Chapter NR 463

NR 463.25(7)(c)2. 2. That you will inspect, operate and maintain each bag leak detection system according to the procedures in the plan.

NR 463.25(7)(c)3. 3. That you will follow the corrective action procedures for bag leak detection system alarms according to the requirements in the plan.

NR 463.25(7)(d) (d) For each pouring area and pouring station in a new or existing foundry, you have demonstrated initial compliance if you have certified both of the following in your notification of compliance status report:

NR 463.25(7)(d)1. 1. That you have submitted the mold vent ignition plan to the department for approval according to the requirements in s. NR 463.23 (3) (b).

NR 463.25(7)(d)2. 2. That you will follow the procedures for igniting mold vent gases according to the requirements in the plan.

NR 463.25 History History: CR 06-110: cr. Register July 2007 No. 619, eff. 8-1-07.

NR 463.26 NR 463.26 Continuous compliance requirements.

NR 463.26(1) (1) What are my monitoring requirements?

NR 463.26(1)(a) (a) For each capture system subject to an operating limit in s. NR 463.23 (1) (b) 1., you shall install, operate and maintain a CPMS according to the requirements in sub. (2) (a) and both of the following requirements, as applicable:

NR 463.26(1)(a)1. 1. If you use a flow measurement device to monitor the operating limit parameter, you shall at all times monitor the hourly average rate.

NR 463.26 Note Note: For example, the hourly average actual volumetric flow rate through each separately ducted hood or the average hourly total volumetric flow rate at the inlet to the control device.

NR 463.26(1)(a)2. 2. For dampers that are not manually set and remain in the same position, you shall make a visual check at least once every 24 hours to verify that each damper for the capture system is in the same position as during the initial performance test. Dampers that are manually set and remain in the same position are exempt from the requirement to install and operate a CPMS.

NR 463.26(1)(b) (b) For each negative pressure baghouse or positive pressure baghouse equipped with a stack that is applied to meet any PM or total metal HAP emissions limitation in this subchapter, you shall at all times monitor the relative change in PM loadings using a bag leak detection system according to the requirements in sub. (2) (b) and do all of the following:

NR 463.26(1)(b)1. 1. Monitor the pressure drop across each baghouse cell each day to ensure pressure drop is within the normal operating range identified in the manual.

NR 463.26(1)(b)2. 2. Confirm that dust is being removed from hoppers through weekly visual inspections or other means of ensuring the proper functioning of removal mechanisms.

NR 463.26(1)(b)3. 3. Check the compressed air supply for pulse-jet baghouses each day.

NR 463.26(1)(b)4. 4. Monitor cleaning cycles to ensure proper operation using an appropriate methodology.

NR 463.26(1)(b)5. 5. Check bag cleaning mechanisms for proper functioning through monthly visual inspection or equivalent means.

NR 463.26(1)(b)6. 6. Make monthly visual checks of bag tension on reverse air and shaker-type baghouses to ensure that bags are not kinked, kneed or bent, or lying on their sides. You do not have to make this check for shaker-type baghouses using self-tensioning, spring-loaded, devices.

NR 463.26(1)(b)7. 7. Confirm the physical integrity of the baghouse through quarterly visual inspections of the baghouse interior for air leaks.

NR 463.26(1)(b)8. 8. Inspect fans for wear, material buildup and corrosion through quarterly visual inspections, vibration detectors or equivalent means.

NR 463.26(1)(c) (c) For each wet scrubber subject to the operating limits in s. NR 463.23 (1) (b) 2., you shall at all times monitor the 3-hour average pressure drop and scrubber water flow rate using CPMS according to the requirements in sub. (2) (c).

NR 463.26(1)(d) (d) For each combustion device subject to the operating limit in s. NR 463.23 (1) (b) 3., you shall at all times monitor the 15-minute average combustion zone temperature using a CPMS according to the requirements of sub. (2) (d).

NR 463.26(1)(e) (e) For each combustion device subject to the operating limit in s. NR 463.23 (1) (b) 4., you shall at all times monitor the 3-hour average combustion zone temperature using CPMS according to the requirements in sub. (2) (d).

NR 463.26(1)(f) (f) For each wet acid scrubber subject to the operating limits in s. NR 463.23 (1) (b) 5., you shall do both of the following at all times:

NR 463.26(1)(f)1. 1. Monitor the 3-hour average scrubbing liquid flow rate using CPMS according to the requirements of sub. (2) (e) 1.

NR 463.26(1)(f)2. 2. Monitor the 3-hour average pH of the scrubber blowdown using CPMS according to the requirements in sub. (2) (e) 1., or measure and record the pH of the scrubber blowdown once per production cycle using a pH probe and meter according to the requirements in sub. (2) (e) 2.

NR 463.26(1)(g) (g) For one or more automated conveyor and pallet cooling lines and automated shakeout lines at a new iron and steel foundry subject to the VOHAP emissions limit in s. NR 463.23 (1) (a) 10., you shall at all times monitor the 3-hour average VOHAP concentration using a CEMS according to the requirements of sub. (2) (g).

NR 463.26(2) (2) What are the installation, operation and maintenance requirements for my monitors?

NR 463.26(2)(a) (a) For each capture system subject to an operating limit in s. NR 463.23 (1) (b) 1., you shall install, operate and maintain each CPMS according to the following requirements, as applicable:

NR 463.26(2)(a)1. 1. If you use a flow measurement device to monitor an operating limit parameter for a capture system, you shall do all of the following:

NR 463.26(2)(a)1.a. a. Locate the flow sensor and other necessary equipment, such as straightening vanes, in a position that provides a representative flow and that reduces swirling flow or abnormal velocity distributions due to upstream and downstream disturbances.

NR 463.26(2)(a)1.b. b. Use a flow sensor with a minimum measurement sensitivity of 2% of the flow rate.

NR 463.26(2)(a)1.c. c. Conduct a flow sensor calibration check at least semiannually.

NR 463.26(2)(a)1.d. d. At least monthly, inspect all components for integrity, all electrical connections for continuity and all mechanical connections for leakage.

NR 463.26(2)(a)1.e. e. Record the results of each inspection, calibration and validation check required under this subdivision.

NR 463.26(2)(a)2. 2. If you use a pressure measurement device to monitor the operating limit parameter for a capture system, you shall do all of the following:

NR 463.26(2)(a)2.a. a. Locate the pressure sensors in, or as close as possible, to a position that provides a representative measurement of the pressure and that minimizes or eliminates pulsating pressure, vibration, and internal and external corrosion.

NR 463.26(2)(a)2.b. b. Use a gauge with a minimum measurement sensitivity of 0.5 inch of water or a transducer with a minimum measurement sensitivity of one percent of the pressure range.

NR 463.26(2)(a)2.c. c. Check the pressure tap for blockage or plugging daily.

NR 463.26(2)(a)2.d. d. Using a manometer, check gauge calibration quarterly and transducer calibration monthly.

NR 463.26(2)(a)2.e. e. Conduct calibration checks any time the sensor exceeds the manufacturer’s specified maximum operating pressure range or install a new pressure sensor.

NR 463.26(2)(a)2.f. f. At least monthly, inspect all components for integrity, all electrical connections for continuity and all mechanical connections for leakage.

NR 463.26(2)(a)2.g. g. Record the results of each inspection, calibration and validation check required under this subdivision.

NR 463.26(2)(b) (b) You shall install, operate and maintain a bag leak detection system according to all of the following requirements:

NR 463.26(2)(b)1. 1. The system shall be certified by the manufacturer to be capable of detecting emissions of particulate matter at concentrations of 10 milligrams per actual cubic meter (0.0044 grains per actual cubic foot) or less.

NR 463.26(2)(b)2. 2. The bag leak detection system sensor shall provide output of relative particulate matter loadings, and the owner or operator shall continuously record the output from the bag leak detection system using electronic or other means such as a strip chart recorder or a data logger.

NR 463.26(2)(b)3. 3. The system shall be equipped with an alarm that will sound when an increase in relative particulate loadings is detected over the alarm set point established in the operation and maintenance plan. The alarm shall be located such that it can be heard by the appropriate plant personnel.

NR 463.26(2)(b)4. 4. The initial adjustment of the system shall, at a minimum, consist of establishing the baseline output by adjusting the sensitivity or range and the averaging period of the device and establishing the alarm set points and the alarm delay time, if applicable.

NR 463.26(2)(b)5. 5. Following the initial adjustment, the sensitivity or range, averaging period, alarm set point or alarm delay time may not be adjusted without approval from the department. Except, once per quarter, you may adjust the sensitivity of the bag leak detection system to account for seasonal effects, including temperature and humidity, according to the procedures in the operation and maintenance plan required by s. NR 463.23 (3) (b).

NR 463.26(2)(b)6. 6. For negative pressure induced air baghouses and positive pressure baghouses that are discharged to the atmosphere through a stack, the bag leak detector sensor shall be installed downstream of the baghouse and upstream of any wet scrubber.

NR 463.26(2)(b)7. 7. Where multiple detectors are required, the system’s instrumentation and alarm may be shared among detectors.

NR 463.26(2)(c) (c) For each wet scrubber subject to the operating limits in s. NR 463.23 (1) (b) 2., you shall install and maintain CPMS to measure and record the pressure drop and scrubber water flow rate according to the requirements in subds. 1. and 2.:

NR 463.26(2)(c)1. 1. For each CPMS for pressure drop, you shall do all of the following:

NR 463.26(2)(c)1.a. a. Locate the pressure sensor in, or as close as possible to, a position that provides a representative measurement of the pressure drop and that minimizes or eliminates pulsating pressure, vibration and internal and external corrosion.

NR 463.26(2)(c)1.b. b. Use a gauge with a minimum measurement sensitivity of 0.5 inch of water or a transducer with a minimum measurement sensitivity of one percent of the pressure range.

NR 463.26(2)(c)1.c. c. Check the pressure tap for blockage or plugging daily.

NR 463.26(2)(c)1.d. d. Using a manometer, check gauge calibration quarterly and transducer calibration monthly.

NR 463.26(2)(c)1.e. e. Conduct calibration checks any time the sensor exceeds the manufacturer’s specified maximum operating pressure range or install a new pressure sensor.

NR 463.26(2)(c)1.f. f. At least monthly, inspect all components for integrity, all electrical connections for continuity and all mechanical connections for leakage.

NR 463.26(2)(c)2. 2. For each CPMS for scrubber liquid flow rate, you shall do all of the following:

NR 463.26(2)(c)2.a. a. Locate the flow sensor and other necessary equipment in a position that provides a representative flow and that reduces swirling flow or abnormal velocity distributions due to upstream and downstream disturbances.

NR 463.26(2)(c)2.b. b. Use a flow sensor with a minimum measurement sensitivity of 2% of the flow rate.

NR 463.26(2)(c)2.c. c. Conduct a flow sensor calibration check at least semiannually according to the manufacturer’s instructions.

NR 463.26(2)(c)2.d. d. At least monthly, inspect all components for integrity, all electrical connections for continuity and all mechanical connections for leakage.

NR 463.26(2)(d) (d) For each combustion device subject to the operating limit in s. NR 463.23 (1) (b) 3. or 4., you shall install and maintain a CPMS to measure and record the combustion zone temperature according to the following requirements, as applicable:

NR 463.26(2)(d)1. 1. Locate the temperature sensor in a position that provides a representative temperature.

NR 463.26(2)(d)2. 2. For a non-cryogenic temperature range, use a temperature sensor with a minimum tolerance of 2.2°C or 0.75% of the temperature value, whichever is larger.

NR 463.26(2)(d)3. 3. For a cryogenic temperature range, use a temperature sensor with a minimum tolerance of 2.2°C or 2% of the temperature value, whichever is larger.

NR 463.26(2)(d)4. 4. Shield the temperature sensor system from electromagnetic interference and chemical contaminants.

NR 463.26(2)(d)5. 5. If you use a chart recorder, it shall have a sensitivity in the minor division of at least 20°F.

NR 463.26(2)(d)6. 6. 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 shall yield a reading within 16.7°C of the process temperature sensor’s reading.

NR 463.26(2)(d)7. 7. Conduct calibration and validation checks any time the sensor indicates a temperature that exceeds the manufacturer’s specified maximum operating temperature range, or install a new temperature sensor.

NR 463.26(2)(d)8. 8. At least monthly, inspect all components for integrity and all electrical connections for continuity, oxidation and galvanic corrosion.

NR 463.26(2)(e) (e) For each wet acid scrubber subject to the operating limits in s. NR 463.23 (1) (b) 5., you shall install and maintain CPMS to measure and record the scrubbing liquid flow rate according to the requirements in par. (c) 2. and do either of the following:

NR 463.26(2)(e)1. 1. Install and maintain CPMS to measure and record the pH of the scrubber blowdown according to all of the following requirements:

NR 463.26(2)(e)1.a. a. Locate the pH sensor in a position that provides a representative measurement of the pH and that minimizes or eliminates internal and external corrosion.

NR 463.26(2)(e)1.b. b. Use a gauge with a minimum measurement sensitivity of 0.1 pH unit or a transducer with a minimum measurement sensitivity of 5% of the pH range.

NR 463.26(2)(e)1.c. c. Check gauge calibration quarterly or transducer calibration monthly using a manual pH gauge.

NR 463.26(2)(e)1.d. d. At least monthly, inspect all components for integrity, all electrical connections for continuity and all mechanical connections for leakage.

NR 463.26(2)(e)2. 2. Extract a sample for analysis by a pH meter that has all of the following:

NR 463.26(2)(e)2.a. a. A range of at least 1 to 5 pH units or more.

NR 463.26(2)(e)2.b. b. An accuracy of 0.1 pH unit.

NR 463.26(2)(e)2.c. c. A resolution of at least 0.1 pH unit.

NR 463.26(2)(f) (f) You shall operate each CPMS used to meet the requirements of this subchapter according to all of the following requirements:

NR 463.26(2)(f)1. 1. Each CPMS shall complete a minimum of one cycle of operation for each successive 15-minute period. You shall have a minimum of 3 of the required 4 data points to constitute a valid hour of data.

NR 463.26(2)(f)2. 2. Each CPMS shall have valid hourly data for 100% of every averaging period.

NR 463.26(2)(f)3. 3. Each CPMS shall calculate and record the hourly average of all recorded readings and the 3-hour average of all recorded readings.

NR 463.26(2)(g) (g) For each automated conveyor and pallet cooling line and automated shakeout line at a new iron and steel foundry subject to the VOHAP emission limit in s. NR 463.23 (1) (a) 10., you shall install, operate and maintain a CEMS to measure and record the concentration of VOHAP emissions according to all of the following requirements: