Eaton Corporation Kearney Nebraska, MDH Company 2007 APR View/Print

OMB No. 2010-0032
Expiration Date 01/31/2010

2007 Performance Track Annual Performance Report

Eaton Corporation Kearney Nebraska, MDH Company
A070038
Year 1 Annual Performance Report
Member Since 2007 (1st Member Term)

SECTION A: GENERAL FACILITY INFORMATION

A.1

Name of your facility:

Eaton Corporation Kearney Nebraska, MDH Company

A.2

Name of your parent company:

Eaton Corporation

A.3

Facility contact person for the Performance Track program:

Name:	Mr. Daniel L. Saathoff
Title:	EHS Manager
Phone:	308-233-5470
Fax:	308-233-5474
Email:	dansaathoff@eaton.com

A.4

Facility location:

Facility Address

Street Address:	4200 Hwy 30 East
Address Cont:
City:	Kearney
State:	NE
Zip Code:	68847

If your facility has multiple street addresses, please list any other addresses for its sites or buildings.

A.5

Facility's website address (if any):

http://

A.6

Number of employees (full-time equivalents) who currently work in the facility:

500-1,000

A.7

For the purposes of where your facility would be listed in our Member Directory, please list the North American Industrial Classification System (NAICS) Code(s) that is (are) used to classify business at the facility:

Primary	Secondary	Tertiary	Quaternary	Quinary
336311	336350

A.8.a

List the activities, products, or services that take place at your facility:

Forging and grinding of gears and engine valves

A.8.b

Provide the size and general description of your site:

Rurally located. Aproximately 2 million sq. ft. property with a 341,000 sq. ft. facility

A.9

Have the environmental requirements applicable to your facility changed during this reporting period?

SECTION B: ENVIRONMENTAL MANAGEMENT SYSTEM

B.1.a

Is your facility certified to ISO 14001?

Yes

B.2

Note: On this facility's Application or a previous Annual Performance Report, they reported having an independent assessment of their EMS in calendar year 2006. Since they are required to have an independent assessment every three years to remain a member of the Performance Track program, they will next report their independent assessment in calendar year 2009.

B.3

EPA recommends that Performance Track members conduct an internal EMS assessment (partial or complete) every year. Did you conduct one in calendar year 2007?

Yes

Internal EMS Assessment #1

When was this EMS assessment?	December 2007
Which EMS elements were included in the audit?	Policy, Planning, Implementation, Checking, Management
Did the assessment cover the entire facility or part of the facility?	Entire Facility

B.4

EPA recommends that Performance Track members conduct a regulatory compliance audit every year. Did your facility conduct any audits in calendar year 2007 to verify compliance with regulatory statutes?

Yes

Regulatory Compliance Audit #1

When was this regulatory compliance audit?	December 2007
Which regulations were included in the audit?	Clean Air Act (CAA) Clean Water Act (CWA) Emergency Planning & Community Right-To-Know Act (EPCRA) National Pollutant Discharge Elimination System (NPDES) Resource Conservation and Recovery Act (RCRA) Toxic Substances Control Act (TSCA) Underground Storage Tank (UST) Regulations

B.5

Note: Facility will be asked to report other audits and inspections in their 3rd reporting year.

B.6.a

Has your facility corrected all instances of potential non-compliance and EMS non-conformance identified during your audits and other assessments?

Yes

B.6.b

Performance Track members should have a Senior Management Review of their EMS every year. Did this review take place in calendar year 2007?

Yes

Who was the senior manager present at the review?

Name: Mr. Kevin Matson

Title: Plant Manager

B.6.c

Performance Track members should conduct a systematic identification and/or review of their environmental aspects at least once every two years. When was your last one conducted?

November 2007

SECTION C: ENVIRONMENTAL PERFORMANCE RESULTS

Goal 1: Eaton Corporation Kearney Nebraska, MDH Company's first goal is to reduce the facility's generation of non-hazardous waste, specifically forge lube.
C.1.a	Briefly describe your activities and achievements related to this goal or, if relevant, any circumstances that delayed progress this year.
	Began installation of evaporation system that will reduce water content on the forging lubricant, thus reducing the amount that must be treated and recycled.
C.1.b	Describe the data collection process and data source(s) that you used to measure progress towards this goal.
	Data collected from manifests of material leaving facility. We also measure the height of the tank levels before and after evaporation to calculate volumes.
C.1.c	Please report your facility's actual performance.

Performance Data
Waste Management Method	Baseline	Year 1	Year 2	Year 3	Units
Waste Management Method	2005	2007	2008	2009	Units
Reused/recycled off-site Specify other:	1,149,667.50	1,050,907.5			Pounds Specify other:
Specify other:					Specify other:
Specify other:					Specify other:
Specify other:					Specify other:
Specify other:					Specify other:

C.1.d

Summarized progress toward goal.

Actual Total	Baseline	Year 1	Year 2	Year 3	Perform. Goal	Units
Total Non Hazardous Waste	574.83	525.45			n/a	Tons Specify other:

Normalized Total	Baseline	Year 1	Year 2	Year 3	Perform. Goal	Units
Normalizing Factor	1.0	0.84
Total Non Hazardous Waste	574.83	625.54			468.75	Tons Specify other:
Basis for your Normalizing Factor:	Pieces produced

Goal 2: Eaton Corporation Kearney Nebraska, MDH Company's second goal is to reduce the facility's generation of hazardous waste, specifically chromium hydroxide.
C.2.a	Briefly describe your activities and achievements related to this goal or, if relevant, any circumstances that delayed progress this year.
	We have installed a screen that helps break the chromium hydroxide sludge into smaller pieces. This increases the surface area, thus increasing the amount of water that can be dried out of the sludge in a given time. Due to contained and collected leak in this area, we were required to treat more waste water than normal, resulting in extra chromium hydroxide.
C.2.b	Describe the data collection process and data source(s) that you used to measure progress towards this goal.
	We weigh each container of waste before it is sent to storage/disposal. An increase was detected in 2007 due to a tank condition that allowed chromic acid to reach the waste treatment system in excess of normal operations.
C.2.c	Please report your facility's actual performance.

Performance Data
Waste Management Method	Baseline	Year 1	Year 2	Year 3	Units
Waste Management Method	2005	2007	2008	2009	Units
Landfill Specify other:	59,452	61,473			Pounds Specify other:
Specify other:					Specify other:
Specify other:					Specify other:
Specify other:					Specify other:
Specify other:					Specify other:

C.2.d

Summarized progress toward goal.

Actual Total	Baseline	Year 1	Year 2	Year 3	Perform. Goal	Units
Total Hazardous Waste	29.73	30.74			n/a	Tons Specify other:

Normalized Total	Baseline	Year 1	Year 2	Year 3	Perform. Goal	Units
Normalizing Factor	1.0	0.83
Total Hazardous Waste	29.73	37.03			26.75	Tons Specify other:
Basis for your Normalizing Factor:	Per piece chrome plated

Goal 3: Eaton Corporation Kearney Nebraska, MDH Company's third goal is to increase the facility's land and habitat conservation.

C.3.a Briefly describe your activities and achievements related to this goal or, if relevant, any circumstances that delayed progress this year.

23 acres of land North of the facility identified for the project. The area was tilled and native grasses and wild flowers were planted in the spring of 2007. During the fall of 2007, we cut a winding path through the grass upon which we spread untreated wood chips for a walking trail.

These wood chips were the result from trees that were chipped after they had fallen in an ice storm earlier in the year. No trees we cut down to create these chips.

We then istalled over a dozen bird houses in the area to attract wildlife. Many species have been seen in our conservation area: mice, rabbits, pheasents, skunks, red fox, hawks, frogs, turkey, and various small birds.

C.3.b Describe the data collection process and data source(s) that you used to measure progress towards this goal.

Data collected by simple measurement.

C.3.c Please report your facility's actual performance.

Performance Data

Baseline Year 1 Year 2 Year 3 Perform.

Calendar Year 2005 2007 2008 2009 Goal Units

Actual Quantity (per year) 0 23 23 acres

Specify other:

C.3.d Normalized progress toward goal.

Normalization is not applicable to this commitment

Goal 4: Eaton Corporation Kearney Nebraska, MDH Company's fourth goal is to reduce the facility's total (non-transportation) energy use.

C.4.a Briefly describe your activities and achievements related to this goal or, if relevant, any circumstances that delayed progress this year.

We sent two people from our facility to an energy reduction seminar for three days to learn of ways we could reduce our energy consumption.

Since that time we have begun phasing out some of our old fluorescent lights for fluorescent lighting that is much more energy efficient.

In January of 2007, our area experience a disasterous ice storm that resulted in rolling blackouts. These blackouts caused us to exert extra energy to heat processes up before they could be operated, only to have them cool off and need heated again.

In 2008 we brought in two individuals from Nebraska Public Power District to conduct an assessment of our energy use within the facility.

C.4.b Describe the data collection process and data source(s) that you used to measure progress towards this goal.

Data collected from monthly billings. We also keep the reports from the assessments.

C.4.c Please report your facility's actual performance.

Energy Generated Off-Site

Baseline Year 1 Year 2 Year 3 Units

Calendar Year 2005 2007 2008 2009

Electricity Purchased

Electricity from Grid/Utility 76,400,000 70,880,092 Kwh

Specify:

Electricity from Off-Grid Renewable Sources 0 0 Kwh

Specify:

Total Electricity Purchased 260,676.80 241,842.87 MMBtus

If your facility purchases electricity from the grid, please confirm that the electricity geographic region shown below is correct. If incorrect, please contact the Performance Track Information Center.
MRO West

Steam

EPA will be determining the greenhouse gases associated with the generation of the steam that you purchase. We will be contacting you for additional information regarding the source of the steam generated.

Specify:

Total Energy Generated Off-Site 260,676.80 241,842.87 MMBtus

Sources of Energy Generated On-Site

Baseline Year 1 Year 2 Year 3 Units

Calendar Year 2005 2007 2008 2009

Coal

Specify:

Natural Gas

Specify:

Crude Oil

Specify:

Fuel Oil

Specify:

Diesel

Specify:

Propane/LPG

Specify:

Gasoline

Specify:

Hydrogen Powered Fuel Cells

Specify:

Natural Gas/Methane Powered Fuel Cells

Specify:

Biomass

Specify:

Biodiesel

Specify:

Solar

Specify:

Wind

Specify:

Landfill Gas

Specify:

Geothermal

Specify:

Hydroelectric

Specify:

Tire Derived Fuel

Specify:

Other Fuel or Source
Specify:

Specify:

Total Energy Generated On-Site 0.00 0.00 MMBtus

C.4.d Total energy use and associated greenhouse gas emissions.

Actual Energy Use Total Baseline Year 1 Year 2 Year 3 Perform.
Goal Units

Total Renewable Energy Use 17,726.02 16,445.32 n/a MMBtus

Total Non-Renewable Energy Use 242,950.78 225,397.56 n/a MMBtus

Total Energy Use 260,676.80 241,842.87 n/a MMBtus

Metric Tons of CO₂ Equivalents 62,877.20 58,334.32 n/a MTCO2E

Metric Tons of CO₂ Equivalents Offset due to Investments in Green Energy, e.g. green tags MTCO2E

Net Metric Tons of CO₂ Equivalents 62,877.20 58,334.32 n/a MTCO2E

Normalized Energy Use Total Baseline Year 1 Year 2 Year 3 Perform.
Goal Units

Normalizing Factor 1.0 0.84

Total Energy Use 260,676.80 287,908.18 234,609.12 MMBtus

Specify other:

Net Metric Tons of CO₂ Equivalents 62,877.20 69,445.62 56,589.48 MTCO2E

Specify other:

Basis for your Normalizing Factor:
Number of Valves and Gears produced.

Progress Towards Other Significant Aspects of your EMS

In the table below, please provide a narrative summary of progress made toward EMS objectives and targets other than those reported as Environmental Performance Goals. You may limit the summary to environmental aspects that are significant and towards which progress has been made during the reporting year.

Do you have additional environmental aspects to report? No

SECTION D: PUBLIC OUTREACH AND PERFORMANCE REPORTING

D.1.a Please describe your process to identify potential community environmental concerns.

Community environmental concerns are addressed immediately when expressed. Some potential concerns could be noise for neighboring bodies, air pollutants from stacks, traffic jams during shift changes, landfill quantities and groundwater issues. These are all areas the 3Rs team reviews and addresses to assure the community is protected in all aspects of the environment. If concerns are brought to our attention, it is taken to the 3Rs meeting and discussed among the members. An action plan is created and the concern is addressed as soon as possible. The person reporting the concern is then contacted to assure all items are explained or taken care of to their satisfaction. EHS has an open door policy when it comes to reporting EHS concerns.

D.1.b If you identified community environmental concerns, how did you respond to them?

Concerns are addressed by the EHS manager as information is requested from us. 3Rs meetings, third party assessments and corporate assessments are used to address and respond to all potential concerns listed in D.1.a. Eaton is dedicated to assuring the commnity that surrounds our facility and TSDFs are in good condition and take responsibility in our environmental well being. In addition to all the reviews we make to our facility, we also complete site audits on all our TSDFs or companies which handle all our hazardous and nonhazardous wastes to make sure they are handling the wastes to our satisfaction. We have a priority list of recycling our wastes and as a last resort, we landfill the waste if no recycling opportunities exist for the materials.

D.1.c Please describe how you informed the community about environmental matters related to your facility.

We have pamphlets about our safety and environmental programs that are distributed to visitors or anyone requesting that information. We are also a part of the LEPC (board member) and attend all meetings on a regular basis for Buffalo County. We report to the Fire Department, LEPC and other agencies our Teir II reporting to notify them our our environmental potentials in what chemicals we have on site. We also have a meeting every year where we invite all the local authorities as well as the state authorities to come to our facility for a meeting where we present them all our emergency response procedures and offer them a tour to familiarize them with our facility in case they are to respond to an emergency. We have and EHS fair each year and invite all our local authorities to participate and demonstrate their equipment on site. We join this event with our company picnic and spend a full day celebrating EHS and thanking our employees and community for their participation in our efforts.

D.2 Please indicate which of the following methods your facility plans to use to make its Performance Track Annual Performance Report available to the public. Please check all that apply.

Open House, Meetings, Building Lobby, Environmental Fairs, Other
Please Specify Other: EPA Web Site

OMB No. 2010-0032
SECTION E: SELF-CERTIFICATION OF CONTINUED PROGRAM PARTICIPATION FOR ANNUAL PERFORMANCE REPORT
The U.S. Environmental Protection Agency is not yet in a position to accept electronic signatures and therefore requests a faxed, signed copy of the Section E page. Please complete Section E online, then print Section E using the link on the Overview page. Section E should be signed by the senior manager of your facility and faxed it to the Performance Track Information Center at (617) 354-0463.
On behalf of Eaton Corporation Kearney Nebraska, MDH Company, I certify that: I have read and agree to the terms and conditions as specified in the National Enviromental Performance Track Program Guide. This facility, to the best of my knowledge, continues to meet all program criteria; I have personally examined and am familiar with the information contained in this Annual Performance Report. The information contained in this report is, to the best of my knowledge and based on reasonable inquiry, true, accurate, and complete; My facility has an environmental management system (EMS), as defined in the Performance Track EMS criteria, including systems to maintain compliance with all applicable federal, state, tribal, and local environmental requirements, in place at the facility, and the EMS will be maintained for the duration of the facility's participation in the program; My facility has conducted an objective assessment of its compliance with all applicable federal, state, tribal, and local environmental requirements; and the facility has corrected all identified instances of potential or actual noncompliance; and Based on the foregoing compliance assessments and subsequent corrective actions (if any were necessary), my facility is, to the best of my knowledge and based on reasonable inquiry, currently in compliance with applicable federal, state, tribal, and local environmental requirements. I agree that EPA's decision whether to accept participants into or remove them from the National Environment Performance Track is wholly discretionary, and I waive any right that may exist under any law to challenge EPA's acceptance or removal decision. I am the senior manager with responsibility for the facility and am fully authorized to execute this statement on behalf of the corporation or other legal entity whose facility is part of the National Environmental Performance Track program.
Signature/Date:	______________________________________________________
Name:	Mr. Daniel L. Saathoff
Title:	EHS Manager
Facility Name:	Eaton Corporation Kearney Nebraska, MDH Company
Facility Street Address:	4200 Hwy 30 East Kearney, NE 68847
Mailing Address:	,
Performance Track ID#:	A070038

Goal 3: Eaton Corporation Kearney Nebraska, MDH Company's third goal is to increase the facility's land and habitat conservation.
C.3.a	Briefly describe your activities and achievements related to this goal or, if relevant, any circumstances that delayed progress this year.
	23 acres of land North of the facility identified for the project. The area was tilled and native grasses and wild flowers were planted in the spring of 2007. During the fall of 2007, we cut a winding path through the grass upon which we spread untreated wood chips for a walking trail. These wood chips were the result from trees that were chipped after they had fallen in an ice storm earlier in the year. No trees we cut down to create these chips. We then istalled over a dozen bird houses in the area to attract wildlife. Many species have been seen in our conservation area: mice, rabbits, pheasents, skunks, red fox, hawks, frogs, turkey, and various small birds.
C.3.b	Describe the data collection process and data source(s) that you used to measure progress towards this goal.
	Data collected by simple measurement.
C.3.c	Please report your facility's actual performance.

Goal 4: Eaton Corporation Kearney Nebraska, MDH Company's fourth goal is to reduce the facility's total (non-transportation) energy use.
C.4.a	Briefly describe your activities and achievements related to this goal or, if relevant, any circumstances that delayed progress this year.
	We sent two people from our facility to an energy reduction seminar for three days to learn of ways we could reduce our energy consumption. Since that time we have begun phasing out some of our old fluorescent lights for fluorescent lighting that is much more energy efficient. In January of 2007, our area experience a disasterous ice storm that resulted in rolling blackouts. These blackouts caused us to exert extra energy to heat processes up before they could be operated, only to have them cool off and need heated again. In 2008 we brought in two individuals from Nebraska Public Power District to conduct an assessment of our energy use within the facility.
C.4.b	Describe the data collection process and data source(s) that you used to measure progress towards this goal.
	Data collected from monthly billings. We also keep the reports from the assessments.
C.4.c	Please report your facility's actual performance.

Energy Generated Off-Site
	Baseline	Year 1	Year 2	Year 3	Units
Calendar Year	2005	2007	2008	2009	Units
Electricity Purchased
Electricity from Grid/Utility	76,400,000	70,880,092			Kwh Specify:
Electricity from Off-Grid Renewable Sources	0	0			Kwh Specify:
Total Electricity Purchased	260,676.80	241,842.87			MMBtus
	If your facility purchases electricity from the grid, please confirm that the electricity geographic region shown below is correct. If incorrect, please contact the Performance Track Information Center. MRO West
Steam EPA will be determining the greenhouse gases associated with the generation of the steam that you purchase. We will be contacting you for additional information regarding the source of the steam generated.					Specify:
Total Energy Generated Off-Site	260,676.80	241,842.87			MMBtus

Sources of Energy Generated On-Site
	Baseline	Year 1	Year 2	Year 3	Units
Calendar Year	2005	2007	2008	2009	Units
Coal					Specify:
Natural Gas					Specify:
Crude Oil					Specify:
Fuel Oil					Specify:
Diesel					Specify:
Propane/LPG					Specify:
Gasoline					Specify:
Hydrogen Powered Fuel Cells					Specify:
Natural Gas/Methane Powered Fuel Cells					Specify:
Biomass					Specify:
Biodiesel					Specify:
Solar					Specify:
Wind					Specify:
Landfill Gas					Specify:
Geothermal					Specify:
Hydroelectric					Specify:
Tire Derived Fuel					Specify:
Other Fuel or Source Specify:					Specify:
Total Energy Generated On-Site	0.00	0.00			MMBtus

Actual Energy Use Total	Baseline	Year 1	Year 2	Year 3	Perform. Goal	Units
Total Renewable Energy Use	17,726.02	16,445.32			n/a	MMBtus
Total Non-Renewable Energy Use	242,950.78	225,397.56			n/a	MMBtus
Total Energy Use	260,676.80	241,842.87			n/a	MMBtus
Metric Tons of CO₂ Equivalents	62,877.20	58,334.32			n/a	MTCO2E
Metric Tons of CO₂ Equivalents Offset due to Investments in Green Energy, e.g. green tags						MTCO2E
Net Metric Tons of CO₂ Equivalents	62,877.20	58,334.32			n/a	MTCO2E

Normalized Energy Use Total	Baseline	Year 1	Year 2	Year 3	Perform. Goal	Units
Normalizing Factor	1.0	0.84
Total Energy Use	260,676.80	287,908.18			234,609.12	MMBtus Specify other:
Net Metric Tons of CO₂ Equivalents	62,877.20	69,445.62			56,589.48	MTCO2E Specify other:
Basis for your Normalizing Factor:	Number of Valves and Gears produced.

D.1.a	Please describe your process to identify potential community environmental concerns.
	Community environmental concerns are addressed immediately when expressed. Some potential concerns could be noise for neighboring bodies, air pollutants from stacks, traffic jams during shift changes, landfill quantities and groundwater issues. These are all areas the 3Rs team reviews and addresses to assure the community is protected in all aspects of the environment. If concerns are brought to our attention, it is taken to the 3Rs meeting and discussed among the members. An action plan is created and the concern is addressed as soon as possible. The person reporting the concern is then contacted to assure all items are explained or taken care of to their satisfaction. EHS has an open door policy when it comes to reporting EHS concerns.
D.1.b	If you identified community environmental concerns, how did you respond to them?
	Concerns are addressed by the EHS manager as information is requested from us. 3Rs meetings, third party assessments and corporate assessments are used to address and respond to all potential concerns listed in D.1.a. Eaton is dedicated to assuring the commnity that surrounds our facility and TSDFs are in good condition and take responsibility in our environmental well being. In addition to all the reviews we make to our facility, we also complete site audits on all our TSDFs or companies which handle all our hazardous and nonhazardous wastes to make sure they are handling the wastes to our satisfaction. We have a priority list of recycling our wastes and as a last resort, we landfill the waste if no recycling opportunities exist for the materials.
D.1.c	Please describe how you informed the community about environmental matters related to your facility.
	We have pamphlets about our safety and environmental programs that are distributed to visitors or anyone requesting that information. We are also a part of the LEPC (board member) and attend all meetings on a regular basis for Buffalo County. We report to the Fire Department, LEPC and other agencies our Teir II reporting to notify them our our environmental potentials in what chemicals we have on site. We also have a meeting every year where we invite all the local authorities as well as the state authorities to come to our facility for a meeting where we present them all our emergency response procedures and offer them a tour to familiarize them with our facility in case they are to respond to an emergency. We have and EHS fair each year and invite all our local authorities to participate and demonstrate their equipment on site. We join this event with our company picnic and spend a full day celebrating EHS and thanking our employees and community for their participation in our efforts.
D.2	Please indicate which of the following methods your facility plans to use to make its Performance Track Annual Performance Report available to the public. Please check all that apply.
	Open House, Meetings, Building Lobby, Environmental Fairs, Other
	Please Specify Other: EPA Web Site

SECTION A: GENERAL FACILITY INFORMATION

SECTION B: ENVIRONMENTAL MANAGEMENT SYSTEM

SECTION C: ENVIRONMENTAL PERFORMANCE RESULTS

SECTION D: PUBLIC OUTREACH AND PERFORMANCE REPORTING

SECTION E: SELF-CERTIFICATION OF CONTINUED PROGRAM PARTICIPATION FOR ANNUAL PERFORMANCE REPORT