Document Mm6a9dNa7JJkwmKVqyGY388x

MEMORANDUM SUBJECT: CLEAN AIR ACT INSPECTION REPORT The Ford Meter Box Company, Inc., Wabash, Indiana FROM: Dakota Prentice, Environmental Engineer AECAB (IL/IN) THRU: Nathan Frank, Section Supervisor AECAB (IL/IN) TO: File BASIC INFORMATION Facility Name: The Ford Meter Box Company, Inc. Facility Location: 775 Manchester Avenue, Wabash, Indiana Date of Inspection: June 4, 2024 EPA Inspector(s): 1. Dakota Prentice, Environmental Engineer 2. Meaghan Pashen, Environmental Engineer Other Attendees: 1. John Haney, The Ford Meter Box Company, Inc. - Environmental Engineer 2. Chris Shanks, The Ford Meter Box Company, Inc. - Executive Vice President 3. Angela G. Verseman, Indiana Department of Environmental Management - Environmental Manager Contact Email Address: John Haney - jhaney@fordmeterbox.com Purpose of Inspection: to determine compliance with the Clean Air Act and Indiana state implementation plan Facility Type: brass foundry Facility Name: The Ford Meter Box Company, Inc. Facility Location: 775 Manchester Avenue, Wabash, Indiana Date of Inspection: June 4, 2024 Regulations Central to Inspection: National Emission Standards for Hazardous Air Pollutants: Area Source Standards for Aluminum, Copper, and Other Nonferrous Foundries (NESHAP ZZZZZZ) at 40 C.F.R. Part 63, Subpart ZZZZZZ Arrival Time: 1:00 PM Departure Time: 2:45 PM Inspection Type: Unannounced Inspection Announced Inspection OPENING CONFERENCE Presented Credentials Stated authority and purpose of inspection Provided Small Business Resource Information Sheet via email following inspection Small Business Resource Information Sheet not provided Provided CBI warning to facility The following information was obtained verbally from John Haney unless otherwise noted. Process Description: The facility produces brass water utility products to connect municipal potable water service main lines to homes and buildings. Production begins with the melting of metal, consisting of brass ingot, internal scrap, and metal shavings at one of eight furnaces. Two of the furnaces are dedicated to leaded brass production and two additional furnaces produce leaded brass, as needed, based on demand. When the melt cycle at the furnace is complete, the molten brass is poured into a ladle. The ladle is moved to a pouring station when the molten brass is poured into molds. The molds are allowed to cool and then moved to shakeout where the sand is removed from the casting. After the sand is removed, the casting moves through a series of finishing steps including shot blasting and grinding. After finishing, the casting to prepared for shipment to customers. The facility also has mold and core production lines and a sand reclamation system. Staff Interview: The facility has a total of 10 baghouse to control particulate matter emissions. The baghouse controlling emissions at melting and pouring has a bag leak detection system (BLDS), but this BLDS has reportedly had technical problems. Leaded brass products are used for products that either do not come into contact with drinking water or are exported. Currently, leaded products make up 30% of production. The highest lead content ingot used at the facility is 5% lead. The facility uses separate furnaces, shot blast units, and sand handling systems for leaded brass. Core production has a scrubber to control amines. TOUR INFORMATION EPA Toured the Facility: Yes Facility Name: The Ford Meter Box Company, Inc. Facility Location: 775 Manchester Avenue, Wabash, Indiana Date of Inspection: June 4, 2024 Data Collected and Observations: EPA observed leaded and non-leaded furnaces in operation. The furnaces had covers with side-draft emission capture systems. The roof located above the furnaces had ventilation fans blowing melt shop air up and out of the building. EPA also observed emissions from an auto-pour system with a dedicated emission capture system above the unit. There is one cooling tower onsite but water does not make contact with lead. Photos and/or Videos: were taken during the inspection and are listed in Appendix A. See Appendix A Field Measurements: were not taken during this inspection. CLOSING CONFERENCE Provided U.S. EPA point of contact to the facility Requested documents: Calculations and assumptions associated with capture efficiency determinations included in the current Title V permit. The most recent performance test at each location at the facility. All BLDS records, with associated compliance setpoints, for the last 12 months. If the BLDS was not in operation or was in malfunction, provide supplemental documentation demonstrating compliance as is appropriate. The last two full years of actual emission calculations. Include a modifiable spreadsheet that documents how the emissions are calculated. DIGITAL SIGNATURES DAKOTA Digitally signed by DAKOTA PRENTICE Report Author: _P_R__E_N__T_IC__E___0_9_:39_:4_5_-0_5'0_0_' ____________ Date: 2024.07.09 Section Supervisor: NATHAN Digitally signed by NATHAN FRANK _F_R__A_N_K_______1_1_:25_:3_5_-0_5'0_0_' _____________ Date: 2024.07.17 Facility Name: The Ford Meter Box Company, Inc. Facility Location: 775 Manchester Avenue, Wabash, Indiana Date of Inspection: June 4, 2024 APPENDICES Appendix A: Digital Image Log and Digital Video Log Facility Name: The Ford Meter Box Company, Inc. Facility Location: 775 Manchester Avenue, Wabash, Indiana Date of Inspection: June 4, 2024 APPENDIX A: DIGITAL IMAGE LOG AND DIGITAL VIDEO LOG Inspector Name: M. Pashen Archival Record Location: R5 Electronic Record Center > AECAB Library > Enf_Ford Meter Box_IN_24 > Inspection > Photos Image Number File Name 1 IMG_0755.JPG 2 IMG_0756.JPG 3 IMG_0757.JPG 4 IMG_0759.JPG 5 IMG_0760.JPG 6 IMG_0761.JPG 7 IMG_0762.JPG 8 IMG_0763.JPG 9 IMG_0764.JPG Date and Time (incl. Time zone and DST) 6/4/2024 13:03 6/4/2024 13:04 6/4/2024 13:04 6/4/2024 13:05 6/4/2024 13:06 6/4/2024 13:22 6/4/2024 13:22 6/4/2024 13:23 6/4/2024 13:23 Description of Image Non-Leaded Furnace Nos. 1 and 2 Roof vent above Furnace Nos. 1 and 2 Roof vent above Furnace Nos. 1 and 2 Melt Deck Pouring Line Auto-Pour Unit Auto-Pour Unit Capture System at Auto-Pour Unit Capture System at Auto-Pour Unit Video Number File Name 1 IMG_0755.JPG Date and Time (incl. Time zone and DST) 6/4/2024 13:03 Description of Video Non-Leaded Furnace Nos. 1 and 2