Chapter NR 440

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.

NR 440.65(2)(a)5. 5. “Ink” means any mixture of ink, coating solids, organic solvents including dilution solvent and water that is applied to the web of flexible vinyl or urethane on a rotogravure printing line.

NR 440.65(2)(a)6. 6. “Ink solids” means the solids content of an ink as determined from Method 24, ink manufacturer’s formulation data, or plant blending records.

NR 440.65(2)(a)7. 7. “Inventory system” means a method of physically accounting for the quantity of ink, solvent and solids used at one or more affected facilities during a time period. The system is based on plant purchase or inventory records.

NR 440.65(2)(a)8. 8. “Plant blending records” means those records which document the weight fraction of organic solvents and solids used in the formulation or preparation of inks at the vinyl or urethane printing plant where they are used.

NR 440.65(2)(a)9. 9. “Rotogravure print station” means any device designed to print or coat inks on one side of a continuous web or substrate using the intaglio printing process with a gravure cylinder.

NR 440.65(2)(a)10. 10. “Rotogravure printing line” means any number of rotogravure print stations and associated dryers capable of printing or coating simultaneously on the same continuous vinyl or urethane web or substrate which is fed from a continuous roll.

NR 440.65(2)(a)11. 11. “Vapor capture system” means any device or combination of devices designed to contain, collect and route organic solvent vapors emitted from the flexible vinyl or urethane rotogravure printing line.

NR 440.65(2)(b) (b) As used in this section, symbols not defined in this paragraph have the meanings given in s. NR 440.03.

NR 440.65(2)(b)1. 1. “a” means the gas stream vents exiting the emission control device.

NR 440.65(2)(b)2. 2. “b” means the gas stream vents entering the emission control device.

NR 440.65(2)(b)3. 3. “f” means the gas stream vents which are not directed to an emission control device.

NR 440.65(2)(b)4. 4. “Caj” means the concentration of VOC in each gas stream (j) for the time period exiting the emission control device, in parts per million by volume.

NR 440.65(2)(b)5. 5. “Cbi” means the concentration of VOC in each gas stream (i) for the time period entering the emission control device, in parts per million by volume.

NR 440.65(2)(b)6. 6. “Cfk” means the concentration of VOC in each gas stream (k) for the time period which is not directed to an emission control device, in parts per million by volume.

NR 440.65(2)(b)7. 7. “G” means the weighted average mass of VOC per mass of ink solids applied, in kilograms per kilogram.

NR 440.65(2)(b)8. 8. “Mci” means the total mass of each dilution solvent (j) added at the print line in the time period determined from plant records, in kilograms.

NR 440.65(2)(b)10. 10. “Qaj” means the volumetric flow rate of each effluent gas stream (j) exiting the emission control device, in standard cubic meters per hour.

NR 440.65(2)(b)11. 11. “Qbi” means the volumetric flow rate of each effluent gas stream (i) entering the emission control device, in standard cubic meters per hour.

NR 440.65(2)(b)12. 12. “Qfk” means the volumetric flow rate of each effluent gas stream (k) not directed to an emission control device, in standard cubic meters per hour.

NR 440.65(2)(b)13. 13. “E” means the VOC emission reduction efficiency (as a fraction) of the emission control device during performance testing.

NR 440.65(2)(b)14. 14. “F” means the VOC emission capture efficiency (as a fraction) of the vapor capture system during performance testing.

NR 440.65(2)(b)15. 15. “Woi” means the weight fraction of VOC in each ink (i) used in the time period as determined from Method 24 of 40 CFR part 60, Appendix A, incorporated by reference in s. NR 440.17 (1), manufacturer’s formulation data, or plant blending records, in kilograms per kilogram.

NR 440.65(2)(b)16. 16. “Wxi” means the weight fraction of solids in each ink (i) used in the time period as determined from Method 24 of 40 CFR part 60, Appendix A, incorporated by reference in s. NR 440.17 (1), manufacturer’s formulation data, or plant blending records, in kilograms per kilogram.

NR 440.65(2)(b)17. 17. “Woj” means the weight fraction of VOC in each dilution solvent (j) added at the print line in the time period determined from Method 24 of 40 CFR part 60, Appendix A, incorporated by reference in s. NR 440.17 (1), manufacturer’s formulation data, or plant blending records, in kilograms per kilogram.

NR 440.65(3) (3) Standard for volatile organic compounds.

NR 440.65(3)(a) (a) On and after the date on which the performance test required by s. NR 440.08 has been completed each owner or operator subject to this section shall either:

NR 440.65(3)(a)1. 1. Use inks with a weighted average VOC content less than 1.0 kilogram VOC per kilogram ink solids at each affected facility, or

NR 440.65(3)(a)2. 2. Reduce VOC emissions to the atmosphere by 85% from each affected facility.

NR 440.65(4) (4) Test methods and procedures.

NR 440.65(4)(a) (a) Methods in 40 CFR part 60, Appendix A, incorporated by reference in s. NR 440.17 (1), except as provided under s. NR 440.08 (2), shall be used to determine compliance with sub. (3), as follows:

NR 440.65(4)(a)1. 1. Method 24 for analysis of inks. If nonphotochemically reactive solvents are used in the inks standard gas chromatographic techniques may be used to identify and quantify these solvents. The results of Method 24 may be adjusted to subtract these solvents from the measured VOC content.

NR 440.65(4)(a)2. 2. Method 24A for VOC concentration (the calibration gas shall be propane);

NR 440.65(4)(a)3. 3. Method 1 for sample and velocity traverses;

NR 440.65(4)(a)4. 4. Method 2 for velocity and volumetric flow rates;

NR 440.65(4)(a)5. 5. Method 3 for gas analysis;

NR 440.65(4)(a)6. 6. Method 4 for stack gas moisture.

NR 440.65(4)(b) (b) To demonstrate compliance with sub. (3) (a) 1. the owner or operator of an affected facility shall determine the weighted average VOC content of the ink according to the following procedures:

NR 440.65(4)(b)1. 1. Determine and record the VOC content and amount of each ink used at the print head, including the VOC content and amount of diluent solvent, for any time periods when VOC emission control equipment is not used.

NR 440.65(4)(b)2. 2. Compute the weighted average VOC content by the following equation: