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(continued)
9. A statement by the owner or operator as to whether the source has complied with the provisions of this section.
Appendix 3 Content of Ongoing Compliance Status Reports.
Ongoing compliance status reports shall contain the following information:
1. The company name and address of the source;
2. An identification of the operating parameter that is monitored for compliance determination, as required by subsection (e);
3. The relevant emission limitation for the source, and the operating parameter value, or range of values, that correspond to compliance with this emission limitation as specified in the notification of initial compliance status required by Appendix 2;
4. The beginning and ending dates of the reporting period;
5. A description of the type of process performed in the source;
6. The actual cumulative rectifier usage expended during the reporting period, on a month-by-month basis, if the source is a hard chromium electroplating tank;
7. A summary of any excess emissions or exceeded monitoring parameters as identified in the records required by subsection (h)(6);
8. A certification by a responsible official that the inspection and maintenance requirements in subsection (f) were followed in accordance with the operation and maintenance plan for the source;
9. If the operation and maintenance plan required by subsection (g) was not followed, an explanation of the reasons for not following the provisions, an assessment of whether any excess emissions and/or monitoring parameter excesses are believed to have occurred, and a copy of the record(s) required by subsection (h)(1) documenting that the operation and maintenance plan was not followed;
10. A description of any changes in monitoring, processes, or controls since the last reporting period;
11. The name, title, and signature of the responsible official who is certifying the accuracy of the report, and
12. The date of the report.
Appendix 4 Notification of Construction Reports.
Notification of Construction Reports shall contain the following information:
(A) The owner or operator's name, title, and address;
(B) The address (i.e., physical location) or proposed address of the source if different from the owner's or operator's;
(C) A notification of intention to construct a new source or make any physical or operational changes to a source that may meet or has been determined to meet the criteria for a modification;
(D) The expected commencement and completion dates of the construction or modification;
(E) The anticipated date of (initial) startup of the source;
(F) The type of process operation to be performed (hard or decorative chromium electroplating, or chromic acid anodizing);
(G) A description of the air pollution control technique to be used to control emissions, such as preliminary design drawings and design capacity if an add-on air pollution control device is used; and
(H) An estimate of emissions from the source based on engineering calculations and vendor information on control device efficiency, expressed in units consistent with the emission limits of this subpart. Calculations of emission estimates should be in sufficient detail to permit assessment of the validity of the calculations.
Note: A facility can fulfill these report content requirements by complying with the permitting agency's new source review rule or policy, provided similar information is obtained.
Appendix 5 Smoke Test for Chrome Tank Covers.
SMOKE TEST TO VERIFY THE SEAL INTEGRITY OF COVERS DESIGNED TO REDUCE CHROMIUM
EMISSIONS FROM ELECTROPLATING AND ANODIZING TANKS
1. Applicability and Principle
1.1 Applicability. This alternative method is applicable to all hard chromium electroplating and anodizing operations where a chrome tank cover is used on the tank for reducing chromium emissions.
1.2 Principle. During chromium electroplating or anodizing operations, bubbles of hydrogen and oxygen gas generated during the process rise to the surface of the tank liquid and burst. Upon bursting, tiny droplets of chromic acid (chromium mist) become entrained in the air above the tank. Because the chrome tank cover completely encloses the air above the tank, the chromium mist either falls back into the solution because of gravity or collects on the inside walls of the chrome tank cover and runs back into the solution. A semi-permeable membrane allows passage of the hydrogen and oxygen out of the chrome tank cover. A lit smoke device is placed inside the chrome tank cover to detect leaks at the membrane, joints, or seals.
2. Apparatus
2.1 Smoke device. Adequate to generate 500 to 1000 ft <>3 of smoke/20 ft <>2 of tank surface area (e.g., Model #1A=15 SECONDS from Superior Signal, New York).
2.2 Small container. To hold the smoke device.
3. Procedure
Place the small container on a stable and flat area at center of the chrome tank cover (you can use a board and place it on the buss bars). Place the smoke device inside the container. After lighting the smoke device, quickly close the access door to avoid smoke from escaping. Let smoke device completely burn; entire space under the chrome tank cover will now be filled with the smoke. Observe for leaks of smoke from each seal, joint, and membrane of the chrome tank cover. Record these observations including the locations and a qualitative assessment of any leaks of smoke.
When all seals, joints, and membranes have been observed, evacuate the unit to remove the smoke from the chrome tank cover.
Appendix 6 Air Pollution Control or Air Quality Management District Breakdown Rules.
DISTRICT RULE4#RULE NAME
Amador 516 Upset and breakdown conditions
Antelope 430 Breakdown provisions
Bay Area 1 General provisions and definitions
Butte 275 Reporting procedures for excess emissions
Calaveras 516 Upset and breakdown conditions
Colusa 1.13 Equipment breakdown
El Dorado 516 Upset and breakdown conditions
Feather River 9.6 Equipment breakdown
Glenn 95.2 Malfunction of equipment
Great Basin 403 Breakdown
Imperial 111 Equipment breakdown
Kern 111 Equipment breakdown
Lake Chapter III, Malfunction
Article II
Lassen 2:15 Equipment breakdown
Mariposa 516 Upset and breakdown conditions
Mendocino R1-5-540 Equipment breakdown
Modoc 2.12 Equipment breakdown
Mojave 430 Breakdown provisions
Monterey Bay 214 Breakdown condition
North Coast 3-4-540 Breakdown and violation reporting
North Coast 1-5-540 Equipment breakdown
Northern 516 Upset and breakdown conditions
Sierra
Northern 1-5-540 Equipment breakdown
Sonoma
Placer 404 Upset cond. Breakdn. Scheduled
maintenance
Sacramento 602 Breakdown conditions: emergency
variance
San Diego 98 Breakdown conditions: emergency
variance
San Joaquin 110 Equipment breakdown
San Luis 107 Breakdown or upset conditions and
Obispo emergency variances
Santa Barbara 505 Breakdown conditions
Santa Barbara 506 Emergency variances for breakdowns
Shasta 3:10 Excess emissions
Siskiyou 2.12 Equipment breakdown (Siskiyou)
South Coast 430 Breakdown provisions
Tehema 4:17 Upset or breakdown conditions
Tuolumne 516 Upset and breakdown conditions
Ventura 32 Breakdown conditions; emergency
variances
Yolo Solano 5.2 Upset/breakdown conditions: emerg.
variance
Note: Authority cited: sections 39600, 39601, 39650 and 39666, Health and Safety Code. Reference: Sections 39650, 39665 and 39666, Health and Safety Code; and 40 CFR Part 63 Subpart N.
s 93102.5. Airborne Toxic Control Measure to Reduce Emissions of Hexavalent Chromium and Nickel from Thermal Spraying.
(a) Applicability
This Airborne Toxic Control Measure (ATCM) shall apply to each thermal spraying operation at a stationary source that uses materials containing chromium, chromium compounds, nickel, or nickel compounds. This ATCM does not apply to portable thermal spraying operations.
(b) Definitions
For the purposes of this section, the following definitions shall apply:
(1) "Air Pollution Control System" means equipment that is installed for the purpose of collecting and containing emissions of airborne particles from thermal spraying processes. "Air Pollution Control System" includes, but is not limited to, enclosures, exhaust hoods, ductwork, fans/blowers, particulate control devices, and exhaust stacks/vents.
(2) "Control Device" means a device that reduces emissions of particulate matter. "Control Device" includes, but is not limited to, dry filter cartridges, HEPA filters, water curtains, cyclones, baghouses, and scrubbers.
(3) "Detonation Gun Spraying" means a thermal spraying process in which the coating material is heated and accelerated to the workpiece by a series of detonations or explosions from oxygen-fuel gas mixtures.
(4) "Dry Filter System" means a dry particulate filter control system that uses filter media to remove particulate emissions from the exhaust air stream.
(5) "Enclosure" means a structure, such as a booth, that surrounds a thermal spraying process and captures and contains particulate emissions and vents them to a control device. Enclosures may have permanent or temporary coverings on open faces.
(6) "Existing Thermal Spraying Operation" means a thermal spraying operation that is in operation before January 1, 2005.
(7) "Flame Spraying" means a thermal spraying process in which an oxygen/fuel gas flame is the source of heat for melting the surfacing material.
(8) "High Efficiency Particulate Air (HEPA) Filter" means a disposable, dry filter that has a minimum particle collection efficiency of 99.97 percent when tested with a mono-disperse 0.3 um test aerosol.
(9) "Hexavalent chromium" means the form of chromium with a valence state of +6.
(10) "High-Velocity Oxy-Fuel (HVOF) Spraying" means a thermal spray process in which particles are injected into a high-velocity jet formed by the combustion of oxygen and fuel.
(11) "Independent Tester" means a person who engages in the testing of stationary sources to determine compliance with air pollution laws or regulations and who meets all of the following criteria:
(A) The independent tester is not owned in whole or in part by the owner/operator of the thermal spraying operation; and
(B) The independent tester has not received gross income from the owner/operator of the thermal spraying operation in excess of $100,000 or in excess of 10% of the tester's annual revenues, other than as a result of source test contracts; and
(C) The independent tester has not manufactured or installed any emission control device or monitor used in connection with the specific source to be tested; and
(D) When conducting the compliance test, the independent tester does not use any employee or agent who:
1. holds a direct or indirect investment of $1,000 or more in the owner/operator of the thermal spraying operation; or
2. has directly received income in excess of $250 from the owner/operator of the thermal spraying operation in the previous 12 months; or
3. is a director, officer, partner, employee, trustee, or holds any position of management in the owner/operator of the thermal spraying operation.
(12) "Initial Startup" means the first time a new thermal spraying operation begins production or the first time additional or modified thermal spraying operations begin operating at a modified source. If such production or operation occurs prior to the operative date of this section, "Initial Startup" means the operative date of this section. "Initial Startup" does not include operation solely for testing of equipment or subsequent startup of permit units following malfunction or shutdown.
(13) "Intake Area" means the area of the opening(s) in an enclosure from which make-up air is drawn from outside the enclosure during normal operations.
(14) "Inward Face Velocity" means the airflow into an enclosure that prevents escape of contaminated air from the enclosure. Inward face velocity is measured in feet per minute, in accordance with Appendix 2.
(15) "Leak" means the release of any particulate matter from any opening in the emission collection system/device other than the intended exhaust or emission point of that emission control system/device.
(16) "Location" means one or more contiguous or adjacent properties. Contiguous or adjacent properties are properties with two or more parcels of land in actual physical contact, or separated solely by a public roadway or other public right-of-way.
(17) "Modification" means:
(A) any existing thermal spraying operation that did not use materials containing chromium, chromium compounds, nickel or nickel compounds before January 1, 2005, but begins using any of these materials on or after January 1, 2005; or
(B) any physical change in, change in the method of operation of, or addition to an existing permit unit that requires an application for an authority to construct and/or a permit to operate issued by the permitting agency. Routine maintenance and/or repair is not considered a physical change. A "change in the method of operation" of equipment, unless previously limited by an enforceable permit condition, shall not include:
1. an increase in the production rate, unless such increase will result in an increase in emissions that causes a move from a lower tier to a higher tier in subsection (c)(1)(A) Table 1 or Table 2 of this regulation; or
2. an increase in the hours of operation; or
3. a change in ownership of a source; or
(C) the replacement of components for which the fixed capital cost exceeds 50 percent of the fixed capital cost that would be required to construct a comparable new source.
(18) "Modified Thermal Spraying Operation" means any thermal spraying operation which has undergone a modification.
(19) "New Thermal Spraying Operation" means any thermal spraying operation that begins initial operations on or after January 1, 2005. "New Thermal Spraying Operation" does not include the installation of a new permit unit at an existing thermal spraying operation or the modification of an existing thermal spraying operation.
(20) "Operating Parameter" means a parameter established for a control device or process parameter which, if achieved by itself or in combination with one or more other operating parameter values, determines that an owner or operator is in compliance with the applicable emission limitation or standard.
(21) "Permit Unit" means any article, machine, piece of equipment, device, process, or combination thereof, which may cause or control the release of air emissions of hexavalent chromium or nickel from a thermal spraying operation and which requires a permit to operate issued by a permitting agency.
(22) "Permitting Agency" means the local air pollution control or air quality management district.
(23) "Plasma Spraying" means a thermal spraying process in which an electric arc is used to ionize a gas and produce a plasma jet that melts and propels the coating material to the workpiece.
(24) "Point Source" means a permit unit that releases air pollutants through an intended opening such as, but not limited to, a stack, chimney, or vent.
(25) "Portable Thermal Spraying Operation" means a thermal spraying operation that is temporarily used for field applications at offsite locations. A thermal spraying operation is not a "Portable Thermal Spraying Operation" if the thermal spraying operation or its replacement resides at the same location for more than 30 consecutive days.
(26) "Potential to Emit" means the maximum capacity of a stationary source to emit a regulated air pollutant based on its physical and operational design. Any physical or operational limitation on the capacity of the stationary source to emit a pollutant, including air pollution control equipment and restrictions on hours of operation or on the type or amount of material combusted, stored, or processed, shall be treated as part of its design only if the limitations are listed as enforceable conditions in an air permit issued by the permitting agency.
(27) "Sensitive Receptor" means any residence including private homes, condominiums, apartments, and living quarters; education resources such as preschools and kindergarten through grade twelve (k-12) schools; daycare centers; and health care facilities such as hospitals or retirement and nursing homes. A sensitive receptor includes individuals housed in long term care hospitals, prisons, and dormitories or similar live-in housing.
(28) "Stationary Source" means any building, structure, facility or installation which emits any affected pollutant directly or as a fugitive emission. "Building, structure, facility, or installation" includes all pollutant emitting activities which meet all of the following criteria:
(A) are under the same ownership or operation, or which are owned or operated by entities which are under common control; and
(B) belong to the same industrial grouping either by virtue of falling within the same two-digit standard industrial classification code or by virtue of being part of a common industrial process, manufacturing process, or connected process involving a common raw material; and
(C) are located on one or more contiguous or adjacent properties.
(29) "Substantial Use" of an Authority to Construct means one or more of the following: (A) the equipment that constitutes the source has been purchased or acquired; (B) construction activities, other than grading or installation of utilities or foundations, have begun and are continuing; or (C) a contract to complete construction of the source within one year has been entered into.
(30) "Thermal Spraying Operation" means one or more of several processes in which metallic or nonmetallic surfacing materials are deposited in a molten or semi-molten condition on a substrate to form a coating. The surfacing material may originate in the form of powder, rod, or wire before it is heated, prior to spraying and deposition. Thermal spraying processes include: detonation gun spraying, flame spraying, high-velocity oxy-fuel spraying, plasma spraying, and twin-wire electric arc spraying. For the purposes of this section, "Thermal Spraying Operation" includes only those operations that are conducted at stationary sources and use materials containing chromium, chromium compounds, nickel, or nickel compounds. "Thermal Spraying Operation" does not include portable thermal spraying operations.
(31) "Twin-Wire Electric Arc Spraying" means a thermal spraying process where two electrically conducting wires are brought close together to create an electric arc. The molten material formed in the arc is then projected by a compressed gas stream towards a work piece on which it forms a coating.
(32) "Volume Source" means a permit unit, either controlled or uncontrolled, from which air pollutants undergo initial dispersion within a building or structure prior to their release into the outdoor ambient air. "Volume Source" also includes a thermal spraying process that is conducted outside of a building or structure and releases pollutants directly into the outdoor ambient air.
(33) "Water Curtain" means a particulate control system that utilizes flowing water (i.e., a conventional water curtain) or a pumpless system to remove particulate emissions from the exhaust air stream.
(c) Standards
(1) Standards for Existing Thermal Spraying Operations
Effective January 1, 2006, each owner or operator of an existing thermal spraying operation must control hexavalent chromium and nickel emissions by complying with the control efficiency requirements specified in subsection (c)(1)(A), the enclosure standards specified in subsection (c)(1)(B), and the ventilation system standards specified in subsection (c)(1)(C). Annual hexavalent chromium and nickel emissions and maximum hourly nickel emissions must be determined in accordance with the emission calculation methods in Appendix 1 or may be based on the results of an emissions source test. The use of data from an emissions source test must be approved by the permitting agency and the test must be conducted by an independent tester.
(A) Control Efficiency Requirements for Existing Thermal Spraying Operations
All existing thermal spraying operations must control hexavalent chromium and nickel emissions as follows:
1. All hexavalent chromium and nickel emissions from thermal spraying operations must be routed through an air pollution control system that meets the enclosure and ventilation standards in subsections (c)(1)(B) and (c)(1)(C).
2. For point sources, maximum hourly emissions of nickel from all thermal spraying operations at a stationary source must not exceed 0.1 lb. For volume sources, maximum hourly emissions of nickel from all thermal spraying operations must not exceed 0.01 lb.
3. For point sources, the air pollution control system must include a control device that is certified by its manufacturer to meet the minimum control efficiency requirements specified in Table 1 of this subsection (c)(1)(A). For volume sources, the air pollution control system must include a control device that is certified by its manufacturer to meet the minimum control efficiency requirements specified in Table 2 of subsection (c)(1)(A). Emissions of hexavalent chromium and/or nickel from all thermal spraying operations at a stationary source must be included when determining the annual emissions from thermal spraying under subsection (c)(1)(A). If an existing control device meets the minimum control efficiency requirements specified in subsection (c)(1)(A), no additional controls are required by this regulation, but the owner or operator must still comply with the enclosure standards in subsection (c)(1)(B), and the ventilation system standards in subsection (c)(1)(C). If a thermal spraying operation has an air permit that limits the use of chromium and nickel to specific thermal spraying permit units, the control efficiency requirements, enclosure standards, and ventilation system standards only apply to those specific thermal spraying permit units.
4. All thermal spraying operations that are subject to more than one minimum control efficiency requirement under subsection (c)(1)(A) must comply with the most stringent applicable requirement.
Table 1: Point Sources - Control Efficiency Requirements for Existing Thermal
Spraying Operations
Annual Hexavalent Annual Nickel Minimum Control
Chromium Emissions Emissions from Efficiency
Tier from Thermal Spraying 1 Thermal Spraying 1 Requirements 2
1 >0.004 lbs/yr and >2.1 lbs/yr and 90% by weight
<0.04 lbs/yr <20.8 lbs./yr (e.g., a water curtain)
2 > 0.04 lbs/yr and > 20.8 lbs/yr and 99.999% @ 0.5
<0.4 lbs/yr <208 lbs/yr microns(e.g., a
high-efficiency
dry filter)
3 > 0.4 lbs/yr > 208 lbs/yr 99.97% @ 0.3
microns (e.g.,
a HEPA filter)
1. Emissions are controlled emissions from all thermal spraying operations at a stationary source, if the thermal spraying operation is already equipped with a control device.
a. For non-permitted sources, annual emissions must be determined in accordance with the emission calculation methods specified in Appendix 1 or based on the results of an emissions source test that has been reviewed and approved by the permitting agency.
b. For permitted sources,annual emissions must be calculated based on the potential to emit or in accordance with the allowable limits set forth in the permit conditions. Emissions must be determined in accordance with the emission calculation methods specified in Appendix 1 or based on the results of an emissions source test that has been reviewed and approved by the permitting agency.
2. Control efficiency requirements must be certified by the manufacturer/supplier of the control device and/or filter media. Thermal spraying operations are not required to conduct an emissions source test to verify the control efficiency at the listed particle sizes.
Table 2: Volume Sources - Control Efficiency Requirements for Existing Thermal
Spraying Operations
Annual Hexavalent Annual Nickel Minimum Control
Chromium Emissions Emissions from Efficiency
Tier from Thermal Spraying 1 Thermal Spraying 1 Requirements 2
1 >0.001 lbs/yr and >0.3 lbs/yr and 99% by weight
<0.01 lbs/yr <3.1 lbs./yr (e.g., a dry filter)
2 > 0.01 lbs/yr and > 3.1 lbs/yr and 99.999% @ 0.5
<0.1lbs/yr <31 lbs/yr microns (e.g., a
high-efficiency
dry filter)
3 > 0.1 lbs/yr > 31 lbs/yr 99.97% @ 0.3
microns (e.g.,
a HEPA filter)
1. Emissions are controlled emissions from all thermal spraying operations at a stationary source, if the thermal spraying operation is already equipped with a control device.
a. For non-permitted sources, annual emissions must be determined in accordance with the emission calculation methods specified in Appendix 1 or based on the results of an emissions source test that has been reviewed and approved by the permitting agency.
b. For permitted sources,annual emissions must be calculated based on the potential to emit or in accordance with the allowable limits set forth in the permit conditions. Emissions must be determined in accordance with the emission calculation methods specified in Appendix 1 or based on the results of an emissions source test that has been reviewed and approved by the permitting agency.
2. Control efficiency requirements must be certified by the manufacturer/supplier of the control device and/or filter media. Thermal spraying operations are not required to conduct an emissions source test to verify the control efficiency at the listed particle sizes.
(B) Enclosure Standards
All existing thermal spraying operations that are subject to subsection (c)(1)(A) must use air pollution control systems that meet the following criteria by January 1, 2006. All modified or new thermal spraying operations that are subject to subsection (c)(2)(A)2. or (c)(3)(A)1., respectively, must use air pollution control systems that meet the following criteria upon initial startup.
1. Enclosures must be exhaust ventilated such that a continuous inward flow of air is maintained from all designed make-up air openings during thermal spraying operations.
2. To ensure good capture of airborne pollutants, the average inward face velocity of air through the enclosure must either be:
a. a minimum of 100 feet per minute; or
b. the minimum velocity for metal spraying facilities as established in "Industrial Ventilation, A Manual of Recommended Practice", 25th Edition, published by the American Conference of Governmental Industrial Hygienists, which is incorporated by reference herein.
The inward face velocity must be confirmed by a velocity measuring device approved by the permitting agency (e.g., a pitot tube or anemometer.) Measurement of inward face velocity must be performed in accordance with the methods set forth in Appendix 2 or an alternative method approved by the permitting agency. This subsection does not require the use of an independent tester to measure inward face velocity.
3. When thermal spraying is being performed, all air inlets and access openings must be covered to prevent the escape of dust or mist contaminants into areas outside the enclosure. This requirement does not apply to any designed or intended make-up air vents or openings. Coverings can be permanent (e.g., a door) or temporary (e.g., plastic flaps). Temporary coverings must be approved by the permitting agency.
4. Before the enclosure is opened, thermal spraying must cease and the exhaust system must be run for a sufficient period of time, as determined by the permitting agency, to remove contaminated air within the enclosure. A minimum of three air exchanges must be exhausted from the booth after thermal spraying ceases.
5. For the purposes of thermal spraying equipment calibration or research and development activities, permitting agencies may allow operators to open the enclosure door during thermal spraying operations, if all of the following conditions are met:
a. The enclosure must be a four-sided booth equipped with a permanent door.
b. The enclosure must be under negative pressure, as demonstrated in accordance with subsection (d)(1)(C).
c. The owner or operator must verify that the average inward face velocity of air through the enclosure is at least 100 feet per minute while the door is open, in accordance with Appendix 2.
d. The owner or operator must obtain approval from the permitting agency before beginning operations pursuant to this subsection.
(C) Ventilation System Standards
1. Installation of Ventilation System for Existing, New, and Modified Thermal Spraying Operations
For existing thermal spraying operations, the exhaust gas stream from the air pollution control system required by subsection (c)(1)(B) must be ducted to a particulate matter control device meeting the applicable control efficiency requirements of subsection (c)(1)(A) by January 1, 2006.
For modified or new thermal spraying operations, the exhaust gas stream from the air pollution control collection system required by subsection (c)(1)(B) must be ducted to a particulate matter control device meeting the applicable control efficiency requirements of subsection (c)(2)(A)2. or (c)(3)(A)1., respectively, upon initial startup.
2. Operating Requirements for Ventilation Systems at Existing, New, and Modified Thermal Spraying Operations
a. The ventilation system and control device must be properly maintained and kept in good operating condition at all times. Any leak, as determined by a visual leak inspection conducted in accordance with Appendix 3, is a violation of this section.
b. Material collected by a particulate matter control system must be discharged into closed containers or an enclosed system that is completely sealed to prevent dust emissions.
c. Dust collectors for control devices must be maintained in a manner that prevents emissions of particulate matter into the ambient air.
(D) Permit Requirements for Existing Thermal Spraying Operations
All unpermitted existing thermal spraying operations must submit a permit application to the permitting agency no later than October 1, 2005. This permitting requirement applies only to existing thermal spraying operations that use materials containing chromium, chromium compounds, nickel, or nickel compounds.
(E) Standards for Remotely Located Existing Thermal Spraying Operations
1. The requirements of subsections (c)(1)(A), (c)(1)(B), and (c)(1)(C) do not apply to existing thermal spraying operations that meet all of the following criteria:
a. The thermal spraying operation is located at least 1,640 feet from a sensitive receptor, as determined by the permitting agency; and
b. Annual emissions of hexavalent chromium from all thermal spraying operations do not exceed 0.5 lb; and
c. The thermal spraying operation uses an air pollution control system that achieves a minimum control efficiency of 90 percent; and
d. The thermal spraying operation complies with the permitting requirements of subsection (c)(1)(D); and
e. The owner or operator of the thermal spraying operation has submitted an annual report to the permitting agency by March 1st of each calendar year, that quantifies emissions of hexavalent chromium and nickel from all thermal spraying operations during the previous calendar year; and
f. The thermal spraying operation has undergone a site specific analysis from the permitting agency to ensure public health protection.
2. Thermal spraying operations that qualify for this standard must undergo an annual evaluation by the permitting agency to ensure that the thermal spraying operation still complies with the conditions of this standard. This standard shall cease to apply if the permitting agency determines that the thermal spraying operation no longer meets all of the criteria in subsection (c)(1)(E)1. If the permitting agency determines that the standard ceases to apply, the owner or operator of the thermal spraying operation must submit a permit application to the permitting agency within 3 months of receipt of the permitting agency's determination. The owner or operator must achieve compliance with the requirements of this section within 9 months of receipt of the permitting agency's determination.
(F) Exemption for Existing Thermal Spraying Operations with Low Emission Levels
1. The requirements in subsections (c)(1)(A), (c)(1)(B), and (c)(1)(C) shall not apply to existing thermal spraying operations that meet all of the following criteria:
a. For point sources, annual emissions of hexavalent chromium are less than 0.004 lb and annual emissions of nickel are less than 2.1 lbs. For volume sources, annual emissions of hexavalent chromium are less than 0.001 lb and annual emissions of nickel are less than 0.3 lb; and
b. For point sources, maximum hourly emissions of nickel from all thermal spraying operations at a stationary source do not exceed 0.1 lb. For volume sources, maximum hourly emissions of nickel from all thermal spraying operations at a stationary source do not exceed 0.01 lb; and
c. The thermal spraying operation complies with the permitting requirements of subsection (c)(1)(D); and
d. The owner or operator of the thermal spraying operation has submitted an annual report to the permitting agency by March 1st of each calendar year, that quantifies emissions of hexavalent chromium and nickel from all thermal spraying operations during the previous calendar year.
(2) Standards for Modified Thermal Spraying Operations
(A) Upon initial startup, each owner or operator of a modified thermal spraying operation must comply with all of the following requirements:
1. Modified thermal spraying operations must control hexavalent chromium and nickel emissions by complying with the control efficiency requirements specified in subsection (c)(2)(A)2.
2. All thermal spraying operations that undergo a modification on or after January 1, 2005, must use a control device that is certified by the manufacturer to achieve 99.97 percent control efficiency for particles that are 0.3 micron in diameter. These thermal spraying operations must also comply with the enclosure standards specified in subsection (c)(1)(B) and the ventilation standards specified in subsection (c)(1)(C).
3. For point sources, the maximum hourly emissions of nickel from all thermal spraying operations at a stationary source must not exceed 0.1 lb. For volume sources, the maximum hourly emissions of nickel from all thermal spraying operations at a stationary source must not exceed 0.01 lb. Maximum hourly nickel emissions must be determined in accordance with the emission calculation methods specified in Appendix 1 or may be based on the results of an emissions source test. The use of source test data must be approved by the permitting agency and the test must be conducted by an independent tester.
4. All thermal spraying operations that undergo a modification on or after January 1, 2005, must submit a permit modification application to the permitting agency, in accordance with permitting agency requirements. This permitting requirement only applies to thermal spraying operations that use materials containing chromium, chromium compounds, nickel, or nickel compounds.
(3) Standards for New Thermal Spraying Operations
(A) 1. No person may operate a new thermal spraying operation unless it is located outside of an area that is zoned for residential or mixed use and is located at least 500 feet from the boundary of any area that is zoned for residential or mixed use.
2. A new thermal spraying operation shall be deemed to meet the standard specified above in subsection (c)(3)(A)1. if one of the following criteria are met, even if the operation does not meet the standard at the time of initial startup (e.g., because of a zoning change that occurs after the authority to construct is issued):
a. A new thermal spraying operation shall be deemed to meet the standard specified above if it meets the standard at the time it is issued an authority to construct by the permitting agency, and substantial use of the authority to construct takes place within one year after it is issued, or
b. A new thermal spraying operation shall be deemed to meet the standard specified above if it meets the standard at the time it is issued an authority to construct by the permitting agency, and substantial use of the authority to construct takes place before any zoning change occurs that affects the operation's ability to meet the standard at the time of initial start-up.
3. Prior to initial startup of a new thermal spraying operation, the owner or operator must demonstrate to the permitting agency that the operation either meets the standard specified above in subsection (c)(3)(A)1., or meets one of the criteria specified above in subsection (c)(3)(A)2.
(B) On and after initial startup, the new thermal spraying operation must use a control device that is certified by the manufacturer to achieve 99.97 percent control efficiency for particles that are 0.3 micron in diameter. These operations must also comply with the enclosure standards specified in subsection (c)(1)(B) and the ventilation standards specified in subsection (c)(1)(C).
(C) The maximum hourly emissions of nickel from all thermal spraying operations at a stationary source must not exceed 0.1 lb. Maximum hourly nickel emissions must be determined in accordance with the emission calculation methods specified in Appendix 1 or may be based on the results of an emissions source test. The use of source test data must be approved by the permitting agency and the test must be conducted by an independent tester.
(D) Prior to initial startup, the thermal spraying operation must undergo a site specific analysis from the permitting agency to ensure public health protection.
(E) Permit Requirements for New Thermal Spraying Operations
All new thermal spraying operations must submit a permit application to the permitting agency prior to initial startup, in accordance with permitting agency requirements. This permitting requirement only applies to new thermal spraying operations that use materials containing chromium, chromium compounds, nickel, or nickel compounds.
(d) Test Requirements and Test Methods
(1) Testing to Demonstrate Compliance with Enclosure and Ventilation Standards
(A) The owner or operator of an existing thermal spraying operation subject to the control efficiency requirements in subsection (c)(1)(A), must conduct a test to demonstrate compliance with the enclosure and ventilation standards specified in subsections (c)(1)(B) and (c)(1)(C). The test must include measurement of the inward face velocity (in accordance with Appendix 2) and a visual leak inspection (in accordance with Appendix 3.) This test must be conducted within 60 days of the operative date of this section. The owner or operator must notify the permitting agency at least 30 days prior to conducting a test. Although 60 days are allowed to conduct the test, all thermal spraying operations must comply with specified control efficiency requirements, enclosure standards, and ventilation standards by January 1, 2006, as specified in subsection (c)(1).
(B) The owner or operator of a modified or new thermal spraying operation subject to the control efficiency requirements in subsections (c)(2)(A)2. or (c)(3)(A)1., respectively, must conduct a test to demonstrate compliance with the enclosure and ventilation standards in subsections (c)(1)(B) and (c)(1)(C). The test must include measurement of the inward face velocity (in accordance with Appendix 2) and a visual leak inspection (in accordance with Appendix 3.) This test must be conducted within 60 days after initial startup. The owner or operator must notify the permitting agency at least 30 days prior to conducting a test. Although 60 days are allowed to conduct the test, all thermal spraying operations must comply with specified control efficiency requirements, enclosure standards, and ventilation standards upon initial startup.
(C) Before beginning operations pursuant to subsection (c)(1)(B)5., the owner or operator must verify that negative pressure is maintained while the enclosure door is open, using one of the following procedures:
1. Measuring with an anemometer at the door opening to demonstrate flow into the enclosure door, or
2. Measuring the static pressure across the enclosure door, or
3. Using smoke tubes to demonstrate flow into the enclosure door.
As specified in subsection (e)(5), this negative pressure verification must have been performed at least once during the12-month period immediately before operations begin, and at least once after the enclosure is changed in any way that may impact air flow.
(2) Verification of Control Efficiency
Existing thermal spraying operations that are subject to Tier 2 or Tier 3 control efficiency requirements specified in subsection(c)(1)(A), modified thermal spraying operations that are subject to the requirements of subsection (c)(2)(A)2., and new thermal spraying operations that are subject to the requirements of subsection (c)(3)(A)1., must use control devices with a control efficiency verified by the manufacturer. This verification must be provided to the permitting agency upon request. The control device manufacturer must verify the control efficiency using one of the following test methods, which are incorporated by reference herein:
(A) ASHRAE Standard 52.2-1999, "Method of Testing General Ventilation Air-Cleaning Devices for Removal Efficiency by Particle Size", American Society of Heating, Refrigerating, and Air-Conditioning Engineers, Inc., 1791 Tullie Circle NE, Atlanta, GA 30329. 1999.
(B) MIL-PRF-51526A(EA), "Filter, Particulate, 340 CMH (200 CFM), 13 March 2000, U.S. Army.
(C) ASME AG-1-2003, "Code on Nuclear Air and Gas Treatment", American Society of Mechanical Engineers, 345 E. 47th St., New York, NY 10017. 2003.
(D) IEST-RP-CC001.3, "HEPA and ULPA Filters", Institute of Environmental Sciences and Technology, 5005 Newport Drive, Suite 506, Rolling Meadows, IL 60008-3841. 1993.
(3) Source Tests to Determine Emissions of Hexavalent Chromium and Nickel
Owners or operators of thermal spraying operations may choose to quantify hexavalent chromium and/or nickel emissions using data from a source test rather than using the calculation methods specified in Appendix 1. In addition, a permitting agency may require that a source test be performed to quantify hexavalent chromium and/or nickel emissions from thermal spraying operations. The use of source test data must comply with the requirements specified in this subsection (d)(3).
(A) Use of Existing Source Tests
A source test conducted prior to January 1, 2006, may be used to quantify emissions or demonstrate compliance with the standards in subsection (c)(1)(A), if the permitting agency approves the use of that test. The test must be conducted by an independent tester, in accordance with a test protocol that was reviewed and approved by the permitting agency.
(B) Test Methods
If the owner or operator of a thermal spraying operation conducts a source test to quantify emissions of hexavalent chromium and/or nickel, the testing must be conducted in accordance with the following listed test methods, which are incorporated by reference herein, or in accordance with alternative test methods approved by the permitting agency.
1. Testing to determine emissions of hexavalent chromium must be conducted in accordance with one of the following test methods, which are incorporated by reference herein:
ARB Test Method 425, "Determination of Total Chromium and Hexavalent Chromium Emissions from Stationary Sources", last amended July 28, 1997, section 94135, title 17, California Code of Regulations (CCR).
EPA Test Method 306, "Determination of Chromium Emissions From Decorative and Hard Chromium Electroplating and Chromium Anodizing Operations - Isokinetic Method", 40 CFR 63, Appendix A, as promulgated on January 25, 1995.
South Coast Air Quality Management District (SCAQMD) Test Method 205.1, "Determination of Hexavalent and Total Chromium from Plating", August 1991.
2. Testing to determine emissions of nickel must be conducted in accordance with one of the following test methods, which are incorporated by reference herein:
ARB Test Method 433, "Determination of Total Nickel Emissions from Stationary Sources", last amended September 12, 1989, section 94145, title 17, California Code of Regulations (CCR).
ARB Test Method 436, "Determination of Multiple Metals Emissions from Stationary Sources" (for nickel only), adopted July 28, 1997, section 94161, title 17, California Code of Regulations (CCR).
(C) The owner or operator of a thermal spraying operation that is conducting a source test must submit a pre-test protocol to the permitting agency, in accordance with permitting agency procedures, at least 60 days prior to conducting a source test. The pre-test protocol must include source test methods, planned sampling parameters, preliminary pollutant analytical data, calculated targets for testing the pollutant, and any proposed modifications to standardized methods. In addition, the pre-test protocol must include information on equipment, logistics, personnel, and any other information required by the permitting agency.
(e) Monitoring, Inspection, and Maintenance Requirements
(1) Monitoring Requirements
All thermal spraying operations with air pollution control systems must comply with the applicable monitoring requirements listed in Table 3 of this subsection (e)(1). In addition, any other operating parameters designated by the permitting agency must be monitored while conducting thermal spraying to ensure compliance with the requirements set forth in subsection (c).
Table 3 - Summary of Monitoring Requirements for Thermal Spraying Operations
Using Add-on Air Pollution Control Devices
Control Equipment Monitoring Requirements
(A) Dry particulate filter system 1.Ensure that the pressure differential
(e.g., dry filter cartridge, gauge continuously monitors
HEPA filter) pressure drop across the control
device while conducting thermal
spraying.
2.Record pressure drop once per week
while conducting thermal
spraying.
(B) Conventional Water Curtain 1.Ensure that the flow meter
continuously monitors the water
flow rate while conducting thermal
spraying.
2.Monitor the water curtain continuity
by visual observation to ensure that
there are no gaps while conducting
thermal spraying.
3.Record water flow rate and water
curtain continuity once per week
while conducting thermal spraying.
(C) Pumpless Water Curtain 1.Monitor parameters that indicate
booth performance, per
manufacturer's recommendations,
while conducting thermal spraying.
2.Visually inspect the water curtain
for continuity to ensure that there are
no gaps while conducting thermal
spraying.
3.Record recommended parameters
and water curtain continuity once
per week while conducting thermal
spraying.
(2) Pressure Drop Monitoring Requirements
All dry particulate control devices (e.g., dry filter cartridges or HEPA filters) must have gauges that continuously monitor the pressure drop across each control device when thermal spraying is occurring. The gauge must have a high and low setting for the pressure drop and must trigger an alarm system when the high or low set points are exceeded. The gauge must be designed to accurately measure pressure drops within the expected range and have an accuracy of at least +5% of full scale. The gauge must be located so that it can be easily visible and in clear sight of the operation or maintenance personnel. The pressure drop must be maintained per manufacturer's specifications. If the pressure drop is outside of the acceptable limits, the owner or operator must shut down the thermal spraying operation immediately and take corrective action. The thermal spraying operation must not be resumed until the pressure drop is within the specified limit(s). (continued)