Mf is the total gaseous organic emissions mass flow rate, kg/per hour (h)
Cc is the concentration of organic compounds as carbon in the vent gas, as determined by Method 25 or Method 25A, parts per million by volume (ppmv), dry basis
Qsd is the volumetric flow rate of gases entering or exiting the add-on control device, as determined by Method 2, 2A, 2C, 2D, 2F or 2G, dry standard cubic meters/hour (dscm/h)
0.0416 = conversion factor for molar volume, kg-moles per cubic meter (mol/m3) (at 293 Kelvin (K) and 760 millimeters of mercury (mm Hg))
NR 465.28(7)(e)
(e) For each test run, determine the add-on control device organic emissions destruction or removal efficiency, using the following equation:
(Equation 9)
where:
DRE is the add-on control device organic emissions destruction or removal efficiency, percent
Mfi is the total gaseous organic emissions mass flow rate at the inlet or inlets to the add-on control device, using Equation 8 in par. (d), kg/h
Mfo is the total gaseous organic emissions mass flow rate at the outlet or outlets of the add-on control device, using Equation 8 in par. (d), kg/h
NR 465.28(7)(f)
(f) Determine the emission destruction or removal efficiency of the add-on control device as the average of the efficiencies determined in the 3 test runs and calculated in Equation 9 in
par. (e).
NR 465.28(8)
(8) How do I establish the emission capture system and add-on control device operating limits during the performance test?. During the performance test required by
sub. (1) and described in
subs. (5) to
(7), you shall establish the operating limits required by
s. NR 465.23 (3) according to the following requirements, as applicable, unless you have received approval for alternative monitoring and operating limits under
s. NR 460.07 (6) as specified in
s. NR 465.23 (3):
NR 465.28(8)(a)
(a)
Thermal oxidizers. If your add-on control device is a thermal oxidizer, according to both of the following:
NR 465.28(8)(a)1.
1. During the performance test, you shall monitor and record the combustion temperature at least once every 15 minutes during each of the 3 test runs. You shall monitor the temperature in the firebox of the thermal oxidizer or immediately downstream of the firebox before any substantial heat exchange occurs.
NR 465.28(8)(a)2.
2. Use the data collected during the performance test to calculate and record the average combustion temperature maintained during the performance test. This average combustion temperature is the minimum operating limit for your thermal oxidizer.
NR 465.28(8)(b)1.1. If your add-on control device is a catalytic oxidizer, according to either of the following:
NR 465.28(8)(b)1.a.
a. During the performance test, monitor and record the temperature just before the catalyst bed and the temperature difference across the catalyst bed at least once every 15 minutes during each of the 3 test runs. Use the data collected during the performance test to calculate and record the average temperature just before the catalyst bed and the average temperature difference across the catalyst bed maintained during the performance test. These are the minimum operating limits for your catalytic oxidizer.
NR 465.28(8)(b)1.b.
b. Monitor the temperature just before the catalyst bed and implement a site-specific inspection and maintenance plan for your catalytic oxidizer as specified in
subd. 2. During the performance test, you shall monitor and record the temperature just before the catalyst bed at least once every 15 minutes during each of the 3 test runs. Use the data collected during the performance test to calculate and record the average temperature just before the catalyst bed during the performance test. This is the minimum operating limit for your catalytic oxidizer.
NR 465.28(8)(b)2.
2. You shall develop and implement an inspection and maintenance plan for any catalytic oxidizer or oxidizers for which you elect to monitor according to
subd. 1. b. The plan shall address, at a minimum, the following elements:
NR 465.28(8)(b)2.a.
a. Annual sampling and analysis of the catalyst activity (i.e., conversion efficiency) following the manufacturer's or catalyst supplier's recommended procedures.
NR 465.28(8)(b)2.b.
b. Monthly inspection of the oxidizer system including the burner assembly and fuel supply lines for problems and, as necessary, adjusting the equipment to assure proper air-to-fuel mixtures.
NR 465.28(8)(b)2.c.
c. Annual internal and monthly external visual inspection of the catalyst bed to check for channeling, abrasion and settling. If problems are found, you shall take corrective action consistent with the manufacturer's recommendations and conduct a new performance test to determine destruction efficiency according to
sub. (7).
NR 465.28(8)(c)
(c)
Carbon adsorbers. If your add-on control device is a carbon absorber, according to both of the following:
NR 465.28(8)(c)1.
1. Monitor and record the total regeneration desorbing gas (e.g., steam or nitrogen) mass flow for each regeneration cycle and the carbon bed temperature after each carbon bed regeneration and cooling cycle for the regeneration cycle either immediately preceding or immediately following the performance test.
NR 465.28(8)(c)2.
2. The operating limits for your carbon absorber are the minimum total desorbing gas mass flow recorded during the regeneration cycle and the maximum carbon bed temperature recorded after the cooling cycle.
NR 465.28(8)(d)
(d)
Condensers. If your add-on control device is a condenser, according to both of the following:
NR 465.28(8)(d)1.
1. During the performance test, monitor and record the condenser outlet (product side) gas temperature at least once every 15 minutes during each of the 3 test runs.
NR 465.28(8)(d)2.
2. Use the data collected during the performance test to calculate and record the average condenser outlet (product side) gas temperature maintained during the performance test. This average condenser outlet gas temperature is the maximum operating limit for your condenser.
NR 465.28(8)(e)
(e)
Concentrators. If your add-on control device includes a concentrator, according to all of the following:
NR 465.28(8)(e)1.
1. During the performance test, monitor and record the desorption concentrate stream gas temperature at least once every 15 minutes during each of the 3 runs of the performance test.
NR 465.28(8)(e)2.
2. Use the data collected during the performance test to calculate and record the average temperature. This is the minimum operating limit for the desorption concentrate gas stream temperature.
NR 465.28(8)(e)3.
3. During the performance test, monitor and record the pressure drop of the dilute stream across the concentrator at least once every 15 minutes during each of the 3 runs of the performance test.
NR 465.28(8)(e)4.
4. Use the data collected during the performance test to calculate and record the average pressure drop. This is the maximum operating limit for the dilute stream across the concentrator.
NR 465.28(8)(f)2.
2. For each capture device that is not part of a PTE that meets the criteria of
sub. (6) (a), according to both of the following:
NR 465.28(8)(f)2.a.
a. During the capture efficiency determination required by
sub. (1) and described in
subs. (5) and
(6), monitor and record either the gas volumetric flow rate or the duct static pressure for each separate capture device in your emission capture system at least once every 15 minutes during each of the 3 test runs at a point in the duct between the capture device and the add-on control device inlet.
NR 465.28(8)(f)2.b.
b. Calculate and record the average gas volumetric flow rate or duct static pressure for the 3 test runs for each capture device. This average gas volumetric flow rate or duct static pressure is the minimum operating limit for that specific capture device.
NR 465.28(9)
(9) What are the requirements for continuous parameter monitoring system installation, operation and maintenance?. NR 465.28(9)(a)1.1. You shall install, operate and maintain each CPMS according to the following requirements, except that
subd. 1. a. and
b. do not apply to capture system bypass lines and carbon adsorbers as specified in
pars. (b) and
(d):
NR 465.28(9)(a)1.a.
a. The CPMS shall complete a minimum of one cycle of operation for each successive 15-minute period. You shall have a minimum of 4 equally spaced successive cycles of CPMS operation in one hour.
NR 465.28(9)(a)1.b.
b. Determine the average of all recorded readings for each successive 3-hour period of the emission capture system and add-on control device operation except as specified in
subd. 1. f.
NR 465.28(9)(a)1.c.
c. Record the results of each inspection, calibration and validation check of the CPMS.
NR 465.28(9)(a)1.d.
d. Maintain the CPMS at all times and have available necessary parts for routine repairs of the monitoring equipment.
NR 465.28(9)(a)1.e.
e. Operate the CPMS and collect emission capture system and add-on control device parameter data at all times that a controlled coating operation is operating except during monitoring malfunctions, associated repairs, and required quality assurance or control activities (including, if applicable, calibration checks and required zero and span adjustments).
NR 465.28(9)(a)1.f.
f. You may not use emission capture system or add-on control device parameter data recorded during monitoring malfunctions, associated repairs, out-of-control periods, or required quality assurance or control activities when calculating data averages. You shall use all the data collected during all other periods in calculating the data averages for determining compliance with the emission capture system and add-on control device operating limits.
NR 465.28(9)(a)2.
2. A monitoring malfunction is any sudden, infrequent, not reasonably preventable failure of the CPMS to provide valid data. Monitoring failures that are caused in part by poor maintenance or careless operation are not malfunctions. Except for periods of required quality assurance or control activities, any period during which the CPMS fails to operate and record data continuously as required by
subd. 1. a., or generates data that cannot be included in calculating averages as specified in
subd. 1. f., is a deviation from the monitoring requirements.
NR 465.28(9)(b)
(b)
Capture system bypass line. You shall comply with all of the following requirements, in addition to those specified in
par. (a) 1. c. to
e., for each emission capture system that contains bypass lines that could divert emissions away from the add-on control device to the atmosphere:
NR 465.28(9)(b)1.
1. Monitor or secure the valve or closure mechanism controlling the bypass line in a nondiverting position in such a way that the valve or closure mechanism cannot be opened without creating a record that the valve was opened. The method used to monitor or secure the valve or closure mechanism shall meet one of the following requirements:
NR 465.28(9)(b)1.a.
a. Install, calibrate, maintain and operate, according to the manufacturer's specifications, a flow control position indicator that takes a reading at least once every 15 minutes and provides a record indicating whether the emissions are directed to the add-on control device or diverted from the add-on control device. The time of occurrence and flow control position shall be recorded, as well as every time the flow direction is changed. The flow control position indicator shall be installed at the entrance to any bypass line that could divert the emissions away from the add-on control device to the atmosphere.
NR 465.28(9)(b)1.b.
b. Secure any bypass line valve in the closed position with a car-seal or a lock-and-key type configuration. You shall visually inspect the seal or closure mechanism at least once every month to ensure that the valve is maintained in the closed position and the emissions are not diverted away from the add-on control device to the atmosphere.
NR 465.28(9)(b)1.c.
c. Ensure that any bypass line valve is in the closed, non-diverting, position through monitoring of valve position at least once every 15 minutes. You shall inspect the monitoring system at least once every month to verify that the monitor will indicate valve position.
NR 465.28(9)(b)1.d.
d. Use an automatic shutdown system in which the coating operation is stopped when flow is diverted by the bypass line away from the add-on control device to the atmosphere when the coating operation is running. You shall inspect the automatic shutdown system at least once every month to verify that it will detect diversions of flow and shutdown the coating operation.
NR 465.28(9)(b)2.
2. If any bypass line is opened, you shall include a description of why the bypass line was opened and the length of time it remained open in the semiannual compliance reports required in
s. NR 465.25 (2).
NR 465.28(9)(c)
(c)
Thermal oxidizers and catalytic oxidizers. If you are using a thermal oxidizer or catalytic oxidizer as an add-on control device, including those used with concentrators or with carbon adsorbers to treat desorbed concentrate streams, you shall comply with the following requirements, as applicable, in addition to those specified in
par. (a) 1.:
NR 465.28(9)(c)1.
1. For a thermal oxidizer, install a gas temperature monitor in the firebox of the thermal oxidizer or in the duct immediately downstream of the firebox before any substantial heat exchange occurs.
NR 465.28(9)(c)2.
2. For a catalytic oxidizer, install a gas temperature monitor in the gas stream immediately before the catalyst bed, and if you establish operating limits according to
sub. (8) (b) 1. and
2., also install a gas temperature monitor in the gas stream immediately after the catalyst bed.
NR 465.28(9)(c)3.
3. For each gas temperature monitoring device, comply with all of the following requirements:
NR 465.28(9)(c)3.a.
a. Locate the temperature sensor in a position that provides a representative temperature.
NR 465.28(9)(c)3.b.
b. Use a temperature sensor with a measurement sensitivity of 4
°F or 0.75% of the temperature value, whichever is larger.
NR 465.28(9)(c)3.c.
c. Shield the temperature sensor system from electromagnetic interference and chemical contaminants.
NR 465.28(9)(c)3.d.
d. If a gas temperature chart recorder is used, ensure that it has a measurement sensitivity in the minor division of at least 20
°F.
NR 465.28(9)(c)3.e.
e. Perform an electronic calibration at least semiannually according to the procedures in the manufacturer's owners manual. Following the electronic calibration, conduct a temperature sensor validation check in which a second or redundant temperature sensor placed nearby the process temperature sensor yields a reading within 30
°F of the process temperature sensor's reading.
NR 465.28(9)(c)3.f.
f. Any time the sensor exceeds the manufacturer's specified maximum operating temperature range, either conduct calibration and validation checks or install a new temperature sensor.
NR 465.28(9)(c)3.g.
g. At least monthly, inspect components for integrity and electrical connections for continuity, oxidation and galvanic corrosion.
NR 465.28(9)(d)
(d)
Carbon adsorbers. If you are using a carbon adsorber as an add-on control device, you shall monitor the total regeneration desorbing gas (e. g., steam or nitrogen) mass flow for each regeneration cycle and the carbon bed temperature after each regeneration and cooling cycle and comply with all of the following requirements, in addition to those specified in
par. (a) 1. c. to
e.:
NR 465.28(9)(d)1.
1. The regeneration desorbing gas mass flow monitor shall be an integrating device having a measurement sensitivity of
±10%, capable of recording the total regeneration desorbing gas mass flow for each regeneration cycle.
NR 465.28(9)(d)2.
2. The carbon bed temperature monitor shall have a measurement sensitivity of 1% of the temperature recorded or 1
°F, whichever is greater, and shall be capable of recording the temperature within 15 minutes of completion of any carbon bed cooling cycle.
NR 465.28(9)(e)
(e)
Condensers. If you are using a condenser, you shall monitor the condenser outlet (product side) gas temperature and comply with all of the following requirements in addition to those specified in
par. (a) 1.:
NR 465.28(9)(e)1.
1. The gas temperature monitor shall have a measurement sensitivity of 1% of the temperature recorded or 1
°F, whichever is greater.
NR 465.28(9)(e)2.
2. The temperature monitor shall provide a gas temperature record at least once every 15 minutes.
NR 465.28(9)(f)
(f)
Concentrators. If you are using a concentrator, such as a zeolite wheel or rotary carbon bed concentrator, you shall comply with all of the following requirements, in addition to those specified in
par. (a) 1.:
NR 465.28(9)(f)2.
2. Install a device to monitor pressure drop across the zeolite wheel or rotary carbon bed and meet all of the following requirements:
NR 465.28(9)(f)2.a.
a. Locate the pressure sensor or sensors in or as close to a position that provides a representative measurement of the pressure.
NR 465.28(9)(f)2.b.
b. Minimize or eliminate pulsating pressure, vibration and internal and external corrosion.
NR 465.28(9)(f)2.c.
c. Use a gauge with a minimum tolerance of 0.5 inch of water or a transducer with a minimum tolerance of 1% of the pressure range.
NR 465.28(9)(f)2.e.
e. Using a manometer, check gauge calibration quarterly and transducer calibration monthly.
NR 465.28(9)(f)2.f.
f. Conduct calibration checks any time the sensor exceeds the manufacturer's specified maximum operating pressure range or install a new pressure sensor.
NR 465.28(9)(f)2.g.
g. At least monthly, inspect components for integrity, electrical connections for continuity, and mechanical connections for leakage.
NR 465.28(9)(g)
(g)
Emission capture systems. You shall comply with the following requirements, as applicable, in addition to those specified in
par. (a) 1., for capture system monitoring:
NR 465.28(9)(g)1.
1. For each flow measurement device, comply with all of the following requirements in addition to those specified in
par. (a):
NR 465.28(9)(g)1.a.
a. Locate a flow sensor in a position that provides a representative flow measurement in the duct from each capture device in the emission capture system to the add-on control device.
NR 465.28(9)(g)1.b.
b. Reduce swirling flow or abnormal velocity distributions due to upstream and downstream disturbances.
