Wis. Admin. Code Department of Natural Resources NR 465.48

Current through October 28, 2024

Section NR 465.48 - 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) For a new or reconstructed affected source, you shall meet the requirements of subds. 1. to 4.

1. All emission capture systems, add-on control devices and CPMS shall be installed and operating no later than the applicable compliance date specified in s. NR 465.41(4). Except for solvent recovery systems for which you conduct liquid-liquid material balances according to sub. (2) (j), you shall conduct a performance test of each capture system and add-on control device according to subs. (5), (6) and (7) and establish the operating limits required by s. NR 465.43(3) no later than 180 days after the applicable compliance date specified in s. NR 465.41(4). For a solvent recovery system for which you conduct liquid-liquid material balances according to sub. (2) (j), you shall initiate the first material balance no later than the applicable compliance date specified in s. NR 465.41(4). For magnet wire coating operations you may, with approval, conduct a performance test of one representative magnet wire coating machine for each group of identical or very similar magnet wire coating machines.

2. You shall develop and begin implementing the work practice plan required by s. NR 465.43(4) no later than the compliance date specified in s. NR 465.41(4).

3. You shall complete the initial 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 465.41(4) and ends on the last day of the 12th month following 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 12 months. You shall determine the mass of organic HAP emissions and volume of coatings solids used each month and then calculate an organic HAP emission rate at the end of the initial compliance period. The initial compliance demonstration includes the results of emission capture system and add-on control device performance tests conducted according to subs. (5), (6) and (7); results of liquid-liquid material balances conducted according to sub. (2) (j); 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 applicable emission limit in s. NR 465.43(1); 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 465.43(4).

4. You do not need to comply with the operating limits for the emission capture system and add-on control device required by s. NR 465.43(3) until after you have completed the performance tests specified in subd. 1. Instead, you shall 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. You shall begin complying with the operating limits for your affected source on the date you complete the performance tests specified in subd. 1. For magnet wire coating operations, you shall begin complying with the operating limits for all identical or very similar magnet wire coating machines on the date you complete the performance test of a representative magnet wire coating machine. The requirements in this subdivision do not apply to solvent recovery systems for which you conduct liquid-liquid material balances according to the requirements in sub. (2) (j).

(b) For an existing affected source, you shall meet the requirements of subds. 1. to 3.

1. All emission capture systems, add-on control devices and CPMS shall be installed and operating no later than the applicable compliance date specified in s. NR 465.41(4). Except for magnet wire coating operations and solvent recovery systems for which you conduct liquid-liquid material balances according to sub. (2) (j), you shall conduct a performance test of each capture system and add-on control device according to the procedures in subs. (5), (6) and (7) and establish the operating limits required by s. NR 465.43(3) no later than the compliance date specified in s. NR 465.41(4). For magnet wire coating operations, you may, with approval, conduct a performance test of a single magnet wire coating machine that represents identical or very similar magnet wire coating machines. For a solvent recovery system for which you conduct liquid-liquid material balances according to sub. (2) (j), you shall initiate the first material balance no later than the compliance date specified in s. NR 465.41(4).

2. You shall develop and begin implementing the work practice plan required by s. NR 465.43(4) no later than the compliance date specified in s. NR 465.41(4).

3. You shall complete the initial 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 465.41(4) and ends on the last day of the 12th month following 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 12 months. You shall determine the mass of organic HAP emissions and volume of coatings solids used each month and then calculate an organic HAP emission rate at the end of the initial compliance period. The initial compliance demonstration includes the results of emission capture system and add-on control device performance tests conducted according to subs. (5), (6) and (7); results of liquid-liquid material balances conducted according to sub. (2) (j); 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 applicable emission limit in s. NR 465.43(1); 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 465.43(4).

(c) You are not required to conduct an initial performance test to determine capture efficiency or destruction efficiency of a capture system or control device if you receive approval to use the results of a performance test that has been previously conducted on that capture system or control device. Any previous tests shall meet the conditions described in subds. 1. to 3.

1. The previous test shall have been conducted using the methods and conditions specified in this subchapter.

2. Either no process or equipment changes have been made since the previous test was performed, or the owner or operator shall be able to demonstrate that the results of the performance test reliably demonstrate compliance despite process or equipment changes.

3. Either the required operating parameters were established in the previous test or sufficient data were collected in the previous test to establish the required operating parameters.

(2) HOW DO I DEMONSTRATE INITIAL COMPLIANCE?

(a)General. 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 in s. NR 465.43(2) (a) or the emission rate without add-on controls option in s. NR 465.43(2) (b) for any coating operation in the affected source for which you do not use the emission rate with add-on controls option. To demonstrate initial compliance, the coating operations for which you use the emission rate with add-on controls option shall meet the applicable emission limits in s. NR 465.43(1), (3) and (4). You shall conduct a separate initial compliance demonstration for each general use, magnet wire, rubber-to-metal and extreme performance fluoropolymer coating operation, unless you are demonstrating compliance with a predominant activity or facility-specific emission limit as provided in s. NR 465.43(1) (c). If you are demonstrating compliance with a predominant activity or facility-specific emission limit, you shall demonstrate that all coating operations included in the predominant activity determination or calculation of the facility-specific emission limit comply with that limit. You shall meet all the requirements of this subsection. When calculating the organic HAP emission rate according to pars. (b) to (n), do not include any coatings, thinners, other additives or cleaning materials used on coating operations for which you use the compliant material option in s. NR 465.43(2) (a) or the emission rate without add-on controls option in s. NR 465.43(2) (b). You do not need to re-determine the mass of organic HAP in coatings, thinners, other additives or cleaning materials that have been reclaimed onsite, or reclaimed off-site if you have documentation showing that you received back the exact same materials that were sent off-site, and reused in the coatings operations for which you use the emission rate with add-on controls option. If you use coatings, thinners, other additives or cleaning materials that have been reclaimed on-site, the amount of each used in a month may be reduced by the amount of each that is reclaimed. That is, the amount used may be calculated as the amount consumed to account for materials that are reclaimed.

(b)Compliance with operating limits. Except as provided in sub. (1) (a) 4., and except for solvent recovery systems for which you conduct liquid-liquid material balances according to the requirements of par. (j), you shall establish and demonstrate continuous compliance during the initial compliance period with the operating limits required by s. NR 465.43(3), using the procedures specified in subs. (8) and (9).

(c)Compliance with work practice requirements. You shall develop, implement and document your implementation of the work practice plan required by s. NR 465.43(4) during the initial compliance period, as specified in s. NR 465.45(3).

(d)Compliance with emission limits. You shall follow the procedures in pars. (e) to (n) to demonstrate compliance with the applicable emission limit in s. NR 465.43(1) for each affected source in each sub-category.

(e)Determine the mass fraction of organic HAP, density, volume used and volume fraction of coating solids. Follow the procedures in s. NR 465.47(2) (a) to (d) to determine the mass fraction of organic HAP, density and volume of each coating, thinner, other additive and cleaning material used during each month; and the volume fraction of coating solids for each coating used during each month.

(f)Calculate the total mass of organic HAP emissions before add-on controls. Using Equation 1 of s. NR 465.47(2), calculate the total mass of organic HAP emissions before add-on controls from all coatings, thinners, other additives and cleaning materials used during each month in the coating operation or group of coating operations for which you use the emission rate with add-on controls option.

(g)Calculate the organic HAP emission reduction for each controlled coating operation. Determine the mass of organic HAP emissions reduced for each controlled coating operation during each month. The emission 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. (h) to calculate the mass of organic HAP emission 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. (j) to calculate the organic HAP emission reduction.

(h)Calculate the organic HAP emission reduction for each controlled coating operation not using liquid-liquid material balance. Use the equations in this paragraph to calculate the organic HAP emission 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. You shall assume zero efficiency for the emission capture system and add-on control device 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, unless you have other data indicating the actual efficiency of the emission capture system and add-on control device and the use of these data is approved by the department.

Note: The calculation applies the emission capture system efficiency and add-on control device efficiency to the mass of organic HAP contained in the coatings, thinners, other additives and cleaning materials that are used in the coating operation served by the emission capture system and add-on control device during each month. Equation 1 treats the materials used during a deviation as if they were used on an uncontrolled coating operation for the time period of the deviation.

See Image

where:

H_C is the mass of organic HAP emission reduction for the controlled coating operation during the month, kg (lb)

A_C is the total mass of organic HAP in the coatings used in the controlled coating operation during the month, kg (lb), as calculated in Equation 1A of this subsection

B_C is the total mass of organic HAP in the thinners and other additives used in the controlled coating operation during the month, kg (lb), as calculated in Equation 1B of this subsection

C_C is the total mass of organic HAP in the cleaning materials used in the controlled coating operation during the month, kg (lb), as calculated in Equation 1C of this subsection

R_W is the total mass of organic HAP in waste materials sent or designated for shipment to a hazardous waste TSDF for treatment or disposal during the compliance period, kg (lb), determined according to s. NR 465.47(2) (e) 2. You may assign a value of zero to RW if you do not wish to use this allowance.

H_UNC is the total mass of organic HAP in the coatings, thinners and other additives, and cleaning materials used during all deviations specified in sub. (4) (c) and (d) that occurred during the month in the controlled coating operation, kg (lb), as calculated in Equation 1D of this subsection

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 (7) to measure and record the organic HAP destruction or removal efficiency.

See Image

where:

A_C is the total mass of organic HAP in the coatings used in the controlled coating operation during the month, kg (lb)

Vol_c,i is the total volume of coating i used during the month, liters (gallons)

D_c,i is the density of coating i, kg per liter (lb per gallon)

W_c,i is the mass fraction of organic HAP in coating i, kg per kg (lb per lb). For reactive adhesives, use the mass fraction of organic HAP that is emitted as determined using the method in to 40 CFR part 63, Subpart PPPP, Appendix A, incorporated by reference in s. NR 484.04(24r).

m is the number of different coatings used

See Image

where:

B_C is the total mass of organic HAP in the thinners and other additives used in the controlled coating operation during the month, kg (lb)

Vol_t,j is the total volume of thinner or other additive j used during the month, liters (gallons)

D_t,j is the density of thinner or other additive j, kg per liter (lb per gallon)

W_t,j is the mass fraction of organic HAP in thinner or other additive, j, kg per kg (lb per lb). For reactive adhesives, use the mass fraction of organic HAP that is emitted as determined using the method in 40 CFR part 63, Subpart PPPP, Appendix A, incorporated by reference in s. NR 484.04(24r).

n is the number of different thinners and other additives used

See Image

where:

C_C is the total mass of organic HAP in the cleaning materials used in the controlled coating operation during the month, kg (lb)

Vol_s,k = Total volume of cleaning material, k, used during the month, liters (gallons)

D_s,k is the density of cleaning material, k, kg per liter (lb per gallon)

W_s,k is the mass fraction of organic HAP in cleaning material, k, kg per kg (lb per lb)

p is the number of different cleaning materials used

See Image

where:

H_UNC is the total mass of organic HAP in the coatings, thinners and other additives, and cleaning materials used during all deviations specified in sub. (4)(c) and (d) that occurred during the month in the controlled coating operation, kg (lb)

Vol_h is the total volume of coating, thinner or other additive, or cleaning material, h, used in the controlled coating operation during deviations, liters (gallons)

D_h is the density of coating, thinner or other additive, or cleaning material, h, kg per liter (lb per gallon)

W_h is the mass fraction of organic HAP in coating, thinner, other additive or cleaning material, h, kg (lb) of organic HAP per kg (lb) of coating. For reactive adhesives, use the mass fraction of organic HAP that is emitted as determined using the method in 40 CFR part 63, Subpart PPPP, Appendix A, incorporated by reference in s. NR 484.04(24r).

q is the number of different coatings, thinners and other additives, and cleaning materials used

(j)Calculate the organic HAP emission reduction for each controlled coating operation using liquid-liquid material balances. For each controlled coating operation using a solvent recovery system for which you conduct liquid-liquid material balances, calculate the organic HAP emission reduction by applying the volatile organic matter collection and recovery efficiency to the mass of organic HAP contained in the coatings, thinners and other additives, and cleaning materials that are used in the coating operation or operations controlled by the solvent recovery system during each month. Perform a liquid-liquid material balance for each month as specified in subds.

1. to 6. Calculate the mass of organic HAP emission reduction by the solvent recovery system as specified in subd. 7. 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 month. The device shall be initially certified by the manufacturer to be accurate to within plus or minus 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 month, based on measurement with the device required in subd. 1.

3. Determine the mass fraction of volatile organic matter for each coating, thinner, other additive and cleaning material used in the coating operation or operations controlled by the solvent recovery system during the month, kg (lb) of volatile organic matter per kg (lb) of coating. You may determine the volatile organic matter mass fraction using Method 24 of 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 take precedence unless, after consultation, you demonstrate to the satisfaction of the department that the formulation data are correct.

4. Determine the density of each coating, thinner, other additive and cleaning material used in the coating operation or operations controlled by the solvent recovery system during the month, kg per liter (lb per gallon), according to s. NR 465.47(2) (c).

5. Measure the volume of each coating, thinner, other additive and cleaning material used in the coating operation or operations controlled by the solvent recovery system during the month, liters (gallons).

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

See Image

where:

R_V is the volatile organic matter collection and recovery efficiency of the solvent recovery system during the month, percent

M_VR is the mass of volatile organic matter recovered by the solvent recovery system during the month, kg (lb)

Vol_i is the volume of coating, i, used in the coating operation controlled by the solvent recovery system during the month, liters (gallons)

D_i is the density of coating, i, kg per liter (lb per gallon)

WV_c,i is the mass fraction of volatile organic matter for coating i, kg (lb) of volatile organic matter per kg (lb) of coating. For reactive adhesives, use the mass fraction of organic HAP that is emitted as determined using the method in 40 CFR part 63, Subpart PPPP, Appendix A, incorporated by reference in s. NR 484.04(24r).

Vol_j is the volume of thinner or other additive, j, used in the coating operation controlled by the solvent recovery system during the month, liters (gallons)

D_j is the density of thinner or other additive, j, kg per liter (lb per gallon)

WV_t,j is the mass fraction of volatile organic matter for thinner or other additive, j, kg (lb) of volatile organic matter per kg (lb) of thinner or other additive. For reactive adhesives, use the mass fraction of organic HAP that is emitted as determined using the method in 40 CFR part 63, Subpart PPPP, Appendix A, incorporated by reference in s. NR 484.04(24r).

Vol_k is the volume of cleaning material, k, used in the coating operation controlled by the solvent recovery system during the month, liters (gallons)

D_k is the density of cleaning material, k, kg per liter (lb per gallon)

WV_s,k is the mass fraction of volatile organic matter for cleaning material, k, kg (lb) of volatile organic matter per kg (lb) of cleaning material

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

n is the number of different thinners and other additives used in the coating operation controlled by the solvent recovery system during the month

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

7. Calculate the mass of organic HAP emission reduction for the coating operations controlled by the solvent recovery system during the month, using the following equations:

See Image

where:

H_CSR is the mass of organic HAP emission reduction for the coating operation or operations controlled by the solvent recovery system using a liquid-liquid material balance during the month, kg (lb)

A_CSR is the total mass of organic HAP in the coatings used in the coating operation or operations controlled by the solvent recovery system, kg (lb), calculated using Equation 3A of this subsection

B_CSR is the total mass of organic HAP in the thinners and other additives used in the coating operation or operations controlled by the solvent recovery system, kg (lb), calculated using Equation 3B of this subsection

C_CSR is the total mass of organic HAP in the cleaning materials used in the coating operation or operations controlled by the solvent recovery system, kg (lb), calculated using Equation 3C of this subsection

R_V is the volatile organic matter collection and recovery efficiency of the solvent recovery system, percent, from Equation 2 of this subsection

See Image

where:

A_CSR is the total mass of organic HAP in the coatings used in the coating operation or operations controlled by the solvent recovery system during the month, kg (lb)

Vol_c,i is the total volume of coating, i, used during the month in the coating operation or operations controlled by the solvent recovery system, liters (gallons)

D_c,i is the density of coating, i, kg per liter (lb per gallon)

W_c,i is the mass fraction of organic HAP in coating, i, kg (lb) of organic HAP per kg (lb) of coating. For reactive adhesives, use the mass fraction of organic HAP emitted as determined using the method in 40 CFR part 63, Subpart PPPP, Appendix A, incorporated by reference in s. NR 484.04(24r).

m is the number of different coatings used

See Image

where:

B_CSR is the total mass of organic HAP in the thinners and other additives used in the coating operation or operations controlled by the solvent recovery system during the month, kg (lb)

Vol_t,j is the total volume of thinner or other additive, j, used during the month in the coating operation or operations controlled by the solvent recovery system, liters (gallons)

D_t,j is the density of thinner or other additive, j, kg per liter (lb per gallon)

W_t,j is the mass fraction of organic HAP in thinner or other additive, j, kg (lb) of organic HAP per kg (lb) of thinner or other additive. For reactive adhesives, use the mass fraction of organic HAP that is emitted as determined using the method in 40 CFR part 63, Subpart PPPP, Appendix A incorporated by reference in s. NR 484.04(24r).

n is the number of different thinners and other additives used

See Image

where:

C_CSR is the total mass of organic HAP in the cleaning materials used in the coating operation or operations controlled by the solvent recovery system during the month, kg (lb)

Vol_s,k is the total volume of cleaning material, k, used during the month in the coating operation or operations controlled by the solvent recovery system, liters (gallons)

D_s,k is the density of cleaning material, k, kg per liter (lb per gallon)

W_s,k is the mass fraction of organic HAP in cleaning material, k, kg (lb) of organic HAP per kg (lb) of cleaning material

p is the number of different cleaning materials used

(k)Calculate the total volume of coating solids used. Determine the total volume of coating solids used, liters (gallons), which is the combined volume of coating solids for all the coatings used during each month in the coating operation or group of coating operations for which you use the emission rate with add-on controls option, using Equation 2 of s. NR 465.47(2).

(L)Calculate the mass of organic HAP emissions for each month. Determine the mass of organic HAP emissions during each month, using Equation 4:

See Image

where:

H_HAP is the total mass of organic HAP emissions for the month, kg (lb)

H_e is the total mass of organic HAP emissions before add-on controls from all the coatings, thinners, other additives and cleaning materials used during the month, kg (lb), determined according to par. (f)

H_c,i is the total mass of organic HAP emission reduction for controlled coating operation, i, not using a liquid-liquid material balance, during the month, kg (lb), from Equation 1 of this subsection

H_CSR,j is the total mass of organic HAP emission reduction for coating operation, j, controlled by a solvent recovery system using a liquid-liquid material balance, during the month, kg (lb), from Equation 3 of this subsection

q is the number of controlled coating operations not controlled by a solvent recovery system using a liquid-liquid material balance

r is the number of coating operations controlled by a solvent recovery system using a liquid-liquid material balance

(m)Calculate the organic HAP emission rate for the compliance period. Determine the organic HAP emission rate for the compliance period using Equation 5:

See Image

where:

H_annual is the organic HAP emission rate for the compliance period, kg (lb) of organic HAP emitted per liter (gallon) of coating solids used

H_HAP,y is the organic HAP emissions for month, y, kg (lb), determined according to Equation 4 of this subsection

V_st,y is the total volume of coating solids used during month, y, liters (gallons), from Equation 2 of s. NR 465.47(2)

y is the number of the month in the compliance period

n is the number of full or partial months in the compliance period. For the initial compliance period, n equals 12 if the compliance date falls on the first day of a month; otherwise n equals 13. For all following compliance periods, n equals 12.

(n)Compliance demonstration. The organic HAP emission rate for the initial compliance period, calculated using Equation 5 of this subsection, shall be less than or equal to the applicable emission limit for each sub-category in s. NR 465.43(1) or the predominant activity or facility-specific emission limit allowed in s. NR 465.43(1) (c). You shall keep all records as required by s. NR 465.45(3) and (4). As part of the notification of compliance status required by s. NR 465.45(1), you shall identify the coating operations for which you used the emission rate with add-on controls option as specified in this section and submit a statement that the coating operations were in compliance with the emission limits in s. NR 465.43(1) during the initial compliance period because the organic HAP emission rate was less than or equal to the applicable emission limit in s. NR 465.43(1), and you achieved the operating limits required by s. NR 465.43(3) and the work practice standards required by s. NR 465.43(4).

(4) HOW DO I DEMONSTRATE CONTINUOUS COMPLIANCE WITH THE EMISSION LIMITS?

(a) To demonstrate continuous compliance with the applicable emission limit in s. NR 465.43(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 465.43(1). A compliance period consists of 12 months. Each month after the end of the initial compliance period described in sub. (1) is the end of a compliance period consisting of that month and the preceding 11 months. You shall perform the calculations in sub. (2) on a monthly basis using data from the previous 12 months of operation. If you are complying with a facility-specific emission limit under s. NR 465.43(1) (c) 2., you shall also perform the calculation using Equation 1 of s. NR 465.43(1) (c) 2. on a monthly basis using the data from the previous 12 months of operation.

(b) If the organic HAP emission rate for any 12-month compliance period exceeded the applicable emission limit in s. NR 465.43(1), this is a deviation from the emission limit for that compliance period that shall be reported as specified in s. NR 465.45(1) (c) 6. and (2) (a) 7.

(c) You shall demonstrate continuous compliance with each operating limit required by s. NR 465.43(3) that applies to you, as specified in Table 1 of this subchapter, when the coating line is in operation. If an operating parameter is out of the allowed range specified in Table 1, you shall do both of the following:

1. Report as a deviation from the operating limit as specified in s. NR 465.45(1) (c) 6. and (2) (a) 7.

2. Assume that the emission capture system and add-on control device were achieving zero efficiency during the time period of the deviation, unless you have other data indicating the actual efficiency of the emission capture system and add-on control device and the use of these data is approved by the department.

(d) You shall meet the requirements for bypass lines in sub. (9) (b) for controlled coating operations for which you do not conduct liquid-liquid material balances. If any bypass line is opened and emissions are diverted to the atmosphere when the coating operation is running, this is a deviation that shall be reported as specified in s. NR 465.45(1) (c) 6. and (2) (a) 7. For the purposes of completing the compliance calculations specified in sub. (2) (h), 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 as indicated in Equation 1 of sub. (2).

(e) You shall demonstrate continuous compliance with the work practice standards in s. NR 465.43(4). If you did not develop a work practice plan, or you did not implement the plan, or you did not keep the records required by s. NR 465.45(3) (k) 8., this is a deviation from the work practice standards that shall be reported as specified in s. NR 465.45(1) (c) 6. and (2) (a) 7.

(f) As part of each semiannual compliance report required in s. NR 465.45(2), you shall identify the coating operations for which you used the emission rate with add-on controls option. If there were no deviations from the emission limits in s. NR 465.43(1), you shall submit a statement that you were in compliance with the emission limits 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 465.43(1), and you achieved the operating limits required by s. NR 465.43(3) and the work practice standards required by s. NR 465.43(4) during each compliance period.

(g) During periods 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, you shall operate in accordance with the startup, shutdown and malfunction plan required by s. NR 465.44(1) (c).

(j) You shall maintain records as specified in s. NR 465.45(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 conditions in this paragraph, unless you obtain a waiver of the performance test according to the provisions in s. NR 460.06(7).

1. `Representative coating operation operating conditions.' You shall conduct the performance test under representative operating conditions for the coating operation. Operations during periods of startup, shutdown or malfunction and during periods of non-operation 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. `Representative emission capture system and add-on control device operating conditions.' You shall conduct the performance test 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). You shall conduct each performance test of an add-on control device according to the requirements in sub. (7).

(6) HOW DO I DETERMINE THE EMISSION CAPTURE SYSTEM EFFICIENCY? You shall use the procedures and test methods in this subsection to determine capture efficiency as part of the performance test required by sub. (1).

(a)Assuming 100% capture efficiency. You may assume the capture system efficiency is 100% if both of the conditions in subds. 1. and 2. are met.

1. The capture system meets the criteria in 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, other additives and cleaning materials used in the coating operation are applied within the capture system; coating solvent flash-off, 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.

Note: This criterion is not met if parts enter the open shop environment when being moved between a spray booth and a curing oven.

(b)Measuring capture efficiency. If the capture system does not meet both of the conditions in par. (a) 1. and 2., then you shall use one of the 3 protocols described in pars. (c), (d) and (e) to measure capture efficiency. The capture efficiency measurements use total volatile hydrocarbon (TVH) capture efficiency as a surrogate for organic HAP capture efficiency. For the protocols in pars. (c) and (d), 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 the production, which includes surface preparation activities and drying and curing time.

(c)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 a temporary total enclosure or a building enclosure and the procedures in subds. 1. to 6. to measure emission capture system efficiency when using the liquid-to-uncaptured-gas protocol.

1. Either use a building enclosure or construct an enclosure around the coating operation where coatings, thinners, other additives 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).

2. 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, other additive 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.

3. Use Equation 1 of this subsection to calculate the total mass of TVH liquid input from all the coatings, thinners, other additives and cleaning materials used in the coating operation during each capture efficiency test run:

See Image

where:

TVH_used is the mass of liquid TVH in materials used in the coating operation during the capture efficiency test run, kg (lb)

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

Vol_i is the total volume of coating, thinner or other additive, or cleaning material, i, used in the coating operation during the capture efficiency test run, liters (gallons)

D_i is the density of coating, thinner or other additive, or cleaning material, i, kg (lb) of material per liter (gallon) of material

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

4. 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 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.

a. Use Method 204D in 40 CFR part 51, Appendix M, incorporated by reference in s. NR 484.04(9), if the enclosure is a temporary total enclosure.

b. Use Method 204E in 40 CFR part 51, Appendix M, incorporated by reference in s. NR 484.04(9), 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.

5. For each capture efficiency test run, determine the percent capture efficiency of the emission capture system using Equation 2:

See Image

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 (lb)

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 (lb)

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

(d)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 a temporary total enclosure or a building enclosure and the procedures in subds. 1. to 5. to measure emission capture system efficiency when using the gas-to-gas protocol.

1. Either use a building enclosure or construct an enclosure around the coating operation where coatings, thinners and other additives, 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).

2. 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 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.

a. 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.

b. If multiple emission streams from the capture system enter the add-on control device without a single common duct, then 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.

3. 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 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.

a. Use Method 204D in 40 CFR part 51, Appendix M, incorporated by reference in s. NR 484.04(9), if the enclosure is a temporary total enclosure.

4. For each capture efficiency test run, determine the percent capture efficiency of the emission capture system using Equation 3:

See Image

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 (lb)

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

(e)Alternative capture efficiency protocol. As an alternative to the procedures specified in pars. (c) and (d) and subject to the approval of the department, 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? You shall use the procedures and test methods in this subsection to determine the add-on control device emission destruction or removal efficiency as part of the performance test required by sub. (1). You shall conduct 3 test runs as specified in s. NR 460.06(4) (c) and each test run shall last at least one hour. If the source is a magnet wire coating machine, you may use the procedures in section 3.0 in 40 CFR part 63, Subpart MMMM, Appendix A, incorporated by reference in s. NR 484.04(24g), as an alternative.

(a) For all types of add-on control devices, use the test methods specified in subds. 1. to 5.

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.

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).

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, then you shall measure emissions at the outlet to the atmosphere of each device.

Note: For example, if one add-on control device is a concentrator with an outlet to the atmosphere 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 to the atmosphere 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.

(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 1 of this subsection. 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 1 for each inlet and each outlet and then total all of the inlet emissions and total all of the outlet emissions.

M_f = Q_sdC_c(12)(0.416)(10^-6)

(Equation 1)

where:

M_f is the total gaseous organic emissions mass flow rate, kg per hour (h)

C_c is the concentration of organic compounds as carbon in the vent gas, as determined by Method 25 or Method 25A in 40 CFR part 60, Appendix A, incorporated by reference in s. NR 484.04(13), parts per million by volume (ppmv), dry basis

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 in 40 CFR part 60, Appendix A, incorporated by reference in s. NR 484.04(13), dry standard cubic meters/hour (dscm/h)

0.0416 is the conversion factor for molar volume, kg-moles per cubic meter (mol/m³) (at 293 Kelvin (K) and 760 millimeters of mercury (mmHg))

(e) For each test run, determine the add-on control device organic emissions destruction or removal efficiency, using Equation 2:

See Image

where:

DRE is the organic emissions destruction or removal efficiency of the add-on control device, percent

M_fi is the total gaseous organic emissions mass flow rate at the inlet to the add-on control device, using Equation 1 of this subsection, kg /h

M_fo is the total gaseous organic emissions mass flow rate at the outlet of the add-on control device, using Equation 1 of this subsection, kg/h

(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 2 of this subsection.

(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), (6) and (7), you shall establish the operating limits required by s. NR 465.43(3) according to this subsection, unless you have received approval for alternative monitoring and operating limits under 40 CFR 63.8(f) as specified in s. NR 465.43(3).

(a)Thermal oxidizers. If your add-on control device is a thermal oxidizer, establish the operating limits according to subds. 1. and 2.

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 shall be the minimum operating limit for your thermal oxidizer.

(b)Catalytic oxidizers. If your add-on control device is a catalytic oxidizer, establish the operating limits according to either subds. 1. and 2. or subds. 3. and 4. If the source is a magnet wire coating machine, you may use the procedures in section 3.0 in 40 CFR part 63, Subpart MMMM, Appendix A, incorporated by reference in s. NR 484.04(24g), as an alternative.

1. During the performance test, you shall 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.

2. 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. The average temperature just before the catalyst bed and the average temperature difference across the catalyst bed shall be the minimum operating limits for your catalytic oxidizer.

3. You shall monitor the temperature at the inlet to the catalyst bed and implement a site-specific inspection and maintenance plan for your catalytic oxidizer as specified in subd. 4. 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 average temperature shall be the minimum operating limit for your catalytic oxidizer.

4. You shall develop and implement an inspection and maintenance plan for your catalytic oxidizers for which you elect to monitor according to subd. 3. The plan shall address, at a minimum, the elements specified in subd. 4. a. to c.

a. Annual sampling and analysis of the catalyst activity, or conversion efficiency, following the manufacturer's or catalyst supplier's recommended procedures. If problems are found during the catalyst activity test, you shall replace the catalyst bed or take other corrective action consistent with the manufacturer's recommendations.

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

c. Annual internal inspection of the catalyst bed to check for channeling, abrasion and settling. If problems are found during the annual internal inspection of the catalyst, you shall replace the catalyst bed or take other corrective action consistent with the manufacturer's recommendations. If the catalyst bed is replaced and is not of like or better kind and quality as the old catalyst, then you shall conduct a new performance test to determine destruction efficiency according to sub. (7). If a catalyst bed is replaced and the replacement catalyst is of like or better kind and quality as the old catalyst, then a new performance test to determine destruction efficiency is not required and you may continue to use the previously established operating limits for that catalytic oxidizer.

(c)Regenerative carbon adsorbers. If your add-on control device is a regenerative carbon adsorber, establish the operating limits according to subds. 1. and 2.

1. You shall monitor and record the total regeneration desorbing gas 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 regenerative carbon adsorber shall be 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, establish the operating limits according to subds. 1. and 2.

1. During the performance test, you shall monitor and record the condenser outlet, or 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, or product side, gas temperature maintained during the performance test. This average condenser outlet gas temperature shall be the maximum operating limit for your condenser.

(e)Concentrators. If your add-on control device includes a concentrator, you shall establish operating limits for the concentrator according to subds. 1. to 4.

1. During the performance test, you shall 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 average temperature shall be the minimum operating limit for the desorption concentrate gas stream temperature.

3. During the performance test, you shall 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 average pressure drop shall be the minimum operating limit for the dilute stream across the concentrator.

(f)Emission capture systems. For each capture device that is not part of a PTE that meets the criteria of sub. (6) (a), establish an operating limit for either the gas volumetric flow rate or duct static pressure, as specified in subds. 1. and 2. The operating limit for a PTE is specified in Table 1 of this subchapter. If the source is a magnet wire coating machine, you may use the procedures in section 2.0 of 40 CFR part 63, Subpart MMMM, Appendix A, incorporated by reference in s. NR 484.04(24g), as an alternative.

1. During the capture efficiency determination required by sub. (1) and described in subs. (5) and (6), you shall 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.

2. 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 shall be 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. You shall install, operate and maintain each CPMS specified in pars. (c), (e), (f) and (g) according to subds. 1. to 6. You shall install, operate and maintain each CPMS specified in pars. (b) and (d) according to subds. 3. to 5.

1. 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.

2. You shall determine the average of all recorded readings for each successive 3-hour period of the emission capture system and add-on control device operation.

3. You shall record the results of each inspection, calibration and validation check of the CPMS.

4. You shall maintain the CPMS at all times and have available necessary parts for routine repairs of the monitoring equipment.

5. You shall 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.

6. 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.

7. 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. Any period for which the monitoring system is out-of-control and data are not available for required calculations is a deviation from the monitoring requirements.

(b)Capture system bypass line. You shall meet the requirements of subds. 1. and 2. for each emission capture system that contains bypass lines that could divert emissions away from the add-on control device to the atmosphere.

1. You shall monitor or secure the valve or closure mechanism controlling the bypass line in a non-diverting 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 requirements specified in subd. 1. a. to e.

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 shut down the coating operation.

e. Install, calibrate, maintain and operate according to the manufacturer's specifications a flow direction 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. Each time the flow direction changes, the next reading of the time of occurrence and flow direction shall be recorded. The flow direction indicator shall be installed in each bypass line or air makeup supply line that could divert the emissions away from the add-on control device to the atmosphere.

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 465.45(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 requirements in subds. 1. to 3.

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 gas temperature monitors upstream or downstream or both of the catalyst bed as required in sub. (8) (b).

3. For all thermal oxidizers and catalytic oxidizers, you shall meet the requirements in par. (a) and subd. 3. a. to e. for each gas temperature monitoring device.

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

b. Use a temperature sensor with a measurement sensitivity of 5°F or 1.0% of the temperature value, whichever is larger.

c. Before using the sensor for the first time or when relocating or replacing the sensor, perform a validation check by comparing the sensor output to a calibrated temperature measurement device or by comparing the sensor output to a simulated temperature.

d. Conduct an accuracy audit every quarter and after every deviation. Accuracy audit methods include comparisons of sensor output to redundant temperature sensors, to calibrated temperature measurement devices, or to temperature simulation devices.

e. Conduct a visual inspection of each sensor every quarter if redundant temperature sensors are not used.

(d)Regenerative carbon adsorbers. If you are using a regenerative carbon adsorber as an add-on control device, you shall monitor the total regeneration desorbing gas mass flow for each regeneration cycle, the carbon bed temperature after each regeneration and cooling cycle, and comply with par. (a) 3. to 5. and subds. 1. to 3.

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

2. The carbon bed temperature monitor shall be capable of recording the temperature within 15 minutes of completing any carbon bed cooling cycle.

3. For all regenerative carbon adsorbers, you shall meet the requirements in par. (c) 3. a. to e. for each temperature monitoring device.

(e)Condensers. If you are using a condenser, you shall monitor the condenser outlet, or product side, gas temperature and comply with par. (a) and subds. 1. and 2.

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

2. For all condensers, you shall meet the requirements in par. (c) 3. a. to e. for each temperature monitoring device.

(f)Concentrators. If you are using a concentrator, such as a zeolite wheel or rotary carbon bed concentrator, you shall comply with the requirements in subds. 1. and 2.

1. You shall install a temperature monitor in the desorption gas stream. The temperature monitor shall meet the requirements in pars. (a) and (c) 3.

2. You shall install a device to monitor pressure drop across the zeolite wheel or rotary carbon bed. The pressure monitoring device shall meet the requirements in pars. (a) and (g) 2.

(g)Emission capture systems. The capture system monitoring system shall comply with the applicable requirements in subds. 1. and 2. If the source is a magnet wire coating machine, you may use the procedures in section 2.0 of 40 CFR part 63, Subpart MMMM, Appendix A, incorporated by reference in s. NR 484.04(24g), as an alternative.

1. For each flow measurement device, you shall meet the requirements in par. (a) and the requirements in subd. 1. a. to g.

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. Use a flow sensor with an accuracy of at least 10% of the flow.

c. Perform an initial sensor calibration in accordance with the manufacturer's requirements.

d. Perform a validation check before initial use or upon relocation or replacement of a sensor. Validation checks include comparison of sensor values with electronic signal simulations or via relative accuracy testing.

e. Conduct an accuracy audit every quarter and after every deviation. Accuracy audit methods include comparisons of sensor values with electronic signal simulations or via relative accuracy testing.

f. Perform leak checks monthly.

g. Perform visual inspections of the sensor system quarterly if there is no redundant sensor.

2. For each pressure drop measurement device, you shall comply with the requirements in par. (a) and the requirements in subd. 2. a. to g.

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

b. Use a pressure sensor with an accuracy of at least 0.5 inches of water column or 5% of the measured value, whichever is larger.

c. Perform an initial calibration of the sensor according to the manufacturer's requirements.

d. Conduct a validation check before initial operation or upon relocation or replacement of a sensor. Validation checks include comparison of sensor values to calibrated pressure measurement devices or to pressure simulation using calibrated pressure sources.

e. Conduct accuracy audits every quarter and after every deviation. Accuracy audits include comparison of sensor values to calibrated pressure measurement devices or to pressure simulation using calibrated pressure sources.

f. Perform monthly leak checks on pressure connections. A pressure of at least 1.0 inches of water column to the connection shall yield a stable sensor result for at least 15 seconds.

g. Perform a visual inspection of the sensor at least monthly if there is no redundant sensor.

Table 1

Operating Limits if Using the Emission Rate With Add-On Controls Option in s. NR 465.43(2) (c)

If you are required to comply with operating limits by s. NR 465.43(3) (b), you shall comply with the applicable operating limits in the following table.

For the following device:	You shall meet the following operating limit:	And you shall demonstrate continuous compliance with the operating limit by:
(1) Thermal oxidizer	(a) The average combustion temperature in any 3-hour period may not fall below the combustion temperature limit established according to s. NR 465.48(8) (a).	1. Collecting the combustion temperature data according to s. NR 465.48(9) (c); 2. Reducing the data to 3-hour block averages; and 3. Maintaining the 3-hour average combustion temperature at or above the temperature limit.
(2) Catalytic oxidizer	(a) The average temperature measured just before the catalyst bed in any 3-hour period may not fall below the limit established according to s. NR 465.48(8) (b); and either par. (b) or (c). For magnet wire coating machines, temperature can be monitored below or after the catalyst bed.	1. Collecting the temperature data according to s. NR 465.48(9) (c); 2. Reducing the data to 3-hour block averages; and 3. Maintaining the 3-hour average temperature before, or, for magnet wire coating machines, after the catalyst bed at or above the temperature limit.
(b) Ensure that the average temperature difference across the catalyst bed in any 3-hour period does not fall below the temperature difference limit established according to s. NR 465.48(8) (b) 2.	1. Collecting the temperature data according to s. NR 465.48(9) (c); 2. Reducing the data to 3-hour block averages; and 3. Maintaining the 3-hour average temperature difference at or above the temperature difference limit.
(c) Develop and implement an inspection and maintenance plan according to s. NR 465.48(8) (b) 4., or, for magnet wire coating machines, according to section 3.0 of 40 CFR part 63, Subpart MMMM, Appendix A, incorporated by reference in s. NR 484.04(24g).	1. Maintaining an up-to-date inspection and maintenance plan, records of annual catalyst activity checks, records of monthly inspections of the oxidizer system, and records of the annual internal inspections of the catalyst bed. If a problem is discovered during a monthly or annual inspection required by s. NR 465.48(8) (b) 4., or, for magnet wire coating machines, by section 3.0 of 40 CFR part 63, Subpart MMMM, Appendix A, incorporated by reference in s. NR 484.04(24g), you shall take corrective action as soon as practicable consistent with the manufacturer's recommendations.
(3) Regenerative carbon adsorber	(a) The total regeneration desorbing gas mass flow for each carbon bed regeneration cycle may not fall below the total regeneration desorbing gas mass flow limit established according to s. NR 465.48(8) (c).	1. Measuring the total regeneration desorbing gas mass flow for each regeneration cycle according to s. NR 465.48(9) (d); and 2. Maintaining the total regeneration desorbing gas mass flow at or above the mass flow limit.
(b) The temperature of the carbon bed, after completing each regeneration and any cooling cycle, may not exceed the carbon bed temperature limit established according to s. NR 465.48(8) (c).	1. Measuring the temperature of the carbon bed after completing each regeneration and any cooling cycle according to s. NR 465.48(9) (d); and 2. Operating the carbon beds so that each carbon bed is not returned to service after completing each regeneration and any cooling cycle until the recorded temperature of the carbon bed is at or below the temperature limit.
(4) Condenser	(a) The average condenser outlet, or product side, gas temperature in any 3-hour period may not exceed the temperature limit established according to s. NR 465.48(8) (d).	1. Collecting the condenser outlet gas temperature according to s. NR 465.48(9) (e); 2. Reducing the data to 3-hour block averages; and 3. Maintaining the 3-hour average gas temperature at the outlet at or below the temperature limit.
(5) Concentrators, including zeolite wheels and rotary carbon adsorbers	(a) The average gas temperature of the desorption concentrate stream in any 3- hour period may not fall below the limit established according to s. NR 465.48(8) (e).	1. Collecting the temperature data according to s. NR 465.48(9) (f); 2. Reducing the data to 3-hour block averages; and 3. Maintaining the 3-hour average temperature at or above the temperature limit.
(b) The average pressure drop of the dilute stream across the concentrator in any 3- hour period may not fall below the limit established according to s. NR 465.48(8) (e).	1. Collecting the pressure drop data according to s. NR 465.48(9) (f); 2. Reducing the pressure drop data to 3-hour block averages; and 3. Maintaining the 3-hour average pressure drop at or above the pressure drop limit.
(6) Emission capture system that is a PTE according to s. NR 465.48(6) (a).	(a) The direction of the air flow at all times shall be into the enclosure; and either (b) or (c) shall be satisfied.	1. Collecting the direction of air flow, and either the facial velocity of air through all natural draft openings according to s. NR 465.48(9) (g) 1. or the pressure drop across the enclosure according to s. NR 465.48(9) (g) 2.; and 2. Maintaining the facial velocity of air flow through all natural draft openings or the pressure drop at or above the facial velocity limit or pressure drop limit, and maintaining the direction of air flow into the enclosure at all times.
(b) The average facial velocity of air through all natural draft openings in the enclosure shall be at least 200 feet per minute.	1. See items (6)(a)1. and 2.
(c) The pressure drop across the enclosure shall be at least 0.007 inch H2O, as established in Method 204 in 40 CFR part 51, Appendix M, incorporated by reference in s. NR 484.04(9).	1. See items (6)(a)1. and 2.
(7) Emission capture system that is not a PTE according to s. NR 465.48(6) (a)	(a) The average gas volumetric flow rate or duct static pressure in each duct between a capture device and add-on control device inlet in any 3-hour period may not fall below the average volumetric flow rate or duct static pressure limit established for that capture device according to s. NR 465.48(8) (f).	1. Collecting the gas volumetric flow rate or duct static pressure for each capture device according to s. NR 465.48(9) (g); 2. Reducing the data to 3-hour block averages; and 3. Maintaining the 3-hour average gas volumetric flow rate or duct static pressure for each capture device at or above the gas volumetric flow rate or duct static pressure limit.

Table 2

Default Organic HAP Mass Fraction for Solvents and Solvent Blends

You may use the mass fraction values in the following table for solvent blends for which you do not have test data or manufacturer's formulation data and which match either the solvent blend name or the chemical abstract series (CAS) number. If a solvent blend matches both the name and CAS number for an entry, that entry's organic HAP mass fraction shall be used for that solvent blend. Otherwise, use the organic HAP mass fraction for the entry matching either the solvent blend name or CAS number, or use the organic HAP mass fraction from Table 3 of this subchapter if neither the name or CAS number match.

Solvent or Solvent Blend	CAS No.	Average Oreanic HAP Mass Fraction	Typical Organic HAP, percent by mass
(1) Toluene	108-88-3	1.0	toluene
(2) Xylenes	1330-20-7	1.0	xylenes, ethylbenzene
(3) Hexane	110-54-3	0.5	n-hexane
(4) n-Hexane	110-54-3	1.0	n-hexane
(5) Ethylbenzene	100-41-4	1.0	ethylbenzene
(6) Aliphatic 140	---	0	none
(7) Aromatic 100	---	0.02	1% xylene, 1% cumene
(8) Aromatic 150	---	0.09	naphthalene
(9) Aromatic naphtha	64742-95-6	0.02	1% xylene, 1% cumene
(10) Aromatic solvent	64742-94-5	0.1	naphthalene
(11) Exempt mineral spirits	8032-32-4	0	none
(12) Ligroines (VM & P)	8032-32-4	0	none
(13) Lactol spirits	64742-89-6	0.15	toluene
(14) Low aromatic white spirit	64742-82-1	0	none
(15) Mineral spirits	64742-88-7	0.01	xylenes
(16) Hydrotreated naphta	64742-48-9	0	none
(17) Hydrotreated light distillate	64742-82-1	0	none
(18) Stoddard solvent	8052-41-3	0.01	xylenes
(19) Super high-flash naphta	64742-95-6	0.05	xylenes
(20) Varsol[] solvent	8052-49-3	0.01	0.5% xylenes, 0.5% ethylbenzene
(21) VM & P naphtha	64742-89-8	0.06	3% toluene, 3% xylene
(22) Petroleum distillate mixture	68477-31-6	0.08	4% naphthalene, 4% biphenyl

Table 3

Default Organic HAP Mass Fraction for Petroleum Solvent Groups ^a

You may use the mass fraction values in the following table for solvent blends for which you do not have test data or manufacturer's formulation data.

Solvent Type	Average Organic HAP Mass Fraction	Typical Organic HAP, percent by mass
Aliphatic ^b	0.03	1% Xylene, 1% Toluene, and 1% Ethylbenzene.
Aromatic ^c	0.06	4% Xylene, 1% Toluene and 1% Ethylbenzene.

Wis. Admin. Code Department of Natural Resources NR 465.48

CR 05-040: cr. Register February 2006 No. 602, eff. 3-1-06.