NR 465.48(4)(c)2.2. Assume that the emission capture system and add-on control device were achieving zero efficiency during the time period of the deviation, unless you have other data indicating the actual efficiency of the emission capture system and add-on control device and the use of these data is approved by the department. NR 465.48(4)(d)(d) You shall meet the requirements for bypass lines in sub. (9) (b) for controlled coating operations for which you do not conduct liquid-liquid material balances. If any bypass line is opened and emissions are diverted to the atmosphere when the coating operation is running, this is a deviation that shall be reported as specified in s. NR 465.45 (1) (c) 6. and (2) (a) 7. For the purposes of completing the compliance calculations specified in sub. (2) (h), you shall treat the materials used during a deviation on a controlled coating operation as if they were used on an uncontrolled coating operation for the time period of the deviation as indicated in Equation 1 of sub. (2). NR 465.48(4)(e)(e) You shall demonstrate continuous compliance with the work practice standards in s. NR 465.43 (4). If you did not develop a work practice plan, or you did not implement the plan, or you did not keep the records required by s. NR 465.45 (3) (k) 8., this is a deviation from the work practice standards that shall be reported as specified in s. NR 465.45 (1) (c) 6. and (2) (a) 7. NR 465.48(4)(f)(f) As part of each semiannual compliance report required in s. NR 465.45 (2), you shall identify the coating operations for which you used the emission rate with add-on controls option. If there were no deviations from the emission limits in s. NR 465.43 (1), you shall submit a statement that you were in compliance with the emission limits during the reporting period because the organic HAP emission rate for each compliance period was less than or equal to the applicable emission limit in s. NR 465.43 (1), and you achieved the operating limits required by s. NR 465.43 (3) and the work practice standards required by s. NR 465.43 (4) during each compliance period. NR 465.48(4)(g)(g) During periods of startup, shutdown or malfunction of the emission capture system, add-on control device, or coating operation that may affect emission capture or control device efficiency, you shall operate in accordance with the startup, shutdown and malfunction plan required by s. NR 465.44 (1) (c). NR 465.48(5)(5) What are the general requirements for performance tests? NR 465.48(5)(a)(a) You shall conduct each performance test required by sub. (1) according to the requirements in s. NR 460.06 (4) (a) and under the conditions in this paragraph, unless you obtain a waiver of the performance test according to the provisions in s. NR 460.06 (7). NR 465.48(5)(a)1.1. ‘Representative coating operation operating conditions.’ You shall conduct the performance test under representative operating conditions for the coating operation. Operations during periods of startup, shutdown or malfunction and during periods of non-operation do not constitute representative conditions. You shall record the process information that is necessary to document operating conditions during the test and explain why the conditions represent normal operation. NR 465.48(5)(a)2.2. ‘Representative emission capture system and add-on control device operating conditions.’ You shall conduct the performance test when the emission capture system and add-on control device are operating at a representative flow rate, and the add-on control device is operating at a representative inlet concentration. You shall record information that is necessary to document emission capture system and add-on control device operating conditions during the test and explain why the conditions represent normal operation. NR 465.48(5)(b)(b) You shall conduct each performance test of an emission capture system according to the requirements in sub. (6). You shall conduct each performance test of an add-on control device according to the requirements in sub. (7). NR 465.48(6)(6) How do i determine the emission capture system efficiency? You shall use the procedures and test methods in this subsection to determine capture efficiency as part of the performance test required by sub. (1). NR 465.48(6)(a)(a) Assuming 100% capture efficiency. You may assume the capture system efficiency is 100% if both of the conditions in subds. 1. and 2. are met. NR 465.48(6)(a)1.1. The capture system meets the criteria in Method 204 in 40 CFR part 51, Appendix M, incorporated by reference in s. NR 484.04 (9), for a PTE and directs all the exhaust gases from the enclosure to an add-on control device. NR 465.48(6)(a)2.2. All coatings, thinners, other additives and cleaning materials used in the coating operation are applied within the capture system; coating solvent flash-off, curing and drying occurs within the capture system; and the removal or evaporation of cleaning materials from the surfaces they are applied to occurs within the capture system. NR 465.48 NoteNote: This criterion is not met if parts enter the open shop environment when being moved between a spray booth and a curing oven.
NR 465.48(6)(b)(b) Measuring capture efficiency. If the capture system does not meet both of the conditions in par. (a) 1. and 2., then you shall use one of the 3 protocols described in pars. (c), (d) and (e) to measure capture efficiency. The capture efficiency measurements use total volatile hydrocarbon (TVH) capture efficiency as a surrogate for organic HAP capture efficiency. For the protocols in pars. (c) and (d), the capture efficiency measurement shall consist of 3 test runs. Each test run shall be at least 3 hours duration or the length of a production run, whichever is longer, up to 8 hours. For the purposes of this test, a production run means the time required for a single part to go from the beginning to the end of the production, which includes surface preparation activities and drying and curing time. NR 465.48(6)(c)(c) Liquid-to-uncaptured-gas protocol using a temporary total enclosure or building enclosure. The liquid-to-uncaptured-gas protocol compares the mass of liquid TVH in materials used in the coating operation to the mass of TVH emissions not captured by the emission capture system. You shall use a temporary total enclosure or a building enclosure and the procedures in subds. 1. to 6. to measure emission capture system efficiency when using the liquid-to-uncaptured-gas protocol. NR 465.48(6)(c)1.1. Either use a building enclosure or construct an enclosure around the coating operation where coatings, thinners, other additives 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 for routing to an add-on control device, such as the entrance and exit areas of an oven or 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 465.48(6)(c)2.2. Use Method 204A or 204F in 40 CFR part 51, Appendix M, incorporated by reference in s. NR 484.04 (9), to determine the mass fraction of TVH liquid input from each coating, thinner, other additive and cleaning material used in the coating operation during each capture efficiency test run. To make the determination, substitute TVH for each occurrence of the term VOC in the methods. NR 465.48(6)(c)3.3. Use Equation 1 of this subsection to calculate the total mass of TVH liquid input from all the coatings, thinners, other additives and cleaning materials used in the coating operation during each capture efficiency test run: where:
TVHused is the mass of liquid TVH in materials used in the coating operation during the capture efficiency test run, kg (lb)
TVHi is the mass fraction of TVH in coating, thinner or other additive, or cleaning material, i, that is used in the coating operation during the capture efficiency test run, kg (lb) of TVH per kg (lb) of material
Voli is the total volume of coating, thinner or other additive, or cleaning material, i, used in the coating operation during the capture efficiency test run, liters (gallons)
Di is the density of coating, thinner or other additive, or cleaning material, i, kg (lb) of material per liter (gallon) of material
n is the number of different coatings, thinners and other additives, and cleaning materials used in the coating operation during the capture efficiency test run
NR 465.48(6)(c)4.4. 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 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. NR 465.48(6)(c)4.b.b. Use Method 204E in 40 CFR part 51, Appendix M, incorporated by reference in s. NR 484.04 (9), 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 465.48(6)(c)5.5. For each capture efficiency test run, determine the percent capture efficiency of the emission capture system using Equation 2: (Equation 2)
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 (lb)
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 (lb)
NR 465.48(6)(c)6.6. Determine the capture efficiency of the emission capture system as the average of the capture efficiencies measured in the 3 test runs. NR 465.48(6)(d)(d) 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 a temporary total enclosure or a building enclosure and the procedures in subds. 1. to 5. to measure emission capture system efficiency when using the gas-to-gas protocol. NR 465.48(6)(d)1.1. Either use a building enclosure or construct an enclosure around the coating operation where coatings, thinners and other additives, 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 465.48(6)(d)2.2. 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 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. NR 465.48(6)(d)2.a.a. 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. NR 465.48(6)(d)2.b.b. If multiple emission streams from the capture system enter the add-on control device without a single common duct, then 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 465.48(6)(d)3.3. 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 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. NR 465.48(6)(d)3.b.b. Use Method 204E in 40 CFR part 51, Appendix M, incorporated by reference in s. NR 484.04 (9), 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 465.48(6)(d)4.4. For each capture efficiency test run, determine the percent capture efficiency of the emission capture system using Equation 3: (Equation 3)
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 (lb)
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 (lb)
NR 465.48(6)(d)5.5. Determine the capture efficiency of the emission capture system as the average of the capture efficiencies measured in the 3 test runs. NR 465.48(6)(e)(e) Alternative capture efficiency protocol. As an alternative to the procedures specified in pars. (c) and (d) and subject to the approval of the department, 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 465.48(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. If the source is a magnet wire coating machine, you may use the procedures in section 3.0 in 40 CFR part 63, Subpart MMMM, Appendix A, incorporated by reference in s. NR 484.04 (24g), as an alternative. NR 465.48(7)(a)(a) For all types of add-on control devices, use the test methods specified in subds. 1. to 5. NR 465.48(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 465.48(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 465.48(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 465.48(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 465.48(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 465.48 NoteNote: 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 465.48(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)
Cc 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 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 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 465.48(7)(e)(e) For each test run, determine the add-on control device organic emissions destruction or removal efficiency, using 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 1of 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 465.48(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 465.48(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 465.43 (3) according to this subsection, unless you have received approval for alternative monitoring and operating limits under 40 CFR 63.8(f) as specified in s. NR 465.43 (3). NR 465.48(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 465.48(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 465.48(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 465.48(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. If the source is a magnet wire coating machine, you may use the procedures in section 3.0 in 40 CFR part 63, Subpart MMMM, Appendix A, incorporated by reference in s. NR 484.04 (24g), as an alternative.
