NR 440.647(5)(a)(a) Whenever a particular item of monitoring equipment specified in this subsection is to be installed, the owner or operator shall install, calibrate, maintain and operate according to manufacturer's specifications that item as follows:
NR 440.647(5)(a)1.
1. A temperature monitoring device to measure and record continuously the operating temperature to within 1% (relative to degrees Celsius) or
"0.5
°C (
"0.9
°F), whichever is greater.
NR 440.647(5)(a)2.
2. A flame monitoring device, such as a thermocouple, an ultra-violet sensor, an infrared beam sensor or similar device to indicate and record continuously whether a flare or pilot light flame is present, as specified.
NR 440.647(5)(a)3.
3. A flow monitoring indicator to indicate and record whether or not flow exists at least once every 15 minutes.
NR 440.647(5)(a)4.
4. An organic monitoring device, based on a detection principle such as infrared, photoionization or thermal conductivity, to indicate and record continuously the concentration level of organic compounds.
NR 440.647(5)(a)5.
5. A specific gravity monitoring device to measure and record continuously to within 0.02 specific gravity unit.
NR 440.647(5)(b)
(b) The owner or operator shall install, as applicable, the monitoring equipment for the control means used to comply with
sub. (3) except
sub. (3) (a) 1. a. 4) as follows:
NR 440.647(5)(b)1.a.
a. For a noncatalytic incinerator, a temperature monitoring device shall be installed in the firebox.
NR 440.647(5)(b)1.b.
b. For a catalytic incinerator, temperature monitoring devices shall be installed in the gas stream immediately before and after the catalytic bed.
NR 440.647(5)(b)2.a.
a. A flame monitoring device shall be installed to indicate the presence of a flare flame or a flame for each pilot light, if the flare is used to comply with
sub. (3) (a) 1. including those flares controlling both continuous and intermittent emissions.
NR 440.647(5)(b)2.b.
b. A thermocouple or equivalent monitoring device to indicate the presence of a flame at each pilot light, if used to comply with
sub. (3) (a) 2.
NR 440.647(5)(b)3.a.
a. If the boiler or process heater has a heat input design capacity of less than 150 million Btu/hr, a temperature monitoring device shall be installed between the radiant section and the convection zone for watertube boilers and between the furnace, combustion zone, and the firetubes for firetube boilers.
NR 440.647(5)(b)3.b.
b. If the boiler or process heater has a heat input design capacity of 150 million Btu/hr or greater, records to indicate the periods of operation of the boiler or process heater shall be maintained. The records shall be readily available for inspection.
NR 440.647(5)(b)4.a.
a. A temperature monitoring device and a specific gravity monitoring device for the scrubber liquid shall be installed; or
NR 440.647(5)(b)4.b.
b. An organic monitoring device shall be installed at the outlet of the absorber.
NR 440.647(5)(b)5.a.
a. A temperature monitoring device shall be installed at the condenser exit (product side); or
NR 440.647(5)(b)5.b.
b. An organic monitoring device shall be installed at the outlet of the condenser.
NR 440.647(5)(b)6.
6. If a carbon adsorber is the final unit in a system, an organic monitoring device shall be installed at the outlet of the carbon bed.
NR 440.647(5)(c)
(c) Owners or operators of control devices used to comply with the provisions of this section, except
sub. (3) (a) 1. a. 4) shall monitor these control devices to ensure that they are operated and maintained in conformance with their designs.
NR 440.647(5)(d)
(d) Owners or operators using a vent system that contains valves that could divert a vent stream from a control device used to comply with the provisions of this section shall do one or a combination of the following:
NR 440.647(5)(d)1.
1. Install a flow indicator immediately downstream of each valve that if opened would allow a vent stream to bypass the control device and be emitted, either directly or indirectly, to the atmosphere. The flow indicator shall be capable of recording flow at least once every 15 minutes.
NR 440.647(5)(d)2.
2. Monitor the valves once a month, checking the position of the valves and the condition of the car seal and identify all times when the car seals have been broken and the valve position has been changed, that is, from opened to closed for valves in the vent piping to the control device and from closed to open for valves that allow the stream to be vented directly or indirectly to the atmosphere.
NR 440.647(5)(e)
(e) An owner or operator complying with the standards specified under
sub. (3) except
sub. (3) (a) 1. a. 4) with control devices other than an incinerator, boiler, process heater, flare, absorber, condenser or carbon adsorber or by any other means shall provide to the department information describing the operation of the control device and the process parameters which would indicate proper operation and maintenance of the device. The department may request further information and will specify appropriate monitoring procedures or requirements.
NR 440.647(6)(a)(a) In conducting the performance tests required in
s. NR 440.08, the owner or operator shall use as reference methods and procedures the test methods in Appendix A of
40 CFR part 60, incorporated by reference in
s. NR 440.17, or other methods and procedures specified in this subsection, except as provided under
s. NR 440.08 (2). Owners or operators complying with
sub. (3) (a) 1. a. 4) need not perform a performance test on the control device, provided the control device is not used to comply with any other requirement of
sub. (3) (a).
NR 440.647(6)(a)1.
1. Whenever changes are made in production capacity, feedstock type or catalyst type or whenever there is replacement, removal or addition of a control device, each owner or operator shall conduct a performance test according to the procedures in this subsection as appropriate, in order to determine compliance with
sub. (3).
NR 440.647(6)(a)2.
2. Where a boiler or process heater with a design heat input capacity of 150 million Btu/hr or greater is used, the requirement for an initial performance test is waived, in accordance with
s. NR 440.08 (2). However, the department reserves the option to require testing at such other times as may be required, as provided for in
ch. NR 439.
NR 440.647(6)(a)3.
3. The owner or operator shall determine the average organic concentration for each performance test run using the equipment described in
sub. (5) (a) 4. The average organic concentration shall be determined from measurements taken at least every 15 minutes during each performance test run. The average of the 3 runs shall be the base value for the monitoring program.
NR 440.647(6)(a)4.
4. When an absorber is the final unit in the system, the owner or operator shall determine the average specific gravity for each performance test run using specific gravity monitoring equipment described in
sub. (5) (a) 5. An average specific gravity shall be determined from measurements taken at least every 15 minutes during each performance test run. The average of the 3 runs shall be the base value for the monitoring program.
NR 440.647(6)(a)5.
5. When a condenser is the final unit in the system, the owner or operator shall determine the average outlet temperature for each performance test run using the temperature monitoring equipment described in
sub. (5) (a) 1. An average temperature shall be determined from measurements taken at least every 15 minutes during each performance test run while the vent stream is normally routed and constituted. The average of the 3 runs shall be the base value for the monitoring program.
NR 440.647(6)(b)
(b) Except as provided for in
par. (c), the owner or operator shall determine compliance with the emission concentration standard in
sub. (3) (a) 1. a. 1) or (b) 1. c. if applicable.
where:
CTOC is the concentration of TOC (minus methane and ethane), dry basis, ppmv
Cj is the concentration of sample component j, ppm
n is the number of components in the sample
NR 440.647(6)(b)1.a.
a. Method 18 of
40 CFR part 60, Appendix A, incorporated by reference in
s. NR 440.17 shall be used to determine the concentration of each individual organic component (C
j) in the gas stream. Method 1 or 1A of
40 CFR part 60, Appendix A, incorporated by reference in
s. NR 440.17, as appropriate, shall be used to determine the sampling site at the outlet of the control device. Method 4 of
40 CFR part 60, Appendix A, incorporated by reference in
s. NR 440.17 shall be used to determine the moisture content, if necessary.
NR 440.647(6)(b)1.b.
b. The sampling time for each run shall be 1 hour in which either an integrated sample or 4 grab samples shall be taken. If grab sampling is used, then the samples shall be taken at 15 minute intervals.
NR 440.647(6)(b)2.
2. If supplemental combustion air is used, the TOC concentration shall be corrected to 3% oxygen and shall be computed using the following equation: -
See PDF for diagram 
where:
CCORR is the concentration of TOC corrected to 3% oxygen, dry basis, ppm by volume
CMEAS is the concentration of TOC (minus methane and ethane), dry basis, ppm by volume, as calculated in subd. 1.
%O2d is the concentration of O2, dry basis, percent by volume
NR 440.647(6)(b)2.a.
a. The emission rate correction factor, integrated sampling and analysis procedure of Method 3 of
40 CFR part 60, Appendix A, incorporated by reference in
s. NR 440.17 shall be used to determine the oxygen concentration (%O
2d ). The sampling site shall be the same as that of the TOC sample and the samples shall be taken during the same time that the TOC samples are taken.
NR 440.647(6)(c)
(c) If
par. (b) is not applicable, then the owner or operator shall determine compliance with the percent emission reduction standard in
sub. (3) (a) 1. a. 1) or (b) 1. c. as follows:
where:
P is the percent emission reduction, by weight
Einlet is the mass rate of TOC entering the control device, kg TOC/hr (lb TOC/hr)
Eoutlet is the mass rate of TOC, discharged to the atmosphere, kg TOC/hr (lb TOC/hr)
where:
Cij and Coj are the concentration of sample component “j" of the gas stream at the inlet and outlet of the control device, respectively, dry basis, ppmv
Mij and Moj are the molecular weight of sample component“j" of the gas stream at the inlet and outlet of the control device respectively, g/g-mole (lb/lb-mole)
Qi and Qo are the flow rate of the gas stream at the inlet and outlet of the control device, respectively, dscm/hr (dscf/hr)
Kl = 4.157 10-8 [(kg) / (g-mole)]/[(g) (ppm) (dscm)] {5.711 10-15 [(lb)/(lb-mole)] / [(lb) (ppm) (dscf)]}
NR 440.647(6)(c)2.a.
a. Method 18 shall be used to determine the concentration of each individual organic component (C
ij,, C
oj) in the gas stream. Method 1 or 1A, as appropriate, shall be used to determine the inlet and outlet sampling sites. The inlet site shall be before the inlet of the control device and after all product recovery units.
NR 440.647(6)(c)2.b.
b. Method 2, 2A, 2C or 2D of
40 CFR part 60, Appendix A, incorporated by reference in
s. NR 440.17, as appropriate, shall be used to determine the volumetric flow rates (Q
i,, Q
o). If necessary, Method 4 shall be used to determine the moisture content. Both determinations shall be compatible with the Method 18 determinations.
NR 440.647(6)(c)2.c.
c. Inlet and outlet samples shall be taken simultaneously. The sampling time for each run shall be 1 hour in which either an integrated sample or 4 grab samples shall be taken. If grab sampling is used, then the samples shall be taken at 15 minute intervals.
NR 440.647(6)(d)
(d) An owner or operator shall determine compliance with the individual stream exemptions in
sub. (1) (g) and the procedures specified in Table 3 for compliance with
sub. (3) (a) 1. as identified in
subd. 1. and
2. An owner or operator using the procedures specified in
sub. (3) (a) 1. for determining which continuous process emissions are to be controlled may use calculations demonstrated to be sufficiently accurate as to preclude the necessity of actual testing for purposes of calculating the uncontrolled annual emissions and weight percent of TOC. Owners or operators seeking to exempt streams under
sub. (1) (g) shall use the appropriate test procedures specified in this subsection.
NR 440.647(6)(d)1.
1. The uncontrolled annual emissions of the individual vent stream shall be determined using the following equation:
where:
Eunc is the uncontrolled annual emissions, Mg/yr (ton/yr)
Cj is the concentration of sample component j of the gas stream, dry basis, ppmv
Mj is the molecular weight of sample component j of the gas stream, g/g-mole (lb/lb-mole)
Q is the flow rate of the gas stream, dscm/hr (dscf/hr)
K2 is 4.157 x 10-11 [(Mg) (g-mole)]/[(g) (ppm) (dscm)] for metric units and 1.298 x 10-12 [(ton) (lb-mole)]/[(lb) (ppm) (dscf)] for English units
8,600 is the operating hours per year
NR 440.647(6)(d)1.a.
a. Method 18 shall be used to determine the concentration of each individual organic component (C
j) in the gas stream. Method 1 or 1A, as appropriate, shall be used to determine the sampling site. If the gas stream is controlled in an existing control device, the sampling site shall be before the inlet of the control device and after all product recovery units.
NR 440.647(6)(d)1.b.
b. Method 2, 2A, 2C or 2D, as appropriate, shall be used to determine the volumetric flow rate (Q). If necessary, Method 4 shall be used to determine the moisture content. Both determinations shall be compatible with the Method 18 determinations.
NR 440.647(6)(d)1.c.
c. The sampling time for each run shall be 1 hour in which either an integrated sample or 4 grab samples shall be taken. If grab sampling is used, then the samples shall be taken at 15 minute intervals.
where:
Cj is the concentration of sample TOC component “j" of the gas stream, dry basis, ppmv
Mj is the molecular weight of sample TOC component “j" of the gas stream, g/g-mole (lb/lb-mole)
MWgas is the average molecular weight of the entire gas stream, g/g-mole (lb/lb-mole)
NR 440.647(6)(d)2.a.
a. Method 18 shall be used to determine the concentration of each individual organic component (C
j) in the gas stream. Method 1 or 1A, as appropriate, shall be used to determine the sampling site. If the gas stream is controlled in an existing control device, the sampling site shall be before the inlet of the control device and after all product recovery units. If necessary, Method 4 shall be used to determine the moisture content. This determination shall be compatible with the Method 18 determinations.
NR 440.647(6)(d)2.b.
b. The average molecular weight of the gas stream shall be determined using methods approved by the department. If the carrier component of the gas stream is nitrogen, then an average molecular weight of 28 g/g-mole (lb/lb- mole) may be used in lieu of testing. If the carrier component of the gas stream is air, then an average molecular weight of 29 g/g-mole (lb/lb-mole) may be used in lieu of testing.
NR 440.647(6)(d)2.c.
c. The sampling time for each run shall be 1 hour in which either an integrated sample or 4 grab samples shall be taken. If grab sampling is used, then the samples shall be taken at 15 minute intervals.
NR 440.647(6)(e)
(e) The owner or operator shall determine compliance of flares with the visible emission and flare provisions in
sub. (3) as follows:
