NR 465.38(7)
(7) How do i determine the add-on control device emission destruction or removal efficiency? You shall use the procedures and test methods in this subsection to determine the add-on control device emission destruction or removal efficiency as part of the performance test required by
sub. (1). You shall conduct 3 test runs as specified in
s. NR 460.06 (4) (c), and each test run shall last at least one hour.
NR 465.38(7)(a)
(a) For all types of add-on control devices, use the test methods specified in
subds. 1. to
5.
NR 465.38(7)(a)5.
5. Methods for determining gas volumetric flow rate, dry molecular weight and stack gas moisture shall be performed, as applicable, during each test run.
NR 465.38(7)(b)
(b) Measure total gaseous organic mass emissions as carbon at the inlet and outlet of the add-on control device simultaneously, using either Method 25 or 25A in
40 CFR part 60, Appendix A, incorporated by reference in
s. NR 484.04 (13).
NR 465.38(7)(b)1.
1. Use Method 25 if the add-on control device is an oxidizer and you expect the total gaseous organic concentration as carbon to be more than 50 parts per million (ppm) at the control device outlet.
NR 465.38(7)(b)2.
2. Use Method 25A if the add-on control device is an oxidizer and you expect the total gaseous organic concentration as carbon to be 50 ppm or less at the control device outlet.
NR 465.38(7)(c)
(c) If 2 or more add-on control devices are used for the same emission stream, then you shall measure emissions at the outlet to the atmosphere of each device.
NR 465.38 Note
Note: For example, if one add-on control device is a concentrator with an outlet to the atmosphere for the high-volume dilute stream that has been treated by the concentrator, and a second add-on control device is an oxidizer with an outlet to the atmosphere for the low-volume concentrated stream that is treated with the oxidizer, you shall measure emissions at the outlet of the oxidizer and the high volume dilute stream outlet of the concentrator.
NR 465.38(7)(d)
(d) For each test run, determine the total gaseous organic emissions mass flow rates for the inlet and the outlet of the add-on control device, using Equation 1 of this subsection. If there is more than one inlet or outlet to the add-on control device, you shall calculate the total gaseous organic mass flow rate using Equation 1 for each inlet and each outlet and then total all of the inlet emissions and total all of the outlet emissions.
(Equation 1)
where:
Mf is the total gaseous organic emissions mass flow rate, kg per hour (h)
C
c is the concentration of organic compounds as carbon in the vent gas, as determined by Method 25 or Method 25A
in
40 CFR part 60, Appendix A, incorporated by reference in
s. NR 484.04 (13), parts per million by volume (ppmv), dry basis
Q
sd 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 in
40 CFR part 60, Appendix A, incorporated by reference in
s. NR 484.04 (13), dry standard cubic meters/hour (dscm/h)
0.0416 is the conversion factor for molar volume, kg-moles per cubic meter (mol/m3) (at 293 Kelvin (K) and 760 millimeters of mercury (mmHg))
NR 465.38(7)(e)
(e) For each test run, determine the add-on control device organic emissions destruction or removal efficiency, using the following equation:
(Equation 2)
where:
DRE is the organic emissions destruction or removal efficiency of the add-on control device, percent
Mfi is the total gaseous organic emissions mass flow rate at the inlet to the add-on control device, using Equation 1 of this subsection, kg/h
Mfo is the total gaseous organic emissions mass flow rate at the outlet of the add-on control device, using Equation 1 of this subsection, kg/h
NR 465.38(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 2 of this subsection.
NR 465.38(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),
(6) and
(7), you shall establish the operating limits required by
s. NR 465.33 (3) according to this subsection, unless you have received approval for alternative monitoring and operating limits under
s. NR 460.07 (6) as specified in
s. NR 465.33 (3).
NR 465.38(8)(a)
(a) Thermal oxidizers. If your add-on control device is a thermal oxidizer, establish the operating limits according to
subds. 1. and
2.
NR 465.38(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 465.38(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 shall be the minimum operating limit for your thermal oxidizer.
NR 465.38(8)(b)
(b) Catalytic oxidizers. If your add-on control device is a catalytic oxidizer, establish the operating limits according to either
subds. 1. and
2. or
subds. 3. and
4.
NR 465.38(8)(b)1.
1. During the performance test, you shall 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.
NR 465.38(8)(b)2.
2. 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. The average temperature just before the catalyst bed and the average temperature difference across the catalyst bed shall be the minimum operating limits for your catalytic oxidizer.
NR 465.38(8)(b)3.
3. You shall monitor the temperature at the inlet to the catalyst bed and implement a site-specific inspection and maintenance plan for your catalytic oxidizer as specified in
subd. 4. 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 average temperature shall be the minimum operating limit for your catalytic oxidizer.
NR 465.38(8)(b)4.
4. You shall develop and implement an inspection and maintenance plan for your catalytic oxidizers for which you elect to monitor according to
subd. 3. The plan shall address, at a minimum, the elements specified in
subd. 4. a. to
c.
NR 465.38(8)(b)4.a.
a. Annual sampling and analysis of the catalyst conversion efficiency following the manufacturer's or catalyst supplier's recommended procedures. If problems are found during the catalyst activity test, you shall replace the catalyst bed or take other corrective action consistent with the manufacturer's recommendations.
NR 465.38(8)(b)4.b.
b. Monthly external inspection of the catalytic oxidizer system, including the burner assembly and fuel supply lines for problems and, as necessary, adjustment of the equipment to assure proper air-to-fuel mixtures.
NR 465.38(8)(b)4.c.
c. Annual internal inspection of the catalyst bed to check for channeling, abrasion and settling. If problems are found during the annual internal inspection of the catalyst, you shall replace the catalyst bed or take other corrective action consistent with the manufacturer's recommendations. If the catalyst bed is replaced and is not of like or better kind and quality as the old catalyst, then you shall conduct a new performance test to determine destruction efficiency according to
sub. (7). If a catalyst bed is replaced and the replacement catalyst is of like or better kind and quality as the old catalyst, then a new performance test to determine destruction efficiency is not required and you may continue to use the previously established operating limits for that catalytic oxidizer.
NR 465.38(8)(c)
(c) Regenerative carbon adsorbers. If your add-on control device is a regenerative carbon adsorber, establish the operating limits according to
subds. 1. and
2.
NR 465.38(8)(c)1.
1. You shall monitor and record the total regeneration desorbing gas 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 465.38(8)(c)2.
2. The operating limits for your regenerative carbon adsorber shall be the minimum total desorbing gas mass flow recorded during the regeneration cycle and the maximum carbon bed temperature recorded after the cooling cycle.
NR 465.38(8)(d)
(d) Condensers. If your add-on control device is a condenser, establish the operating limits according to
subds. 1. and
2.
NR 465.38(8)(d)1.
1. During the performance test, you shall monitor and record the product side condenser outlet gas temperature at least once every 15 minutes during each of the 3 test runs.
NR 465.38(8)(d)2.
2. Use the data collected during the performance test to calculate and record the average condenser outlet gas temperature maintained during the performance test. This average condenser outlet gas temperature shall be the maximum operating limit for your condenser.
NR 465.38(8)(e)
(e) Concentrators. If your add-on control device includes a concentrator, you shall establish operating limits for the concentrator according to
subds. 1. to
4.
NR 465.38(8)(e)1.
1. During the performance test, you shall 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 465.38(8)(e)2.
2. Use the data collected during the performance test to calculate and record the average temperature. This average temperature
shall be the minimum operating limit for the desorption concentrate gas stream temperature.
NR 465.38(8)(e)3.
3. During the performance test, you shall 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 465.38(8)(e)4.
4. Use the data collected during the performance test to calculate and record the average pressure drop. This average pressure drop shall be the minimum operating limit for the dilute stream across the concentrator.
NR 465.38(8)(f)
(f) Emission capture systems. For each capture device that is not part of a PTE that meets the criteria of
sub. (6) (a), establish an operating limit for either the gas volumetric flow rate or duct static pressure, as specified in
subds. 1. and
2. The operating limit for a PTE is specified in Table 1 of this subchapter.
NR 465.38(8)(f)1.
1. During the capture efficiency determination required by
sub. (1) and described in
subs. (5) and
(6), you shall 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 465.38(8)(f)2.
2. 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 shall be the minimum operating limit for that specific capture device.
NR 465.38(9)
(9) What are the requirements for continuous parameter monitoring system installation, operation and maintenance? NR 465.38(9)(a)(a)
General. You shall install, operate and maintain each CPMS specified in
pars. (c),
(e),
(f) and
(g) according to
subds. 1. to
6. You shall install, operate and maintain each CPMS specified in
pars. (b) and
(d) according to
subds. 3. to
5.
NR 465.38(9)(a)1.
1. 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 465.38(9)(a)2.
2. You shall determine the average of all recorded readings for each successive 3-hour period of the emission capture system and add-on control device operation.
NR 465.38(9)(a)3.
3. You shall record the results of each inspection, calibration and validation check of the CPMS.
NR 465.38(9)(a)4.
4. You shall maintain the CPMS at all times and have available necessary parts for routine repairs of the monitoring equipment.
NR 465.38(9)(a)5.
5. You shall 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 465.38(9)(a)6.
6. 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 465.38(9)(a)7.
7. 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. Any period for which the monitoring system is out-of-control and data are not available for required calculations is a deviation from the monitoring requirements.
NR 465.38(9)(b)
(b) Capture system bypass line. You shall meet the requirements of
subds. 1. and
2. for each emission capture system that contains bypass lines that could divert emissions away from the add-on control device to the atmosphere.
NR 465.38(9)(b)1.
1. You shall monitor or secure the valve or closure mechanism controlling the bypass line in a non-diverting 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 requirements specified in
subd. 1. a. to
e.
NR 465.38(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 465.38(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 465.38(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 465.38(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 shut down the coating operation.
NR 465.38(9)(b)1.e.
e. Install, calibrate, maintain and operate according to the manufacturer's specifications a flow direction 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. Each time the flow direction changes, the next reading of the time of occurrence and flow direction shall be recorded. The flow direction indicator shall be installed in each bypass line or air makeup supply line that could divert the emissions away from the add-on control device to the atmosphere.
NR 465.38(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 465.35 (2).
NR 465.38(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 requirements in
subds. 1. to
3.
NR 465.38(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 465.38(9)(c)2.
2. For a catalytic oxidizer, install gas temperature monitors upstream or downstream or both of the catalyst bed as required in
sub. (8) (b).
NR 465.38(9)(c)3.
3. For all thermal oxidizers and catalytic oxidizers, you shall meet the requirements in
par. (a) and the requirements in
subd. 3. a. to
e. for each gas temperature monitoring device.
NR 465.38(9)(c)3.a.
a. Locate the temperature sensor in a position that provides a representative temperature.
NR 465.38(9)(c)3.b.
b. Use a temperature sensor with a measurement sensitivity of 5
°F or 1.0% of the temperature value, whichever is larger.
NR 465.38(9)(c)3.c.
c. Before using the sensor for the first time or when relocating or replacing the sensor, perform a validation check by comparing the sensor output to a calibrated temperature measurement device or by comparing the sensor output to a simulated temperature.
NR 465.38(9)(c)3.d.
d. Conduct an accuracy audit every quarter and after every deviation. Accuracy audit methods include comparisons of sensor output to redundant temperature sensors, to calibrated temperature measurement devices, or to temperature simulation devices.
NR 465.38(9)(c)3.e.
e. Conduct a visual inspection of each sensor every quarter if redundant temperature sensors are not used.
NR 465.38(9)(d)
(d) Regenerative carbon adsorbers. If you are using a regenerative carbon adsorber as an add-on control device, you shall monitor the total regeneration desorbing gas mass flow for each regeneration cycle, the carbon bed temperature after each regeneration and cooling cycle, and comply with
par. (a) 3. to
5. and
subds. 1. to
3.
NR 465.38(9)(d)1.
1. The regeneration desorbing gas mass flow monitor shall be an integrating device having a measurement sensitivity of plus or minus 10% capable of recording the total regeneration desorbing gas mass flow for each regeneration cycle.
NR 465.38(9)(d)2.
2. The carbon bed temperature monitor shall be capable of recording the temperature within 15 minutes of completing any carbon bed cooling cycle.
NR 465.38(9)(d)3.
3. For all regenerative carbon adsorbers, you shall meet the requirements in
par. (c) 3. a. to
e. for each temperature monitoring device.
NR 465.38(9)(e)
(e) Condensers. If you are using a condenser, you shall monitor the product side condenser outlet gas temperature and comply with
par. (a) and
subds. 1. and
2.
NR 465.38(9)(e)1.
1. The temperature monitor shall provide a gas temperature record at least once every 15 minutes.
NR 465.38(9)(e)2.
2. For all condensers, you shall meet the requirements in
par. (c) 3. for each temperature monitoring device.
NR 465.38(9)(f)
(f) Concentrators. If you are using a concentrator, such as a zeolite wheel or rotary carbon bed concentrator, you shall comply with the requirements in
subds. 1. and
2.
