Section 465.28. Compliance requirements for the emission rate with add-on controls option.

 

(1)   By what date must I conduct performance tests and other initial compliance demonstrations?.

(a) Existing affected sources. For an existing affected source, you shall do all of the following:

1. Install and operate all emission capture systems, add-on control devices, and CPMS you use to demonstrate compliance no later than the applicable compliance date specified in s. NR 465.21 (4) . Except for solvent recovery systems for which you conduct liquid-liquid material balances according to sub. (2) (g) , you shall conduct a performance test of each capture system and add-on control device according to the procedures in subs. (5) to (7) , and establish the operating limits required by s. NR 465.23 (3) no later than the compliance date specified in s. NR 465.21 (4) . For a solvent recovery system for which you conduct liquid-liquid material balances according to sub. (2) (g) , you shall initiate the first material balance no later than the compliance date specified in s. NR 465.21 (4) .

2. Develop and begin implementing the work practice plan required by s. NR 465.23 (4) no later than the compliance date specified in s. NR 465.21 (4) .

3. Complete the compliance demonstration for the initial compliance period according to the requirements of sub. (2) . The initial compliance period begins on the applicable compliance date specified in s. NR 465.21 (4) and ends on the last day of the first full month after the compliance date. If the compliance date occurs on any day other than the first day of a month, then the initial compliance period extends through the end of that month plus the next month. The initial compliance demonstration includes the results of emission capture system and add-on control device performance tests conducted according to subs. (5) to (7) ; results of liquid-liquid material balances conducted according to sub. (2) (g) ; calculations according to sub. (2) and supporting documentation showing that, during the initial compliance period, the organic HAP emission rate was equal to or less than the emission limit in s. NR 465.23 (1) (a) ; the operating limits established during the performance tests and the results of the continuous parameter monitoring required by sub. (9) ; and documentation of whether you developed and implemented the work practice plan required by s. NR 465.23 (4) .

(b) New and reconstructed affected sources. For a new or reconstructed affected source, you shall do all of the following:

1. Install and operate all emission capture systems, add-on control devices, and CPMS you use to demonstrate compliance no later than the applicable compliance date specified in s. NR 465.21 (4) . Except for solvent recovery systems for which you conduct liquid-liquid material balances according to sub. (2) (g) , conduct a performance test of each capture system and add-on control device according to the procedures in subs. (5) to (7) , and establish the operating limits required by s. NR 465.23 (3) no later than 180 days after the applicable compliance date specified in s. NR 465.21 (4) . For a solvent recovery system for which you conduct liquid-liquid material balances according to sub. (2) (g) , initiate the first material balance no later than 180 days after the applicable compliance date specified in s. NR 465.21 (4) .

2. Develop and begin implementing the work practice plan required by s. NR 465.23 (4) no later than the compliance date specified in s. NR 465.21 (4) .

3. Complete the compliance demonstration for the initial compliance period according to the requirements of sub. (2) . The initial compliance period begins on the applicable compliance date specified in s. NR 465.21 (4) and ends on the last day of the first full month after the compliance date, or the date you conduct the performance tests of the emission capture systems and add-on control devices, or initiate the first liquid-liquid material balance for a solvent recovery system; whichever is later. The initial compliance demonstration includes the results of emission capture system and add-on control device performance tests conducted according to subs. (5) to (7) ; results of liquid-liquid material balances conducted according to sub. (2) (g) ; calculations according to sub. (2) and supporting documentation showing that, during the initial compliance period, the organic HAP emission rate was equal to or less than the emission limit in s. NR 465.23 (1) (b) ; the operating limits established during the performance tests and the results of the continuous parameter monitoring required by sub. (9) ; and documentation of whether you developed and implemented the work practice plan required by s. NR 465.23 (4) .

4. Maintain a log detailing the operation and maintenance of the emission capture system, add-on control device and continuous parameter monitors during the period between the compliance date and the performance test conducted as specified in subd. 1. Begin complying with the operating limits for your affected source on the date you complete the performance tests specified in subd. 1. You do not need to comply with the operating limits for the emission capture system and add-on control device required by s. NR 465.23 (3) until after you have completed the performance tests specified in subd. 1. This requirement does not apply to solvent recovery systems for which you conduct liquid-liquid material balances according to sub. (2) (g) .

(2)   How do I demonstrate initial compliance?. You may use the emission rate with add-on controls option for any coating operation, for any group of coating operations in the affected source or for all of the coating operations in the affected source. You may include both controlled and uncontrolled coating operations in a group for which you use this option. You shall use either the compliant material option or the emission rate without add-on controls option for any coating operation or operations in the affected source for which you do not use this option. To demonstrate initial compliance, the coating operation or operations for which you use the emission rate with add-on controls option shall meet the applicable emission limit in s. NR 465.23 (1) and the work practice standards required in s. NR 465.23 (4) , and each controlled coating operation shall meet the operating limits required in s. NR 465.23 (3) . When calculating the organic HAP emission rate according to this subsection, do not include any coatings, thinners or cleaning materials used on coating operations for which you use the compliant material option or the emission rate without add-on controls option. You do not need to redetermine the mass of organic HAP in coatings, thinners or cleaning materials that have been reclaimed onsite and reused in the coating operation or operations for which you use the emission rate with add-on controls option. You shall meet all of the following requirements to demonstrate initial compliance with the emission limitations:

(a) Except as provided in sub. (1) (b) 4. and except for solvent recovery systems for which you conduct liquid-liquid material balances according to the requirements of par. (g) , establish and demonstrate continuous compliance during the initial compliance period with the operating limits required by s. NR 465.23 (3) , using the procedures specified in subs. (8) and (9) .

(b) Develop, implement and document your implementation of the work practice plan required by s. NR 465.23 (4) during the initial compliance period as specified in s. NR 465.25 (3) .

(c) Follow the procedures specified in s. NR 465.27 (2) (a) to (d) , to determine the mass fraction of organic HAP, density and volume of each coating, thinner and cleaning material used during the compliance period, and the volume fraction of coating solids for each coating used during the compliance period.

(d) Using Equation 1 in s. NR 465.27 (2) , calculate the total mass of organic HAP emissions before add-on controls from all coatings, thinners and cleaning materials used during the compliance period in the coating operation or group of coating operations for which you use the emission rate with add-on controls option.

(e) Determine the mass of organic HAP emissions reduced for each controlled coating operation during the compliance period. The emissions reduction determination quantifies the total organic HAP emissions that pass through the emission capture system and are destroyed or removed by the add-on control device. Use the procedures in par. (f) to calculate the mass of organic HAP emissions reduction for each controlled coating operation using an emission capture system and add-on control device other than a solvent recovery system for which you conduct liquid-liquid material balances. For each controlled coating operation using a solvent recovery system for which you conduct a liquid-liquid material balance, use the procedures in par. (g) to calculate the organic HAP emissions reduction.

(f) For each controlled coating operation using an emission capture system and add-on control device other than a solvent recovery system for which you conduct liquid-liquid material balances, calculate the organic HAP emissions reduction by applying the emission capture system efficiency and add-on control device efficiency to the mass of organic HAP contained in the coatings, thinners and cleaning materials that are used in the coating operation served by the emission capture system and add-on control device during the compliance period. For any period of time a deviation specified in sub. (4) (c) or (d) occurs in the controlled coating operation, including a deviation during a period of startup, shutdown or malfunction, you shall assume zero efficiency for the emission capture system and add-on control device. For the purposes of completing the compliance calculations, you shall treat the materials used during a deviation on a controlled coating operation as if they were used on an uncontrolled coating operation for the time period of the deviation. You may not include those materials in the calculations of organic HAP emissions reduction in Equation 1. The organic HAP emissions reduction shall be calculated using the following equations:

- See PDF for diagram

(Equation 1)

where:

  H c is the mass of organic HAP emissions reduction for the controlled coating operation during the compliance period, kg

  A I is the total mass of organic HAP in the coatings used in the controlled coating operation, kg, as calculated in Equation 1A

  B I is the total mass of organic HAP in the thinners used in the controlled coating operation, kg, as calculated in Equation 1B

  C I is the total mass of organic HAP in the cleaning materials used in the controlled coating operation during the compliance period, kg, as calculated in Equation 1C

  CE is the capture efficiency of the emission capture system vented to the add-on control device, percent. Use the test methods and procedures specified in subs. (5) and (6) to measure and record capture efficiency.

  DRE is the organic HAP destruction or removal efficiency of the add-on control device, percent. Use the test methods and procedures in subs. (5) and (6) to measure and record the organic HAP destruction or removal efficiency.

- See PDF for diagram

(Equation 1A)

where:

  A I is the mass of organic HAP in the coatings used in the controlled coating operation, kg

  Vol c,i is the total volume of coating, i, used, liters

  D c,i is the density of coating, i, kg per liter

  W c,i is the mass fraction of organic HAP in coating, i, kg per kg

  m is the number of different coatings used

- See PDF for diagram

(Equation 1B)

where:

  B I is the mass of organic HAP in the thinners used in the controlled coating operation, kg

  Vol t,j is the total volume of thinner, j, used, liters

  D t,j is the density of thinner, j, kg per liter

  W t,j is the mass fraction of organic HAP in thinner, j, kg per kg

  n is the number of different thinners used

- See PDF for diagram

(Equation 1C)

where:

  C I is the mass of organic HAP in the cleaning materials used in the controlled coating operation, kg

  Vol s,k is the total volume of cleaning material, k, used, liters

  D s,k is the density of cleaning material, k, kg per liter

  W s,k is the mass fraction of organic HAP in cleaning material, k, kg per kg

  p is the number of different cleaning materials used

(g) For each controlled coating operation using a solvent recovery system for which you conduct liquid-liquid material balances, calculate the organic HAP emissions reduction by applying the volatile organic matter collection and recovery efficiency to the mass of organic HAP contained in the coatings, thinners and cleaning materials that are used in the coating operation controlled by the solvent recovery system during the compliance period. The mass of organic HAP emission reduction by the solvent recovery system shall be calculated using the following procedures and equations:

1. For each solvent recovery system, install, calibrate, maintain and operate according to the manufacturer's specifications, a device that indicates the cumulative amount of volatile organic matter recovered by the solvent recovery system each compliance period. The device shall be initially certified by the manufacturer to be accurate to within ± 2.0% of the mass of volatile organic matter recovered.

2. For each solvent recovery system, determine the mass of volatile organic matter recovered for the compliance period, kg, based on measurement with the device required in subd. 1.

3. Determine the mass fraction of volatile organic matter for each coating used in the coating operation controlled by the solvent recovery system during the compliance period, kg volatile organic matter per kg coating. You may determine the volatile organic matter mass fraction using Method 24 in 40 CFR part 60 , Appendix A, incorporated by reference in s. NR 484.04 (13) , or an EPA approved alternative method, or you may use information provided by the manufacturer or supplier of the coating. In the event of any inconsistency between information provided by the manufacturer or supplier and the results of Method 24, or an approved alternative method, the test method results will govern.

4. Determine the density of each coating, thinner and cleaning material used in the coating operation controlled by the solvent recovery system during the compliance period, kg per liter, according to s. NR 465.27 (2) (c) .

5. Measure the volume of each coating, thinner and cleaning material used in the coating operation controlled by the solvent recovery system during the compliance period, liters.

6. Calculate the solvent recovery system's volatile organic matter collection and recovery efficiency, using the following equation:

- See PDF for diagram

(Equation 2)

where:

  R V is the volatile organic matter collection and recovery efficiency of the solvent recovery system during the compliance period, percent

  M VR is the mass of volatile organic matter recovered by the solvent recovery system during the compliance period, kg

  Vol i is the volume of coating, i, used in the coating operation controlled by the solvent recovery system during the compliance period, liters

  D i is the density of coating, i, kg coating per liter coating

  C Vi is the mass fraction of volatile organic matter for coating, i, kg volatile organic matter per kg coating

  Vol j is the volume of thinner, j, used in the coating operation controlled by the solvent recovery system during the compliance period, liters

  D j is the density of thinner, j, kg thinner per liter thinner

  Vol k is the volume of cleaning material, k, used in the coating operation controlled by the solvent recovery system during the compliance period, liters

  D k is the density of cleaning material, k, kg cleaning material per liter cleaning material

  m is the number of different coatings used in the coating operation controlled by the solvent recovery system during the compliance period

  n is the number of different thinners used in the coating operation controlled by the solvent recovery system during the compliance period

  p is the number of different cleaning materials used in the coating operation controlled by the solvent recovery system during the compliance period

7. Calculate the mass of organic HAP emissions reduction for the coating operation controlled by the solvent recovery system during the compliance period, using the following equation:

- See PDF for diagram

(Equation 3)

where:

  H CSR is the mass of organic HAP emissions reduction for the coating operation controlled by the solvent recovery system using a liquid-liquid material balance during the compliance period, kg

  A I is the total mass of organic HAP in the coatings used in the coating operation controlled by the solvent recovery system, kg, calculated using Equation 1A in par. (f)

  B I is the total mass of organic HAP in the thinners used in the coating operation controlled by the solvent recovery system, kg, calculated using Equation 1B in par. (f)

  C I is the total mass of organic HAP in the cleaning materials used in the coating operation controlled by the solvent recovery system, kg, calculated using Equation 1C in par. (f)

  R V is the volatile organic matter collection and recovery efficiency of the solvent recovery system, percent, from Equation 2 in subd. 6.

(h) Determine the total volume of coating solids used, liters, which is the combined volume of coating solids for all the coatings used during the compliance period, using Equation 2 in s. NR 465.27 (2) (f) .

(i) Determine the organic HAP emission rate to the atmosphere, kg organic HAP per liter coating solids used during the compliance period, using the following equation:

- See PDF for diagram

(Equation 4)

where:

  H HAP is the organic HAP emission rate to the atmosphere during the compliance period, kg organic HAP per liter coating solids used

  H e is the total mass of organic HAP emissions before add-on controls from all the coatings, thinners and cleaning materials used during the compliance period, kg, determined according to par. (d)

  H C,i is the total mass of organic HAP emissions reduction for controlled coating operation, i, during the compliance period, kg, from Equation 1 in par. (f)

  H CSR,j is the total mass of organic HAP emissions reduction for controlled coating operation, j, during the compliance period, kg, from Equation 3 in par. (g)

  V st is the total volume of coating solids used during the compliance period, liters, from Equation 2 in s. NR 465.27 (2) (f)

  q is the number of controlled coating operations except those controlled with a solvent recovery system

  r is the number of coating operations controlled with a solvent recovery system

(j) Demonstrate initial compliance with the emission limit, by ensuring that the organic HAP emission rate calculated using Equation 4 in par. (i) , is less than or equal to the applicable emission limit in s. NR 465.25 (3) . Keep all records as required by s. NR 465.25 (3) and (4) . As part of the notification of compliance status required by s. NR 465.25 (1) , identify the coating operation or operations for which you used the emission rate with add-on controls option and submit a statement that the coating operation or operations was or were in compliance with the emission limitations during the initial compliance period because the organic HAP emission rate was less than or equal to the applicable emission limit in s. NR 465.23 (1) , and you achieved the operating limits and the work practice standards required by s. NR 465.23 (3) and (4) respectively.

(4)   How do I demonstrate continuous compliance with the emission limitations?.

(a) To demonstrate continuous compliance with the applicable emission limit in s. NR 465.23 (1) , the organic HAP emission rate for each compliance period determined according to the procedures in sub. (2) shall be equal to or less than the applicable emission limit in s. NR 465.23 (1) . Each month following the initial compliance period described in sub. (1) is a compliance period.

(b) If the organic HAP emission rate for any compliance period exceeded the applicable emission limit in s. NR 465.23 (1) , this is a deviation from the emission limitation for that compliance period and shall be reported as specified in s. NR 465.25 (1) (b) 6. and (2) (g) .

(c) You shall demonstrate continuous compliance with each operating limit required by s. NR 465.23 (3) that applies to you as specified in Table 1 of this subchapter, and shall do the following as applicable:

1. Report as a deviation from the operating limit, as specified in s. NR 465.25 (1) (b) 6. and (2) (g) , if an operating parameter is out of the allowed range specified in Table 1 of this subchapter.

2. If an operating parameter deviates from the operating limit specified in Table 1 of this subchapter, assume that the emission capture system and add-on control device were achieving zero efficiency during the time period of the deviation. For the purposes of completing the compliance calculations specified in sub. (2) , treat the materials used during a deviation on a controlled coating operation as if they were used on an uncontrolled coating operation for the time period of the deviation. You may not include those materials in the calculation of organic HAP emissions reductions in Equation 1 in sub. (2) (f) .

(d) You shall meet the requirements for bypass lines in sub. (9) (b) . You shall report it as a deviation, as specified in s. NR 465.25 (1) (b) 6. and (2) (g) , if any bypass line is opened and emissions are diverted to the atmosphere when the coating operation is running. For the purposes of completing the compliance calculations specified in sub. (2) , you shall treat the materials used during a deviation on a controlled coating operation as if they were used on an uncontrolled coating operation for the time period of the deviation. You may not include those materials in the calculation of organic HAP emissions reductions in Equation 1 in sub. (2) (f) .

(e) You shall demonstrate continuous compliance with the work practice standards in s. NR 465.23 (4) . You shall report it as a deviation from the work practice standards, as specified in s. NR 465.25 (1) (b) 6. and (2) (g) , if you did not develop a work practice plan, did not implement the plan, or you did not keep the records required by s. NR 465.25 (3) (k) 9.

(f) As part of each semiannual compliance report required in s. NR 465.25 (2) , you shall submit a statement that you were in compliance with the emission limitations during the reporting period because the organic HAP emission rate for each compliance period was less than or equal to the applicable emission limit in s. NR 465.23 (1) , and you achieved the operating limits and the work practice standards required by s. NR 465.23 (3) and (4) , respectively, during each compliance period.

(g) During periods of startup, shutdown and malfunction of the emission capture system, add-on control device or coating operation that may affect emission capture or control device efficiency, you shall operate in accordance with the SSMP required by s. NR 465.24 (1) (d) .

(h) Consistent with ss. NR 460.05 (4) and 460.06 (4) (a) , deviations that occur during a period of startup, shutdown or malfunction of the emission capture system, add-on control device or coating operation that may affect emission capture or control device efficiency are not violations if you demonstrate to the department's satisfaction that you were operating in accordance with the SSMP. The department will determine whether deviations that occur during a period of startup, shutdown or malfunction are violations according to the provisions in s. NR 460.05 (4) .

(j) You shall maintain records as specified in s. NR 465.25 (3) and (4) .

(5)   What are the general requirements for performance tests?.

(a) You shall conduct each performance test required by sub. (1) according to the requirements in s. NR 460.06 (4) (a) and under the following conditions unless you obtain a waiver of the performance test according to the provisions in s. NR 460.06 (7) :

1. Representative operating conditions for the coating operation. Operations during periods of startup, shutdown or malfunction and periods of nonoperation do not constitute representative conditions. You shall record the process information that is necessary to document operating conditions during the test and explain why the conditions represent normal operation.

2. When the emission capture system and add-on control device are operating at a representative flow rate, and the add-on control device is operating at a representative inlet concentration. You shall record information that is necessary to document emission capture system and add-on control device operating conditions during the test and explain why the conditions represent normal operation.

(b) You shall conduct each performance test of an emission capture system according to the requirements in sub. (6) and of an add-on control device according to the requirements in sub. (7) .

(c) The performance test to determine add-on control device organic HAP destruction or removal efficiency shall consist of 3 runs as specified in s. NR 460.06 (4) (c) and each run shall last at least one hour.

(6)   How do I determine the emission capture system efficiency?. You shall use the following procedures and test methods to determine capture efficiency as part of the performance test required by sub. (1) :

(a) You may assume the capture system efficiency is 100% if both of the following conditions are met:

1. The capture system meets the criteria of Method 204 in 40 CFR part 51 , Appendix M, incorporated by reference in s. NR 484.04 (9) , for a PTE and directs all the exhaust gases from the enclosure to an add-on control device.

2. All coatings, thinners and cleaning materials used in the coating operation are applied within the capture system; coating solvent flash-off and coating, curing and drying occurs within the capture system; and the removal or evaporation of cleaning materials from the surfaces they are applied to occurs within the capture system. For example, this criterion is not met if parts enter the open shop environment when being moved between a spray booth and a curing oven.

(b) If the capture system does not meet both of the criteria in par. (a) , use one of the 3 protocols described in subds. 1. to 3. to measure capture efficiency. The capture efficiency measurements use TVH capture efficiency as a surrogate for organic HAP capture efficiency. For the protocols in subds. 1. and 2. , the capture efficiency measurement shall consist of 3 test runs. Each test run shall be at least 3 hours duration or the length of a production run, whichever is longer, up to 8 hours. For the purposes of this test, a production run means the time required for a single part to go from the beginning to the end of production which includes surface preparation activities and drying or curing time. The protocols are as follows:

1. `Liquid-to-uncaptured-gas protocol using a temporary total enclosure or building enclosure.' The liquid-to-uncaptured-gas protocol compares the mass of liquid TVH in materials used in the coating operation to the mass of TVH emissions not captured by the emission capture system. You shall use the following procedures to measure emission capture system efficiency using the liquid-to-uncaptured-gas protocol:

a. Either use a building enclosure or construct an enclosure around the coating operation where coatings, thinners and cleaning materials are applied, and all areas where emissions from these applied coatings and materials subsequently occur, such as flash-off, curing and drying areas. The areas of the coating operation where capture devices collect emissions for routing to an add-on control device, such as the entrance and exit areas of an oven or spray booth, shall also be inside the enclosure. The enclosure shall meet the applicable definition of a temporary total enclosure or building enclosure in Method 204 in 40 CFR part 51 , Appendix M, incorporated by reference in s. NR 484.04 (9) .

b. Use Method 204A or 204F in 40 CFR part 51 , Appendix M, incorporated by reference in s. NR 484.04 (9) , to determine the mass fraction of TVH liquid input from each coating, thinner and cleaning material used in the coating operation during each capture efficiency test run. To make the determination, substitute TVH for each occurrence of the term VOC in the methods.

c. Use the following equation to calculate the total mass of TVH liquid input from all the coatings, thinners and cleaning materials used in the coating operation during each capture efficiency test run:

- See PDF for diagram

(Equation 5)

where:

  TVH used is the total mass of TVH liquid input from all coatings, thinners and cleaning materials used in the coating operation during the capture efficiency test run, kg

  TVH i is the mass fraction of TVH in coating, thinner or cleaning material, i, that is used in the coating operation during the capture efficiency test run, kg TVH per kg material

  Vol i is the total volume of coating, thinner or cleaning material, i, used in the coating operation during the capture efficiency test run, liters

  D i is the density of coating, thinner or cleaning material, i, kg material per liter material

  n is the number of different coatings, thinners and cleaning materials used in the coating operation during the capture efficiency test run

d. Use Method 204D or 204E in 40 CFR part 51 , Appendix M, incorporated by reference in s. NR 484.04 (9) , to measure the total mass, kg, of TVH emissions that are not captured by the emission capture system; they are measured as they exit the temporary total enclosure or building enclosure during each capture efficiency test run. To make the measurement substitute TVH for each occurrence of the term VOC in the methods. Use Method 204D if the enclosure is a temporary total enclosure. Use Method 204E if the enclosure is a building enclosure. During the capture efficiency measurement, all organic compound emitting operations inside a building enclosure, other than the coating operation for which capture efficiency is being determined, shall be shut down, but all fans and blowers shall be operating normally.

e. For each capture efficiency test run, determine the percent capture efficiency of the emission capture system, using the following equation:

- See PDF for diagram

(Equation 6)

where:

  CE is the capture efficiency of the emission capture system vented to the add-on control device, percent

  TVH used is the total mass of TVH liquid input used in the coating operation during the capture efficiency test run, kg

  TVH uncaptured is the total mass of TVH that is not captured by the emission capture system and that exits from the temporary total enclosure or building enclosure during the capture efficiency test run, kg

f. Determine the capture efficiency of the emission capture system as the average of the capture efficiencies measured in the 3 test runs.

2. `Gas-to-gas protocol using a temporary total enclosure or a building enclosure.' The gas-to-gas protocol compares the mass of TVH emissions captured by the emission capture system to the mass of TVH emissions not captured. You shall use the following procedures to measure emission capture system efficiency using the gas-to-gas protocol.

a. Either use a building enclosure or construct an enclosure around the coating operation where coatings, thinners and cleaning materials are applied and all areas where emissions from these applied coatings and materials subsequently occur such as flash-off, curing and drying areas. The areas of the coating operation where capture devices collect emissions generated by the coating operation for routing to an add-on control device, such as the entrance and exit areas of an oven or a spray booth, shall also be inside the enclosure. The enclosure shall meet the applicable definition of a temporary total enclosure or building enclosure in Method 204 in 40 CFR part 51 , Appendix M, incorporated by reference in s. NR 484.04 (9) .

b. Use Method 204B or 204C in 40 CFR part 51 , Appendix M, incorporated by reference in s. NR 484.04 (9) , to measure the total mass, kg, of TVH emissions captured by the emission capture system during each capture efficiency test run as measured at the inlet to the add-on control device. To make the measurement, substitute TVH for each occurrence of the term VOC in the methods. The sampling points for the Method 204B or 204C measurement shall be upstream from the add-on control device and shall represent total emissions routed from the capture system and entering the add-on control device. If multiple emission streams from the capture system enter the add-on control device without a single common duct, the emissions entering the add-on control device shall be simultaneously measured in each duct, and the total emissions entering the add-on control device shall be determined.

c. Use Method 204D or 204E in 40 CFR part 51 , Appendix M, incorporated by reference in s. NR 484.04 (9) , to measure the total mass, kg, of TVH emissions that are not captured by the emission capture system; they are measured as they exit the temporary total enclosure or building enclosure during each capture efficiency test run. To make the measurement, substitute TVH for each occurrence of the term VOC in the methods. Use Method 204D if the enclosure is a temporary total enclosure. Use Method 204E if the enclosure is a building enclosure. During the capture efficiency measurement, all organic compound emitting operations inside the building enclosure other than the coating operation for which capture efficiency is being determined shall be shut down, but all fans and blowers shall be operating normally.

d. For each capture efficiency test run, determine the percent capture efficiency of the emission capture system, using the following equation:

- See PDF for diagram

(Equation 7)

where:

  CE is the capture efficiency of the emission capture system vented to the add-on control device, percent

  TVH captured is the total mass of TVH captured by the emission capture system as measured at the inlet to the add-on control device during the emission capture efficiency test run, kg

  TVH uncaptured is the total mass of TVH that is not captured by the emission capture system and that exits from the temporary total enclosure or building enclosure during the capture efficiency test run, kg

e. Determine the capture efficiency of the emission capture system as the average of the capture efficiencies measured in the 3 test runs.

3. `Alternative capture efficiency protocol.' As an alternative to the procedures specified in subds. 1. and 2. , you may determine capture efficiency using any other capture efficiency protocol and test methods that satisfy the criteria of either the DQO or LCL approach as described in 40 CFR part 63 , Subpart KK, Appendix A, incorporated by reference in s. NR 484.04 (24) .

(7)   How do I determine the add-on control device emission destruction or removal efficiency?.

(a) For all types of add-on control devices, use the following test methods:

1. Method 1 or 1A in 40 CFR part 60 , Appendix A, incorporated by reference in s. NR 484.04 (13) , as appropriate, to select sampling sites and velocity traverse points.

2. Method 2, 2A, 2C, 2D, 2F or 2G in 40 CFR part 60 , Appendix A, incorporated by reference in s. NR 484.04 (13) , as appropriate, to measure gas volumetric flow rate.

3. Method 3, 3A or 3B in 40 CFR part 60 , Appendix A, incorporated by reference in s. NR 484.04 (13) , as appropriate, for gas analysis to determine dry molecular weight. You may also use, as an alternative to Method 3B, the manual method for measuring the oxygen, carbon dioxide and carbon monoxide content of exhaust gas in ANSI/ASME, PTC 19.10-1981, "Flue and Exhaust Gas Analyses", incorporated by reference in s. NR 484.11 (6) .

4. Method 4 in 40 CFR part 60 , Appendix A, incorporated by reference in s. NR 484.04 (13) , to determine stack gas moisture.

5. Methods for determining gas volumetric flow rate, dry molecular weight, and stack gas moisture shall be performed, as applicable, during each test run.

(b) Measure total gaseous organic mass emissions as carbon at the inlet and outlet of the add-on control device simultaneously, using either Method 25 or 25A in 40 CFR part 60 , Appendix A, incorporated by reference in s. NR 484.04 (13) , and using the same method for both the inlet and outlet measurements according to the following criteria:

1. Use Method 25 if the add-on control device is an oxidizer and you expect the total gaseous organic concentration as carbon to be more than 50 parts per million (ppm) at the control device outlet.

2. Use Method 25A if the add-on control device is an oxidizer and you expect the total gaseous organic concentration as carbon to be 50 ppm or less at the control device outlet.

3. Use Method 25A if the add-on control device is not an oxidizer.

(c) If 2 or more add-on control devices are used for the same emission stream, you shall measure emissions at the outlet of each device.

(d) For each test run, determine the total gaseous organic emissions mass flow rates for the inlet and the outlet of the add-on control device, using Equation 8 in this paragraph. If there is more than one inlet or outlet to the add-on control device, you shall calculate the total gaseous organic mass flow rate using Equation 8 in this paragraph for each inlet and each outlet and then total all of the inlet emissions and total all of the outlet emissions.

(e) For each test run, determine the add-on control device organic emissions destruction or removal efficiency, using the following equation:

(f) Determine the emission destruction or removal efficiency of the add-on control device as the average of the efficiencies determined in the 3 test runs and calculated in Equation 9 in par. (e) .

(8)   How do I establish the emission capture system and add-on control device operating limits during the performance test?. During the performance test required by sub. (1) and described in subs. (5) to (7) , you shall establish the operating limits required by s. NR 465.23 (3) according to the following requirements, as applicable, unless you have received approval for alternative monitoring and operating limits under s. NR 460.07 (6) as specified in s. NR 465.23 (3) :

(a) Thermal oxidizers. If your add-on control device is a thermal oxidizer, according to both of the following:

1. During the performance test, you shall monitor and record the combustion temperature at least once every 15 minutes during each of the 3 test runs. You shall monitor the temperature in the firebox of the thermal oxidizer or immediately downstream of the firebox before any substantial heat exchange occurs.

2. Use the data collected during the performance test to calculate and record the average combustion temperature maintained during the performance test. This average combustion temperature is the minimum operating limit for your thermal oxidizer.

(b) Catalytic oxidizers.

1. If your add-on control device is a catalytic oxidizer, according to either of the following:

a. During the performance test, monitor and record the temperature just before the catalyst bed and the temperature difference across the catalyst bed at least once every 15 minutes during each of the 3 test runs. Use the data collected during the performance test to calculate and record the average temperature just before the catalyst bed and the average temperature difference across the catalyst bed maintained during the performance test. These are the minimum operating limits for your catalytic oxidizer.

b. Monitor the temperature just before the catalyst bed and implement a site-specific inspection and maintenance plan for your catalytic oxidizer as specified in subd. 2. During the performance test, you shall monitor and record the temperature just before the catalyst bed at least once every 15 minutes during each of the 3 test runs. Use the data collected during the performance test to calculate and record the average temperature just before the catalyst bed during the performance test. This is the minimum operating limit for your catalytic oxidizer.

2. You shall develop and implement an inspection and maintenance plan for any catalytic oxidizer or oxidizers for which you elect to monitor according to subd. 1. b. The plan shall address, at a minimum, the following elements:

a. Annual sampling and analysis of the catalyst activity (i.e., conversion efficiency) following the manufacturer's or catalyst supplier's recommended procedures.

b. Monthly inspection of the oxidizer system including the burner assembly and fuel supply lines for problems and, as necessary, adjusting the equipment to assure proper air-to-fuel mixtures.

c. Annual internal and monthly external visual inspection of the catalyst bed to check for channeling, abrasion and settling. If problems are found, you shall take corrective action consistent with the manufacturer's recommendations and conduct a new performance test to determine destruction efficiency according to sub. (7) .

(c) Carbon adsorbers. If your add-on control device is a carbon absorber, according to both of the following:

1. Monitor and record the total regeneration desorbing gas (e.g., steam or nitrogen) mass flow for each regeneration cycle and the carbon bed temperature after each carbon bed regeneration and cooling cycle for the regeneration cycle either immediately preceding or immediately following the performance test.

2. The operating limits for your carbon absorber are the minimum total desorbing gas mass flow recorded during the regeneration cycle and the maximum carbon bed temperature recorded after the cooling cycle.

(d) Condensers. If your add-on control device is a condenser, according to both of the following:

1. During the performance test, monitor and record the condenser outlet (product side) gas temperature at least once every 15 minutes during each of the 3 test runs.

2. Use the data collected during the performance test to calculate and record the average condenser outlet (product side) gas temperature maintained during the performance test. This average condenser outlet gas temperature is the maximum operating limit for your condenser.

(e) Concentrators. If your add-on control device includes a concentrator, according to all of the following:

1. During the performance test, monitor and record the desorption concentrate stream gas temperature at least once every 15 minutes during each of the 3 runs of the performance test.

2. Use the data collected during the performance test to calculate and record the average temperature. This is the minimum operating limit for the desorption concentrate gas stream temperature.

3. During the performance test, monitor and record the pressure drop of the dilute stream across the concentrator at least once every 15 minutes during each of the 3 runs of the performance test.

4. Use the data collected during the performance test to calculate and record the average pressure drop. This is the maximum operating limit for the dilute stream across the concentrator.

(f) Emission capture system.

1. For a PTE, according to Table 1 of this subchapter.

2. For each capture device that is not part of a PTE that meets the criteria of sub. (6) (a) , according to both of the following:

a. During the capture efficiency determination required by sub. (1) and described in subs. (5) and (6) , monitor and record either the gas volumetric flow rate or the duct static pressure for each separate capture device in your emission capture system at least once every 15 minutes during each of the 3 test runs at a point in the duct between the capture device and the add-on control device inlet.

b. Calculate and record the average gas volumetric flow rate or duct static pressure for the 3 test runs for each capture device. This average gas volumetric flow rate or duct static pressure is the minimum operating limit for that specific capture device.

(9)   What are the requirements for continuous parameter monitoring system installation, operation and maintenance?.

(a) General.

1. You shall install, operate and maintain each CPMS according to the following requirements, except that subd. 1. a. and b. do not apply to capture system bypass lines and carbon adsorbers as specified in pars. (b) and (d) :

a. The CPMS shall complete a minimum of one cycle of operation for each successive 15-minute period. You shall have a minimum of 4 equally spaced successive cycles of CPMS operation in one hour.

b. Determine the average of all recorded readings for each successive 3-hour period of the emission capture system and add-on control device operation except as specified in subd. 1. f.

c. Record the results of each inspection, calibration and validation check of the CPMS.

d. Maintain the CPMS at all times and have available necessary parts for routine repairs of the monitoring equipment.

e. Operate the CPMS and collect emission capture system and add-on control device parameter data at all times that a controlled coating operation is operating except during monitoring malfunctions, associated repairs, and required quality assurance or control activities (including, if applicable, calibration checks and required zero and span adjustments).

f. You may not use emission capture system or add-on control device parameter data recorded during monitoring malfunctions, associated repairs, out-of-control periods, or required quality assurance or control activities when calculating data averages. You shall use all the data collected during all other periods in calculating the data averages for determining compliance with the emission capture system and add-on control device operating limits.

2. A monitoring malfunction is any sudden, infrequent, not reasonably preventable failure of the CPMS to provide valid data. Monitoring failures that are caused in part by poor maintenance or careless operation are not malfunctions. Except for periods of required quality assurance or control activities, any period during which the CPMS fails to operate and record data continuously as required by subd. 1. a. , or generates data that cannot be included in calculating averages as specified in subd. 1. f. , is a deviation from the monitoring requirements.

(b) Capture system bypass line. You shall comply with all of the following requirements, in addition to those specified in par. (a) 1. c. to e. , for each emission capture system that contains bypass lines that could divert emissions away from the add-on control device to the atmosphere:

1. Monitor or secure the valve or closure mechanism controlling the bypass line in a nondiverting position in such a way that the valve or closure mechanism cannot be opened without creating a record that the valve was opened. The method used to monitor or secure the valve or closure mechanism shall meet one of the following requirements:

a. Install, calibrate, maintain and operate, according to the manufacturer's specifications, a flow control position indicator that takes a reading at least once every 15 minutes and provides a record indicating whether the emissions are directed to the add-on control device or diverted from the add-on control device. The time of occurrence and flow control position shall be recorded, as well as every time the flow direction is changed. The flow control position indicator shall be installed at the entrance to any bypass line that could divert the emissions away from the add-on control device to the atmosphere.

b. Secure any bypass line valve in the closed position with a car-seal or a lock-and-key type configuration. You shall visually inspect the seal or closure mechanism at least once every month to ensure that the valve is maintained in the closed position and the emissions are not diverted away from the add-on control device to the atmosphere.

c. Ensure that any bypass line valve is in the closed, non-diverting, position through monitoring of valve position at least once every 15 minutes. You shall inspect the monitoring system at least once every month to verify that the monitor will indicate valve position.

d. Use an automatic shutdown system in which the coating operation is stopped when flow is diverted by the bypass line away from the add-on control device to the atmosphere when the coating operation is running. You shall inspect the automatic shutdown system at least once every month to verify that it will detect diversions of flow and shutdown the coating operation.

2. If any bypass line is opened, you shall include a description of why the bypass line was opened and the length of time it remained open in the semiannual compliance reports required in s. NR 465.25 (2) .

(c) Thermal oxidizers and catalytic oxidizers. If you are using a thermal oxidizer or catalytic oxidizer as an add-on control device, including those used with concentrators or with carbon adsorbers to treat desorbed concentrate streams, you shall comply with the following requirements, as applicable, in addition to those specified in par. (a) 1. :

1. For a thermal oxidizer, install a gas temperature monitor in the firebox of the thermal oxidizer or in the duct immediately downstream of the firebox before any substantial heat exchange occurs.

2. For a catalytic oxidizer, install a gas temperature monitor in the gas stream immediately before the catalyst bed, and if you establish operating limits according to sub. (8) (b) 1. and 2. , also install a gas temperature monitor in the gas stream immediately after the catalyst bed.

3. For each gas temperature monitoring device, comply with all of the following requirements:

a. Locate the temperature sensor in a position that provides a representative temperature.

b. Use a temperature sensor with a measurement sensitivity of 4 ° F or 0.75% of the temperature value, whichever is larger.

c. Shield the temperature sensor system from electromagnetic interference and chemical contaminants.

d. If a gas temperature chart recorder is used, ensure that it has a measurement sensitivity in the minor division of at least 20 ° F.

e. Perform an electronic calibration at least semiannually according to the procedures in the manufacturer's owners manual. Following the electronic calibration, conduct a temperature sensor validation check in which a second or redundant temperature sensor placed nearby the process temperature sensor yields a reading within 30 ° F of the process temperature sensor's reading.

f. Any time the sensor exceeds the manufacturer's specified maximum operating temperature range, either conduct calibration and validation checks or install a new temperature sensor.

g. At least monthly, inspect components for integrity and electrical connections for continuity, oxidation and galvanic corrosion.

(d) Carbon adsorbers. If you are using a carbon adsorber as an add-on control device, you shall monitor the total regeneration desorbing gas (e. g., steam or nitrogen) mass flow for each regeneration cycle and the carbon bed temperature after each regeneration and cooling cycle and comply with all of the following requirements, in addition to those specified in par. (a) 1. c. to e. :

1. The regeneration desorbing gas mass flow monitor shall be an integrating device having a measurement sensitivity of ± 10%, capable of recording the total regeneration desorbing gas mass flow for each regeneration cycle.

2. The carbon bed temperature monitor shall have a measurement sensitivity of 1% of the temperature recorded or 1 ° F, whichever is greater, and shall be capable of recording the temperature within 15 minutes of completion of any carbon bed cooling cycle.

(e) Condensers. If you are using a condenser, you shall monitor the condenser outlet (product side) gas temperature and comply with all of the following requirements in addition to those specified in par. (a) 1. :

1. The gas temperature monitor shall have a measurement sensitivity of 1% of the temperature recorded or 1 ° F, whichever is greater.

2. The temperature monitor shall provide a gas temperature record at least once every 15 minutes.

(f) Concentrators. If you are using a concentrator, such as a zeolite wheel or rotary carbon bed concentrator, you shall comply with all of the following requirements, in addition to those specified in par. (a) 1. :

1. Install a temperature monitor in the desorption gas stream and meet the requirements in pars. (a) 1. and (c) 3.

2. Install a device to monitor pressure drop across the zeolite wheel or rotary carbon bed and meet all of the following requirements:

a. Locate the pressure sensor or sensors in or as close to a position that provides a representative measurement of the pressure.

b. Minimize or eliminate pulsating pressure, vibration and internal and external corrosion.

c. Use a gauge with a minimum tolerance of 0.5 inch of water or a transducer with a minimum tolerance of 1% of the pressure range.

d. Check the pressure tap daily.

e. Using a manometer, check gauge calibration quarterly and transducer calibration monthly.

f. Conduct calibration checks any time the sensor exceeds the manufacturer's specified maximum operating pressure range or install a new pressure sensor.

g. At least monthly, inspect components for integrity, electrical connections for continuity, and mechanical connections for leakage.

(g) Emission capture systems. You shall comply with the following requirements, as applicable, in addition to those specified in par. (a) 1. , for capture system monitoring:

1. For each flow measurement device, comply with all of the following requirements in addition to those specified in par. (a) :

a. Locate a flow sensor in a position that provides a representative flow measurement in the duct from each capture device in the emission capture system to the add-on control device.

b. Reduce swirling flow or abnormal velocity distributions due to upstream and downstream disturbances.

c. Conduct a flow sensor calibration check at least semiannually.

d. At least monthly, inspect components for integrity, electrical connections for continuity, and mechanical connections for leakage.

2. For each pressure drop measurement device, comply with all of the following requirements in addition to those specified in par. (a) :

a. Locate the pressure sensor or sensors in or as close to a position that provides a representative measurement of the pressure drop across each opening you are monitoring.

b. Minimize or eliminate pulsating pressure, vibration and internal and external corrosion.

c. Check pressure tap pluggage daily.

d. Using an inclined manometer with a measurement sensitivity of 0.0002 inch water, check gauge calibration quarterly and transducer calibration monthly.

e. Conduct calibration checks any time the sensor exceeds the manufacturer's specified maximum operating pressure range or install a new pressure sensor.

f. At least monthly, inspect components for integrity, electrical connections for continuity, and mechanical connections for leakage. - See PDF for table - See PDF for table - See PDF for table

History: CR 03-037 : cr. Register March 2004 No. 579 , eff. 4-1-04; CR 05-040 : renum. Tables 3 and 4 to be Tables 2 and 3, Register February 2006 No. 602 , eff. 3-1-06.

Note

For example, if one add-on control device is a concentrator with an outlet for the high-volume, dilute stream that has been treated by the concentrator, and a second add-on control device is an oxidizer with an outlet for the low-volume, concentrated stream that is treated with the oxidizer, you shall measure emissions at the outlet of the oxidizer and the high-volume dilute stream outlet of the concentrator. Microsoft Windows NT 6.1.7601 Service Pack 1 - See PDF for diagram Microsoft Windows NT 6.1.7601 Service Pack 1 (Equation 8) Microsoft Windows NT 6.1.7601 Service Pack 1 where: Microsoft Windows NT 6.1.7601 Service Pack 1   M f is the total gaseous organic emissions mass flow rate, kg/per hour (h) Microsoft Windows NT 6.1.7601 Service Pack 1   C c is the concentration of organic compounds as carbon in the vent gas, as determined by Method 25 or Method 25A, parts per million by volume (ppmv), dry basis Microsoft Windows NT 6.1.7601 Service Pack 1   Q sd is the volumetric flow rate of gases entering or exiting the add-on control device, as determined by Method 2, 2A, 2C, 2D, 2F or 2G, dry standard cubic meters/hour (dscm/h) Microsoft Windows NT 6.1.7601 Service Pack 1   0.0416 = conversion factor for molar volume, kg-moles per cubic meter (mol/m 3 ) (at 293 Kelvin (K) and 760 millimeters of mercury (mm Hg)) Microsoft Windows NT 6.1.7601 Service Pack 1 - See PDF for diagram Microsoft Windows NT 6.1.7601 Service Pack 1 (Equation 9) Microsoft Windows NT 6.1.7601 Service Pack 1 where: Microsoft Windows NT 6.1.7601 Service Pack 1   DRE is the add-on control device organic emissions destruction or removal efficiency, percent Microsoft Windows NT 6.1.7601 Service Pack 1   M fi is the total gaseous organic emissions mass flow rate at the inlet or inlets to the add-on control device, using Equation 8 in par. (d) , kg/h Microsoft Windows NT 6.1.7601 Service Pack 1   M fo is the total gaseous organic emissions mass flow rate at the outlet or outlets of the add-on control device, using Equation 8 in par. (d) , kg/h Microsoft Windows NT 6.1.7601 Service Pack 1 a : Use this table only if the solvent blend does not match any of the solvent blends in Table 2 and you only know whether the blend is aliphatic or aromatic. Microsoft Windows NT 6.1.7601 Service Pack 1 b : e.g., mineral spirits 135, mineral spirits 150 EC, naphtha, mixed hydrocarbon, aliphatic hydrocarbon, aliphatic naphtha, naphthol spirits, petroleum spirits, petroleum oil, petroleum naphtha, solvent naphtha, solvent blend. Microsoft Windows NT 6.1.7601 Service Pack 1 c : e.g., medium-flash naphtha, high-flash naphtha, aromatic naphtha, light aromatic naphtha, light aromatic hydrocarbons, aromatic hydrocarbons, light aromatic solvent. Microsoft Windows NT 6.1.7601 Service Pack 1