NR 439.096(1)
(1)
General. All combustion optimizations conducted shall be performed according to methods approved in writing by the department. The owner or operator responsible for combustion optimizations shall follow the procedures in this section.
NR 439.096(2)
(2)
Combustion optimization notification and plan submittal. The department shall be notified in writing at least 45 days in advance of a combustion optimization to provide the department an opportunity to evaluate the plan and to have a representative present to witness the combustion optimization procedures. The notice shall provide a combustion optimization plan which includes, but need not be limited to, the following information:
NR 439.096(2)(a)
(a) The results of an engineering study of the process to be optimized. The engineering report shall identify and evaluate the options available for modifications to the process that would optimize combustion while minimizing NO
x emissions.
NR 439.096(2)(b)
(b) A description of the process or operation variables which affect the air contaminant source's emissions.
NR 439.096(2)(d)
(d) A description of the sampling equipment and the combustion optimization methods and procedures to be used.
NR 439.096(2)(f)
(f) A description of the number and location of any sampling ports and sampling points and an identification of the combustion gases to be sampled.
NR 439.096(2)(g)
(g) A statement indicating the production rate and the operating conditions at which the combustion optimization will be conducted.
NR 439.096(3)
(3)
Combustion optimization plan evaluation. In evaluating the combustion optimization plan, the department shall respond to the source owner or operator within 15 business days of receipt of the plan and may require one or more of the following activities:
NR 439.096(3)(a)
(a) A pre-combustion optimization conference which includes the owner or operator of the source, the person conducting the combustion optimization and the department to discuss any deficiencies in the plan or settle any combustion optimization procedure questions the department, the person conducting the combustion optimization or the source owner or operator might have.
NR 439.096(3)(b)
(b) Any change to the sampling method that is deemed necessary by the department to conduct a proper combustion optimization.
NR 439.096(3)(c)
(c) A rescheduling of the combustion optimization to accommodate witnessing or source production schedules.
NR 439.096(4)
(4)
Notification of combustion optimization plan revision. The source owner or operator shall notify the department of any modifications to a combustion optimization plan at least 5 business days prior to the combustion optimization. In the event the owner or operator is unable to conduct the combustion optimization on the date specified in the plan, due to unforeseeable circumstances beyond the owner or operator's control, the owner or operator shall notify the department at least 5 business days prior to the scheduled combustion optimization date and specify the date when the combustion optimization is to be rescheduled.
NR 439.096(5)
(5)
Proper facilities for combustion optimization. The department may require the owner or operator of a source to provide proper facilities for conducting combustion optimization tests which may include the testing facilities listed in s.
NR 439.07 (5) (a) to
(e).
NR 439.096(6)
(6)
Witnessing requirements. The department may require that a department representative be present at any combustion optimization. The department may require the following activities:
NR 439.096(6)(a)
(a) The department may require the person conducting the combustion optimization to provide the department a copy of all test data and equipment calibration data prepared or collected for the combustion optimization.
NR 439.096(6)(b)
(b) The department may require the source owner or operator and person conducting the combustion optimization to correct any deficiency in the performance of the combustion optimization provided that the department notifies the source owner or operator and person conducting the combustion optimization of the deficiency as soon as it is discovered. The failure of a source owner or operator and person conducting the combustion optimization to correct any deficiency may result in the department refusing to accept the results of the combustion optimization.
NR 439.096(7)
(7)
Combustion optimization equipment calibration requirements. The components of any emission sampling train or associated sampling equipment listed in this subsection shall be calibrated not more than 60 days before the test. This includes the following:
NR 439.096(7)(g)
(g) Any other sampling equipment that requires periodic calibration.
NR 439.096(8)
(8)
Procedures for conducting combustion optimizations. Any emissions testing conducted in conjunction with combustion optimization shall be conducted in accordance with s.
NR 439.07. The combustion optimization shall include the following procedures:
NR 439.096(8)(a)
(a) An engineering study to identify the optimized combustion profile or equipment modifications needed to optimize combustion. The study shall address, but is not limited to, the modification of the following systems: fuel delivery, burner, primary and secondary combustion monitoring, combustion air delivery and burner management.
NR 439.096(8)(b)
(b) The combustion optimization shall be based on burner tune-up procedures which result in maximum combustion efficiency and a low NO
x operating curve. This curve shall determine the operating range of combustion variables such as CO and O
2 at set points within the following ranges: 20-30% load, 45-55% load, 70-80% load and 95-100% load, for those set points that represent at least 10% of boiler operating hours in a typical year.
NR 439.096(8)(c)
(c) A continuous combustion analyzer shall be used to monitor the operation of the combustion unit in accordance with the combustion efficiency and low NO
x operating curve required under this section. The analyzer shall monitor the combustion parameters CO and O
2 or monitor NO
x directly. The fuel flow rate shall be monitored.
NR 439.096(9)
(9)
Combustion optimization reporting requirements. The owner or operator of a source that conducts a combustion optimization shall submit a copy of the report of the combustion optimization to the department within 60 days after its completion. If requested, the department may grant an extension of up to 30 days for combustion optimization report submittal. The failure to include the following information in a combustion optimization report may result in rejection of the combustion optimization. The combustion optimization report shall include, but need not be limited to, the following information:
NR 439.096(9)(a)
(a) A detailed description of the process optimized and the procedures employed.
NR 439.096(9)(b)
(b) A log of the operating conditions of the process optimized and of any associated air pollution control device.
NR 439.096(9)(c)
(c) A summary of results, expressed in terms of the concentrations of NO
x, O
2 and CO, prior to and following the combustion optimization.
NR 439.096(9)(d)
(d) Sample calculations employing all the formulas used to calculate the results.
NR 439.096(9)(f)
(f) The engineering study and combustion efficiency and low NO
x operating curve required under sub.
(8) (a) and
(b).
NR 439.096(9)(g)
(g) The report of any visible emission evaluations performed during the combustion optimization.
NR 439.096(9)(h)
(h) A copy of any steam, opacity or airflow charts made during the optimization.
NR 439.096(9)(i)
(i) The report of any fuel analysis performed on the fuel burned during the optimization.
NR 439.096(9)(j)
(j) Documentation of any process upset occurring during the optimization.
NR 439.096(9)(k)
(k) If the combustion optimization being conducted is one required under sub.
(10), the changes made to the process or control device since the last test.
NR 439.096(10)(a)
(a) The department may require an NO
x emissions source to conduct an additional combustion optimization if the department determines that a source has not satisfied the requirements of sub.
(8) or
(9).
NR 439.096(10)(b)
(b) Combustion units that are modified sources with respect to NO
x due to a change in the method of operation shall perform a new combustion optimization including the determination of a new combustion efficiency and low NO
x operating curve.
NR 439.096 History
History: Cr.
Register, January, 2001, No. 541, eff. 2-1-01.
NR 439.098
NR 439.098 Methods and procedures for parametric testing of NOx emissions pursuant to an acid rain program alternative NOx emission limitation. NR 439.098(1)(a)
(a) An ultimate analysis of coal conducted according to ASTM D 3176-89, incorporated by reference in s.
NR 484.10 (44).
NR 439.098(1)(b)
(b) A proximate analysis of coal conducted according to ASTM D 3172-89, incorporated by reference in s.
NR 484.10 (41m).
NR 439.098(1)(c)
(c) A measurement of the coal mass flow rate to each individual burner using ASME Performance Test Code 4.2-1969 (1997) or ISO 9931 (1991), incorporated by reference in s.
NR 484.11 (6) and
(8).
NR 439.098(2)
(2) The owner or operator of an affected unit subject to the requirements of s.
NR 409.065 may measure and record the actual NO
x emission rate in accordance with the requirements of s.
NR 409.065 while varying the following parameters where possible to determine their effects on the emissions of NO
x from the affected boiler:
NR 439.098(2)(b)
(b) Settings of burners or coal and air nozzles, including tilt and yaw, or swirl.
NR 439.098(2)(c)
(c) For tangentially fired boilers, distribution of combustion air within the NO
x emission control system.
NR 439.098(2)(e)
(e) Coal-to-primary air ratio (based on pound per hour) for each burner, the average coal-to-primary air ratio for all burners, and the deviations of individual burners' coal-to-primary air ratios from the average value.
NR 439.098(2)(f)
(f) If the boiler uses varying types of coal, the type of coal; in this case the owner or operator shall provide the results of proximate and ultimate analyses of each type of as-fired coal.
NR 439.098(3)
(3) In performing the tests specified in sub.
(1), the owner or operator shall begin the tests using the equipment settings for which the NO
x emission control system was designed to meet the NO
x emission rate guaranteed by the primary NO
x emission control system vendor. These results constitute the baseline controlled condition.
NR 439.098(4)
(4) After establishing the baseline controlled condition under sub.
(3), the owner or operator may do any of the following:
NR 439.098(4)(a)
(a) Change excess air levels
$5% from the baseline controlled condition to determine the effects on emissions of NO
x, by providing a minimum of 3 readings.
NR 439.098 Note
Note: For example, with a baseline reading of 20% excess air, excess air levels will be changed to 19% and 21%.
NR 439.098(4)(b)
(b) For tangentially fired boilers, change the distribution of combustion air within the NO
x emission control system to determine the effects on NO
x emissions by providing a minimum of 3 readings, one with the minimum, one with the baseline, and one with the maximum amounts of staged combustion air.
NR 439.098(4)(c)
(c) Show that the combustion process within the boiler is optimized.
NR 439.098 Note
Note: For example, boiler optimization can mean that the burners are balanced.
NR 439.098 History
History: Cr.
Register, November, 1999, No. 527, eff. 12-1-99; correction in (1) (c) made under s. 13.93 (2m) (b) 7., Stats.,
Register August 2001 No. 548.
NR 439.10
NR 439.10 Circumvention. No person may cause, allow or permit the installation or use of any article, machine, equipment, process or method which conceals an emission which would otherwise constitute a violation of an applicable rule. Concealment includes, but is not limited to, the use of gaseous diluents to achieve compliance and the unnecessary separation of an operation into parts to avoid coverage by a rule that applies only to operations larger than a specified size.
NR 439.10 History
History: Renum. from NR 154.06 (8),
Register, September, 1986, No. 369, eff.10-1-86; renum. from NR 439.08 and am.
Register, September, 1987, No. 381, eff. 10-1-87;
CR 02-146: am.
Register October 2003 No. 574, eff. 11-1-03.
NR 439.11
NR 439.11 Malfunction prevention and abatement plans. NR 439.11(1)(1)
The owner or operator of any direct or portable source which may emit hazardous substances or emits more than 15 pounds in any day or 3 pounds in any hour of any air contaminant for which emission limits have been adopted shall prepare a malfunction prevention and abatement plan to prevent, detect and correct malfunctions or equipment failures which may cause any applicable emission limitation to be violated or which may cause air pollution. The plan shall be in writing and updated at least every 5 years, and shall include:
NR 439.11(1)(a)
(a) Identification of the individual responsible for inspecting, maintaining and repairing the air pollution control equipment.
NR 439.11(1)(b)
(b) The maximum intervals for inspection and routine maintenance of the air pollution control equipment. The maximum interval for routine inspection and maintenance may not exceed that recommended by the manufacturer unless otherwise specified in a plan prepared under this section.
NR 439.11(1)(c)
(c) A description of the items or conditions that will be checked.
NR 439.11(1)(d)
(d) A listing of materials and spare parts that will be maintained in inventory.
NR 439.11(1)(e)
(e) A description of the corrective procedures that will be taken in the event of a malfunction or failure which results in the exceedance of the applicable emission limitation. These corrective procedures shall achieve and maintain compliance with the applicable emission limitations as expeditiously as possible but not longer than the time necessary to discontinue operation of the source consistent with safe operating procedures.
NR 439.11(1)(f)
(f) A description of the activities and maximum intervals for routine maintenance and inspection of instrumentation installed and operated to monitor the operation of air pollution control equipment as required under s.
NR 439.055 (1). The maximum interval for inspection and routine maintenance may not exceed that recommended by the manufacturer of the instrumentation unless otherwise specified in a plan prepared under this section.
NR 439.11(1)(g)
(g) The calibration schedule for any device which monitors either a source or air pollution control equipment operational variables. The time between calibrations may not exceed one year or as specified in a plan prepared under this section, whichever is shorter.
NR 439.11(1)(h)
(h) Such other information as the department may deem pertinent.
NR 439.11(2)
(2) The department may order any owner or operator to submit the plan required by sub.
(1) for review and approval. The department may amend the plan if deemed necessary for malfunction prevention or the reduction of excess emissions during malfunctions.
NR 439.11(3)
(3) No owner or operator may fail to carry out a plan required under sub.
(1) or as amended under sub.
(2).
NR 439.11(4)
(4) All air pollution control equipment shall be operated and maintained in conformance with good engineering practices to minimize the possibility for the exceedance of any emission limitations.
NR 439.11 History
History: Renum. from NR 154.06 (9) and am.
Register, September, 1986, No. 369, eff. 10-1-86; renum. from NR 439.09 and am.
Register, September, 1987, No. 381, eff. 10-1-87; am. (1) (g),
Register, May, 1992, No. 437, eff. 6-1-92; am. (1) (intro.) and (b), r. and recr. (1) (e) to (g),
Register, December, 1993, No. 456, eff. 1-1-94.
