as temporary protective coatings. Naval Surface Warfare Center Crane Division Crane, Indiana Permit Reviewer: Kimberly Paurazas Significant Source Modification: 101-14493-00005 Modified by: ERG/MH Page 20 of 121 101-7341-00005 (9) Machining where an aqueous cutting coolant continuously floods the machine interface. (10) Solvent recycling systems with less than 100 gallon batch capacity. (11) Activities associated with the treatment of wastewater streams with an oil and grease content less than 1% by volume. Activities associated with the transportation and treatment of sanitary sewage, provided discharge to the treatment plant is under the control of the owner/operator, that is, an on site sewage treatment facility. (12) (13) Natural draft cooling towers circulating less than or equal to 340,000 gallons per day. (14) Quenching operations used with heat treating processes. (15) Replacement or repair of electrostatic precipitators, bags in baghouses and filters in other air filtration equipment. (16) Paved and unpaved roads and parking lots with public access. (17) Asbestos abatement projects regulated by 326 IAC 14-10. (18) Equipment used to collect any material that might be released during a malfunction, process upset, or spill cleanup, including catch tanks, temporary liquid separators, tanks and fluid handling equipment. (19) Blowdown for any of the following: sight glass, boiler, compressors, pumps and cooling tower. (20) On-site fire and emergency response training approved by the department. (21) Gasoline generators not exceeding 110 hp. (22) Diesel generators not exceeding 1800 hp. (23) Natural gas turbines not exceeding 16,000 hp. (24) Stationary fire pumps. (25) Filter or coalescer media changeout. (26) A laboratory as defined in 326 IAC 2-7-1(21)(D). (27) Activities with emissions equal to or less than thresholds: Lead(Pb=0.6 ton/year or 3.29 lbs/day Carbon Monoxide(CO)=25 lbs/day Sulfur Dioxide(SO2)=5 lbs/hour or 25 lbs/day Particulate matter(PM)=5 lbs/hour or 25 lbs/day Nitrogen Oxides (NOx)=5 lbs/hour or 25 lbs/day Volatile Organic Compounds (VOC)=3 lbs/hour or 15 lbs/day (1) (2) (3) Alphos tank, located in Building 2521. Brown oxide line, located in Building 38 Bubble tester. Located in Building 2931 Naval Surface Warfare Center Crane Division Crane, Indiana Permit Reviewer: Kimberly Paurazas (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14) (15) (16) (17) (19) (20) (21) (22) (23) (24) (25) (26) (27) (28) (29) (30) (31) (32) (33) (34) (35) (36) (37) (38) (39) (40) (41) (42) (43) (44) (45) (46) Significant Source Modification: 101-14493-00005 Modified by: ERG/MH Page 21 of 121 101-7341-00005 Coating, phosphorous, located in Building 1884 Curing room, located in Building 3148 Four (4) Detonations Cells, located in Building 142 Electrical discharge, located in Building 198 Environmental chamber, located in Building 2167 Explosives chamber, located in Building 142 Explosives removal (Steam-out and Autoclave), located in Building 160 Explosives mixing, located in Building 200 Explosives molding, located in Building 126 Heating oil bath, located in Building 39 Two (2) hood, fumes, located in 2940 Hood, vent, located in Building 38 Hood, vent, located in Building 174 Hood, vent, located in Building 226 (18) One (1) incinerator used for the destruction of classified materials, located in Building 45 Infrared dry, located in Building 2036 Three (3) injection molders, located in Building 198 IR Heater, located in Building 38 Mold release unit, located in 226 Oven, located in Building 2940 Curing oven, located in Building 226 Three (3) drying ovens, located in Building 3234 Laboratory oven, located in Building 109 Paint booth, located in Building 2044 Fugitive emissions from painting Passivation process PDL Foam, located in Building 2698 Plating lines A, B, and C, located in Building 3234 Quench tank, located in Building 125 Rust inhibitor, located in Building 1884 Solvent hand wiping, located in Building 155 Solvent System, located in Building 226 Miscellaneous solvent usage in Building 2728 Nineteen (19) above ground storage tanks Seventy (70) underground storage tanks One (1) fuel storage tank, located at Building 2760 Paint stripper, resistant, located in Building 38 Tank, brighteners, located at Building 1884 Vapor carbon fluid, located in Building 125 Washer, roller, located in Building 18 Washout unit, located in Building 18 Six (6) Underground Storage Tanks, identified as: (1) CRN-0003-02-17-U21 (2) CRN-2737-06-12-M41 (3) CRN-2737-07-12-M41 (4) CRN-2984-02-17-W22 (5) CRN-2984-03-17-W22 (6) CRN-3149-02-16-DD12 Seventeen (17) Air Compressors: (1) (2) Worthington, located in Building 1820, with a maximum capacity of 365 acfm; Worthington, located in Building 1820, with a maximum capacity of 365 acfm; Naval Surface Warfare Center Crane Division Crane, Indiana Permit Reviewer: Kimberly Paurazas Significant Source Modification: 101-14493-00005 Modified by: ERG/MH (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14) (15) (16) (17) Page 22 of 121 101-7341-00005 Davey, located in the Car Shop, with a maximum capacity of 365 acfm; Davey, located in Building 1820, with a maximum capacity of 365 acfm; Davey, located in Building 1820, with a maximum capacity of 365 acfm; Ingersoll, located in Building 1820, with a maximum capacity of 600 acfm; Davey, located in Building 1820, with a maximum capacity of 365 acfm; Ingersoll, located in Building 1820, with a maximum capacity of 250 acfm; Davey, located in Building 1820, with a maximum capacity of 125 acfm; Sullair, located in Building 160, with a maximum capacity of 600 acfm; Sullair, located in Building 198, with a maximum capacity of 600acfm; Sullair, located in Building 105, with a maximum capacity of 750 acfm; Davey, located in Building 2391, with a maximum capacity of 125 acfm; Davey, located in Building 2394, with a maximum capacity of 125 acfm; Ingersoll, located at Sullivan Lake, with a maximum capacity of 375 acfm; Ingersoll, located in Building 224, with a maximum capacity of 750 acfm; and Ingersoll, located in Building 200, with a maximum capacity of 750 acfm. (47) (48) One (1) fuel cell power plant utilizing a fuel processor to extract hydrogen from natural gas to produce a maximum of 212 kW of net, continuous 480 volt, 3-phrase, ac electric power from natural gas. (49) One (1) Dispo Spray Booth, Model L130, with a maximum capacity of nine (9) twelve (12) ounce paint cans per month, with no overspray and used for repairing small microwave warfare components consisting of aluminum and glass. (50) A.4 One (1) Krypton Leak Test Unit, constructed in 1990, identified as CRN2931-05-17-V25, with a maximum capacity of 1.0 ci/year, and exhausting to stack CRN-2931-05-17-V25. one (1) closed loop conversion process, used to convert ammonium picrate to picric acid with a maximum production capacity of 7 tons of picric acid per day, and exhausting to stacks S2 and V1. Part 70 Permit Applicability [326 IAC 2-7-2] This stationary source is required to have a Part 70 permit by 326 IAC 2-7-2 (Applicability) because: (a) It is a major source, as defined in 326 IAC 2-7-1(22); Naval Surface Warfare Center Crane Division Crane, Indiana Permit Reviewer: Kimberly Paurazas (b) Significant Source Modification: 101-14493-00005 Modified by: ERG/MH Page 23 of 121 101-7341-00005 It is a source in a source category designated by the United States Environmental Protection Agency (U.S. EPA) under 40 CFR 70.3 (Part 70 Applicability). Naval Surface Warfare Center Crane Division Crane, Indiana Permit Reviewer: Kimberly Paurazas SECTION B Significant Source Modification: 101-14493-00005 Modified by: ERG/MH Page 24 of 121 101-7341-00005 GENERAL CONDITIONS B.1 Definitions [326 IAC 2-7-1] Terms in this permit shall have the definition assigned to such terms in the referenced regulation. In the absence of definitions in the referenced regulation, the applicable definitions found in the statutes or regulations (IC 13-11, 326 IAC 1-2 and 326 IAC 2-7) shall prevail. B.2 Permit Term [326 IAC 2-7-5(2)] This permit is issued for a fixed term of five (5) years from the original date, as determined in accordance with IC 4-21.5-3-5(f) and IC 13-15-5-3. Subsequent revisions, modifications, or amendments of this permit do not affect the expiration date. B.3 Enforceability [326 IAC 2-7-7] Unless otherwise stated, all terms and conditions in this permit, including any provisions designed to limit the source's potential to emit, are enforceable by IDEM, the United States Environmental Protection Agency (U.S. EPA) and by citizens in accordance with the Clean Air Act. B.4 Termination of Right to Operate [326 IAC 2-7-10] [326 IAC 2-7-4(a)] The Permittee's right to operate this source terminates with the expiration of this permit unless a timely and complete renewal application is submitted at least nine (9) months prior to the date of expiration of the source=s existing permit, consistent with 326 IAC 2-7-3 and 326 IAC 2-7-4(a). B.5 Severability [326 IAC 2-7-5(5)] The provisions of this permit are severable; a determination that any portion of this permit is invalid shall not affect the validity of the remainder of the permit. B.6 Property Rights or Exclusive Privilege [326 IAC 2-7-5(6)(D)] This permit does not convey any property rights of any sort or any exclusive privilege. B.7 Duty to Supplement and Provide Information [326 IAC 2-7-4(b)] [326 IAC 2-7-5(6)(E)] [326 IAC 2-7-6(6)] (a) The Permittee, upon becoming aware that any relevant facts were omitted or incorrect information was submitted in the permit application, shall promptly submit such supplementary facts or corrected information to: Indiana Department of Environmental Management Permits Branch, Office of Air Quality 100 North Senate Avenue, P. O. Box 6015 Indianapolis, Indiana 46206-6015 The submittal by the Permittee does require the certification by the "A responsible official" as defined by 326 IAC 2-7-1(34). (b) The Permittee shall furnish to IDEM, OAQ, within a reasonable time, any information that IDEM, OAQ, may request in writing to determine whether cause exists for modifying, revoking and reissuing, or terminating this permit, or to determine compliance with this permit. The submittal by the Permittee does require the certification by the "A responsible official" as defined by 326 IAC 2-7-1(34). Upon request, the Permittee shall also furnish to IDEM, OAQ, copies of records required to be kept by this permit or, for information claimed to be confidential, the Permittee may furnish such records directly to the U. S. EPA along with a claim of confidentiality. [326 IAC 2-7-5(6)(E)] (c) The Permittee may include a claim of confidentiality in accordance with 326 IAC 17. When furnishing copies of requested records directly to U. S. EPA, the Permittee may assert a claim of confidentiality in accordance with 40 CFR 2, Subpart B. Naval Surface Warfare Center Crane Division Crane, Indiana Permit Reviewer: Kimberly Paurazas B.8 Significant Source Modification: 101-14493-00005 Modified by: ERG/MH Page 25 of 121 101-7341-00005 Compliance with Permit Conditions [326 IAC 2-7-5(6)(A)] [326 IAC 2-7-5(6)(B)] (a) The Permittee must comply with all conditions of this permit. Noncompliance with any provisions of this permit, except those specifically designated as not federally enforceable, constitutes a violation of the Clean Air Act and is grounds for: (1) Enforcement action; (2) Permit termination, revocation and reissuance, or modification; or (3) Denial of a permit renewal application. (b) (c) B.9 It shall not be a defense for the Permittee in an enforcement action that it would have been necessary to halt or reduce the permitted activity in order to maintain compliance with the conditions of this permit. An emergency does constitute an affirmative defense in an enforcement action provided the Permittee complies with the applicable requirements set forth in condition B, Emergency Provisions. Certification [326 IAC 2-7-4(f)] [326 IAC 2-7-6(1)] [326 IAC 2-7-5(3)(C)] (a) Where specifically designated by this permit or required by an applicable requirement, any application form, report, or compliance certification submitted shall contain certification by a responsible official of truth, accuracy, and completeness. This certification shall state that, based on information and belief formed after reasonable inquiry, the statements and information in the document are true, accurate, and complete. (b) (c) B.10 One (1) certification shall be included, using the attached Certification Form, with each submittal requiring certification. A responsible official is defined at 326 IAC 2-7-1(34). Annual Compliance Certification [326 IAC 2-7-6(5)] (a) The Permittee shall annually submit a compliance certification report which addresses the status of the source=s compliance with the terms and conditions contained in this permit, including emission limitations, standards, or work practices. The initial certification shall cover the time period from the date of final permit issuance through December 31 of the same year. All subsequent certifications shall cover the time period from January 1 to December 31 of the previous year, and shall be submitted in letter form no later than July 1 of each year to: Indiana Department of Environmental Management Compliance Branch, Office of Air Quality 100 North Senate Avenue, P. O. Box 6015 Indianapolis, Indiana 46206-6015 and United States Environmental Protection Agency, Region V Air and Radiation Division, Air Enforcement Branch - Indiana (AE-17J) 77 West Jackson Boulevard Chicago, Illinois 60604-3590 (b) The annual compliance certification report required by this permit shall be considered timely if the date postmarked on the envelope or certified mail receipt, or affixed by the shipper on the private shipping receipt, is on or before the date it is due. If the document Naval Surface Warfare Center Crane Division Crane, Indiana Permit Reviewer: Kimberly Paurazas Significant Source Modification: 101-14493-00005 Modified by: ERG/MH Page 26 of 121 101-7341-00005 is submitted by any other means, it shall be considered timely if received by IDEM, OAQ, on or before the date it is due. (c) The annual compliance certification report