NR 440.565(5)(c)2.
2. Determine for each affected facility prior to each test run the weighted average mass of VOC per mass of coating solids applied being used at the facility. The weighted average shall be determined as specified in
sub. (4) (a). In this application the quantities of W
oi, W
si and M
ci shall be determined for the time period of each test run and not a calendar month as specified in
sub. (2).
NR 440.565(5)(c)4.a.
a. The owner or operator of the affected facility shall construct the overall VOC emission reduction system so that all volumetric flow rates and total VOC emissions can be accurately determined by the applicable test methods and procedures specified in
sub. (7) (b).
NR 440.565(5)(c)4.b.
b. The owner or operator of an affected facility shall construct a temporary total enclosure around the coating line applicator and flashoff area during the performance test for the purpose of capturing fugitive VOC emissions. If a permanent total enclosure exists in the affected facility prior to the performance test and the department is satisfied that the enclosure is totally capturing fugitive VOC emissions then no additional total enclosure will be required for the performance test.
NR 440.565(5)(c)4.c.
c. For each affected facility where the value of R is greater than or equal to the value R
q calculated in
sub. (4) (b) compliance with
sub. (3) (a) 2. is demonstrated.
NR 440.565(6)(a)(a) The owner or operator of an affected facility subject to this section shall maintain a calendar month record of all coatings used and the results of the reference test methods specified in
sub. (7) (a) or the manufacturer's formulation data used for determining the VOC content of those coatings.
NR 440.565(6)(b)
(b) The owner or operator of an affected facility controlled by a solvent recovery device shall maintain a calendar month record of the amount of solvent applied in the coating at each affected facility.
NR 440.565(6)(c)
(c) The owner or operator of an affected facility controlled by a solvent recovery device shall install, calibrate, maintain and operate a monitoring device for indicating the cumulative amount of solvent recovery by the device over a calendar month period. The monitoring device shall be accurate within
"2.0%. The owner or operator shall maintain a calendar month record of the amount of solvent recovery by the device.
NR 440.565(6)(d)
(d) The owner or operator of an affected facility operating at the conditions specified in
sub. (1) (b) shall maintain a 12 month record of the amount of solvent applied in the coating at the facility.
NR 440.565(6)(e)
(e) The owner or operator of an affected facility controlled by a thermal incineration solvent destruction device shall install, calibrate, maintain and operate a monitoring device which continuously indicates and records the temperature of the solvent destruction device's exhaust gases. The monitoring device shall have an accuracy of the greater of
" 0.75% of the temperature being measured expressed in degrees Celsius or
" 2.5
°C.
NR 440.565(6)(f)
(f) The owner or operator of an affected facility controlled by a catalytic incinerator solvent destruction device shall install, calibrate, maintain, and operate a monitoring device which continuously indicates and records the gas temperature both upstream and downstream of the catalyst bed.
NR 440.565(6)(g)
(g) The owner or operator of an affected facility controlled by a solvent destruction device which uses a hood or enclosure to capture fugitive VOC emissions shall install, calibrate, maintain and operate a monitoring device which continuously indicates that the hood or enclosure is operating. No continuous monitor is required if the owner or operator can demonstrate that the hood or enclosure system is interlocked with the affected facility's oven recirculation air system.
NR 440.565(6)(h)
(h) Records of the measurements required in
subs. (4) and
(6) must be retained for at least two years following the date of the measurements.
NR 440.565(7)(a)(a) The VOC contents per unit of coating solids applied and compliance with
sub. (3) (a) 1. shall be determined by either Method 24 of
40 CFR part 60, Appendix A, incorporated by reference in
s. NR 440.17 (1), and the equations specified in
sub. (4) or by manufacturer's formulation data. In the event of any inconsistency between a Method 24 test and manufacturer's formulation data, the Method 24 test will govern. The department may require an owner or operator to perform Method 24 tests during such months as it deems appropriate. For Method 24, the coating sample shall be a one liter sample taken into a one liter container at a point where the sample will be representative of the coating applied to the web substrate.
NR 440.565(7)(b)
(b) Method 25 of
40 CFR part 60, Appendix A, incorporated by reference in
s. NR 440.17 (1), shall be used to determine the VOC concentration, in parts per million by volume, of each effluent gas stream entering and exiting the solvent destruction device or its equivalent and each effluent gas stream emitted directly to the atmosphere. Methods 1, 2, 3, and 4 of
40 CFR part 60, Appendix A, incorporated by reference in
s. NR 440.17 (1), shall be used to determine the sampling location, volumetric flow rate, molecular weight and moisture of all sampled gas streams. For Method 25, the sampling time for each of 3 runs shall be at least one hour. The minimum sampling volume shall be 0.003 dscm except that shorter sampling times or smaller volumes, when necessitated by process variables or other factors, may be approved by the department.
NR 440.565(7)(c)
(c) If the owner or operator can demonstrate to the department's satisfaction that testing of representative stacks yields results comparable to those that would be obtained by testing all stacks the department will approve testing of representative stacks on a case-by-case basis.
NR 440.565(8)(a)(a) For all affected facilities subject to compliance with
sub. (3) the performance test data and results from the performance test shall be submitted to the department as specified in
s. NR 440.08 (1).
NR 440.565(8)(b)
(b) Following the initial performance test, the owner or operator of each affected facility shall submit quarterly reports to the department of exceedances of the VOC emission limits specified in
sub. (3). If no exceedances occur during a particular quarter, a report stating this shall be submitted to the department semiannually.
NR 440.565(8)(c)
(c) The owner or operator of each affected facility shall also submit reports at the frequency specified in
s. NR 440.07 (3) when the incinerator temperature drops as defined under
sub. (4) (e). If no such periods occur, the owner or operator shall state this in the report.
NR 440.565 History
History: Cr.
Register, September, 1986, No. 369, eff. 10-1-86; renum. to be NR 440.565 and am. (2) (a) (intro.) and (b) (intro.), (5) (b) 1. and (c) 1. and (6) (g), r. (8) (c),
Register, September, 1990, No. 417, eff. 10-1-90; r. and recr. (8) (b), cr. (8) (c),
Register, June, 1993, No. 450, eff. 8-1-93;
CR 06-109: am. (1) (b), (2) (a) 3. and (b) 14. and 15., (3) (a) 2. a., (4) (e), and (7) (a) and (b) Register May 2008 No. 629, eff. 6-1-08. NR 440.57
NR 440.57 Industrial surface coating: large appliances. NR 440.57(1)(1)
Applicability and designation of affected facility. NR 440.57(1)(a)(a) The provisions of this section apply to each surface coating operation in a large appliance surface coating line.
NR 440.57(1)(b)
(b) Any facility under
par. (a) that commences construction, modification or reconstruction after December 24, 1980, is subject to the requirements of this section.
NR 440.57(2)(a)(a) As used in this section, terms not defined in this paragraph have the meanings given in
s. NR 440.02.
NR 440.57(2)(a)1.
1. “Applied coating solids" means the coating solids that adhere to the surface of the large appliance part being coated.
NR 440.57(2)(a)2.
2. “Coating application station" means that portion of the large appliance surface coating operation where a prime coat or a topcoat is applied to large appliances parts or products (e.g., dip tank, spray booth or flow coating unit).
NR 440.57(2)(a)3.
3. “Curing oven" means a device that uses heat to dry or cure the coatings applied to large appliance parts or products.
NR 440.57(2)(a)4.
4. “Electrodeposition" or “EDP" means a method of coating application in which the large appliance part or product is submerged in a tank filled with coating material suspended in water and an electrical potential is used to enhance deposition of the material on the part or product.
NR 440.57(2)(a)5.
5. “Flashoff area" means the portion of a surface coating line between the coating application station and the curing oven.
NR 440.57(2)(a)6.
6. “Large appliance part" means any organic surface-coated metal lid, door, casing, panel or other interior or exterior metal part or accessory that is assembled to form a large appliance product. Parts subject to in-use temperatures in excess of 250
°F are not included in this definition.
NR 440.57(2)(a)7.
7. “Large appliance product" means any organic surface-coated metal range, oven, microwave oven, refrigerator, freezer, washer, dryer, dishwasher, water heater or trash compactor manufactured for household, commercial or recreational use.
NR 440.57(2)(a)8.
8. “Large appliance surface coating line" means that portion of a large appliance assembly plant engaged in the application and curing of organic surface coatings on large appliance parts or products.
NR 440.57(2)(a)9.
9. “Organic coating" means any coating used in a surface coating operation, including dilution solvents, from which VOC emissions occur during the application or the curing process. For the purpose of this section, powder coatings are not included in this definition.
NR 440.57(2)(a)10.
10. “Powder coating" means any surface coating that is applied as a dry powder and is fused into a continuous coating film through the use of heat.
NR 440.57(2)(a)11.
11. “Spray booth" means the structure housing automatic or manual spray application equipment where a coating is applied to large appliance parts or products.
NR 440.57(2)(a)12.
12. “Surface coating operation" means the system on a large appliance surface coating line used to apply and dry or cure an organic coating on the surface of large appliance parts or products. The surface coating operation may be a prime coat or a topcoat operation and includes the coating application station or stations, flashoff area and curing oven.
NR 440.57(2)(a)13.
13. “Transfer efficiency" means the ratio of the amount of coating solids deposited onto the surface of a large appliance part or product to the total amount of the coating solids used.
NR 440.57(2)(a)14.
14. “VOC content" means the proportion of a coating that is volatile organic compounds (VOCs), expressed as kilograms of VOCs per liter of coating solids.
NR 440.57(2)(a)15.
15. “VOC emissions" means the mass of volatile organic compounds (VOCs), expressed as kilograms of VOCs per liter of applied coating solids, emitted from a surface coating operation.
NR 440.57(2)(b)
(b) As used in this section, symbols not defined in this paragraph have the meanings given in
s. NR 440.03.
NR 440.57(2)(b)1.
1. C
a is
the concentration of VOCs in a gas stream leaving a control device and entering the atmosphere (parts per million by volume, as carbon).
NR 440.57(2)(b)2.
2. C
b is the concentration of VOCs in a gas stream entering a control device (parts per million by volume, as carbon).
NR 440.57(2)(b)3.
3. C
f is the concentration of VOCs in a gas stream emitted directly to the atmosphere (parts per million by volume, as carbon).
NR 440.57(2)(b)4.
4. D
c is the density of coating (or input stream), as received (kilograms per liter).
NR 440.57(2)(b)5.
5. D
d is the density of a VOC solvent added to coatings (kilograms per liter).
NR 440.57(2)(b)6.
6. D
r is the density of a VOC solvent recovered by an emission control device (kilograms per liter).
NR 440.57(2)(b)7.
7. E is the VOC destruction efficiency of a control device (fraction).
NR 440.57(2)(b)8.
8. F is the proportion of total VOCs emitted by an affected facility that enters a control device (fraction).
NR 440.57(2)(b)9.
9. G is the volume-weighted average mass of VOCs in coatings consumed in a calendar month per unit volume of applied coating solids (kilograms per liter).
NR 440.57(2)(b)12.
12. L
r is the volume of VOC solvent recovered by an emission control device (liters).
NR 440.57(2)(b)15.
15. M
o is the mass of VOCs in coatings consumed, as received (kilograms).
NR 440.57(2)(b)16.
16. M
r is the mass of VOCs recovered by an emission control device (kilograms).
NR 440.57(2)(b)17.
17. Q
a is the volumetric flow rate of a gas stream leaving a control device and entering the atmosphere (dry standard cubic meters per hour).
NR 440.57(2)(b)18.
18. Q
b is the volumetric flow rate of a gas stream entering a control device (dry standard cubic meters per hour).
NR 440.57(2)(b)19.
19. Q
f is the volumetric flow rate of a gas stream emitted directly to the atmosphere (dry standard cubic meters per hour).
NR 440.57(2)(b)20.
20. R is the overall VOC emission reduction achieved for an affected facility (fraction).
NR 440.57(2)(b)22.
22. V
s is the proportion of solids in a coating (or input stream), as received (fraction by volume).
NR 440.57(2)(b)23.
23. W
o is the proportion of VOCs in a coating (or input stream), as received (fraction by weight).
NR 440.57(3)
(3) Standard for volatile organic compounds. On and after the date on which the performance test required by
s. NR 440.08 is completed, no owner or operator of an affected facility subject to the provisions of this section may discharge or cause the discharge of VOC emissions that exceed 0.90 kilogram of VOCs per liter of applied coating solids from any surface coating operation on a large appliance surface coating line.
NR 440.57(4)
(4) Performance test and compliance provisions. NR 440.57(4)(b)
(b) The owner or operator of an affected facility shall conduct an initial performance test as required under
s. NR 440.08 (1) and thereafter a performance test each calendar month for each affected facility according to the procedures in this paragraph.
NR 440.57(4)(b)1.
1. An owner or operator shall use the following procedures for an affected facility that does not use a capture system and control device to comply with the emissions limit specified under
sub. (3). The owner or operator shall determine the composition of the coatings by formulation data supplied by the coating manufacturer or by analysis of each coating, as received, using Method 24 of
40 CFR part 60, Appendix A, incorporated by reference in
s. NR 440.17 (1). The department may require the owner or operator who uses formulation data supplied by the coating manufacturer to determine the VOC content of coatings using Method 24. The owner or operator shall determine the volume of coating and the mass of VOC-solvent used for thinning purposes from company records on a monthly basis. If a common coating distribution system serves more than one affected facility or serves both affected and existing facilities, the owner or operator shall estimate the volume of coatings used at each facility by using the average dry weight of coating and the surface area coated by each affected and existing facility or by other procedures acceptable to the department.
NR 440.57(4)(b)1.a.
a. Except as provided in
subd. 1. d., the weighted average of the total mass of VOCs consumed per unit volume of coatings solids applied each calendar month shall be determined as follows:
1) Calculate the mass of VOCs consumed (M
o+ M
d) during the calendar month for each affected facility by the following equation: -
See PDF for diagram 
(SLdj Ddj will be zero if no VOC-solvent is added to the coatings, as received.)
where:
n is the number of different coatings used during the calender month
m is the number of different VOC solvents added to coatings during the calendar month
2) Calculate the total volume of coatings solids used (L
s) in the calendar month for each affected facility by the following equation: -
See PDF for diagram
where:
n is the number of different coatings used during the calendar month
3) Select the appropriate transfer efficiency from Table 1. If the owner or operator can demonstrate to the satisfaction of the department that transfer efficiencies other than those shown are appropriate, the department shall approve their use on a case-by-case basis. Transfer efficiencies for application methods not listed shall be determined by the department on a case-by-case basis. An owner or operator shall submit sufficient data for the department to judge the accuracy of the transfer efficiency claims.
-
See PDF for table
Where more than one application method is used within a single surface coating operation, the owner or operator shall determine the composition and volume of each coating applied by each method through a means acceptable to the department and compute the weighted average transfer efficiency by the following equation: -
See PDF for diagram
where:
n is the number of coatings (or input streams) used
m is the number of application methods used
4) Calculate the volume-weighted average mass of VOCs consumed per unit volume of coating solids applied (G) during the calendar month for each affected facility by the following equation: -
See PDF for diagram
