Section NR 463.09 - Performance test requirements and test methods(1) PERFORMANCE TEST REQUIREMENTS. Performance tests shall be conducted using the test methods and procedures in this section and s. NR 460.06. The test plan to be followed shall be made available to the department prior to the testing, if requested. Performance test results shall be documented in complete test reports that contain all of the following information:(a) A brief process description.(b) Sampling location description.(c) A description of sampling and analytical procedures and any modifications to standard procedures.(e) Quality assurance procedures and results.(f) Records of operating conditions during the test, preparation of calibration standards, and calibration procedures.(g) Raw data sheets for field sampling and field and laboratory analyses.(h) Documentation of calculations.(i) Any other information required by the test method.(2) USE OF OPERATION PERMIT PERFORMANCE TEST RESULTS FOR COMPLIANCE DEMONSTRATION. (a) If the owner or operator of an affected source conducts performance testing at startup to obtain an operation permit under ch. NR 407, the results of the testing may be used to demonstrate compliance with this subchapter if all of the following conditions are met: 1. The test methods and procedures identified in sub. (3) were used during the performance test.2. The performance test was conducted under representative operating conditions for the source.3. The performance test report contains the elements required by sub. (1). 4. The owner or operator of the affected source for which the performance test was conducted has sufficient data to establish the operating parameter values that correspond to compliance with the standards in s. NR 463.04, as required for continuous compliance monitoring under s. NR 463.07.(b) The results of tests conducted prior to December 1991 in which Method 306A in Appendix A of 40 CFR part 63, incorporated by reference in s. NR 484.04, was used to demonstrate the performance of a control technique are not acceptable.(3) TEST METHODS. Each owner or operator subject to the provisions of this subchapter and required by s. NR 463.06(3) to conduct an initial performance test shall use the test methods identified in this section to demonstrate compliance with the standards in s. NR 463.04. (a) Method 306 or Method 306A in Appendix A of 40 CFR part 63, both titled "Determination of Chromium Emissions From Decorative and Hard Chromium Electroplating and Anodizing Operations," which are incorporated by reference in s. NR 484.04, shall be used to determine the chromium concentration from hard or decorative chromium electroplating tanks or chromium anodizing tanks. The sampling time and sample volume for each run of Methods 306 and 306A shall be at least 120 minutes and 1.70 dscm (60 dscf), respectively. Methods 306 and 306A allow the measurement of either total chromium or hexavalent chromium emissions. For the purposes of this subchapter, sources using chromic acid baths may demonstrate compliance with the emission limits of s. NR 463.04 by measuring either total chromium or hexavalent chromium. The hexavalent chromium concentration measured by these methods is equal to the total chromium concentration for the affected operations.(b) Method 306B in Appendix A of 40 CFR part 63, "Surface Tension Measurement and Recordkeeping for Tanks Used at Decorative Chromium Electroplating and Anodizing Facilities," incorporated by reference in s. NR 484.04, shall be used to measure the surface tension of electroplating and anodizing baths.(c) Alternate test methods may also be used if the method has been validated using Method 301 in Appendix A of 40 CFR part 63, incorporated by reference in s. NR 484.04, and if approved by the department. Procedures for requesting and obtaining approval are contained in s. NR 460.06(5).(4) ESTABLISHING SITE-SPECIFIC OPERATING PARAMETER VALUES. (a) Each owner or operator required to establish site-specific operating parameters shall follow the procedures in this subsection.(b) All monitoring equipment shall be installed such that representative measurements of emissions or process parameters from the affected source are obtained. For monitoring equipment purchased from a vendor, verification of the operational status of the monitoring equipment shall include execution of the manufacturer's written specifications or recommendations for installation, operation and calibration of the system.1. Specifications for differential pressure measurement devices used to measure velocity pressure shall be in accordance with section 2.2 of Method 2 in Appendix A of 40 CFR part 60, incorporated by reference in s. NR 484.04.2. Specifications for differential pressure measurement devices used to measure pressure drop across a control system shall be in accordance with manufacturer's accuracy specifications.(c) The surface tension of electroplating and anodizing baths shall be measured using Method 306B in Appendix A of 40 CFR part 63, "Surface Tension Measurement and Recordkeeping for Tanks Used at Decorative Chromium Electroplating and Anodizing Facilities," incorporated by reference in s. NR 484.04. This method shall also be followed when wetting agent type or combination wetting agent/foam blanket type fume suppressants are used to control chromium emissions from a hard chromium electroplating tank and surface tension measurement is conducted to demonstrate continuous compliance.(d) The owner or operator of a source required to measure the velocity pressure at the inlet to an add-on air pollution control device in accordance with s. NR 463.07(2), shall establish the site-specific velocity pressure as follows: 1. Locate a velocity traverse port in a section of straight duct that connects the hooding on the plating tank or tanks with the control device. The port shall be located as close to the control system as possible, and shall be placed a minimum of 2 duct diameters downstream and 0.5 diameter upstream of any flow disturbance such as a bend, expansion or contraction (see Method 1 in Appendix A of 40 CFR part 60, incorporated by reference in s. NR 484.04). If 2.5 diameters of straight duct work does not exist, locate the port 0.8 of the distance between flow disturbances downstream and 0.2 of the distance between flow disturbances upstream from the respective flow disturbances.2. A 12-point velocity traverse of the duct to the control device shall be conducted along a single axis according to Method 2 in Appendix A of 40 CFR part 60, incorporated by reference in s. NR 484.04, using an S-type pitot tube; measurement of the barometric pressure and duct temperature at each traverse point is not required, but is suggested. Mark the S-type pitot tube as specified in Method 1 in Appendix A of 40 CFR part 60, incorporated by reference in s. NR 484.04, with 12 points. Measure the velocity pressure (Dp) values for the velocity points and record. Determine the square root of the individual velocity point Dp values and average. The point with the square root value that comes closest to the average square root value is the point of average velocity. The Dp value measured for this point during the performance test shall be used as the reference for future monitoring.(e) The owner or operator of a source required to measure the pressure drop across the add-on air pollution control device in accordance with s. NR 463.07(1) to (4) may establish the pressure drop in accordance with the following guidelines: 1. Pressure taps shall be installed at any of the following locations: a. At the inlet and outlet of the control system. In this case the inlet tap would be installed in the ductwork just prior to the control device and the corresponding outlet pressure tap would be installed on the outlet side of the control device prior to the blower or on the downstream side of the blower.b. On each side of the packed bed within the control system or on each side of each mesh pad within the control system.c. On the front side of the first mesh pad and back side of the last mesh pad within the control system.2. Pressure taps shall be sited at locations that are:a. As free from pluggage as possible and away from any flow disturbances such as cyclonic demisters.b. Situated such that no air infiltration at the measurement site will occur that could bias the measurement.3. Pressure taps shall be constructed of either polyethylene, polybutylene or other nonreactive materials.4. Nonreactive plastic tubing shall be used to connect the pressure taps to the device used to measure pressure drop.5. Any of the following pressure gauges may be used to monitor pressure drop: a magnehelic gauge, an inclined manometer or a "U" tube manometer.6. Prior to connecting any pressure lines to the pressure gauges, each gauge shall be zeroed. No calibration of the pressure gauges is required.(5) SPECIAL COMPLIANCE PROVISIONS FOR MULTIPLE SOURCES CONTROLLED BY A COMMON ADD-ON AIR POLLUTION CONTROL DEVICE. (a) This subsection identifies procedures for measuring the outlet chromium concentration from an add-on air pollution control device that is used to control multiple sources that may or may not include sources not affected by this subchapter.(b) When multiple affected sources performing the same type of operation (for example, all are performing hard chromium electroplating), and subject to the same emission limitation, are controlled with an add-on air pollution control device that is not controlling emissions from any other type of affected operation or from any sources not affected by this subchapter, the applicable emission limitation identified in s. NR 463.04 shall be met at the outlet of the add-on air pollution control device.(c) When multiple affected sources performing the same type of operation and subject to the same emission limitation are controlled with a common add-on air pollution control device that is also controlling emissions from sources not affected by this subchapter, the following procedures shall be followed to determine compliance with the applicable emission limitation in s. NR 463.04: 1. Calculate the cross-sectional area of each inlet duct (uptakes from each hood) including those not affected by this subchapter.2. Determine the total sample time per test run by dividing the total inlet area from all tanks connected to the control system by the total inlet area for all ducts associated with affected sources, and then multiply this number by 2 hours. The calculated time is the minimum sample time required per test run.3. Perform testing using Method 306 in Appendix A of 40 CFR part 63, incorporated by reference in s. NR 484.04, and calculate an outlet mass emission rate.4. Determine the total ventilation rate from the affected sources by using equation 1: where VRtot is the average total ventilation rate in dscm/min for the 3 test runs as determined at the outlet by means of the Method 306 testing; IDAi is the total inlet area for all ducts associated with affected sources; IAtotal is the sum of all inlet duct areas from both affected sources and sources not affected by this subchapter; and VRinlet is the total ventilation rate from all inlet ducts associated with affected sources.
5. Establish the allowable mass emission rate of the system (AMRsys) in milligrams of total chromium per hour (mg/hr) using equation 2: [SIGMA]VRinlet x EL x 60 minutes/hour = AMRsys Equation (2)
where [SIGMA] VRinlet is the total ventilation rate in dscm/min from the affected sources, and EL is the applicable emission limitation froms. NR 463.04 in mg/dscm. The allowable mass emission rate (AMRsys) calculated from equation 2 shall be equal to or more than the outlet 3-run average mass emission rate determined from Method 306 testing in order for the source to be in compliance with the standard.
(d) When multiple affected sources performing different types of operations (for example, hard chromium electroplating, decorative chromium electroplating or chromium anodizing) are controlled by a common add-on air pollution control device that may or may not also be controlling emissions from sources not affected by this subchapter, or if the affected sources controlled by the common add-on air pollution control device perform the same operation but are subject to different emission limitations (for example, because one is a new hard chromium plating tank and one is an existing small, hard chromium plating tank), the following procedures shall be followed to determine compliance with the applicable emission limitation in s. NR 463.04: 1. Follow the steps outlined in par. (c) 1. to 3.2. Determine the total ventilation rate for each type of affected source using equation 3: See Image
where VRtot is the average total ventilation rate in dscm/min for the 3 test runs as determined at the outlet by means of the Method 306 testing; IDAi,a is the total inlet duct area for all ducts conveying chromic acid from each type of affected source performing the same operation, or each type of affected source subject to the same emission limitation; IAtotal is the sum of all duct areas from both affected sources and sources not affected by this subchapter; and VRinlet,a is the total ventilation rate from all inlet ducts conveying chromic acid from each type of affected source performing the same operation, or each type of affected source subject to the same emission limitation.
3. Establish the allowable mass emission rate in mg/hr for each type of affected source that is controlled by the add-on air pollution control device using equation 4, 5, 6 or 7 as appropriate: See Image
where "hc" applies to the total of ventilation rates for all hard chromium electroplating tanks subject to the same emission limitation, "dc" applies to the total of ventilation rates for the decorative chromium electroplating tanks, "ca" applies to the total of ventilation rates for the chromium anodizing tanks, and EL is the applicable emission limitation from s. NR 463.04 in mg/dscm. There are 2 equations for hard chromium electroplating tanks because different emission limitations may apply (for example, a new tank versus an existing, small tank).
4. Establish the allowable mass emission rate (AMR) in mg/hr for the system using equation 8, including each type of affected source as appropriate: See Image
The allowable mass emission rate calculated from equation 8 shall be equal to or more than the outlet 3-run average mass emission rate determined from Method 306 testing in order for the source to be in compliance with the standards in s. NR 463.04.
(e) Each owner or operator that uses the special compliance provisions of this subsection to demonstrate compliance with the emission limitations of s. NR 463.04 shall submit the measurements and calculations to support these compliance methods with the notification of compliance status required by s. NR 463.106(5).(f) Each owner or operator that uses the special compliance provisions of this subsection to demonstrate compliance with the emission limitations of s. NR 463.04 shall repeat these procedures if a tank is added or removed from the control system regardless of whether that tank is not an affected source. If neither the new tank nor the existing tank is an affected source and the new tank replaces an existing tank of the same size and is connected to the control system through the same size inlet duct, then this procedure does not have to be repeated.(6) COMPLIANCE PROVISIONS FOR MASS RATE EMISSION STANDARD FOR ENCLOSED HARD CHROMIUM ELECTROPLATING TANKS. (a) This subsection identifies procedures for calculating the maximum allowable mass emission rate for owners or operators of affected sources who choose to meet the mass emission rate standard in s. NR 463.04(3) (b) 4. or 5.(b) The owner or operator of an enclosed hard chromium electroplating tank that is an affected source other than an existing affected source located at a small hard chromium electroplating facility who chooses to meet the mass emission rate standard in s. NR 463.04(3) (b) 4. shall determine compliance by not allowing the mass rate of total chromium in the exhaust gas stream discharged to the atmosphere to exceed the maximum allowable mass emission rate calculated using equation 9: MAMER = ETSA x K x 0.015 mg/dscm Equation (9)
where:
MAMER is the alternative emission rate for enclosed hard chromium electroplating tanks in mg/hr
ETSA is the hard chromium electroplating tank surface area in square feet (ft2)
K is the conversion factor, 425 dscm/(ft2 x hr)
(c) Compliance with the alternative mass emission limit in s. NR 463.04(3) (b) 4. is demonstrated if the 3-run average mass emission rate determined from Method 306 in Appendix A of 40 CFR part 63, incorporated by reference in s. NR 484.04(25), testing is less than or equal to the maximum allowable mass emission rate calculated from equation 9 in par. (b).(d) The owner or operator of an enclosed hard chromium electroplating tank that is an existing affected source located at a small hard chromium electroplating facility who chooses to meet the mass emission rate standard in s. NR 463.04(3) (b) 5. shall determine compliance by not allowing the mass rate of total chromium in the exhaust gas stream discharged to the atmosphere to exceed the maximum allowable mass emission rate calculated using equation 10: MAMER = ETSA x K x 0.03 mg/dscm Equation (10)
where:
MAMER is the alternative emission rate for enclosed hard chromium electroplating tanks in mg/hr
ETSA is the hard chromium electroplating tank surface area in square feet (ft2)
K is the conversion factor, 425 dscm/(ft2 x hr)
(e) Compliance with the alternative mass emission limit in s. NR 463.04(3) (b) 5. is demonstrated if the 3-run average mass emission rate determined from Method 306 in Appendix A of 40 CFR part 63, incorporated by reference in s. NR 484.04(25), testing is less than or equal to the maximum allowable mass emission rate calculated from equation 10 in par. (d).Wis. Admin. Code Department of Natural Resources NR 463.09
Cr. Register, September, 1997, No. 501, eff. 10-1-97; CR 05-039: am. (5) (e), cr. (6) Register February 2006 No. 602, eff. 3-1-06; CR 04-023: am. (2) (a) (intro.), (3) (intro.), (a), (5) (a), (b), (c) (intro.), 1., 4., (d) (intro.) and 2. Register December 2008 No. 636, eff. 1-1-09.