where:
CE is the capture efficiency of the emission capture system vented to the add-on control device, percent
TVHused is the total mass of TVH liquid input used in the coating operation during the capture efficiency test run, kg
TVHuncaptured is the total mass of TVH that is not captured by the emission capture system and that exits from the temporary total enclosure or building enclosure during the capture efficiency test run, kg
NR 465.28(6)(b)1.f.f. Determine the capture efficiency of the emission capture system as the average of the capture efficiencies measured in the 3 test runs. NR 465.28(6)(b)2.2. ‘Gas-to-gas protocol using a temporary total enclosure or a building enclosure.’ The gas-to-gas protocol compares the mass of TVH emissions captured by the emission capture system to the mass of TVH emissions not captured. You shall use the following procedures to measure emission capture system efficiency using the gas-to-gas protocol. NR 465.28(6)(b)2.a.a. Either use a building enclosure or construct an enclosure around the coating operation where coatings, thinners and cleaning materials are applied and all areas where emissions from these applied coatings and materials subsequently occur such as flash-off, curing and drying areas. The areas of the coating operation where capture devices collect emissions generated by the coating operation for routing to an add-on control device, such as the entrance and exit areas of an oven or a spray booth, shall also be inside the enclosure. The enclosure shall meet the applicable definition of a temporary total enclosure or building enclosure in Method 204 in 40 CFR part 51, Appendix M, incorporated by reference in s. NR 484.04 (9). NR 465.28(6)(b)2.b.b. Use Method 204B or 204C in 40 CFR part 51, Appendix M, incorporated by reference in s. NR 484.04 (9), to measure the total mass, kg, of TVH emissions captured by the emission capture system during each capture efficiency test run as measured at the inlet to the add-on control device. To make the measurement, substitute TVH for each occurrence of the term VOC in the methods. The sampling points for the Method 204B or 204C measurement shall be upstream from the add-on control device and shall represent total emissions routed from the capture system and entering the add-on control device. If multiple emission streams from the capture system enter the add-on control device without a single common duct, the emissions entering the add-on control device shall be simultaneously measured in each duct, and the total emissions entering the add-on control device shall be determined. NR 465.28(6)(b)2.c.c. Use Method 204D or 204E in 40 CFR part 51, Appendix M, incorporated by reference in s. NR 484.04 (9), to measure the total mass, kg, of TVH emissions that are not captured by the emission capture system; they are measured as they exit the temporary total enclosure or building enclosure during each capture efficiency test run. To make the measurement, substitute TVH for each occurrence of the term VOC in the methods. Use Method 204D if the enclosure is a temporary total enclosure. Use Method 204E if the enclosure is a building enclosure. During the capture efficiency measurement, all organic compound emitting operations inside the building enclosure other than the coating operation for which capture efficiency is being determined shall be shut down, but all fans and blowers shall be operating normally. NR 465.28(6)(b)2.d.d. For each capture efficiency test run, determine the percent capture efficiency of the emission capture system, using the following equation: (Equation 7)
where:
CE is the capture efficiency of the emission capture system vented to the add-on control device, percent
TVHcaptured is the total mass of TVH captured by the emission capture system as measured at the inlet to the add-on control device during the emission capture efficiency test run, kg
TVHuncaptured is the total mass of TVH that is not captured by the emission capture system and that exits from the temporary total enclosure or building enclosure during the capture efficiency test run, kg
NR 465.28(6)(b)2.e.e. Determine the capture efficiency of the emission capture system as the average of the capture efficiencies measured in the 3 test runs. NR 465.28(6)(b)3.3. ‘Alternative capture efficiency protocol.’ As an alternative to the procedures specified in subds. 1. and 2., you may determine capture efficiency using any other capture efficiency protocol and test methods that satisfy the criteria of either the DQO or LCL approach as described in 40 CFR part 63, Subpart KK, Appendix A, incorporated by reference in s. NR 484.04 (24). NR 465.28(7)(7) How do I determine the add-on control device emission destruction or removal efficiency?. NR 465.28(7)(a)(a) For all types of add-on control devices, use the following test methods: NR 465.28(7)(a)3.3. Method 3, 3A or 3B in 40 CFR part 60, Appendix A, incorporated by reference in s. NR 484.04 (13), as appropriate, for gas analysis to determine dry molecular weight. You may also use, as an alternative to Method 3B, the manual method for measuring the oxygen, carbon dioxide and carbon monoxide content of exhaust gas in ANSI/ASME, PTC 19.10-1981, “Flue and Exhaust Gas Analyses”, incorporated by reference in s. NR 484.11 (6). NR 465.28(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 465.28(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), and using the same method for both the inlet and outlet measurements according to the following criteria: NR 465.28(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 465.28(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 465.28(7)(c)(c) If 2 or more add-on control devices are used for the same emission stream, you shall measure emissions at the outlet of each device. NR 465.28 NoteNote: For example, if one add-on control device is a concentrator with an outlet 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 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 465.28(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 8 in this paragraph. 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 8 in this paragraph for each inlet and each outlet and then total all of the inlet emissions and total all of the outlet emissions. (Equation 8)
where:
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.
