Chapter NR 463

NR 463.26(4)(a)7. 7. For each building or structure housing any emission source at the iron and steel foundry, you shall maintain the opacity of any fugitive emissions discharged to the atmosphere at or below 20% opacity (6-minute average), except for one 6-minute average per hour that does not exceed 27% opacity.

NR 463.26(4)(a)8. 8. For each cupola metal melting furnace at a new or existing iron and steel foundry, you shall maintain the average VOHAP concentration in the exhaust stream at or below 20 ppmv corrected to 10% oxygen.

NR 463.26(4)(a)9. 9. For each scrap preheater at an existing iron and steel foundry that does not comply with the work practice standard in s. NR 463.23 (2) (e) 1. or 2. and for each scrap preheater at a new iron and steel foundry that does not comply with the work practice standard in s. NR 463.23 (2) (f), you shall maintain the average VOHAP concentration in the exhaust stream at or below 20 ppmv.

NR 463.26(4)(a)10. 10. For one or more automated conveyor and pallet cooling lines or automated shakeout lines that use a sand mold system at a new iron and steel foundry, you shall do all of the following:

NR 463.26(4)(a)10.a. a. Maintain the 3-hour flow-weighted average VOHAP concentration in the exhaust stream at or below 20 ppmv.

NR 463.26(4)(a)10.b. b. Inspect and maintain each CEMS according to the requirements of sub. (2) (g) and record all information needed to document conformance with these requirements.

NR 463.26(4)(a)10.c. c. Collect and reduce monitoring data according to the requirements of sub. (2) (g) and record all information needed to document conformance with these requirements.

NR 463.26(4)(a)11. 11. For each TEA cold box mold or core making line at a new or existing iron and steel foundry, you shall maintain a 99% reduction in the VOHAP concentration in the exhaust stream or maintain the average VOHAP concentration in the exhaust stream at or below 1 ppmv.

NR 463.26(4)(a)12. 12. You shall conduct subsequent performance tests at least every 5 years for each emission source subject to an emission limit for PM, total metal HAP, VOHAP or TEA in s. NR 463.23 (1) (a) and subsequent performance tests at least every 6 months for each building or structure subject to the opacity limit in s. NR 463.23 (1) (a) 7.

NR 463.26(4)(b) (b) You shall demonstrate continuous compliance for each capture system subject to an operating limit in s. NR 463.23 (1) (b) 1. by doing both of the following:

NR 463.26(4)(b)1. 1. Operate the capture system at or above the lowest values or settings established for the operating limits in your operation and maintenance plan.

NR 463.26(4)(b)2. 2. Monitor the capture system according to the requirements in sub. (1) (a) and collect, reduce and record the monitoring data for each of the operating limit parameters according to the applicable requirements in this subchapter.

NR 463.26(4)(c) (c) You shall demonstrate continuous compliance for each baghouse equipped with a bag leak detection system doing both of the following:

NR 463.26(4)(c)1. 1. Maintain records of the times the bag leak detection system alarm sounded, and for each valid alarm, the time you initiated corrective action, the corrective action taken and the date on which corrective action was completed.

NR 463.26(4)(c)2. 2. Inspect and maintain each baghouse according to the requirements of sub. (1) (b) 1. to 8., and record all information needed to document conformance with these requirements.

NR 463.26(4)(d) (d) You shall demonstrate continuous compliance for each wet scrubber that is subject to the operating limits in s. NR 463.23 (1) (b) 2., by doing all of the following:

NR 463.26(4)(d)1. 1. Maintaining the 3-hour average pressure drop and 3-hour average scrubber water flow rate at levels no lower than those established during the initial or subsequent performance test.

NR 463.26(4)(d)2. 2. Inspecting and maintaining each CPMS according to the requirements of sub. (2) (c) and recording all information needed to document conformance with the requirements.

NR 463.26(4)(d)3. 3. Collecting and reducing monitoring data for pressure drop and scrubber water flow rate according to the requirements of sub. (2) (f) and recording all information needed to document conformance with the requirements.

NR 463.26(4)(e) (e) You shall demonstrate continuous compliance for each combustion device that is subject to the operating limit in s. NR 463.23 (1) (b) 3., by doing all of the following:

NR 463.26(4)(e)1. 1. Maintaining the 15-minute average combustion zone temperature at a level no lower than 1,300°F.

NR 463.26(4)(e)2. 2. Inspecting and maintaining each CPMS according to the requirements of sub. (2) (d) and recording all information needed to document conformance with the requirements.

NR 463.26(4)(e)3. 3. Collecting and reducing monitoring data for combustion zone temperature according to the requirements of sub. (2) (f) and recording all information needed to document conformance with the requirements.

NR 463.26(4)(f) (f) You shall demonstrate continuous compliance for each combustion device that is subject to the operating limit in s. NR 463.23 (1) (b) 4., by doing all of the following:

NR 463.26(4)(f)1. 1. Maintaining the 3-hour average combustion zone temperature at a level no lower than that established during the initial or subsequent performance test.

NR 463.26(4)(f)2. 2. Inspecting and maintaining each CPMS according to the requirements of sub. (2) (d) and recording all information needed to document conformance with these requirements.

NR 463.26(4)(f)3. 3. Collecting and reducing monitoring data for combustion zone temperature according to the requirements of sub. (2) (f) and recording all information needed to document conformance with these requirements.

NR 463.26(4)(g) (g) You shall demonstrate continuous compliance for each acid wet scrubber subject to the operating limits in s. NR 463.23 (1) (b) 5., by doing all of the following:

NR 463.26(4)(g)1. 1. Maintaining the 3-hour average scrubbing liquid flow rate at a level no lower than the level established during the initial or subsequent performance test.

NR 463.26(4)(g)2. 2. Maintaining the 3-hour average pH of the scrubber blowdown at a level no higher than 4.5, if measured by a CPMS, or maintaining the pH level of the scrubber blowdown during each production shift no higher than 4.5.

NR 463.26(4)(g)3. 3. Inspecting and maintaining each CPMS according to the requirements of sub. (2) (e) and recording all information needed to document conformance with the requirements.

NR 463.26(4)(g)4. 4. Collecting and reducing monitoring data for scrubbing liquid flow rate and scrubber blowdown pH according to the requirements of sub. (2) (f) and recording all information needed to document conformance with the requirements. If the pH level of the scrubber blowdown is measured by a probe and meter, you shall demonstrate continuous compliance by maintaining records that document the date, time and results of each sample taken for each production shift.

NR 463.26(5) (5) How do I demonstrate continuous compliance with the work practice standards that apply to me?

NR 463.26(5)(a) (a) You shall maintain records that document continuous compliance with the certification requirements in s. NR 463.23 (2) (b) or with the procedures in your scrap selection and inspection plan required in s. NR 463.23 (2) (c). Your records documenting compliance with the scrap selection and inspection plan shall include a copy kept onsite of the procedures used by the scrap supplier for either removing accessible mercury switches or for purchasing automobile bodies that have had mercury switches removed, as applicable.

NR 463.26(5)(b) (b) You shall keep records of the chemical composition of all catalyst binder formulations applied in each furan warm box mold or core making line at a new or existing iron and steel foundry to demonstrate continuous compliance with the requirements in s. NR 463.23 (2) (d).

NR 463.26(5)(c) (c) For a scrap preheater at an existing iron and steel foundry, you shall operate and maintain each gas-fired preheater so that the flame directly contacts the scrap charged to demonstrate continuous compliance with the requirement s. NR 463.23 (2) (e) 1. If you choose to meet the work practice standard in s. NR 463.23 (2) (e) 2., you shall keep records to document that the scrap preheater charges only material that is subject to and in compliance with the scrap certification requirements in s. NR 463.23 (2) (b).

NR 463.26(5)(d) (d) For a scrap preheater at a new iron and steel foundry, you shall keep records to document that each scrap preheater charges only material that is subject to and in compliance with the scrap certification requirements in s. NR 463.23 (2) (b) to demonstrate continuous compliance with the requirement in s. NR 463.23 (2) (f).

NR 463.26(6) (6) How do I demonstrate continuous compliance with the operation and maintenance requirements that apply to me?

NR 463.26(6)(a) (a) For each capture system and control device for an emission source subject to an emission limit in s. NR 463.23 (1) (a), you shall demonstrate continuous compliance with the operation and maintenance requirements of s. NR 463.23 (3) by doing all of the following:

NR 463.26(6)(a)1. 1. Making monthly inspections of capture systems and initiating corrective action according to s. NR 463.23 (3) (b) 1., and recording all information needed to document conformance with the requirements.

NR 463.26(6)(a)2. 2. Performing preventive maintenance for each control device according to the preventive maintenance plan required by s. NR 463.23 (3) (b) 3., and recording all information needed to document conformance with the requirements.

NR 463.26(6)(a)3. 3. Operating and maintaining each bag leak detection system according to the site-specific monitoring plan required by s. NR 463.23 (3) (b) 4., and recording all information needed to demonstrate conformance with the requirements.

NR 463.26(6)(a)4. 4. Initiating and completing corrective action for a bag leak detection system alarm according to the corrective action plan required by s. NR 463.23 (3) (b) 5., and recording all information needed to document conformance with the requirements.

NR 463.26(6)(a)5. 5. Igniting gases from mold vents according to the procedures in the plan required by s. NR 463.23 (3) (b) 6.

NR 463.26(6)(b) (b) Any instance where you fail to follow the procedures in par. (a) is a deviation that shall be included in your semiannual compliance report.

NR 463.26(6)(c) (c) You shall maintain a current copy of the operation and maintenance plans required by s. NR 463.23 (3) (b) onsite and available for inspection upon request. You shall keep the plans for the life of the iron and steel foundry or until the iron and steel foundry is no longer subject to the requirements of this subchapter.

NR 463.26(7) (7) What other requirements must I meet to demonstrate continuous compliance?

NR 463.26(7)(a) (a) Deviations. You shall report each instance in which you did not meet each emission limitation in s. NR 463.23 (1), including each operating limit, that applies to you. This requirement includes periods of startup, shutdown and malfunction. You also shall report each instance in which you did not meet each work practice standard in s. NR 463.23 (2) and each operation and maintenance requirement of s. NR 463.23 (3) that applies to you. Failure to meet the requirements described in this paragraph are deviations from the emission limitations, work practice standards and operation and maintenance requirements in this subchapter and shall be reported according to the requirements of s. NR 463.27 (2).

NR 463.26(7)(b) (b) Startups, shutdowns and malfunctions.

NR 463.26(7)(b)1. 1. Consistent with the requirements of ss. NR 460.05 (4) and 460.06 (4) (a), deviations that occur during a period of startup, shutdown or malfunction are not violations if you demonstrate to the department’s satisfaction that you were operating in accordance with s. NR 460.05 (4) (a).

NR 463.26(7)(b)2. 2. The department shall determine whether deviations that occur during a period of startup, shutdown or malfunction are violations according to the provisions in s. NR 460.05 (4).

NR 463.26(8) (8) How do I apply for alternative monitoring requirements for a continuous emissions monitoring system?

NR 463.26(8)(a) (a) You may submit a request to the administrator for an alternative monitoring method to demonstrate compliance with the VOHAP emission limits in s. NR 463.23 (1) (a) 10. for automated pallet cooling lines or automated shakeout lines at a new iron and steel foundry according to the procedures in this section.

NR 463.26(8)(b) (b) You may request approval to use an alternative monitoring method in the notification of construction or for new sources, or at any time.

NR 463.26(8)(c) (c) You shall submit a monitoring plan to the administrator that includes a description of the control technique or pollution prevention technique, a description of the continuous monitoring system or method, including appropriate operating parameters that will be monitored, test results demonstrating compliance with the emission limit, operating limits, if applicable, determined according to the test results, and the frequency of measuring and recording to establish continuous compliance. If applicable, you shall also include operation and maintenance requirements for the monitors.

NR 463.26(8)(d) (d) The monitoring plan is subject to approval by the administrator. Use of the alternative monitoring method may not begin until approval is granted by the administrator.

NR 463.26 Note Note: The Administrator of the US Environmental Protection Agency retains the authority to approve major alternatives to monitoring according to 40 CFR 63.7761 (c) (3).

NR 463.26 History History: CR 06-110: cr. Register July 2007 No. 619, eff. 8-1-07.

NR 463.27 NR 463.27 Notifications, reports and records.

NR 463.27(1) (1) What notifications must I submit and when?

NR 463.27(1)(a) (a) You shall submit all of the notifications to the department required by ss. NR 460.05 (6) (c) and (d), 460.06 (2), 460.07 (5) (b) and (6) (c) and (e), and 460.08 (2) to (8) that apply to you by the following specified dates:

NR 463.27(1)(b) (b) As specified in s. NR 460.08 (2) (b), if you start up your iron and steel foundry before April 22, 2004, you shall submit your initial notification no later than August 20, 2004.

NR 463.27(1)(c) (c) If you start up your new iron and steel foundry on or after April 22, 2004, you shall submit your initial notification no later than 120 calendar days after you become subject to this subchapter.

NR 463.27(1)(d) (d) If you are required to conduct a performance test, you shall submit a notification of intent to conduct a performance test at least 20 business days before the performance test is scheduled to begin, as required by s. NR 460.06 (2).

NR 463.27(1)(e) (e) If you are required to conduct a performance test or other initial compliance demonstration, you shall submit a notification of compliance status according to the requirements of s. NR 460.08 (8) and either of the following, as applicable:

NR 463.27(1)(e)1. 1. For each initial compliance demonstration that does not include a performance test, you shall submit the notification of compliance status before the close of business on the 30th calendar day following completion of the initial compliance demonstration.

NR 463.27(1)(e)2. 2. For each initial compliance demonstration that does include a performance test, you shall submit the notification of compliance status, including the performance test results, before the close of business on the 60th calendar day following the completion of the performance test according to the requirement specified in s. NR 460.09 (4) (b).

NR 463.27(2) (2) What reports must I submit and when?

NR 463.27(2)(a) (a) Compliance report due dates. Unless the department has approved a different schedule, you shall submit a semiannual compliance report to the department according to the following requirements:

NR 463.27(2)(a)1. 1. The first compliance report shall cover the period beginning on the compliance date that is specified for your iron and steel foundry in s. NR 463.21 (4) and ending on June 30 or December 31, whichever date comes first after the compliance date that is specified for your iron and steel foundry.

NR 463.27(2)(a)2. 2. The first compliance report shall be postmarked or delivered no later than July 31 or January 31, whichever date comes first after your first compliance report is due.

NR 463.27(2)(a)3. 3. Each subsequent compliance report shall cover the semiannual reporting period from January 1 to June 30 or the semiannual reporting period from July 1 to December 31.

NR 463.27(2)(a)4. 4. Each subsequent compliance report shall be postmarked or delivered no later than July 31 or January 31, whichever date comes first after the end of the semiannual reporting period.

NR 463.27(2)(a)5. 5. For each iron and steel foundry that is subject to permitting regulations pursuant to ch. NR 407, and if the department has established dates for submitting semiannual reports pursuant to s. NR 407.09 (1) (c) 3. a., you may submit the first and subsequent compliance reports according to the dates the department has established instead of the dates specified in subds. 1. to 4.

NR 463.27(2)(b) (b) Compliance report contents. Each compliance report shall include the information specified in subds. 1. to 3. and, as applicable, subds. 4. to 8.

NR 463.27(2)(b)1. 1. The company name and address.

NR 463.27(2)(b)2. 2. A statement by a responsible official, with that official’s name, title and signature, certifying the truth, accuracy and completeness of the content of the report.

NR 463.27(2)(b)3. 3. The date of the report and the beginning and ending dates of the reporting period.

NR 463.27(2)(b)4. 4. If you had a startup, shutdown or malfunction during the reporting period and you took action consistent with your startup, shutdown and malfunction plan, the information in s. NR 460.09 (4) (e) 1.

NR 463.27(2)(b)5. 5. If there were no deviations from any emission limitation, operating limit, work practice standard or operation and maintenance requirement, a statement that there were no deviations from any emission limitation, work practice standard or operation and maintenance requirement during the reporting period.

NR 463.27(2)(b)6. 6. If there were no periods during which a continuous monitoring system, including a CPMS or CEMS, was out-of-control as specified by s. NR 460.07 (3) (g), a statement that there were no periods during which the CPMS or CEMS was out-of-control during the reporting period.

NR 463.27(2)(b)7. 7. For each deviation from an emission limitation, including an operating limit, that occurs at an iron and steel foundry for which you are not using a continuous monitoring system, including a CPMS or CEMS, to comply with an emission limitation or work practice standard required in this subchapter, the information specified in subds. 1. to 4. and in this subdivision. This requirement applies to periods of startup, shutdown and malfunction.

NR 463.27(2)(b)7.a. a. The total operating time of each emissions source during the reporting period.

NR 463.27(2)(b)7.b. b. Information on the number, duration and cause of deviations, including unknown cause, as applicable, and the corrective action taken.

NR 463.27(2)(b)8. 8. For each deviation from an emission limitation, including an operating limit, or work practice standard occurring at an iron and steel foundry where you are using a continuous monitoring system, including a CPMS or CEMS, to comply with the emission limitation or work practice standard in this subchapter, the information specified in subds. 1. to 4. and in this subdivision. This requirement applies to periods of startup, shutdown and malfunction.

NR 463.27(2)(b)8.a. a. The date and time that each malfunction started and stopped.

NR 463.27(2)(b)8.b. b. The date and time that each continuous monitoring system was inoperative, except for zero, low-level and high-level checks.

NR 463.27(2)(b)8.c. c. The date, time and duration that each continuous monitoring system was out-of-control, including the information required in s. NR 460.07 (3) (h).

NR 463.27(2)(b)8.d. d. The date and time that each deviation started and stopped and whether each deviation occurred during a period of startup, shutdown or malfunction or during another period.