Chapter NR 465

NR 465.48(8)(b)3. 3. You shall monitor the temperature at the inlet to the catalyst bed and implement a site-specific inspection and maintenance plan for your catalytic oxidizer as specified in subd. 4. 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 average temperature shall be the minimum operating limit for your catalytic oxidizer.

NR 465.48(8)(b)4. 4. You shall develop and implement an inspection and maintenance plan for your catalytic oxidizers for which you elect to monitor according to subd. 3. The plan shall address, at a minimum, the elements specified in subd. 4. a. to c.

NR 465.48(8)(b)4.a. a. Annual sampling and analysis of the catalyst activity, or conversion efficiency, following the manufacturer’s or catalyst supplier’s recommended procedures. If problems are found during the catalyst activity test, you shall replace the catalyst bed or take other corrective action consistent with the manufacturer’s recommendations.

NR 465.48(8)(b)4.b. b. Monthly external inspection of the catalytic oxidizer system, including the burner assembly and fuel supply lines for problems and, as necessary, adjustment of the equipment to assure proper air-to-fuel mixtures.

NR 465.48(8)(b)4.c. c. Annual internal inspection of the catalyst bed to check for channeling, abrasion and settling. If problems are found during the annual internal inspection of the catalyst, you shall replace the catalyst bed or take other corrective action consistent with the manufacturer’s recommendations. If the catalyst bed is replaced and is not of like or better kind and quality as the old catalyst, then you shall conduct a new performance test to determine destruction efficiency according to sub. (7). If a catalyst bed is replaced and the replacement catalyst is of like or better kind and quality as the old catalyst, then a new performance test to determine destruction efficiency is not required and you may continue to use the previously established operating limits for that catalytic oxidizer.

NR 465.48(8)(c) (c) Regenerative carbon adsorbers. If your add-on control device is a regenerative carbon adsorber, establish the operating limits according to subds. 1. and 2.

NR 465.48(8)(c)1. 1. You shall monitor and record the total regeneration desorbing gas 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 465.48(8)(c)2. 2. The operating limits for your regenerative carbon adsorber shall be the minimum total desorbing gas mass flow recorded during the regeneration cycle and the maximum carbon bed temperature recorded after the cooling cycle.

NR 465.48(8)(d) (d) Condensers. If your add-on control device is a condenser, establish the operating limits according to subds. 1. and 2.

NR 465.48(8)(d)1. 1. During the performance test, you shall monitor and record the condenser outlet, or product side, gas temperature at least once every 15 minutes during each of the 3 test runs.

NR 465.48(8)(d)2. 2. Use the data collected during the performance test to calculate and record the average condenser outlet, or product side, gas temperature maintained during the performance test. This average condenser outlet gas temperature shall be the maximum operating limit for your condenser.

NR 465.48(8)(e) (e) Concentrators. If your add-on control device includes a concentrator, you shall establish operating limits for the concentrator according to subds. 1. to 4.

NR 465.48(8)(e)1. 1. During the performance test, you shall 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 465.48(8)(e)2. 2. Use the data collected during the performance test to calculate and record the average temperature. This average temperature shall be the minimum operating limit for the desorption concentrate gas stream temperature.

NR 465.48(8)(e)3. 3. During the performance test, you shall 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 465.48(8)(e)4. 4. Use the data collected during the performance test to calculate and record the average pressure drop. This average pressure drop shall be the minimum operating limit for the dilute stream across the concentrator.

NR 465.48(8)(f) (f) Emission capture systems. For each capture device that is not part of a PTE that meets the criteria of sub. (6) (a), establish an operating limit for either the gas volumetric flow rate or duct static pressure, as specified in subds. 1. and 2. The operating limit for a PTE is specified in Table 1 of this subchapter. If the source is a magnet wire coating machine, you may use the procedures in section 2.0 of 40 CFR part 63, Subpart MMMM, Appendix A, incorporated by reference in s. NR 484.04 (24g), as an alternative.

NR 465.48(8)(f)1. 1. During the capture efficiency determination required by sub. (1) and described in subs. (5) and (6), you shall 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 465.48(8)(f)2. 2. 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 shall be the minimum operating limit for that specific capture device.

NR 465.48(9) (9) What are the requirements for continuous parameter monitoring system installation, operation and maintenance?

NR 465.48(9)(a) (a) General. You shall install, operate and maintain each CPMS specified in pars. (c), (e), (f) and (g) according to subds. 1. to 6. You shall install, operate and maintain each CPMS specified in pars. (b) and (d) according to subds. 3. to 5.

NR 465.48(9)(a)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 equally spaced successive cycles of CPMS operation in one hour.

NR 465.48(9)(a)2. 2. You shall determine the average of all recorded readings for each successive 3-hour period of the emission capture system and add-on control device operation.

NR 465.48(9)(a)3. 3. You shall record the results of each inspection, calibration and validation check of the CPMS.

NR 465.48(9)(a)4. 4. You shall maintain the CPMS at all times and have available necessary parts for routine repairs of the monitoring equipment.

NR 465.48(9)(a)5. 5. You shall 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 465.48(9)(a)6. 6. 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 465.48(9)(a)7. 7. 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. Any period for which the monitoring system is out-of-control and data are not available for required calculations is a deviation from the monitoring requirements.

NR 465.48(9)(b) (b) Capture system bypass line. You shall meet the requirements of subds. 1. and 2. for each emission capture system that contains bypass lines that could divert emissions away from the add-on control device to the atmosphere.

NR 465.48(9)(b)1. 1. You shall monitor or secure the valve or closure mechanism controlling the bypass line in a non-diverting 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 requirements specified in subd. 1. a. to e.

NR 465.48(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 465.48(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.

NR 465.48(9)(b)1.c. c. Ensure that any bypass line valve is in the closed (non-diverting) position through monitoring of valve position at least once every 15 minutes. You shall inspect the monitoring system at least once every month to verify that the monitor will indicate valve position.

NR 465.48(9)(b)1.d. d. Use an automatic shutdown system in which the coating operation is stopped when flow is diverted by the bypass line away from the add-on control device to the atmosphere when the coating operation is running. You shall inspect the automatic shutdown system at least once every month to verify that it will detect diversions of flow and shut down the coating operation.

NR 465.48(9)(b)1.e. e. Install, calibrate, maintain and operate according to the manufacturer’s specifications a flow direction 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. Each time the flow direction changes, the next reading of the time of occurrence and flow direction shall be recorded. The flow direction indicator shall be installed in each bypass line or air makeup supply line that could divert the emissions away from the add-on control device to the atmosphere.

NR 465.48(9)(b)2. 2. If any bypass line is opened, you shall include a description of why the bypass line was opened and the length of time it remained open in the semiannual compliance reports required in s. NR 465.45 (2).

NR 465.48(9)(c) (c) Thermal oxidizers and catalytic oxidizers. If you are using a thermal oxidizer or catalytic oxidizer as an add-on control device, including those used with concentrators or with carbon adsorbers to treat desorbed concentrate streams, you shall comply with the requirements in subds. 1. to 3.

NR 465.48(9)(c)1. 1. For a thermal oxidizer, install a gas temperature monitor in the firebox of the thermal oxidizer or in the duct immediately downstream of the firebox before any substantial heat exchange occurs.

NR 465.48(9)(c)2. 2. For a catalytic oxidizer, install gas temperature monitors upstream or downstream or both of the catalyst bed as required in sub. (8) (b).

NR 465.48(9)(c)3. 3. For all thermal oxidizers and catalytic oxidizers, you shall meet the requirements in par. (a) and subd. 3. a. to e. for each gas temperature monitoring device.

NR 465.48(9)(c)3.a. a. Locate the temperature sensor in a position that provides a representative temperature.

NR 465.48(9)(c)3.b. b. Use a temperature sensor with a measurement sensitivity of 5°F or 1.0% of the temperature value, whichever is larger.

NR 465.48(9)(c)3.c. c. Before using the sensor for the first time or when relocating or replacing the sensor, perform a validation check by comparing the sensor output to a calibrated temperature measurement device or by comparing the sensor output to a simulated temperature.

NR 465.48(9)(c)3.d. d. Conduct an accuracy audit every quarter and after every deviation. Accuracy audit methods include comparisons of sensor output to redundant temperature sensors, to calibrated temperature measurement devices, or to temperature simulation devices.

NR 465.48(9)(c)3.e. e. Conduct a visual inspection of each sensor every quarter if redundant temperature sensors are not used.

NR 465.48(9)(d) (d) Regenerative carbon adsorbers. If you are using a regenerative carbon adsorber as an add-on control device, you shall monitor the total regeneration desorbing gas mass flow for each regeneration cycle, the carbon bed temperature after each regeneration and cooling cycle, and comply with par. (a) 3. to 5. and subds. 1. to 3.

NR 465.48(9)(d)1. 1. The regeneration desorbing gas mass flow monitor shall be an integrating device having a measurement sensitivity of plus or minus 10% capable of recording the total regeneration desorbing gas mass flow for each regeneration cycle.

NR 465.48(9)(d)2. 2. The carbon bed temperature monitor shall be capable of recording the temperature within 15 minutes of completing any carbon bed cooling cycle.

NR 465.48(9)(d)3. 3. For all regenerative carbon adsorbers, you shall meet the requirements in par. (c) 3. a. to e. for each temperature monitoring device.

NR 465.48(9)(e) (e) Condensers. If you are using a condenser, you shall monitor the condenser outlet, or product side, gas temperature and comply with par. (a) and subds. 1. and 2.

NR 465.48(9)(e)1. 1. The temperature monitor shall provide a gas temperature record at least once every 15 minutes.

NR 465.48(9)(e)2. 2. For all condensers, you shall meet the requirements in par. (c) 3. a. to e. for each temperature monitoring device.

NR 465.48(9)(f) (f) Concentrators. If you are using a concentrator, such as a zeolite wheel or rotary carbon bed concentrator, you shall comply with the requirements in subds. 1. and 2.

NR 465.48(9)(f)1. 1. You shall install a temperature monitor in the desorption gas stream. The temperature monitor shall meet the requirements in pars. (a) and (c) 3.

NR 465.48(9)(f)2. 2. You shall install a device to monitor pressure drop across the zeolite wheel or rotary carbon bed. The pressure monitoring device shall meet the requirements in pars. (a) and (g) 2.

NR 465.48(9)(g) (g) Emission capture systems. The capture system monitoring system shall comply with the applicable requirements in subds. 1. and 2. If the source is a magnet wire coating machine, you may use the procedures in section 2.0 of 40 CFR part 63, Subpart MMMM, Appendix A, incorporated by reference in s. NR 484.04 (24g), as an alternative.

NR 465.48(9)(g)1. 1. For each flow measurement device, you shall meet the requirements in par. (a) and the requirements in subd. 1. a. to g.

NR 465.48(9)(g)1.a. a. Locate a flow sensor in a position that provides a representative flow measurement in the duct from each capture device in the emission capture system to the add-on control device.

NR 465.48(9)(g)1.b. b. Use a flow sensor with an accuracy of at least 10% of the flow.

NR 465.48(9)(g)1.c. c. Perform an initial sensor calibration in accordance with the manufacturer’s requirements.

NR 465.48(9)(g)1.d. d. Perform a validation check before initial use or upon relocation or replacement of a sensor. Validation checks include comparison of sensor values with electronic signal simulations or via relative accuracy testing.

NR 465.48(9)(g)1.e. e. Conduct an accuracy audit every quarter and after every deviation. Accuracy audit methods include comparisons of sensor values with electronic signal simulations or via relative accuracy testing.

NR 465.48(9)(g)1.f. f. Perform leak checks monthly.

NR 465.48(9)(g)1.g. g. Perform visual inspections of the sensor system quarterly if there is no redundant sensor.

NR 465.48(9)(g)2. 2. For each pressure drop measurement device, you shall comply with the requirements in par. (a) and the requirements in subd. 2. a. to g.

NR 465.48(9)(g)2.a. a. Locate the pressure sensor in or as close to a position that provides a representative measurement of the pressure drop across each opening you are monitoring.

NR 465.48(9)(g)2.b. b. Use a pressure sensor with an accuracy of at least 0.5 inches of water column or 5% of the measured value, whichever is larger.

NR 465.48(9)(g)2.c. c. Perform an initial calibration of the sensor according to the manufacturer’s requirements.

NR 465.48(9)(g)2.d. d. Conduct a validation check before initial operation or upon relocation or replacement of a sensor. Validation checks include comparison of sensor values to calibrated pressure measurement devices or to pressure simulation using calibrated pressure sources.

NR 465.48(9)(g)2.e. e. Conduct accuracy audits every quarter and after every deviation. Accuracy audits include comparison of sensor values to calibrated pressure measurement devices or to pressure simulation using calibrated pressure sources.

NR 465.48(9)(g)2.f. f. Perform monthly leak checks on pressure connections. A pressure of at least 1.0 inches of water column to the connection shall yield a stable sensor result for at least 15 seconds.

NR 465.48(9)(g)2.g. g. Perform a visual inspection of the sensor at least monthly if there is no redundant sensor.

Table 1

Operating Limits if Using the Emission Rate With Add-On Controls Option in s. NR 465.43 (2) (c)

If you are required to comply with operating limits by s. NR 465.43 (3) (b), you shall comply with the applicable operating limits in the following table.

Table 2

Default Organic HAP Mass Fraction for Solvents and Solvent Blends

You may use the mass fraction values in the following table for solvent blends for which you do not have test data or manufacturer’s formulation data and which match either the solvent blend name or the chemical abstract series (CAS) number. If a solvent blend matches both the name and CAS number for an entry, that entry’s organic HAP mass fraction shall be used for that solvent blend. Otherwise, use the organic HAP mass fraction for the entry matching either the solvent blend name or CAS number, or use the organic HAP mass fraction from Table 3 of this subchapter if neither the name or CAS number match.

Table 3

Default Organic HAP Mass Fraction for Petroleum Solvent Groups a

You may use the mass fraction values in the following table for solvent blends for which you do not have test data or manufacturer’s formulation data.

NR 465.48 History History: CR 05-040: cr. Register February 2006 No. 602, eff. 3-1-06.