Chapter NR 463

NR 463.15(2) (2) Operation, maintenance, and monitoring plan. The owner or operator shall prepare and implement for each new or existing affected source and emission unit, a written operation, maintenance and monitoring (OM&M) plan. The owner or operator of an existing affected source shall submit the OM&M plan to the department no later than the compliance date established by s. NR 463.115 (1). The owner or operator of any new MACT source subject to this subchapter shall submit the OM&M plan to the department within 90 days after a successful initial performance test under s. NR 463.16 (2) or within 90 days after the compliance date established by s. NR 463.115 (2) if no initial performance test is required. The plan shall be accompanied by a written certification by the owner or operator that the OM&M plan satisfies all requirements of this section and is otherwise consistent with the requirements of this subchapter. The owner or operator shall comply with all of the provisions of the OM&M plan as submitted to the department, unless and until the plan is revised in accordance with the following procedures. If the department determines at any time after receipt of the OM&M plan that any revisions of the plan are necessary to satisfy the requirements of this subchapter, the owner or operator shall promptly make all necessary revisions and resubmit the revised plan. If the owner or operator determines that any other revisions of the OM&M plan are necessary, the revisions may not become effective until the owner or operator submits a description of the changes and a revised plan incorporating them to the department. Each plan shall contain all of the following information:

NR 463.15(2)(a) (a) Process and control device parameters to be monitored to determine compliance, along with established operating levels or ranges, as applicable, for each process and control device.

NR 463.15(2)(b) (b) A monitoring schedule for each affected source and emission unit.

NR 463.15(2)(c) (c) Procedures for the proper operation and maintenance of each process unit and add-on control device used to meet the applicable emission limits or standards in s. NR 463.13.

NR 463.15(2)(d) (d) Procedures for the proper operation and maintenance of monitoring devices or systems used to determine compliance, including the following:

NR 463.15(2)(d)1. 1. Calibration and certification of accuracy of each monitoring device, at least once every 6 months, according to the manufacturer’s instructions.

NR 463.15(2)(d)2. 2. Procedures for the quality control and quality assurance of continuous emission or opacity monitoring systems as required by the general provisions in ch. NR 460.

NR 463.15(2)(e) (e) Procedures for monitoring process and control device parameters, including procedures for annual inspections of afterburners, and if applicable, the procedure to be used for determining charge or feed or throughput weight if a measurement device is not used.

NR 463.15(2)(f) (f) Corrective actions to be taken when process or operating parameters or add-on control device parameters deviate from the value or range established in par. (a), including the following:

NR 463.15(2)(f)1. 1. Procedures to determine and record the cause of a deviation or excursion, and the time the deviation or excursion began and ended.

NR 463.15(2)(f)2. 2. Procedures for recording the corrective action taken, the time corrective action was initiated, and the time and date corrective action was completed.

NR 463.15(2)(g) (g) A maintenance schedule for each process and control device that is consistent with the manufacturer’s instructions and recommendations for routine and long-term maintenance.

NR 463.15(2)(h) (h) Documentation of the work practice and pollution prevention measures used to achieve compliance with the applicable emission limits and a site-specific monitoring plan as required in sub. (15) for each group 1 furnace not equipped with an add-on air pollution control device.

NR 463.15(3) (3) Labeling. The owner or operator shall inspect the labels for each group 1 furnace, group 2 furnace, in-line fluxer, scrap dryer, delacquering kiln and decoating kiln at least once per calendar month to confirm that posted labels as required by the operational standard in s. NR 463.14 (2) are intact and legible.

NR 463.15(4) (4) Capture and collection system. The owner or operator shall do both of the following:

NR 463.15(4)(a) (a) Install, operate and maintain a capture and collection system for each affected source and emission unit equipped with an add-on air pollution control device.

NR 463.15(4)(b) (b) Inspect each capture and collection and closed vent system at least once each calendar year to ensure that each system is operating in accordance with the operating requirements in s. NR 463.14 (3) and record the results of each inspection.

NR 463.15(5) (5) Feed or charge weight. The owner or operator of an affected source or emission unit subject to an emission limit in kg/Mg (lb/ton) or mg/Mg (gr/ton) of feed or charge shall install, calibrate, operate and maintain a device to measure and record the total weight of feed or charge to, or the aluminum production from, the affected source or emission unit over the same operating cycle or time period used in the performance test. Feed or charge or aluminum production within SAPUs shall be measured and recorded on an emission unit-by-emission unit basis. As an alternative to a measurement device, the owner or operator may use a procedure acceptable to the department to determine the total weight of feed or charge or aluminum production to the affected source or emission unit.

NR 463.15(5)(a) (a) The weight measurement device or procedure shall have an accuracy of ± 1% of the weight being measured. The owner or operator may apply to the department for approval to use a device of alternative accuracy if the required accuracy cannot be achieved as a result of equipment layout or charging practices. A device of alternative accuracy may not be approved unless the owner or operator provides assurance through data and information that the affected source will meet the relevant emission standard.

NR 463.15(5)(b) (b) The owner or operator shall verify the calibration of the weight measurement device in accordance with the schedule specified by the manufacturer, or if no calibration schedule is specified, at least once every 6 months.

NR 463.15(6) (6) Fabric filters and lime-injected fabric filters. The owner or operator of an affected source or emission unit using a fabric filter or lime-injected fabric filter to comply with the requirements of this subchapter shall install, calibrate, maintain and continuously operate a bag leak detection system as required in par. (a) or a continuous opacity monitoring system as required in par. (b). The owner or operator of an aluminum scrap shredder shall install and operate a bag leak detection system as required in par. (a), install and operate a continuous opacity monitoring system as required in par. (b), or conduct visible emission observations as required in par. (c).

NR 463.15(6)(a) (a) The requirements of this paragraph apply to the owner or operator of a new or existing affected source or existing emission unit using a bag leak detection system.

NR 463.15(6)(a)1. 1. The owner or operator shall install and operate a bag leak detection system for each exhaust stack of a fabric filter.

NR 463.15(6)(a)2. 2. Each triboelectric bag leak detection system shall be installed, calibrated, operated and maintained according to the Fabric Filter Bag Leak Detection Guidance, EPA, OAQPS, September 1997, incorporated by reference in s. NR 484.05 (10). Other bag leak detection systems shall be installed, operated, calibrated, and maintained in a manner consistent with the manufacturer’s written specifications and recommendations.

NR 463.15(6)(a)3. 3. The bag leak detection system shall be certified by the manufacturer to be capable of detecting PM emissions at concentrations of 10 milligrams per actual cubic meter (0.0044 grains per actual cubic foot) or less.

NR 463.15(6)(a)4. 4. The bag leak detection system sensor shall provide output of relative or absolute PM loadings.

NR 463.15(6)(a)5. 5. The bag leak detection system shall be equipped with a device to continuously record the output signal from the sensor.

NR 463.15(6)(a)6. 6. The bag leak detection system shall be equipped with an alarm system that shall sound automatically when an increase in relative PM emissions over a preset level is detected. The alarm shall be located where it is easily heard by plant operating personnel.

NR 463.15(6)(a)7. 7. For positive pressure fabric filter systems, a bag leak detection system shall be installed in each baghouse compartment or cell. For negative pressure or induced air fabric filters, the bag leak detector shall be installed downstream of the fabric filter.

NR 463.15(6)(a)8. 8. Where multiple detectors are required, the system’s instrumentation and alarm may be shared among detectors.

NR 463.15(6)(a)9. 9. The baseline output shall be established by adjusting the range and the averaging period of the device and establishing the alarm set points and the alarm delay time.

NR 463.15(6)(a)10. 10. Following initial adjustment of the system, the owner or operator may not adjust the sensitivity or range, averaging period, alarm set points, or alarm delay time except as detailed in the OM&M plan. In no case may the sensitivity be increased by more than 100% or decreased more than 50% over a 365-day period unless the adjustment follows a complete fabric filter inspection which demonstrates that the fabric filter is in good operating condition.

NR 463.15(6)(b) (b) The requirements of this paragraph apply to the owner or operator of a new or existing affected source or an existing emission unit using a continuous opacity monitoring system.

NR 463.15(6)(b)1. 1. The owner or operator shall install, calibrate, maintain and operate a continuous opacity monitoring system to measure and record the opacity of emissions exiting each exhaust stack.

NR 463.15(6)(b)2. 2. Each continuous opacity monitoring system shall meet the design and installation requirements of Performance Specification 1 in Appendix B to 40 CFR part 60, incorporated by reference in s. NR 484.04 (21).

NR 463.15(6)(c) (c) The requirements of this paragraph apply to the owner or operator of a new or existing aluminum scrap shredder who conducts visible emission observations. The owner or operator shall do both of the following:

NR 463.15(6)(c)1. 1. Perform a visible emissions test for each aluminum scrap shredder using a certified observer at least once a day according to the requirements of Method 9 in Appendix A to 40 CFR part 60, incorporated by reference in s. NR 484.04 (13). Each Method 9 test shall consist of 5 6-minute observations in a 30-minute period.

NR 463.15(6)(c)2. 2. Record the results of each test required under subd. 1.

NR 463.15(7) (7) Afterburner. The requirements of this subsection apply to the owner or operator of an affected source using an afterburner to comply with the requirements of this subchapter.

NR 463.15(7)(a) (a) The owner or operator shall install, calibrate, maintain, and operate a device to continuously monitor and record the operating temperature of the afterburner consistent with the requirements for continuous monitoring systems in s. NR 460.07 (3).

NR 463.15(7)(b) (b) The temperature monitoring device shall meet each of the following performance and equipment specifications:

NR 463.15(7)(b)1. 1. The temperature monitoring device shall be installed at the exit of the combustion zone of each afterburner.

NR 463.15(7)(b)2. 2. The monitoring system shall record the temperature in 15-minute block averages and determine and record the average temperature for each 3-hour block period.

NR 463.15(7)(b)3. 3. The recorder response range shall include zero and 1.5 times the average temperature established according to the requirements in s. NR 463.163 (13).

NR 463.15(7)(b)4. 4. The reference method shall be a National Institute of Standards and Technology calibrated reference thermocouple-potentiometer system or alternate reference, subject to approval by the department.

NR 463.15(7)(c) (c) The owner or operator shall conduct an inspection of each afterburner at least once a year and record the results. At a minimum, an inspection and resulting steps shall include all of the following:

NR 463.15(7)(c)1. 1. Inspection of all burners, pilot assemblies, and pilot sensing devices for proper operation and clean pilot sensor.

NR 463.15(7)(c)2. 2. Inspection for proper adjustment of combustion air.

NR 463.15(7)(c)3. 3. Inspection of internal structures, such as baffles, to ensure structural integrity.

NR 463.15(7)(c)4. 4. Inspection of dampers, fans, and blowers for proper operation.

NR 463.15(7)(c)5. 5. Inspection for proper sealing.

NR 463.15(7)(c)6. 6. Inspection of motors for proper operation.

NR 463.15(7)(c)7. 7. Inspection of combustion chamber refractory lining and cleaning and replacement of lining as necessary.

NR 463.15(7)(c)8. 8. Inspection of afterburner shell for corrosion and hot spots.

NR 463.15(7)(c)9. 9. Documentation, for the burn cycle that follows the inspection, that the afterburner is operating properly and any necessary adjustments have been made.

NR 463.15(7)(c)10. 10. Verification that the equipment is maintained in good operating condition.

NR 463.15(7)(c)11. 11. Following an equipment inspection, completion of all necessary repairs in accordance with the requirements of the OM&M plan.

NR 463.15(8) (8) Fabric filter inlet temperature. The requirements of this subsection apply to the owner or operator of a scrap dryer, delacquering kiln or decoating kiln or a group 1 furnace using a lime-injected fabric filter to comply with the requirements of this subchapter.

NR 463.15(8)(a) (a) The owner or operator shall install, calibrate, maintain and operate a device to continuously monitor and record the temperature of the fabric filter inlet gases consistent with the requirements for continuous monitoring systems in s. NR 460.07 (3).

NR 463.15(8)(b) (b) The temperature monitoring device shall meet each of the following performance and equipment specifications:

NR 463.15(8)(b)1. 1. The monitoring system shall record the temperature in 15-minute block averages and calculate and record the average temperature for each 3-hour block period.

NR 463.15(8)(b)2. 2. The recorder response range shall include zero and 1.5 times the average temperature established according to the requirements in s. NR 463.163 (14).

NR 463.15(8)(b)3. 3. The reference method shall be a National Institute of Standards and Technology calibrated reference thermocouple-potentiometer system or alternate reference, subject to approval by the department.

NR 463.15(9) (9) Lime injection. The requirements of this subsection apply to the owner or operator of an affected source or emission unit using a lime-injected fabric filter to comply with the requirements of this subchapter.

NR 463.15(9)(a) (a) The owner or operator of a continuous lime injection system shall verify that lime is always free-flowing by one of the following methods:

NR 463.15(9)(a)1. 1. Inspecting each feed hopper or silo at least once each 8-hour period and recording the results of each inspection. If lime is found not to be free-flowing during any of the 8-hour periods, the owner or operator shall increase the frequency of inspections to at least once every 4-hour period for the next 3 days. The owner or operator may return to inspections at least once every 8-hour period if corrective action results in no further blockages of lime during the 3-day period.

NR 463.15(9)(a)2. 2. Subject to the approval of the department, installing, operating and maintaining a load cell, carrier gas or lime flow indicator, carrier gas pressure drop measurement system or other system to confirm that lime is free-flowing. If lime is found not to be free-flowing, the owner or operator shall promptly initiate and complete corrective action.

NR 463.15(9)(a)3. 3. Subject to the approval of the department, installing, operating and maintaining a device to monitor the concentration of HCl at the outlet of the fabric filter. If an increase in the concentration of HCl indicates that the lime is not free-flowing, the owner or operator shall promptly initiate and complete corrective action.

NR 463.15(9)(b) (b) The owner or operator of a continuous lime injection system shall record the lime feeder setting once each day of operation.

NR 463.15(9)(c) (c) An owner or operator who intermittently adds lime to a lime coated fabric filter shall obtain approval from the department for a lime addition monitoring procedure. The department may not approve a monitoring procedure unless data and information are submitted establishing that the procedure is adequate to ensure that relevant emission standards will be met on a continuous basis.

NR 463.15(10) (10) Total reactive flux injection rate. The requirements of this subsection apply to the owner or operator of a group 1 furnace or in-line fluxer. The owner or operator shall meet pars. (a) to (d) or apply for approval of an alternate method under par. (e):

NR 463.15(10)(a) (a) Install, calibrate, operate and maintain a device to continuously measure and record the weight of gaseous or liquid reactive flux injected to each affected source or emission unit.

NR 463.15(10)(a)1. 1. The monitoring system shall record the weight for each 15-minute block period, during which reactive fluxing occurs, over the same operating cycle or time period used in the performance test.

NR 463.15(10)(a)2. 2. The weight measurement device shall be accurate to ± 1% of the weight of the reactive component of the flux being measured. The owner or operator may apply to the department for permission to use a weight measurement device of alternative accuracy in cases where the reactive flux flow rates are so low as to make the use of a weight measurement device of ±1% impracticable. A device of alternative accuracy may not be approved unless the owner or operator provides assurance through data and information that the affected source will meet the relevant emission standards.

NR 463.15(10)(a)3. 3. The owner or operator shall verify the calibration of the weight measurement device in accordance with the schedule specified by the manufacturer, or if no calibration schedule is specified, at least once every 6 months.

NR 463.15(10)(b) (b) Calculate and record the gaseous or liquid reactive flux injection rate (kg/Mg or lb/ton) for each operating cycle or time period used in the performance test using the procedure in s. NR 463.163 (15).

NR 463.15(10)(c) (c) Record, for each 15-minute block period during each operating cycle or time period used in the performance test during which reactive fluxing occurs, the time, weight and type of flux for each addition of the following:

NR 463.15(10)(c)1. 1. Gaseous or liquid reactive flux other than chlorine.

NR 463.15(10)(c)2. 2. Solid reactive flux.

NR 463.15(10)(d) (d) Calculate and record the total reactive flux injection rate for each operating cycle or time period used in the performance test using the procedure in s. NR 463.163 (15).

NR 463.15(10)(e) (e) At their discretion, apply to the department for approval of an alternative method for monitoring and recording the total reactive flux addition rate based on monitoring the weight or quantity of reactive flux per ton of feed or charge for each operating cycle or time period used in the performance test. An alternative monitoring method may not be approved unless the owner or operator provides assurance through data and information that the affected source will meet the relevant emission standards on a continuous basis.

NR 463.15(11) (11) Thermal chip dryer. The requirements of this subsection apply to the owner or operator of a thermal chip dryer with emissions controlled by an afterburner. The owner or operator shall do both of the following:

NR 463.15(11)(a) (a) Record the type of materials charged to the unit for each operating cycle or time period used in the performance test.

NR 463.15(11)(b) (b) Submit a certification of compliance with the applicable operational standard for charge materials in s. NR 463.14 (6) (c) for each 6-month reporting period. Each certification shall contain the information in s. NR 463.18 (2) (b) 1.

NR 463.15(12) (12) Dross-only furnace. The requirements of this subsection apply to the owner or operator of a dross-only furnace. The owner or operator shall do both of the following:

NR 463.15(12)(a) (a) Record the materials charged to each unit for each operating cycle or time period used in the performance test.

NR 463.15(12)(b) (b) Submit a certification of compliance with the applicable operational standard for charge materials in s. NR 463.14 (9) (c) for each 6-month reporting period. Each certification shall contain the information in s. NR 463.18 (2) (b) 2.

NR 463.15(13) (13) In-line fluxers using no reactive flux. The owner or operator of an in-line fluxer that uses no reactive flux materials shall submit a certification of compliance with the operational standard for no reactive flux materials in s. NR 463.14 (12) for each 6-month reporting period. Each certification shall contain the information in s. NR 463.18 (2) (b) 6.

NR 463.15(14) (14) Sidewell group 1 furnace with add-on air pollution control devices. The requirements of this subsection apply to the owner or operator of a sidewell group 1 furnace using add-on air pollution control devices. The owner or operator shall do both of the following: