NR 463.23(2)(c)3.d.d. If the inspections are performed at the scrap supplier’s facility, include an explanation of how the periodic inspections ensure that not less than 10% of scrap purchased from each supplier is subject to inspection. NR 463.23(2)(d)(d) For each furan warm box mold or core making line in a new or existing iron and steel foundry, you shall use a binder chemical formulation that does not contain methanol as a specific ingredient of the catalyst formulation as determined by the material safety data sheet. This requirement does not apply to the resin portion of the binder system. NR 463.23(2)(e)(e) For each scrap preheater at an existing iron and steel foundry, you shall meet either of the following requirements, or, as an alternative, you may meet the VOHAP emissions limit in sub. (1) (a) 9.: NR 463.23(2)(e)1.1. You shall install, operate and maintain a gas-fired preheater where the flame directly contacts the scrap charged. NR 463.23(2)(e)2.2. You shall charge only material that is subject to and in compliance with the scrap certification requirement in par. (b). NR 463.23(2)(f)(f) For each scrap preheater at a new iron and steel foundry, you shall charge only material that is subject to, and in compliance with, the scrap certification requirement in par. (b). As an alternative to this requirement, you may meet the VOHAP emissions limit in sub. (1) (a) 9. NR 463.23(3)(3) What are my operation and maintenance requirements? NR 463.23(3)(a)(a) As required by s. NR 460.05 (4) (a) 1., you shall always operate and maintain your iron and steel foundry, including air pollution control and monitoring equipment, in a manner consistent with good air pollution control practices for minimizing emissions at least to the levels required by this subchapter. NR 463.23(3)(b)(b) You shall prepare, and operate at all times according to, a written operation and maintenance plan for each capture and collection system and control device for an emissions source subject to an emissions limit in sub. (1) (a). Your operation and maintenance plan shall also include procedures for igniting gases from mold vents in pouring areas and pouring stations that use a sand mold system. The operation and maintenance plan is subject to approval by the department and shall contain all of the following elements: NR 463.23(3)(b)1.1. Monthly inspections of the equipment that is important to the performance of the total capture system, such as pressure sensors, dampers and damper switches. The inspections shall include observations of the physical appearance of the equipment, such as the presence of holes in the ductwork or hoods, flow constrictions caused by dents or accumulated dust in the ductwork and fan erosion. The operation and maintenance plan shall also include requirements to repair the defect or deficiency as soon as practicable. NR 463.23(3)(b)2.2. Operating limits for each capture system for an emissions source subject to an emissions limit or standard for VOHAP or TEA in sub. (1) (a) 8. to 11. You shall establish the operating limits according to all of the following requirements: NR 463.23(3)(b)2.a.a. You shall select operating limit parameters appropriate for the capture system design that are representative and reliable indicators of the performance of the capture system. At a minimum, you shall use appropriate operating limit parameters that indicate the level of the ventilation draft and damper position settings for the capture system when operating to collect emissions, including revised settings for seasonal variations. Appropriate operating limit parameters for ventilation draft include volumetric flow rate through each separately ducted hood, total volumetric flow rate at the inlet to the control device to which the capture system is vented, fan motor amperage or static pressure. Any parameter for damper position setting may be used that indicates the duct damper position related to the fully open setting. NR 463.23(3)(b)2.b.b. For each operating limit parameter selected in subd. 2. a., you shall designate the value or setting for the parameter at which the capture system operates during the process operation. If your operation allows for more than one process to be operating simultaneously, you shall designate the value or setting for the parameter at which the capture system operates during each possible configuration that you may operate, for example the operating limits with one furnace melting or 2 melting, as applicable to your plant. NR 463.23(3)(b)2.c.c. You shall include documentation in your plan to support your selection of the operating limits established for your capture system. This documentation shall include a description of the capture system design, a description of the capture system operating during production, a description of each selected operating limit parameter, a rationale for why you chose the parameter, a description of the method used to monitor the parameter according to the requirements of s. NR 463.26 (1) (a) and the data used to establish the value or setting for the parameter for each of your process configurations. NR 463.23(3)(b)3.3. A preventive maintenance plan for each control device, including a preventive maintenance schedule that is consistent with the manufacturer’s instructions for routine and long-term maintenance. NR 463.23(3)(b)4.4. A site-specific monitoring plan for each bag leak detection system. For each bag leak detection system that operates on the triboelectric effect, the monitoring plan shall be consistent with the recommendations contained in the U.S. Environmental Protection Agency guidance document “Fabric Filter Bag Leak Detection Guidance’’, EPA-454/R-98-015, incorporated by reference in s. NR 484.06 (4) (c). The owner or operator shall operate and maintain the bag leak detection system according to the site-specific monitoring plan at all times. The baghouse monitoring plan is subject to approval by the department and shall address all of the following items: NR 463.23(3)(b)4.b.b. Initial and periodic adjustment of the bag leak detection system, including how the alarm set-point will be established. NR 463.23(3)(b)4.c.c. Operation of the bag leak detection system including quality assurance procedures. NR 463.23(3)(b)4.d.d. How the bag leak detection system will be maintained, including a routine maintenance schedule and spare parts inventory list. NR 463.23(3)(b)5.5. A corrective action plan for each baghouse. The plan shall include the requirement that, in the event a bag leak detection system alarm is triggered, you shall initiate corrective action to determine the cause of the alarm within one hour of the alarm, initiate corrective action to correct the cause of the problem within 24 hours of the alarm and complete the corrective action as soon as practicable. Corrective actions taken may include any of the following: NR 463.23(3)(b)5.a.a. Inspecting the baghouse for air leaks, torn or broken bags or filter media or any other condition that may cause an increase in emissions. NR 463.23(3)(b)5.c.c. Replacing defective bags or filter media or otherwise repairing the control device. NR 463.23(3)(b)5.e.e. Cleaning the bag leak detection system probe or otherwise repairing the bag leak detection system. NR 463.23(3)(b)6.6. Procedures for providing an ignition source to mold vents of sand mold systems in each pouring area and pouring station unless you determine the mold vent gases either are not ignitable, ignite automatically or cannot be ignited due to accessibility or safety issues. You shall document and maintain records of the determination of ignitability, accessibility and safety. The determination may encompass multiple casting patterns provided the castings utilize similar sand-to-metal ratios, binder formulations and coating materials. The determination of ignitability shall be based on observations of the mold vents within 5 minutes of pouring, and the flame shall be present for at least 15 seconds for the mold vent to be considered ignited. For the purpose of the determination made under this subdivision, both of the following apply: NR 463.23(3)(b)6.a.a. Mold vents that ignite more than 75% of the time without the presence of an auxiliary ignition source are considered to ignite automatically. NR 463.23(3)(b)6.b.b. Mold vents that do not ignite automatically and cannot be ignited in the presence of an auxiliary ignition source more than 25% of the time are considered to be not ignitable. NR 463.23 HistoryHistory: CR 06-110: cr. Register July 2007 No. 619, eff. 8-1-07. NR 463.24NR 463.24 General compliance requirements. NR 463.24(1)(1) What are my general requirements for complying with this subchapter? NR 463.24(1)(a)(a) You shall be in compliance with the emissions limitations, work practice standards and operation and maintenance requirements in this subchapter at all times, except during periods of startup, shutdown or malfunction. NR 463.24(1)(b)(b) During the period between the compliance date specified for your iron and steel foundry in s. NR 463.21 (4) and the date when applicable operating limits have been established during the initial performance test, you shall maintain a log detailing the operation and maintenance of the process and emissions control equipment. NR 463.24(1)(c)(c) You shall develop a written startup, shutdown and malfunction plan according to the provisions in s. NR 460.05 (4) (c). The startup, shutdown and malfunction plan shall also specify what constitutes a shutdown of a cupola and how to determine that operating conditions are normal following startup of a cupola. NR 463.24(2)(2) What parts of the general provisions apply to me? You shall comply with the applicable general provisions requirements in ch. NR 460. Chapter NR 460 Appendix EEEEE shows which parts of the general provisions in ch. NR 460 apply to you. NR 463.24 HistoryHistory: CR 06-110: cr. Register July 2007 No. 619, eff. 8-1-07; correction in (2) made under s. 35.17, Stats., Register June 2015 No. 714. NR 463.25NR 463.25 Initial compliance requirements. NR 463.25(1)(1) By what date must I conduct initial performance tests or other initial compliance demonstrations? NR 463.25(1)(a)(a) As required by s. NR 460.06 (1) (b), you shall conduct a performance test no later than 180 calendar days after the compliance date that is specified in s. NR 463.21 (4) for your iron and steel foundry to demonstrate initial compliance with each emission limitation in s. NR 463.23 (1) that applies to you. NR 463.25(1)(b)(b) For each work practice standard in s. NR 463.23 (2) and each operation and maintenance requirement in s. NR 463.23 (3) that applies to you where initial compliance is not demonstrated using a performance test, you shall demonstrate initial compliance no later than 30 calendar days after the compliance date that is specified for your iron and steel foundry in s. NR 463.21 (4). NR 463.25(1)(c)(c) If you commenced construction or reconstruction between December 23, 2002 and April 22, 2004, you shall demonstrate initial compliance with either the proposed emissions limit or the promulgated emissions limit no later than October 19, 2004 or no later than 180 calendar days after startup of the source, whichever is later, according to s. NR 460.06 (1) (c). NR 463.25(1)(d)(d) If you commenced construction or reconstruction between December 23, 2002 and April 22, 2004, and you chose to comply with the proposed emissions limit when demonstrating initial compliance, you shall conduct a second performance test to demonstrate compliance with the promulgated emissions limit by October 19, 2007 or after startup of the source, whichever is later, according to s. NR 460.06 (1) (c). NR 463.25(2)(2) When must I conduct subsequent performance tests? NR 463.25(2)(a)(a) You shall conduct subsequent performance tests to demonstrate compliance with all applicable PM or total metal HAP, VOHAP and TEA emissions limitations in s. NR 463.23 (1) for your iron and steel foundry no less frequently than every 5 years. The requirement to conduct performance tests every 5 years does not apply to an emissions source for which a continuous emissions monitoring system (CEMS) is used to demonstrate continuous compliance. NR 463.25(2)(b)(b) You shall conduct subsequent performance tests to demonstrate compliance with the opacity limit in s. NR 463.23 (1) (a) 7. for your iron and steel foundry no less frequently than once every 6 months. NR 463.25(3)(3) What test methods and other procedures must I use to demonstrate initial compliance with the emission limitations? You shall conduct each performance test that applies to your iron and steel foundry according to the requirements in s. NR 460.06 (4) (a) and the following conditions, as applicable: NR 463.25(3)(a)(a) Particulate matter. To determine compliance with the applicable emission limit for PM in s. NR 463.23 (1) (a) 1. to 6. for a metal melting furnace, scrap preheater, pouring station or pouring area, you shall use the following test methods and procedures: NR 463.25(3)(a)1.a.a. Method 1 or 1A to select sampling port locations and the number of traverse points in each stack or duct. Sampling sites shall be located at the outlet of the control device, or at the outlet of the emission source if no control device is present, prior to any releases to the atmosphere. NR 463.25(3)(a)1.b.b. Method 2, 2A, 2C, 2D, 2F or 2G to determine the volumetric flow rate of the stack gas. NR 463.25(3)(a)1.c.c. Method 3, 3A or 3B to determine the dry molecular weight of the stack gas. NR 463.25(3)(a)1.e.e. Method 5, 5B, 5D, 5F or 5I, as applicable, to determine the PM concentration. The PM concentration is determined using only the front-half, probe rinse and filter, of the PM catch. NR 463.25(3)(a)2.2. Collect a minimum sample volume of 60 dscf of gas during each PM sampling run. A minimum of 3 valid test runs are needed to comprise a performance test. NR 463.25(3)(a)3.3. For cupola metal melting furnaces, sample only during times when the cupola is on blast. NR 463.25(3)(a)4.4. For electric arc and electric induction metal melting furnaces, sample only when metal is being melted. NR 463.25(3)(b)(b) Total metal HAP. To determine compliance with the applicable emission limit for total metal HAP in s. NR 463.23 (1) (a) 1. to 6. for a metal melting furnace, scrap preheater, pouring station, or pouring area, you shall use the following test methods and procedures: NR 463.25(3)(b)1.a.a. Method 1 or 1A to select sampling port locations and the number of traverse points in each stack or duct. Sampling sites shall be located at the outlet of the control device, or at the outlet of the emissions source if no control device is present, prior to any releases to the atmosphere. NR 463.25(3)(b)1.b.b. Method 2, 2A, 2C, 2D, 2F or 2G to determine the volumetric flow rate of the stack gas. NR 463.25(3)(b)1.c.c. Method 3, 3A or 3B to determine the dry molecular weight of the stack gas. NR 463.25(3)(b)2.2. Collect a minimum sample volume of 60 dscf of gas during each total metal HAP sampling run. A minimum of 3 valid test runs are needed to comprise a performance test. NR 463.25(3)(b)3.3. For cupola metal melting furnaces, sample only during times when the cupola is on blast. NR 463.25(3)(b)4.4. For electric arc and electric induction metal melting furnaces, sample only when metal is being melted. NR 463.25(3)(c)(c) Fugitive emissions. To determine compliance with the opacity limit in s. NR 463.23 (1) (a) 7. for fugitive emissions from buildings or structures housing any emissions source at the iron and steel foundry, you shall use the following test method and procedures: NR 463.25(3)(c)2.2. Conduct each test such that the opacity observations overlap with the PM performance tests. NR 463.25(3)(d)(d) Volatile organic HAP emissions from cupola furnaces and scrap preheaters. To determine compliance with the applicable VOHAP emissions limit in s. NR 463.23 (1) (a) 8. for a cupola metal melting furnace or in s. NR 463.23 (1) (a) 9. for a scrap preheater, you shall use the following test methods and procedures: NR 463.25(3)(d)1.a.a. Method 1 or 1A to select sampling port locations and the number of traverse points in each stack or duct. Sampling sites shall be located at the outlet of the control device, or at the outlet of the emissions source if no control device is present, prior to any releases to the atmosphere. NR 463.25(3)(d)1.b.b. Method 2, 2A, 2C, 2D, 2F or 2G to determine the volumetric flow rate of the stack gas. NR 463.25(3)(d)1.c.c. Method 3, 3A or 3B to determine the dry molecular weight of the stack gas. NR 463.25(3)(d)1.e.e. Method 18 to determine the VOHAP concentration. Alternatively, you may use Method 25 to determine the concentration of total gaseous nonmethane organics (TGNMO) or Method 25A to determine the concentration of total organic compounds (TOC), using hexane as the calibration gas. NR 463.25(3)(d)2.2. Determine the average VOHAP, TGNMO or TOC concentration using a minimum of 3 valid test runs. Each test run shall include a minimum of 60 continuous operating minutes. NR 463.25(3)(d)3.3. For a cupola metal melting furnace, correct the measured concentration of VOHAP, TGNMO or TOC for oxygen content in the gas stream using Equation 1: where:
CVOHAP is the concentration of VOHAP in ppmv as measured by Method 18 in 40 CFR part 60, Appendix A, incorporated by reference in s. NR 484.04 (16) or the concentration of TGNMO or TOC in ppmv as hexane as measured by Method 25 or 25A in 40 CFR part 60, Appendix A, incorporated by reference in s. NR 484.04 (19) or (20) %O2 is the oxygen concentration in gas stream, percent by volume (dry basis)
NR 463.25(3)(d)4.4. For a cupola metal melting furnace, measure the combustion zone temperature of the combustion device with the CPMS required in s. NR 463.26 (1) (d) during each sampling run in 15-minute intervals. Determine and record the 15-minute average of the 3 runs.
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