ILLINOIS POLLUTION CONTROL BOARD
May
2,
1985
IN THE MATTER OF:
CLIFFORD—JACOBS FORGING COMPANY
PETITION FOR A SITE—SPECIFIC
)
R83—25
OPERATIONAL LEVEL PURSUANT TO 35
ILL.
ADM. CODE 901.105(d)
ADOPTED RULE.
FINAL OPINION AND ORDER.
OPINION
~ND ORDER OF THE BOARD
(by J. Marlin):
In its Proposed Opinion and Order
of December
6,
1984,
the
Board proposed
to adopt
a new rule,
35
Ill. Adm.
Code 901.119.
First notice of this proposal was published at
9
Ill. Reg.
29 on
January
4,
1985.
The first notice comment period expired on
February 19,
1985.
The Administrative Code Unit submitted
a
comment
on January
24, 1985 concerning Illinois Register first
notice format.
On January
3,
1985, Engi~ering Dynamics
International of
St.
Louis, Missouri
submitted
a comment.
No
other comments have been received.
By Order of the Board
dat.ed February 20,
1985,
the proposed
rule was submitted
to the Joint Committee
on Administrative Rules
(JCAR),
Second notice review commenced on
February
28,
1985.
JCAR issued
a Certification of No Objection on April
16,
1985
which ended the second notice period.
This rulemaking was initiated on November
10, 1983 when
Clifford-Jacobs Forging Company (Clifford—Jacobs) petitioned for
a site—specific operational
level for its forging shop as an
alternative
to compliance with the noise limits contained
in
35
Ills Adm. Code 901.105
(Old Rule 206 of Chapter 8).
The Illinois
Environmental Protection Agency (Agency)
filed
its response
on
January
11,
1984,
A public hearing was held
in Peoria,
Illinois
on March
12,
1984,
No members
of the public or press attended.
This hearing was scheduled with three other similar forging noise
cases
involving central Illinois shops
in order
to conserve the
time and funds of all the parties involved.
Additional economic
information requested
by the Illinois Department of Energy and
Natural Resources
~DENR) was submitted on July
29,
1984.
A
negative declaration was filed by the DENR on September
28,
1984.
The Economic and Technical Advisory Committee concurred on
November
1,
1984,
*The Board acknowledges
the work
of Kevin
F.
Duerinck, hearing
officer and administrative assistant for this rulemaking.
64-41
2
Section
901.105(d) allows an existing forging shop to
petition the Board
for a site—specific operational plan which
will
limit noise emissions from the shop.
Petitioner must
demonstrate that
it
is
technically and economically
infeasible
for its shop
to meet the numerical limits.
Petitioner must also
propose measures
to reduce
impulsive noise where possible and
assess the consequential health and welfare
impacts on the
surrounding community.
Clifford—Jacobs
is
located at North Market Street,
Champaign,
Illinois.
To the north
is farmland,
to the east
is
a
railroad switching yard,
to the south
is
a commercial
soybean
processing mill,
to the southwest are residences, and
to the west
is farmland.
The main building, which houses the die and forge shops was
built
in 1923.
The forge
shop
is marked as #lB on Exhibit
B to
the petition.
It
is
300 feet
long,
60 feet wide and
27
feet high
to the roof
line.
The forge shop contains fourteen
Erie steam drop forging hammers weighing 1,500 to
25,000 pounds
apiece with twenty—one slot furnaces and one induction heating
unit.
The heat from the furnaces, 2350°F, raises the temperature
of
the shop to 120° to 130°F.
Side grade—level openings and a
big double door draw fresh air into the building and over fifty—
six roof ventilators draw warm air out.
The forging hammers currently operate from 7:00 a.m.
to 3:00
p.m.
five days per week.
Historically, during normal economic
conditions,
the hammers have been operated two shifts between
6:00 a.m.
and 11:00 p.m.,
five days per week, with occasional
work on Saturday.
The current work force of 140 employees
is
down from
250 employees during normal economic conditions.
Clifford—Jacobs
requests that
it be allowed to operate
its
fourteen hammers six days per week,
from 6:00 a.m. until
11:00
p.m. Monday through Saturday (Petition at
9).
Production
at Clifford—Jacobs has decreased from 1980 levels
as
is shown
by the table below.
This decline resulted
in less
hammer blows and less impulsive noise.
The production decline
is
expected to stabilize
in
1983
(Petition at
5).
Total forgings
No.
of
Tonnage of all
on hammers
blows/yr.
forgings
1980
670,000
9,447,000
12,838
1981
580,000
8,178,000
12,536
1982
286,000
4,032,600
6,556
Permissible impulsive sound levels for existing forge shops
are found at
35
Ill. Adm. Code 901.105.
The impulsive sound
level emitted to residences
(Class A land)
cannot exceed 58.5 Leq
84-42
3
during the day or 53.5 Leg at night.
As to commercial
establishments
(Class B), the level cannot
exceed 64.5 Leq.
Based upon actual noise
level measurements, Exhibit A to the
petition shows that the maximum noise
level
is
65 Leq.
Approximately 66 houses potentially could be exposed to sound
levels
in excess of
53.5 Leq while thirty two houses could be
exposed to sound levels
in excess
of
58.5
Leq.
The noise
level
will vary depending on wind velocity and direction.
Any noise
violations
at night would end as Clifford—Jacobs suspended
operations
at
11:00 p.m.
Clifford—Jacobs
has not zeceived any
noise complaints.
Various measures have been proposed to reduce the sound
levels
at Clifford—Jacobs.
The installation of barriers
is
ineffective.
Enclosing the forge shop in a new warehouse would
cost over one million dollars and there
is doubt whether this
would
be effective.
The addition of more fans and silencers to
the present roof is infeasible because the roof will not accept
the added weight
(Exh. D to Petition),
Clifford—Jacobs has tried to control excessive noise
at
its
forge shop.
A new building was built between the forge shop and
the Class A residences.
This did not effectively reduce
the
noise
level.
If forced to implement these costly measurements,
the facility would close.
The Board proposes granting Clifford—Jacobs’
site—specific
operational
level
for fourteen har~mers, two shifts Monday through
Saturday.
Clifford—Jacobs does not foresee any adverse health
effects from
65 Leg
(R.
48).
The Agency states that there would
be
no danger of hearing loss
to area residents (Agency Response
at
4).
Although no specific numerical noise
level limitations are
being imposed,
it
is assumed that noise levels will approximate
those testified to by Clifford—Jacobs and its witnesses.
Clifford-Jacobs should make efforts to lessen noise levels
in the
future
as equipment
is replaced and new technology for noise
suppression becomes available.
The following operational plan as set out below will be
incorporated into 35
Ill. Adm. Code 901.119.
Clifford—Jacobs
will be required
to comply upon the filing of the rule with the
Secretary of State.
64-43
4
ORDER
The Board hereby adopts the following rule,
to be codified
as
35
Ill. Adm. Code 901.119 and instructs the Clerk
to file this
rule with the Secretary of State:
TITLE
35:
ENVIRONMENTAL PROTECTION
SUBTITLE
H:
NOISE
CHAPTER
I:
POLLUTION CONTROL BOARD
PART
901
SOUND EMISSION STANDARDS AND LIMITATIONS
FOR PROPERTY LINE—NOISE—SOURCES
Section 901,119
Clifford—Jacobs Operational Level
Clifford—Jacobs Forging Company and future owners of the
forging facility located at North Market Street,
Champaign,
Illinois,
shall comply with the following site—specific
operational
level:
a)
Operate no more than fourteen hammers
at any one time;
and
b)
Operate
its forging hammers only between the hours of
6:00 a.m.
and 11:00 p.m. Monday through Saturday.
IT
IS SO ORDERED.
I, Dorothy M. Gunn, Clerk of the Illinois Pollution Control
Board, hereby certify that the above Opinion and Order was
adopted on the
_______________
day of
____________________,
1985
by
a vote of
____________.
/
Dorothy M, G nn, Clerk
Illinois Pollution Control Board
64-44