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)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)(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)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)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. 8-1-9
3; 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)(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. “C
aj" 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. “C
bi" 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. “C
fk" 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. “M
ci" 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. “Q
aj" 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. “Q
bi" 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. “Q
fk" 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. “W
oi" 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. “W
xi" 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. “W
oj" 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)(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)(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)(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)3.
3. The weighted average VOC content of the inks shall be calculated over a period that does not exceed one calendar month or 4 consecutive weeks. A facility that uses an accounting system based on quarters consisting of two 28 calendar day periods and one 35 calendar day period may use an averaging period of 35 calendar days 4 times per year, provided the use of such an accounting system is documented in the initial performance test.
NR 440.65(4)(b)4.
4. Each determination of the weighted average VOC content shall constitute a performance test for any period when VOC emission control equipment is not used. Results of the initial performance test shall be reported to the department. Method 24 or ink manufacturers' formulation data along with plant blending records (if plant blending is done) may be used to determine VOC content. The department may require the use of Method 24 if there is a question concerning the accuracy of the ink manufacturer's data or plant blending records.
NR 440.65(4)(b)5.
5. If, during the time periods when emission control equipment is not used, all inks used contain less than 1.0 kilogram VOC per kilogram ink solids the owner or operator is not required to calculate the weighted average VOC content but shall verify and record the VOC content of each ink (including any added dilution solvent) used as determined by Method 24, ink manufacturers' formulation data or plant blending records.
NR 440.65(4)(c)
(c) To determine compliance with
sub. (3) (a) 1. the owner or operator may determine the weighted average VOC content using an inventory system.
NR 440.65(4)(c)1.
1. The inventory system shall accurately account to the nearest kilogram for the VOC content of all inks and dilution solvent used, recycled and discarded for each affected facility during the averaging period. Separate records must be kept for each affected facility.
NR 440.65(4)(c)2.
2. To determine VOC content of inks and dilution solvent used or recycled, Method 24 or ink manufacturers' formulation data shall be used in combination with plant blending records (if plant blending is done) or inventory records or purchase records for new inks or dilution solvent.
NR 440.65(4)(c)3.
3. For inks to be discarded only Method 24 shall be used to determine the VOC content. Inks to be discarded may be combined prior to measurement of volume or weight and tested by Method 24.
NR 440.65(4)(c)4.
4. The department may require the use of Method 24 if there is a question concerning the accuracy of the ink manufacturer's data or plant records.
NR 440.65(4)(c)5.
5. The department shall approve the inventory system of accounting for VOC content prior to the initial performance test.
NR 440.65(4)(d)
(d) To demonstrate compliance with
sub. (3) (a) 2. the owner or operator of an affected facility controlled by a solvent recovery emission control device or an incineration control device shall conduct a performance test to determine overall VOC emission control efficiency according to the following procedures:
NR 440.65(4)(d)1.
1. The performance test shall consist of 3 runs. Each test run must last a minimum of 30 minutes and shall continue until the printing operation is interrupted or until 180 minutes of continuous operation occurs. During each test run the print line shall be printing continuously and operating normally. The VOC emission reduction efficiency achieved from each test run is averaged over the entire test run period.
NR 440.65(4)(d)2.
2. VOC concentration values at each site shall be measured simultaneously.
NR 440.65(4)(d)3.
3. The volumetric flow rate shall be determined from one Method 2 measurement for each test run conducted immediately prior to, during, or after that test run. Volumetric flow rates at each site do not need to be measured simultaneously.
