Stack Test Data

Johnson Controls is required to test its processes for air pollutant emissions. The test results are used to determine if the facility is in compliance with the emission limitations in its air permit. A facility may use its own stack testing group or hire a third party contractor to conduct the stack tests. In preparation for testing, facilities must prepare a Stack Test Protocol. It is the responsibility of DHEC to approve or disapprove the Stack Test Protocol. Like all facilities, Johnson Controls is required to notify DHEC at least 15 days before the test to give us the opportunity to observe the test. Once the stack tests are conducted, the facility must send a report of the results to DHEC for review. If the results are validated, DHEC will issue a letter approving the stack test. The links below will provide future information about the stack tests.

• Notifications and Special Requests - Prior to testing sources are required to notify the Department of the exact testing date(s). Sometimes unusual circumstances arise that require special consideration. Documents relating to these topics will appear in this section.
  • August 15, 2012 Extension Request for Testing Unit ID 03 – PP Storage and Extrusion
  • August 29, 2012 Approval of August 15, 2012 Extension Request
• Stack Test Protocol – A protocol is sent to DHEC for review and approval prior to the stack test. The protocol provides the details of how the test will be conducted. It includes the process and pollutants to be tested, the stack test method to be used and the facility's operating conditions during the test. This protocol must be sent to DHEC at least 45 days before the test date.
  • Relative Accuracy Test Audit Test Plan Submitted November 21, 2012
  • Facility Source Test Plan Revision 1 Dated October 15, 2012
• Letter Approving Stack Test Protocol – DHEC's approval of the stack test protocol describing any final information and/or reminders.
  • December 12, 2012 Test Plan Approval Letter
• Stack Test Results - After the stack test has been conducted, the facility is required to send a detailed stack test report to DHEC within 30 days of the stack test (or as otherwise approved by DHEC).
• Letter Approving Stack Test - Once the stack test data is reviewed, DHEC will issue a final summary report. If DHEC approves the results, the summary report will contain the test results and any relevant operational parameters to be included in the operating permit. Otherwise, it would include the justification for the rejection of the tests and requirements for retesting.
  • CX Plant and PP Storage and Extrusion Emissions Testin2 — Conducted December 18, 2012 — Revision 1
  • Charge Preparation and Melter Emissions Testing — Conducted January 12-13, 2013 — Revision 1
  • No. I and No. 2 Smelter Furnaces, Hornito Melter, Kettle Combustion, and Kettle Process CEMS Initial Certification Testing — Conducted January 16-18, 22-23, and 31, 2013 — Revision 1
    
    No. 3 Smelter Furnace CEMS Initial Certification Testing and Kettle Process and Hornito Melter Alternative RATA Testing — Conducted May 21, 2013 — Revision 1
  • Furnaces 1 & 2 (ID 07 & 08), Foundry Ventilation (ID 10), Refining Kettles (ID 11A), Refining Kettles and Casting Baghouse (ID 11B), Refining Ventilation (ID 12), and Slag Warehouse (ID 14) Emissions Testing – Conducted February 4-12, 2013 – Revision 1
  • Furnace 3 (ID 09) Emissions Testing — Conducted June 4-6, 2013

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