Chapter NR 440

Pp is the rate of polymer production, kg/hr (lb/hr)

K5 is 1,000 kg/Mg for metric units and 2,000 lb/ton for English units

NR 440.647(6)(h)2. 2. The mass rate of TOC, ETOC, shall be determined according to the procedures, as appropriate, in par. (c) 2. The sampling site for determining compliance with sub. (1) (d) and (e) shall be before any add-on control devices and after all product recovery devices. Otherwise, the sampling site shall be at the outlet of the control device.

NR 440.647(6)(h)3. 3. The rate of polymer production, Pp, shall be determined by dividing the weight of polymer pulled (in kg (lb)) from the process line during the performance test by the number of hours taken to perform the performance test. The weight of polymer pulled shall be determined by direct measurement or, subject to prior approval by the department, computed from materials balance by good engineering practice.

NR 440.647(6)(i) (i) The owner or operator shall determine continuous compliance with the temperature requirements in sub. (3) (b) 1. b. and 1. a. 2) by using the temperature monitoring equipment described in sub. (5) (a) 1. An average temperature shall be determined from measurements taken at least every 15 minutes every 3 hours while the vent stream is normally routed and constituted. Each 3-hour period constitutes a performance test.

NR 440.647(6)(j) (j) For purposes of determining compliance with sub. (3) (c) 1. b. 2), 3), 2. b. 2) or 3), the ethylene glycol concentration in either the cooling tower or the liquid effluent from steam-jet ejectors used to produce a vacuum in the polymerization reactors, whichever is applicable, shall be determined:

NR 440.647(6)(j)1. 1. Using procedures that conform to the methods described in ASTM D2908-91, Standard Practice for Measuring Volatile Organic Matter in Water by Aqueous-Injection Gas Chromatography, incorporated by reference in s. NR 440.17 (2) (a) 37., except as provided in subd. 2.:

NR 440.647(6)(j)1.a. a. At least one sample per operating day shall be collected using the grab sampling procedures of ASTM D3370-95a, Standard Practices for Sampling Water, incorporated by reference in s. NR 440.17 (2) (a) 47. An average ethylene glycol concentration by weight shall be calculated on a daily basis over a rolling 14-day period of operating days, except as provided in subd. 1. b. and c. Each daily average ethylene glycol concentration so calculated constitutes a performance test. Exceedance of the standard during the reduced testing program specified in subd. 1. b. and c. is a violation of these standards.

NR 440.647(6)(j)1.b. b. For those determining compliance with sub. (3) (c) 1. b. 2) or 2. b. 2), the owner or operator may elect to reduce the sampling program to any 14 consecutive day period once every 2 calendar months, if at least 17 consecutive 14-day rolling average concentrations immediately preceding the reduced sampling program are each less than 0.10 weight percent ethylene glycol. If the average concentration obtained over the 14 day sampling during the reduced testing period exceeds the upper 95% confidence interval calculated from the most recent test results in which no one 14-day average exceeded 0.10 weight percent ethylene glycol, then the owner or operator shall reinstitute a daily sampling program. A reduced sampling program can be reinstituted if the requirements specified in this paragraph are met.

NR 440.647(6)(j)1.c. c. For those determining compliance with sub. (3) (c) 1. b. 3) or 2. b. 3) the owner or operator may elect to reduce the sampling program to any 14 consecutive day period once every 2 calendar months, if at least 17 consecutive 14-day rolling average concentrations immediately preceding the reduced sampling program are each less than 1.8 weight percent ethylene glycol. If the average concentration obtained over the 14 day sampling during the reduced test period exceeds the upper 95% confidence interval calculated from the most recent test results in which no one 14-day average exceeded 1.8 weight percent ethylene glycol, then the owner or operator shall reinstitute a daily sampling program. A reduced program can be reinstituted if the requirements specified in this paragraph are met.

NR 440.647(6)(j)1.d. d. The upper 95% confidence interval shall be calculated using the following equation:

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Xi is the daily ethylene glycol concentration for each day used to calculate the 14-day rolling average used in test results to justify implementing the reduced testing program

n is the number of ethylene glycol concentrations

NR 440.647(6)(j)2. 2. Measuring an alternative parameter, such as carbon oxygen demand or biological oxygen demand, that is demonstrated to be directly proportional to the ethylene glycol concentration. The parameter shall be measured during the initial 14-day performance test during which the facility is shown to be in compliance with the ethylene glycol concentration standard whereby the ethylene glycol concentration is determined using the procedures described in subd. 1. The alternative parameter shall be measured on a daily basis and the average value of the alternative parameter shall be calculated on a daily basis over a rolling 14-day period of operating days. Each daily average value of the alternative parameter constitutes a performance test.

NR 440.647(7) (7) Reporting and recordkeeping requirements.

NR 440.647(7)(a) (a) Each owner or operator subject to the provisions of this section shall keep an up-to-date, readily-accessible record of the following information measured during each performance test and shall include the following information in the report of the initial performance test in addition to the written results of such performance tests as required under s. NR 440.08. Where a control device is used to comply with sub. (3) (a) 1. a. 4) only, a report containing performance test data need not be submitted, but a report containing the information in subd. 11. is required. Where a boiler or process heater with a design heat input capacity of 150 million Btu/hr or greater is used to comply with sub. (3) (a) a report containing performance test data need not be submitted, but a report containing the information in subd. 2. a. is required. The same information specified in this subsection shall be submitted in the reports of all subsequently required performance tests where either the emission control efficiency of a combustion device or the outlet concentration of TOC, minus methane and ethane, is determined.

NR 440.647(7)(a)1. 1. When an incinerator is used to demonstrate compliance with sub. (3) except sub. (3) (a) 2.:

NR 440.647(7)(a)1.a. a. The average firebox temperature of the incinerator (or the average temperature upstream and downstream of the catalyst bed), measured at least every 15 minutes and averaged over the performance test period, and

NR 440.647(7)(a)1.b. b. The percent reduction of TOC (minus methane and ethane) achieved by the incinerator, the concentration of TOC (minus methane and ethane) (ppmv, by compound) at the outlet of the control device on a dry basis or the emission rate in terms of kg TOC (minus methane and ethane) per Mg of product (lb TOC/ton) at the outlet of the control device, whichever is appropriate. If supplemental combustion air is used, the TOC concentration corrected to 3% oxygen shall be recorded and reported.

NR 440.647(7)(a)2. 2. When a boiler or process heater is used to demonstrate compliance with sub. (3) except sub. (3) (a) 2.:

NR 440.647(7)(a)2.a. a. A description of the location at which the vent stream is introduced into the boiler or process heater, and

NR 440.647(7)(a)2.b. b. For boilers or process heaters with a design heat input capacity of less than 150 million Btu/hr, all 3-hour periods of operation during which the average combustion temperature was more than 28°C (50°F) below the average combustion temperature during the most recent performance test at which compliance was determined.

NR 440.647(7)(a)3. 3. When a flare is used to demonstrate compliance with sub. (3) except sub. (3) (a) 2.:

NR 440.647(7)(a)3.a. a. All visible emission readings, heat content determinations, flow rate measurements and exit velocity determinations made during the performance test,

NR 440.647(7)(a)3.b. b. Continuous records of the pilot flame heat-sensing monitoring, and

NR 440.647(7)(a)3.c. c. Records of all periods of operations during which the pilot flame is absent.

NR 440.647(7)(a)4. 4. When an incinerator, boiler or process heater is used to demonstrate compliance with sub. (3) (a) 2., a description of the location at which the vent stream is introduced into the incinerator, boiler or process heater.

NR 440.647(7)(a)5. 5. When a flare is used to demonstrate compliance with sub. (3) (a) 2.:

NR 440.647(7)(a)5.a. a. All visible emission readings made during the performance test,

NR 440.647(7)(a)5.b. b. Continuous records of the pilot flame heat-sensing monitoring, and

NR 440.647(7)(a)5.c. c. Records of all periods of operation during which the pilot flame is absent.

NR 440.647(7)(a)6. 6. When an absorber is the final unit in a system to demonstrate compliance with sub. (3) except sub. (3) (a) 2., the specific gravity, or alternative parameter that is a measure of the degree of absorbing liquid saturation, if approved by the department, and average temperature, measured at least every 15 minutes and averaged over the performance test period, of the absorbing liquid, both measured while the vent stream is normally routed and constituted.

NR 440.647(7)(a)7. 7. When a condenser is the final unit in a system to demonstrate compliance with sub. (3) except sub. (3) (a) 2. the average exit (product side) temperature, measured at least every 15 minutes and averaged over the performance test period while the vent stream is normally routed and constituted.

NR 440.647(7)(a)8. 8. Daily measurement and daily average 14-day rolling average of the ethylene glycol concentration in the liquid effluent exiting the vacuum system servicing the polymerization reaction section, if an owner or operator is subject to sub. (3) (c) 1. b. 2) or 2. b. 2) or of the ethylene glycol concentration in the cooling water in the cooling tower, if subject to sub. (3) (c) 2. b. 3) or c. 3).

NR 440.647(7)(a)9. 9. When a carbon adsorber is the final unit in a system to demonstrate compliance with sub. (3) except sub. (3) (a) 2., the concentration level or reading indicated by the organics monitoring device at the outlet of the adsorber, measured at least every 15 minutes and averaged over the performance test period while the vent stream is normally routed and constituted.

NR 440.647(7)(a)10. 10. When an owner or operator seeks to comply with the requirements of this section by complying with the uncontrolled threshold emission rate cutoff provision in sub. (1) (d) and (e) or with the individual stream exemptions in sub. (1) (g), each process operation variable, for example, pressure, temperature, type of catalyst, that may result in an increase in the uncontrolled emission rate, if sub. (1) (d) or (e) is applicable or in an increase in the uncontrolled annual emissions or the VOC weight percent, as appropriate, if sub. (1) (g) is applicable, should such operating variable be changed.

NR 440.647(7)(a)11. 11. When an owner or operator uses a control device to comply with sub. (3) (a) 1. a. 4) alone: all periods when the control device is not operating.

NR 440.647(7)(b) (b)

NR 440.647(7)(b)1. 1. Each owner or operator subject to the provisions of this section shall submit with the initial performance test or, if complying with sub. (3) (a) 1. a. 4) as a separate report, an engineering report describing in detail the vent system used to vent each affected vent stream to a control device. This report shall include all valves and vent pipes that could vent the stream to the atmosphere, thereby bypassing the control device and identify which valves are car-sealed opened and which valves are car-sealed closed.

NR 440.647(7)(b)2. 2. If a vent system containing valves that could divert the emission stream away from the control device is used, each owner or operator subject to the provisions of this section shall keep for at least 2 years up-to-date, readily accessible continuous records of:

NR 440.647(7)(b)2.a. a. All periods when flow is indicated if flow indicators are installed under sub. (5) (d) 1.

NR 440.647(7)(b)2.b. b. All times when maintenance is performed on car-sealed valves, when the car seal is broken and when the valve position is changed, that is, from open to closed for valves in the vent piping to the control device and from closed to open for valves that vent the stream directly or indirectly to the atmosphere bypassing the control device.

NR 440.647(7)(c) (c) Where an incinerator is used to comply with sub. (3), except sub. (3) (a) 1. a. 4) and 2., each owner or operator subject to the provisions of this section shall keep for at least 2 years up-to-date, readily accessible continuous records of:

NR 440.647(7)(c)1. 1. The temperature measurements specified under sub. (5) (b) 1.

NR 440.647(7)(c)2. 2. Records of periods of operation during which the parameter boundaries established during the most recent performance test are exceeded. Periods of operation during which the parameter boundaries established during the most recent performance test are exceeded are defined as follows:

NR 440.647(7)(c)2.a. a. For noncatalytic incinerators, all 3-hour periods of operation during which the average combustion temperature was more than 28°C (50°F) below the average combustion temperature during the most recent performance test at which compliance was demonstrated.

NR 440.647(7)(c)2.b. b. For catalytic incinerators, all 3-hour periods of operation during which the average temperature of the vent stream immediately before the catalyst bed is more than 28°C (50°F) below the average temperature of the vent stream during the most recent performance test at which compliance was demonstrated. The owner or operator also shall record all 3-hour periods of operation during which the average temperature difference across the catalyst bed is less than 80% of the average temperature difference across the catalyst bed during the most recent performance test at which compliance was demonstrated.

NR 440.647(7)(d) (d) Where a boiler or process heater is used to comply with sub. (3) except sub. (3) (a) 1. a. 4) and (a) 2., each owner or operator subject to the provisions of this section shall keep for at least 2 years up-to-date, readily accessible continuous records of:

NR 440.647(7)(d)1. 1. Where a boiler or process heater with a heat input design capacity of 150 million Btu/hr or greater is used, all periods of operation of the boiler or process heater,

NR 440.647 Note Note: Examples of such records could include records of steam use, fuel use or monitoring data collected pursuant to other state or federal regulatory requirements.

NR 440.647(7)(d)2. 2. Where a boiler or process heater with a heat input design capacity of less than 150 million Btu/hr is used, all periods of operation during which the parameter boundaries established during the most recent performance test are exceeded. Periods of operation during which the parameter boundaries established during the most recent performance test are exceeded are defined as all 3-hour periods of operation during which the average combustion temperature was more than 28°C (50°F) below the average combustion temperature during the most recent performance test at which compliance was demonstrated.

NR 440.647(7)(e) (e) Where a flare is used to comply with sub. (3) except sub. (3) (a) 1. a. 4), each owner or operator subject to the provisions of this section shall keep for at least 2 years up-to-date, readily accessible continuous records of:

NR 440.647(7)(e)1. 1. The flare or pilot light flame heat sensing monitoring specified under sub. (5) (b) 2., and

NR 440.647(7)(e)2. 2. All periods of operation in which the flare or pilot flame, as appropriate, is absent.

NR 440.647(7)(f) (f) Where an adsorber, condenser, absorber or a control device other than a flare, incinerator, boiler or process heater is used to comply with sub. (3) except sub. (3) (a) 1. a. 4), each owner or operator subject to the provisions of this section shall keep for at least 2 years up-to-date, readily-accessible continuous records of the periods of operation during which the parameter boundaries established during the most recent performance test are exceeded. Where an owner or operator seeks to comply with sub. (3), periods of operation during which the parameter boundaries established during the most recent performance tests are exceeded are defined as follows:

NR 440.647(7)(f)1. 1. Where an absorber is the final unit in a system, both of the following:

NR 440.647(7)(f)1.a. a. All 3-hour periods of operation during which the average absorbing liquid temperature was more than 11°C (20°F) above the average absorbing liquid temperature during the most recent performance test at which compliance was demonstrated.

NR 440.647(7)(f)1.b. b. All 3-hour periods of operation during which the average absorbing liquid specific gravity was more than 0.1 unit above or more than 0.1 unit below, the average absorbing liquid specific gravity during the most recent performance test at which compliance was demonstrated, unless monitoring of an alternative parameter that is a measure of the degree of absorbing liquid saturation is approved by the department, in which case appropriate parameter boundaries and periods of operation during which they are exceeded will be defined.

NR 440.647(7)(f)2. 2. Where a condenser is the final unit in a system, all 3-hour periods of operation during which the average condenser operating temperature was more than 6°C (10°F) above the average operating temperature during the most recent performance test at which compliance was demonstrated.

NR 440.647(7)(f)3. 3. Where a carbon adsorber is the final unit in a system, all 3-hour periods of operation during which the average organic concentration level in the carbon adsorber gases is more than 20% greater than the exhaust gas concentration level or reading measured by the organics monitoring system during the most recent performance test at which compliance was demonstrated.

NR 440.647(7)(g) (g) Each owner or operator of an affected facility subject to the provisions of this section and seeking to demonstrate compliance with sub. (1) (j) or (3) shall keep up-to-date, readily accessible records of both of the following:

NR 440.647(7)(g)1. 1. Any changes in production capacity, feedstock type or catalyst type or of any replacement, removal or addition of product recovery equipment.

NR 440.647(7)(g)2. 2. The results of any performance test performed pursuant to the procedures specified by sub. (6).

NR 440.647(7)(h) (h) Each owner or operator of an affected facility that seeks to comply with the requirements of this section by complying with the uncontrolled threshold emission rate cutoff provision in sub. (1) (d) and (e) or with the individual stream exemptions in sub. (1) (g) shall keep for at least 2 years up-to-date, readily accessible records of any change in process operation that increases the uncontrolled emission rate of the process line in which the affected facility is located, if sub. (1) (d) or (e) is applicable or that increase the uncontrolled annual emissions or the VOC weight percent of the individual stream, if sub. (1) (g) is applicable.

NR 440.647(7)(i) (i) Each owner and operator subject to the provisions of this section is exempt from s. NR 440.07 (3).

NR 440.647(7)(j) (j) The department will specify appropriate reporting and recordkeeping requirements where the owner or operator of an affected facility complies with the standards specified under sub. (3) other than as provided under par. (a) to (e).

NR 440.647(7)(k) (k) Each owner or operator that seeks to comply with the requirements of this section by complying with the uncontrolled threshold emission rate cutoff provision of sub. (1) (d) and (e), the individual stream exemptions of sub. (1) (g) or the requirements of sub. (3) shall submit to the department semiannual reports of the following recorded information, as applicable. The initial report shall be submitted within 6 months after the initial startup date.

NR 440.647(7)(k)1. 1. Exceedances of monitored parameters recorded under pars. (c), (d) 2. and (f).

NR 440.647(7)(k)2. 2. All periods recorded under par. (b) when the vent stream has been diverted from the control device.

NR 440.647(7)(k)3. 3. All periods recorded under par. (d) when the boiler or process heater was not operating.

NR 440.647(7)(k)4. 4. All periods recorded under par. (e) in which the flare or pilot flame was absent.

NR 440.647(7)(k)5. 5. All periods recorded under par. (a) 8. when the 14-day rolling average exceeded the standard specified in sub. (3) (c) 1. b. 2), 3), 2. b. 2) or 3) as applicable.

NR 440.647(7)(k)6. 6. Any change in process operations that increases the uncontrolled emission rate of the process line in which the affected facility is located, as recorded in par. (h).

NR 440.647(7)(k)7. 7. Any change in process operations that increases the uncontrolled annual emissions or the VOC weight percent of the individual stream, as recorded in par. (h).

NR 440.647(7)(L) (L) Each owner or operator subject to the provisions of this section shall notify the department of the specific provisions of sub. (1) (d) or (e), (3) or (4), as applicable, with which the owner or operator has elected to comply. Notification shall be submitted with the notification of initial startup required by sub. (1) (c). If an owner or operator elects at a later date to use an alternative provision of sub. (3) or (4) with which he or she will comply or becomes subject to sub. (3) or (4) for the first time, that is, the owner or operator can no longer meet the requirements of this section by complying with the uncontrolled threshold emission rate cutoff provision in sub. (1) (d) or (e), then the owner or operator shall notify the department 90 days before implementing a change and, upon implementing a change, a performance test shall be performed as specified in sub. (6).

NR 440.647 History History: Cr. Register, July, 1993, No. 451, eff. 8-1-93; am. (4) (c), Register, December, 1995, No. 480, eff. 1-1-96; CR 06-109: am. (1) (a) 4. a., (b) 1. b. and (d), (2) (a) 12., 21., 22., 30. and 31., (3) (a) 1. c. (intro.), (b) 1. a. and b., (c) 1. a. 1) to 3), 2. a. and b. 1) to 3), (4) (d), (6) (c) 1., (f) 1. and 3., (j) 1. (intro.), a. and 2., (7) (a) 1. b., (f) 1. (intro.) and a. and (g) (intro.) and 1., cr. (1) (j) and (6) (h) 1., r. and recr. (6) (d) 1. (intro.), (f) (intro.), (g) 2. and 3., (h) (intro.), (j) 1. d., renum. (6) (h) 1. and 2. to be 2. and 3. and am. 3. Register May 2008 No. 629, eff. 6-1-08; correction in (1) (j) 2. made under s. 13.92 (4) (b) 7., Stats., Register May 2008 No 629.

NR 440.65 NR 440.65 Flexible vinyl and urethane coating and printing.

NR 440.65(1) (1) Applicability and designation of affected facility.

NR 440.65(1)(a) (a) The affected facility to which the provisions of this section apply is each rotogravure printing line used to print or coat flexible vinyl or urethane products.

NR 440.65(1)(b) (b) This section applies to any affected facility which begins construction, modification, or reconstruction after January 18, 1983.

NR 440.65(1)(c) (c) For facilities controlled by a solvent recovery emission control device, the provisions of sub. (5) (a) requiring monitoring of operations will not apply until performance specifications are promulgated under 40 CFR part 60, Appendix B, incorporated by reference in s. NR 440.17, for the continuous monitoring system. After the promulgation of performance specifications these provisions will apply to each affected facility under par. (b). Facilities controlled by a solvent recovery emission control device that become subject to the standard prior to promulgation of performance specifications must conduct performance tests in accordance with s. NR 440.13 (2) after performance specifications are promulgated.

NR 440.65(2) (2) Definitions and symbols.

NR 440.65(2)(a) (a) As used in this section, terms not defined in this paragraph have the meanings given in s. NR 440.02.

NR 440.65(2)(a)1. 1. “Emission control device” means any solvent recovery or solvent destruction device used to control volatile organic compounds (VOC) emissions from flexible vinyl and urethane rotogravure printing lines.

NR 440.65(2)(a)2. 2. “Emission control system” means the combination of an emission control device and a vapor capture system for the purpose of reducing VOC emissions from flexible vinyl and urethane rotogravure printing lines.

NR 440.65(2)(a)3. 3. “Flexible vinyl and urethane products” means those products, except for resilient floor coverings (1977 Standard Industry Code 3996) and flexible packaging, that are more than 50 micrometers (0.002 inches) thick and that consist of or contain a vinyl or urethane sheet or a vinyl or urethane coated web.

NR 440.65(2)(a)4. 4. “Gravure cylinder” means a plated cylinder with a printing image consisting of minute cells or indentations specifically engraved or etched into the cylinder’s surface to hold ink when continuously resolved through a fountain of ink.