NR 462.05(6)(6) What are my monitoring, installation, operation and maintenance requirements? NR 462.05(6)(a)(a) If you have an applicable work practice standard for carbon monoxide and your boiler or process heater is in any of the large subcategories and has a heat input capacity of 100 mmBtu per hour or greater, you shall install, operate and maintain a continuous emission monitoring system (CEMS) for carbon monoxide according to the procedures in subds. 1. to 6. by the compliance date specified in s. NR 462.01 (5). NR 462.05(6)(a)1.1. Each CEMS shall be installed, operated and maintained according to Performance Specification (PS) 4A of 40 CFR part 60, Appendix B, incorporated by reference in s. NR 484.04 (21), and according to the site-specific monitoring plan developed according to s. NR 462.04 (1) (d). NR 462.05(6)(a)3.3. Each CEMS shall complete a minimum of one cycle of operation, which includes sampling, analyzing and data recording, for each successive 15-minute period. NR 462.05(6)(a)5.5. You shall calculate and record a 30-day rolling average emission rate on a daily basis. A new 30-day rolling average emission rate is calculated as the average of all of the hourly CO emission data for the preceding 30 operating days. NR 462.05(6)(a)6.6. For purposes of calculating data averages, you may not use data recorded during periods of monitoring malfunctions, associated repairs, out-of-control periods, required quality assurance or control activities or when your boiler or process heater is operating at less than 50% of its rated capacity. You shall use all the data collected during all other periods in assessing compliance. Any period for which the monitoring system is out of control and data are not available for required calculations constitutes a deviation from the monitoring requirements. NR 462.05(6)(b)(b) If you have an applicable opacity operating limit, you shall install, operate, certify and maintain each continuous opacity monitoring system (COMS) according to the procedures in subds. 1. to 7. by the compliance date specified in s. NR 462.01 (5). NR 462.05(6)(b)3.3. As specified in s. NR 460.07 (3) (d) 1., each COMS shall complete a minimum of one cycle of sampling and analyzing for each successive 10-second period and one cycle of data recording for each successive 6-minute period. NR 462.05(6)(b)5.5. You shall include in your site-specific monitoring plan procedures and acceptance criteria for operating and maintaining each COMS according to the requirements in s. NR 460.07 (4). At a minimum, the monitoring plan shall include a daily calibration drift assessment, a quarterly performance audit and an annual zero alignment audit of each COMS. NR 462.05(6)(b)6.6. You shall operate and maintain each COMS according to the requirements in the monitoring plan and the requirements of s. NR 460.07 (5). Identify periods the COMS is out of control, including any periods that the COMS fails to pass a daily calibration drift assessment, a quarterly performance audit or an annual zero alignment audit. NR 462.05(6)(b)7.7. You shall determine and record all the 6-minute averages, and one-hour block averages, as applicable, collected for periods during which the COMS is not out of control. NR 462.05(6)(c)(c) If you have an operating limit that requires the use of a CMS, you shall install, operate and maintain each continuous parameter monitoring system (CPMS) according to the procedures in subds. 1. to 5. by the compliance date specified in s. NR 462.01 (5). NR 462.05(6)(c)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 successive cycles of operation to have a valid hour of data. NR 462.05(6)(c)2.2. Except for monitoring malfunctions, associated repairs and required quality assurance or control activities, including, as applicable, calibration checks and required zero and span adjustments, you shall conduct all monitoring in continuous operation at all times that the unit is operating. A monitoring malfunction is any sudden, infrequent, not reasonably preventable failure of the monitoring to provide valid data. Monitoring failures that are caused in part by poor maintenance or careless operation are not malfunctions. NR 462.05(6)(c)3.3. For purposes of calculating data averages, you may not use data recorded during monitoring malfunctions, associated repairs, out of control periods or required quality assurance or control activities. You shall use all the data collected during all other periods in assessing compliance. Any period for which the monitoring system is out-of-control and data are not available for required calculations constitutes a deviation from the monitoring requirements. NR 462.05(6)(c)4.4. Determine the 3-hour block average of all recorded readings, except as provided in subd. 3. NR 462.05(6)(c)5.5. Record the results of each inspection, calibration and validation check. NR 462.05(6)(d)(d) If you have an operating limit that requires the use of a flow measurement device, you shall meet the requirements in par. (c) and subds. 1. to 4. NR 462.05(6)(d)1.1. Locate the flow sensor and other necessary equipment in a position that provides a representative measurement of the flow. NR 462.05(6)(d)2.2. Use a flow sensor with a measurement sensitivity of 2% of the flow rate. NR 462.05(6)(d)3.3. Reduce swirling flow or abnormal velocity distributions due to upstream and downstream disturbances. NR 462.05(6)(e)(e) If you have an operating limit that requires the use of a pressure measurement device, you shall meet the requirements in par. (c) and subds. 1. to 6. NR 462.05(6)(e)1.1. Locate the pressure sensor in a position that provides a representative measurement of the pressure. NR 462.05(6)(e)2.2. Minimize or eliminate pulsating pressure, vibration and internal and external corrosion. NR 462.05(6)(e)3.3. Use a gauge with a minimum tolerance of 1.27 centimeters of water or a transducer with a minimum tolerance of one percent of the pressure range. NR 462.05(6)(e)5.5. Using a manometer, check gauge calibration quarterly and transducer calibration monthly. NR 462.05(6)(e)6.6. Conduct calibration checks any time the sensor exceeds the manufacturer’s specified maximum operating pressure range or install a new pressure sensor. NR 462.05(6)(f)(f) If you have an operating limit that requires the use of a pH measurement device, you shall meet the requirements in par. (c) and subds. 1. to 3. NR 462.05(6)(f)1.1. Locate the pH sensor in a position that provides a representative measurement of scrubber effluent pH. NR 462.05(6)(f)2.2. Ensure that the sample is properly mixed and representative of the fluid to be measured. NR 462.05(6)(f)3.3. Check the pH meter’s calibration on at least 2 points every 8 hours of process operation. NR 462.05(6)(g)(g) If you have an operating limit that requires the use of equipment to monitor voltage and secondary current, or total power input, of an electrostatic precipitator (ESP), you shall use voltage and secondary current monitoring equipment to measure voltage and secondary current to the ESP. NR 462.05(6)(h)(h) If you have an operating limit that requires the use of equipment to monitor sorbent injection rate, such as a weigh belt, weigh hopper or hopper flow measurement device, you shall meet the requirements in par. (c) and subds. 1. to 3. NR 462.05(6)(h)1.1. Locate the device in a position that provides a representative measurement of the total sorbent injection rate. NR 462.05(6)(h)2.2. Install and calibrate the device in accordance with manufacturer’s procedures and specifications. NR 462.05(6)(h)3.3. At least annually, calibrate the device in accordance with the manufacturer’s procedures and specifications. NR 462.05(6)(i)(i) If you elect to use a fabric filter bag leak detection system to comply with the requirements of this chapter, you shall install, calibrate, maintain and continuously operate a bag leak detection system as specified in subds. 1. to 8. NR 462.05(6)(i)1.1. You shall install and operate a bag leak detection system for each exhaust stack of the fabric filter. NR 462.05(6)(i)2.2. Each bag leak detection system shall be installed, operated, calibrated and maintained in a manner consistent with the manufacturer’s written specifications and recommendations and in accordance with the guidance provided in EPA-454/R-98-015, September 1997, incorporated by reference in s. NR 484.06 (4) (c). NR 462.05(6)(i)3.3. The bag leak detection system shall be certified by the manufacturer to be capable of detecting particulate matter emissions at concentrations of 10 milligrams per actual cubic meter or less. NR 462.05(6)(i)4.4. The bag leak detection system sensor shall provide output of relative or absolute particulate matter loadings. NR 462.05(6)(i)5.5. The bag leak detection system shall be equipped with a device to continuously record the output signal from the sensor. NR 462.05(6)(i)6.6. The bag leak detection system shall be equipped with an alarm system that will sound automatically when an increase in relative particulate matter emissions over a preset level is detected. The alarm shall be located where it is easily heard by plant operating personnel. NR 462.05(6)(i)7.7. For positive pressure fabric filter systems that do not duct all compartments or cells to a common stack, a bag leak detection system shall be installed in each baghouse compartment or cell. NR 462.05(6)(i)8.8. Where multiple bag leak detectors are required, the system’s instrumentation and alarm may be shared among detectors. NR 462.05(7)(7) How do I demonstrate initial compliance with the emission limits and work practice standards? NR 462.05(7)(a)(a) You shall demonstrate initial compliance with each emission limit and work practice standard that applies to you by either conducting initial performance tests and establishing operating limits, as applicable, according to sub. (3) (c) and Tables 5 and 7 of this chapter OR conducting initial fuel analyses to determine emission rates and establishing operating limits, as applicable, according to sub. (4) (d) and Tables 6 and 8 of this chapter. NR 462.05(7)(b)(b) New or reconstructed boilers or process heaters in one of the liquid fuel subcategories that burn only fossil fuels and other gases and do not burn any residual oil shall demonstrate compliance according to s. NR 462.04 (2) (a). NR 462.05(7)(c)(c) If you demonstrate compliance through performance testing, you shall establish each site-specific operating limit in Tables 2 to 4 of this chapter that applies to you according to the requirements in sub. (3), Table 7 of this chapter, and subd. 4., as applicable. You shall also conduct fuel analyses according to sub. (4) and establish maximum fuel pollutant input levels according to subds. 1. to 3., as applicable. NR 462.05(7)(c)1.1. You shall establish the maximum chlorine fuel input (Cinput) during the initial performance testing according to the procedures in subd. 1. a. to c. NR 462.05(7)(c)1.a.a. You shall determine the fuel type or fuel mixture that you could burn in your boiler or process heater that has the highest content of chlorine. NR 462.05(7)(c)1.b.b. During the performance testing for HCl, you shall determine the fraction of the total heat input for each fuel type burned (Qi) based on the fuel mixture that has the highest content of chlorine and the average chlorine concentration of each fuel type burned (Ci). where:
Cinput is the maximum amount of chlorine entering the boiler or process heater through fuels burned in units of pounds per million Btu
Ci is the arithmetic average concentration of chlorine in fuel type, i, analyzed according to sub. (4), in units of pounds per million Btu
Qi is the fraction of total heat input from fuel type, i, based on the fuel mixture that has the highest content of chlorine. If you do not burn multiple fuel types during the performance testing, it is not necessary to determine the value of this term. Insert a value of “1” for Qi.
n is the number of different fuel types burned in your boiler or process heater for the mixture that has the highest content of chlorine
NR 462.05(7)(c)2.2. If you choose to comply with the alternative TSM emission limit instead of the particulate matter emission limit, you shall establish the maximum TSM fuel input level (TSMinput) during the initial performance testing according to the procedures in subd. 2. a. to c. NR 462.05(7)(c)2.a.a. You shall determine the fuel type or fuel mixture that you could burn in your boiler or process heater that has the highest content of TSM. NR 462.05(7)(c)2.b.b. During the performance testing for TSM, you shall determine the fraction of total heat input from each fuel burned (Qi) based on the fuel mixture that has the highest content of total selected metals and the average TSM concentration of each fuel type burned (Mi). where:
TSMinput is the maximum amount of TSM entering the boiler or process heater through fuels burned, in units of pounds per million Btu
Mi is the arithmetic average concentration of TSM in fuel type, i, analyzed according to sub. (4), in units of pounds per million Btu
Qi is the fraction of total heat input from fuel type, i, based on the fuel mixture that has the highest content of TSM. If you do not burn multiple fuel types during the performance test, it is not necessary to determine the value of this term. Insert a value of “1” for Qi.
n is the number of different fuel types burned in your boiler or process heater for the mixture that has the highest content of TSM
NR 462.05(7)(c)3.3. You shall establish the maximum mercury fuel input level (Mercuryinput) during the initial performance testing using the procedures in subd. 3. a. to c. NR 462.05(7)(c)3.a.a. You shall determine the fuel type or fuel mixture that you could burn in your boiler or process heater that has the highest content of mercury. NR 462.05(7)(c)3.b.b. During the compliance demonstration for mercury, you shall determine the fraction of total heat input for each fuel burned (Qi) based on the fuel mixture that has the highest content of mercury, and you shall determine the average mercury concentration of each fuel type burned (HGi). where:
Mercuryinput is the maximum amount of mercury entering the boiler or process heater through fuels burned, in units of pounds per million Btu
HGi is the arithmetic average concentration of mercury in fuel type, i, analyzed according to sub. (4), in units of pounds per million Btu
Qi is the fraction of total heat input from fuel type, i, based on the fuel mixture that has the highest mercury content. If you do not burn multiple fuel types during the performance test, it is not necessary to determine the value of this term. Insert a value of “1” for Qi.
n is the number of different fuel types burned in your boiler or process heater for the mixture that has the highest content of mercury
NR 462.05(7)(c)4.a.a. For a wet scrubber, you shall establish the minimum scrubber effluent pH, liquid flow rate and pressure drop, as defined in s. NR 462.02 (32) to (34), as your operating limits during the 3-run performance test. If you use a wet scrubber and you conduct separate performance tests for particulate matter, HCl and mercury emissions, you shall establish one set of minimum scrubber effluent pH, liquid flow rate and pressure drop operating limits. The minimum scrubber effluent pH operating limit shall be established during the HCl performance test. If you conduct multiple performance tests, you shall set the minimum liquid flow rate and pressure drop operating limits at the highest minimum values established during the performance tests. NR 462.05(7)(c)4.b.b. For an electrostatic precipitator, you shall establish the minimum voltage and the minimum secondary current or the minimum total power input, as defined in s. NR 462.02 (36), as your operating limits during the 3-run performance test.
