NR 463.07(4)(a)(a) During the initial performance test, the owner or operator of an affected source, or group of affected sources under common control, complying with the emission limitations in
s. NR 463.04 through the use of a fiber-bed mist eliminator shall determine the outlet chromium concentration using the procedures in
s. NR 463.09 (3), and shall establish as a site-specific operating parameter the pressure drop across the fiber-bed mist eliminator and the pressure drop across the control device installed upstream of the fiber bed to prevent plugging, setting the value that corresponds to compliance with the applicable emission limitation using the procedures in
s. NR 463.09 (4) (e). An owner or operator may conduct multiple performance tests to establish a range of compliant pressure drop values, or may set as the compliant value the average pressure drop measured over the 3 test runs of one performance test and accept
±1 inch of water column from this value as the compliant range.
NR 463.07(4)(b)
(b) On and after the date on which the initial performance test is required to be completed under
s. NR 460.06, the owner or operator of an affected source, or group of affected sources under common control, shall monitor and record the pressure drop across the fiber-bed mist eliminator, and the control device installed upstream of the fiber bed to prevent plugging, once each day that any affected source is operating. To be in compliance with the standards in
s. NR 463.04, the fiber-bed mist eliminator and the upstream control device shall be operated within
±
1 inch of water column of the pressure drop value established during the initial performance test, or shall be operated within the range of compliant values for pressure drop established during multiple performance tests.
NR 463.07(5)
(5) Wetting agent-type or combination wetting agent-type/foam blanket fume suppressants. NR 463.07(5)(a)(a) During the initial performance test, the owner or operator of an affected source complying with the emission limitations in
s. NR 463.04 through the use of a wetting agent in the electroplating or anodizing bath shall determine the outlet chromium concentration using the procedures in
s. NR 463.09 (3). The owner or operator shall establish as the site-specific operating parameter the surface tension of the bath using Method 306B in Appendix A of
40 CFR part 63, incorporated by reference in
s. NR 484.04 (25), setting the maximum value that corresponds to compliance with the applicable emission limitation. In lieu of establishing the maximum surface tension during the performance test, the owner or operator may accept 45 dynes/cm (3.1 x 10
-3 pound-force per foot (lb
f /ft)) as measured by a stalagmometer or 35 dynes/cm (2.4 x 10
-3 lb
f /ft) as measured by a tensiometer as the maximum surface tension value that corresponds to compliance with the applicable emission limitation. However, the owner or operator is exempt from conducting a performance test only if the criteria of
s. NR 463.06 (3) (b) are met.
NR 463.07(5)(b)
(b) On and after the date on which the initial performance test is required to be completed under
s. NR 460.06, the owner or operator of an affected source shall monitor the surface tension of the electroplating or anodizing bath. Operation of the affected source at a surface tension greater than the value established during the performance test or greater than 45 dynes/cm (3.1 x 10
-3 lb
f /ft) as measured by a stalagmometer or 35 dynes/cm (2.4 x 10
-3 lb
f /ft) as measured by a tensiometer if the owner or operator is using this value in accordance with
par. (a), shall constitute noncompliance with the standards in
s. NR 463.04. The surface tension shall be monitored according to the following schedule:
NR 463.07(5)(b)1.
1. The surface tension shall be measured once every 4 hours during operation of the tank with a stalagmometer or a tensiometer as specified in Method 306B in Appendix A of
40 CFR part 63, incorporated by reference in
s. NR 484.04.
NR 463.07(5)(b)2.
2. The time between monitoring may be increased if there have been no exceedances. The surface tension shall be measured once every 4 hours of tank operation for the first 40 hours of tank operation after the compliance date. Once there are no exceedances during 40 hours of tank operation, surface tension measurement may be conducted once every 8 hours of tank operation. Once there are no exceedances during 40 more hours of tank operation, surface tension measurement may be conducted once every 40 hours of tank operation on an ongoing basis, until an exceedance occurs. The minimum frequency of monitoring allowed by this subchapter is once every 40 hours of tank operation.
NR 463.07(5)(b)3.
3. Once an exceedance occurs as indicated through surface tension monitoring, the original monitoring schedule of once every 4 hours shall be resumed. A subsequent decrease in frequency shall follow the schedule laid out in
subd. 2. For example, if an owner or operator had been monitoring an affected source once every 40 hours and an exceedance occurs, subsequent monitoring would take place once every 4 hours of tank operation. Once an exceedance does not occur for 40 hours of tank operation, monitoring may occur once every 8 hours of tank operation. Once an exceedance does not occur for 40 hours of tank operation on this schedule, monitoring may occur once every 40 hours of tank operation.
NR 463.07(5)(c)
(c) Once a bath solution is drained from the affected tank and a new solution added, the original monitoring schedule of once every 4 hours shall be resumed, with a decrease in monitoring frequency allowed following the procedures of
par. (b) 2. and
3.
NR 463.07(6)(a)(a) During the initial performance test, the owner or operator of an affected source complying with the emission limitations in
s. NR 463.04 through the use of a foam blanket in the electroplating or anodizing bath shall determine the outlet chromium concentration using the procedures in
s. NR 463.09 (3), and shall establish as the site-specific operating parameter the thickness of the foam blanket, setting the minimum thickness that corresponds to compliance with the applicable emission limitation. In lieu of establishing the minimum foam blanket thickness during the performance test, the owner or operator may accept 2.54 centimeters (1 inch) as the minimum foam blanket thickness that corresponds to compliance with the applicable emission limitation. All foam blanket measurements shall be taken in close proximity to the workpiece or cathode area in the plating tank.
NR 463.07(6)(b)
(b) On and after the date on which the initial performance test is required to be completed under
s. NR 460.06, the owner or operator of an affected source shall monitor the foam blanket thickness of the electroplating or anodizing bath. Operation of the affected source at a foam blanket thickness less than the value established during the performance test, or less than 2.54 cm (1 inch) if the owner or operator is using this value in accordance with
par. (a), constitutes noncompliance with the standards in
s. NR 463.04. The foam blanket thickness shall be measured according to the following schedule:
NR 463.07(6)(b)1.
1. The foam blanket thickness shall be measured once every hour of tank operation.
NR 463.07(6)(b)2.
2. The time between monitoring may be increased if there have been no exceedances. The foam blanket thickness shall be measured once every hour of tank operation for the first 40 hours of tank operation after the compliance date. Once there are no exceedances for 40 hours of tank operation, foam blanket thickness measurement may be conducted once every 4 hours of tank operation. Once there are no exceedances during 40 more hours of tank operation, foam blanket thickness measurement may be conducted once every 8 hours of tank operation on an ongoing basis, until an exceedance occurs. The minimum frequency of monitoring allowed by this subchapter is once per 8 hours of tank operation.
NR 463.07(6)(b)3.
3. Once an exceedance occurs as indicated through foam blanket thickness monitoring, the original monitoring schedule of once every hour shall be resumed. A subsequent decrease in frequency shall follow the schedule laid out in
subd. 2. For example, if an owner or operator had been monitoring an affected source once every 8 hours and an exceedance occurs, subsequent monitoring would take place once every hour of tank operation. Once an exceedance does not occur for 40 hours of tank operation, monitoring may occur once every 4 hours of tank operation. Once an exceedance does not occur for 40 hours of tank operation on this schedule, monitoring may occur once every 8 hours of tank operation.
NR 463.07(6)(c)
(c) Once a bath solution is drained from the affected tank and a new solution added, the original monitoring schedule of once every hour shall be resumed, with a decrease in monitoring frequency allowed following the procedures of
par. (b) 2. and
3.
NR 463.07(7)(a)(a) If the owner or operator of an affected source uses both a fume suppressant and add-on control device and both are needed to comply with the applicable emission limit, monitoring requirements as identified in
subs. (1) to
(6), and the work practice standards of Table 1 of this subchapter, apply for each of the control techniques used.
NR 463.07(7)(b)
(b) If the owner or operator of an affected source uses both a fume suppressant and add-on control device, but only one of these techniques is needed to comply with the applicable emission limit, monitoring requirements as identified in
subs. (1) to
(6), and work practice standards of Table 1 of this subchapter, apply only for the control technique used to achieve compliance.
NR 463.07(8)(b)
(b) After receipt and consideration of an application for an alternative monitoring method, the department may approve alternatives to any monitoring methods or procedures of this subchapter including, but not limited to, the following:
NR 463.07(8)(b)1.
1. Alternative monitoring requirements when installation or use of monitoring devices specified in this subchapter would not provide accurate measurements due to interferences caused by substances within the effluent gases.
NR 463.07(8)(b)2.
2. Alternative locations for installing monitoring devices when the owner or operator can demonstrate that installation at alternate locations will enable accurate and representative measurements.
NR 463.07 History
History: Cr.
Register, September, 1997, No. 501, eff. 10-1-97;
CR 05-039: am. (1) (a), (b), (5) (a), (b) (intro.) and (7) (b), cr. (1) (c) and (d)
Register February 2006 No. 602, eff. 3-1-06;
CR 04-023: am. (intro.), (5) (b) 2., (6) (b) 2., (7) (a), (8) (b) (intro.) and 1.
Register December 2008 No. 636, eff. 1-1-09.
NR 463.08
NR 463.08 Alternative control devices. An owner or operator who uses an air pollution control device not listed in
s. NR 463.07 shall submit a description of the device, test results collected in accordance with
s. NR 463.09 (3) verifying the performance of the device for reducing chromium emissions to the atmosphere to the level required by this subchapter, a copy of the operation and maintenance plan referenced in
s. NR 463.05 including proposed work practice standards, and appropriate operating parameters that will be monitored to establish continuous compliance with the standards in
s. NR 463.04. The monitoring plan submitted identifying the continuous compliance monitoring is subject to the department's approval.
NR 463.09
NR 463.09 Performance test requirements and test methods. NR 463.09(1)(1)
Performance test requirements. Performance tests shall be conducted using the test methods and procedures in this section and
s. NR 460.06. The test plan to be followed shall be made available to the department prior to the testing, if requested. Performance test results shall be documented in complete test reports that contain all of the following information:
NR 463.09(1)(c)
(c) A description of sampling and analytical procedures and any modifications to standard procedures.
NR 463.09(1)(f)
(f) Records of operating conditions during the test, preparation of calibration standards, and calibration procedures.
NR 463.09(1)(g)
(g) Raw data sheets for field sampling and field and laboratory analyses.
NR 463.09(2)
(2) Use of operation permit performance test results for compliance demonstration. NR 463.09(2)(a)(a) If the owner or operator of an affected source conducts performance testing at startup to obtain an operation permit under
ch. NR 407, the results of the testing may be used to demonstrate compliance with this subchapter if all of the following conditions are met:
NR 463.09(2)(a)1.
1. The test methods and procedures identified in
sub. (3) were used during the performance test.
NR 463.09(2)(a)2.
2. The performance test was conducted under representative operating conditions for the source.
NR 463.09(2)(a)4.
4. The owner or operator of the affected source for which the performance test was conducted has sufficient data to establish the operating parameter values that correspond to compliance with the standards in
s. NR 463.04, as required for continuous compliance monitoring under
s. NR 463.07.
NR 463.09(2)(b)
(b) The results of tests conducted prior to December 1991 in which Method 306A in Appendix A of
40 CFR part 63, incorporated by reference in
s. NR 484.04, was used to demonstrate the performance of a control technique are not acceptable.
NR 463.09(3)
(3) Test methods. Each owner or operator subject to the provisions of this subchapter and required by
s. NR 463.06 (3) to conduct an initial performance test shall use the test methods identified in this section to demonstrate compliance with the standards in
s. NR 463.04.
NR 463.09(3)(a)
(a) Method 306 or Method 306A in Appendix A of
40 CFR part 63, both titled “Determination of Chromium Emissions From Decorative and Hard Chromium Electroplating and Anodizing Operations," which are incorporated by reference in
s. NR 484.04, shall be used to determine the chromium concentration from hard or decorative chromium electroplating tanks or chromium anodizing tanks. The sampling time and sample volume for each run of Methods 306 and 306A shall be at least 120 minutes and 1.70 dscm (60 dscf), respectively. Methods 306 and 306A allow the measurement of either total chromium or hexavalent chromium emissions. For the purposes of this subchapter, sources using chromic acid baths may demonstrate compliance with the emission limits of
s. NR 463.04 by measuring either total chromium or hexavalent chromium. The hexavalent chromium concentration measured by these methods is equal to the total chromium concentration for the affected operations.
NR 463.09(3)(b)
(b) Method 306B in Appendix A of
40 CFR part 63, “Surface Tension Measurement and Recordkeeping for Tanks Used at Decorative Chromium Electroplating and Anodizing Facilities," incorporated by reference in
s. NR 484.04, shall be used to measure the surface tension of electroplating and anodizing baths.
NR 463.09(3)(c)
(c) Alternate test methods may also be used if the method has been validated using Method 301 in Appendix A of
40 CFR part 63, incorporated by reference in
s. NR 484.04, and if approved by the department. Procedures for requesting and obtaining approval are contained in
s. NR 460.06 (5).
NR 463.09(4)
(4) Establishing site-specific operating parameter values. NR 463.09(4)(a)(a) Each owner or operator required to establish site-specific operating parameters shall follow the procedures in this subsection.
NR 463.09(4)(b)
(b) All monitoring equipment shall be installed such that representative measurements of emissions or process parameters from the affected source are obtained. For monitoring equipment purchased from a vendor, verification of the operational status of the monitoring equipment shall include execution of the manufacturer's written specifications or recommendations for installation, operation and calibration of the system.
NR 463.09(4)(b)1.
1. Specifications for differential pressure measurement devices used to measure velocity pressure shall be in accordance with section 2.2 of Method 2 in Appendix A of
40 CFR part 60, incorporated by reference in
s. NR 484.04.
NR 463.09(4)(b)2.
2. Specifications for differential pressure measurement devices used to measure pressure drop across a control system shall be in accordance with manufacturer's accuracy specifications.
NR 463.09(4)(c)
(c) The surface tension of electroplating and anodizing baths shall be measured using Method 306B in Appendix A of
40 CFR part 63, “Surface Tension Measurement and Recordkeeping for Tanks Used at Decorative Chromium Electroplating and Anodizing Facilities," incorporated by reference in
s. NR 484.04. This method shall also be followed when wetting agent type or combination wetting agent/foam blanket type fume suppressants are used to control chromium emissions from a hard chromium electroplating tank and surface tension measurement is conducted to demonstrate continuous compliance.
NR 463.09(4)(d)
(d) The owner or operator of a source required to measure the velocity pressure at the inlet to an add-on air pollution control device in accordance with
s. NR 463.07 (2), shall establish the site-specific velocity pressure as follows:
NR 463.09(4)(d)1.
1. Locate a velocity traverse port in a section of straight duct that connects the hooding on the plating tank or tanks with the control device. The port shall be located as close to the control system as possible, and shall be placed a minimum of 2 duct diameters downstream and 0.5 diameter upstream of any flow disturbance such as a bend, expansion or contraction (see Method 1 in Appendix A of
40 CFR part 60, incorporated by reference in
s. NR 484.04). If 2.5 diameters of straight duct work does not exist, locate the port 0.8 of the distance between flow disturbances downstream and 0.2 of the distance between flow disturbances upstream from the respective flow disturbances.
NR 463.09(4)(d)2.
2. A 12-point velocity traverse of the duct to the control device shall be conducted along a single axis according to Method 2 in Appendix A of
40 CFR part 60, incorporated by reference in
s. NR 484.04, using an S-type pitot tube; measurement of the barometric pressure and duct temperature at each traverse point is not required, but is suggested. Mark the S-type pitot tube as specified in Method 1 in Appendix A of
40 CFR part 60, incorporated by reference in
s. NR 484.04, with 12 points. Measure the velocity pressure (
Dp) values for the velocity points and record. Determine the square root of the individual velocity point
Dp values and average. The point with the square root value that comes closest to the average square root value is the point of average velocity. The
Dp value measured for this point during the performance test shall be used as the reference for future monitoring.
NR 463.09(4)(e)
(e) The owner or operator of a source required to measure the pressure drop across the add-on air pollution control device in accordance with
s. NR 463.07 (1) to
(4) may establish the pressure drop in accordance with the following guidelines:
NR 463.09(4)(e)1.
1. Pressure taps shall be installed at any of the following locations:
NR 463.09(4)(e)1.a.
a. At the inlet and outlet of the control system. In this case the inlet tap would be installed in the ductwork just prior to the control device and the corresponding outlet pressure tap would be installed on the outlet side of the control device prior to the blower or on the downstream side of the blower.
NR 463.09(4)(e)1.b.
b. On each side of the packed bed within the control system or on each side of each mesh pad within the control system.
NR 463.09(4)(e)1.c.
c. On the front side of the first mesh pad and back side of the last mesh pad within the control system.
NR 463.09(4)(e)2.a.
a. As free from pluggage as possible and away from any flow disturbances such as cyclonic demisters.
NR 463.09(4)(e)2.b.
b. Situated such that no air infiltration at the measurement site will occur that could bias the measurement.
NR 463.09(4)(e)3.
3. Pressure taps shall be constructed of either polyethylene, polybutylene or other nonreactive materials.
NR 463.09(4)(e)4.
4. Nonreactive plastic tubing shall be used to connect the pressure taps to the device used to measure pressure drop.
NR 463.09(4)(e)5.
5. Any of the following pressure gauges may be used to monitor pressure drop: a magnehelic gauge, an inclined manometer or a “U" tube manometer.
NR 463.09(4)(e)6.
6. Prior to connecting any pressure lines to the pressure gauges, each gauge shall be zeroed. No calibration of the pressure gauges is required.
NR 463.09(5)
(5) Special compliance provisions for multiple sources controlled by a common add-on air pollution control device. NR 463.09(5)(a)(a) This subsection identifies procedures for measuring the outlet chromium concentration from an add-on air pollution control device that is used to control multiple sources that may or may not include sources not affected by this subchapter.
NR 463.09(5)(b)
(b) When multiple affected sources performing the same type of operation (for example, all are performing hard chromium electroplating), and subject to the same emission limitation, are controlled with an add-on air pollution control device that is not controlling emissions from any other type of affected operation or from any sources not affected by this subchapter, the applicable emission limitation identified in
s. NR 463.04 shall be met at the outlet of the add-on air pollution control device.
NR 463.09(5)(c)
(c) When multiple affected sources performing the same type of operation and subject to the same emission limitation are controlled with a common add-on air pollution control device that is also controlling emissions from sources not affected by this subchapter, the following procedures shall be followed to determine compliance with the applicable emission limitation in
s. NR 463.04:
NR 463.09(5)(c)1.
1. Calculate the cross-sectional area of each inlet duct (uptakes from each hood) including those not affected by this subchapter.
NR 463.09(5)(c)2.
2. Determine the total sample time per test run by dividing the total inlet area from all tanks connected to the control system by the total inlet area for all ducts associated with affected sources, and then multiply this number by 2 hours. The calculated time is the minimum sample time required per test run.
NR 463.09(5)(c)4.
4. Determine the total ventilation rate from the affected sources by using equation 1:
where VRtot is the average total ventilation rate in dscm/min for the 3 test runs as determined at the outlet by means of the Method 306 testing; IDAi is the total inlet area for all ducts associated with affected sources; IAtotal is the sum of all inlet duct areas from both affected sources and sources not affected by this subchapter; and VRinlet is the total ventilation rate from all inlet ducts associated with affected sources.
NR 463.09(5)(c)5.
5. Establish the allowable mass emission rate of the system (AMR
sys) in milligrams of total chromium per hour (mg/hr) using equation 2:
where
S VR
inlet is the total ventilation rate in dscm/min from the affected sources, and EL is the applicable emission limitation from
s. NR 463.04 in mg/dscm. The allowable mass emission rate (AMR
sys) calculated from equation 2 shall be equal to or more than the outlet 3-run average mass emission rate determined from Method 306 testing in order for the source to be in compliance with the standard.
NR 463.09(5)(d)
(d) When multiple affected sources performing different types of operations (for example, hard chromium electroplating, decorative chromium electroplating or chromium anodizing) are controlled by a common add-on air pollution control device that may or may not also be controlling emissions from sources not affected by this subchapter, or if the affected sources controlled by the common add-on air pollution control device perform the same operation but are subject to different emission limitations (for example, because one is a new hard chromium plating tank and one is an existing small, hard chromium plating tank), the following procedures shall be followed to determine compliance with the applicable emission limitation in
s. NR 463.04:
NR 463.09(5)(d)2.
2. Determine the total ventilation rate for each type of affected source using equation 3:
where VRtot is the average total ventilation rate in dscm/min for the 3 test runs as determined at the outlet by means of the Method 306 testing; IDAi,a is the total inlet duct area for all ducts conveying chromic acid from each type of affected source performing the same operation, or each type of affected source subject to the same emission limitation; IAtotal is the sum of all duct areas from both affected sources and sources not affected by this subchapter; and VRinlet,a is the total ventilation rate from all inlet ducts conveying chromic acid from each type of affected source performing the same operation, or each type of affected source subject to the same emission limitation.
NR 463.09(5)(d)3.
3. Establish the allowable mass emission rate in mg/hr for each type of affected source that is controlled by the add-on air pollution control device using equation 4, 5, 6 or 7 as appropriate:
