Wisconsin Administrative Code, Subchapter II, Section NR 440.53 - Automobile and light-duty truck surface coating operations | Wisconsin Administrative Code

(1) APPLICABILITY AND DESIGNATION OF AFFECTED FACILITY.

(a) The provisions of this section apply to the following affected facilities in an automobile or light-duty truck assembly plant: each prime coat operation, each guide coat operation and each topcoat operation.

(b) Exempt from the provisions of this section are operations used to coat plastic body components or all-plastic automobile or light-duty truck bodies on separate coating lines. The attachment of plastic body parts to a metal body before the body is coated does not cause the metal body coating operation to be exempted.

(c) Any facility under par. (a) that commences construction, reconstruction or modification after October 5, 1979 is subject to the requirements of this section.

(2) DEFINITIONS AND SYMBOLS.

(a) As used in this section, terms not defined in this paragraph have the meanings given in s. NR 440.02.

1. "Applied coating solids" means the volume of dried or cured coating solids which is deposited and remains on the surface of the automobile or light-duty truck body.

2. "Automobile" means a motor vehicle capable of carrying no more than 12 passengers.

3. "Automobile and light-duty truck body" means the exterior surface of an automobile or light-duty truck including hoods, fenders, cargo boxes, doors and grill opening panels.

4. "Bake oven" means a device that uses heat to dry or cure coatings.

5. "Electrodeposition" or "EDP" means a method of applying a prime coat by which the automobile or light-duty truck body is submerged in a tank filled with coating material and an electrical field is used to effect the deposition of the coating material on the body.

6. "Electrostatic spray application" means a spray application method that uses an electrical potential to increase the transfer efficiency of the coating solids. Electrostatic spray application can be used for prime coat, guide coat or topcoat operations.

6e. "Flashoff area" means the structure on automobile and light-duty truck assembly lines between the coating application system (dip tank or spray booth) and the bake oven.

6g. "Guide coat operation" means the guide coat spray booth, flashoff area and bake ovens which are used to apply and dry or cure a surface coating between the prime coat and topcoat operation on the components of automobile and light-duty truck bodies.

6k. "Light-duty truck" means any motor vehicle rated at 3,850 kilograms gross vehicle weight or less, designed mainly to transport property.

6p. "Plastic body" means an automobile or light-duty truck body constructed of synthetic organic material.

7. "Plastic body component" means any component of an automobile or light-duty truck exterior surface constructed of synthetic organic material.

8. "Prime coat operation" means the prime coat spray booth or dip tank, flashoff area and bake oven or ovens which are used to apply and dry or cure the initial coating on components of automobile or light-duty truck bodies.

9. "Purge" or "line purge" means the coating material expelled from the spray system when clearing it.

10. "Solventborne" means a coating which contains 5% or less water by weight in its volatile fraction.

11. "Spray application" means a method of applying coatings by atomizing the coating material and directing the atomized material toward the part to be coated. Spray applications can be used for prime coat, guide coat and topcoat operations.

12. "Spray booth" means a structure housing automatic or manual spray application equipment where prime coat, guide coat or topcoat is applied to components of automobile or light-duty truck bodies.

13. "Surface coating operation" means any prime coat, guide coat or topcoat operation on an automobile or light-duty truck surface coating line.

14. "Topcoat operation" means the topcoat spray booth, flashoff area and bake oven or ovens which are used to apply and dry or cure the final coating or coatings on components of automobile and light-duty truck bodies.

15. "Transfer efficiency" means the ratio of the amount of coating solids transferred onto the surface of a part or product to the total amount of coating solids used.

16. "VOC content" means all volatile organic compounds that are in a coating expressed as kilograms of VOC per liter of coating solids.

17. "Waterborne" or "water reducible" means a coating which contains more than 5 weight percent water in its volatile fraction.

(b) As used in this section, symbols not defined in this paragraph have the meanings given in s. NR 440.03.

1. Caj is the concentration of VOC (as carbon) in the effluent gas flowing through stack (j) leaving the control device (parts per million by volume).

2. Cbi is the concentration of VOC (as carbon) in the effluent gas flowing through stack (i) entering the control device (parts per million by volume).

3. Cfk is the concentration of VOC (as carbon) in the effluent gas flowing through exhaust stack (k) not entering the control device (parts per million by volume).

4. Dci is the density of each coating (i) as received (kilograms per liter).

5. D dj is the density of each type VOC dilution solvent (j) added to the coatings, as received (kilograms per liter).

6. Dr is the density of VOC recovered from an affected facility (kilograms per liter).

7. E is the VOC destruction or removal efficiency of the control device.

8. F is the fraction of total VOC which is emitted by an affected facility that enters the control device.

9. G is the volume weighted average mass of VOC per volume of applied solids (kilograms per liter).

10. Lci is the volume of each coating (i) consumed, as received (liters).

11. Lcil is the volume of each coating (i) consumed by each application method (l), as received (liters).

12. Ldj is the volume of each type VOC dilution solvent (j) added to the coatings, as received (liters).

13. Lr is the volume of VOC recovered from an affected facility (liters).

14. Ls is the volume of solids in coatings consumed (liters).

15. Md is the total mass of VOC in dilution solvent (kilograms).

16. Mo is the total mass of VOC in coatings as received (kilograms).

17. Mr is the total mass of VOC recovered from an affected facility (kilograms).

18. N is the volume weighted average mass of VOC per volume of applied coating solids after the control device,

See PDF for diagram

19. Qaj is the volumetric flow rate of the effluent gas flowing through stack (j) leaving the control device (dry standard cubic meters per hour).

20. Qbi is the volumetric flow rate of the effluent gas flowing through stack (i) entering the control device (dry standard cubic meters per hour).

21. Qfk is the volumetric flow rate of the effluent gas flowing through exhaust stack (k) not entering the control device (dry standard cubic meters per hour).

22. T is the overall transfer efficiency.

23. Tl is the transfer efficiency for application method (l).

24. Vsi is the proportion of solids by volume in each coating (i) as received,

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25. Woi is the proportion of VOC by weight in each coating (i), as received,

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(3) STANDARDS FOR VOLATILE ORGANIC COMPOUNDS. On and after the date on which the initial performance test required by s. NR 440.08 is completed, no owner or operator subject to the provisions of this section may discharge or cause the discharge into the atmosphere from any affected facility VOC emissions in excess of:

(a) 0.16 kilograms of VOC per liter of applied coating solids from each prime coat operation.

(b) 1.40 kilograms of VOC per liter of applied coating solids from each guide coat operation.

(c) 1.47 kilograms of VOC per liter of applied coating solids from each topcoat operation.

(4) PERFORMANCE TEST AND COMPLIANCE PROVISIONS.

(a) Section NR 440.08(4) and (6) do not apply to the performance test procedures required by this subsection.

(b) The owner or operator of an affected facility shall conduct an initial performance test in accordance with s. NR 440.08(1), and thereafter for each calendar month for each affected facility according to the procedures in this subsection.

(c) The owner or operator shall use the following procedures for determining the monthly volume weighted average mass of VOC emitted per volume of applied coating solids.

1. The owner or operator shall use the following procedures for each affected facility which does not use a capture system and a control device to comply with the applicable emission limit specified under sub. (3).

a. Calculate the volume weighted average mass of VOC per volume of applied coating solids for each calendar month for each affected facility. The owner or operator shall determine the composition of the coatings by formulation data supplied by the manufacturer of the coating or from data determined by an analysis of each coating, as received, by 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 manufacturer of the coating to determine data used in the calculation of the VOC content of coatings by Method 24 or an equivalent or alternative method. The owner or operator shall determine from company records on a monthly basis the volume of coating consumed, as received, and the mass of solvent used for thinning purposes. The volume weighted average of the total mass of VOC per volume of coating solids used each calendar month shall be determined by the following procedures:

1) Calculate the mass of VOC used in each calendar month for each affected facility by the following equation where "n" is the total number of coatings used and "m" is the total number of VOC solvents used:

See PDF for diagram

) (S) Ldj Ddj will be zero if no VOC solvent is added to the coatings, as received.)

2) Calculate the total volume of coating solids used in each calendar month for each affected facility by the following equation where"n" is the total number of coatings used:

See PDF for diagram

3) Select the appropriate transfer efficiency (T) from the following tables for each surface coating operation:

Table 1 - Transfer Efficiencies

Application method	Transfer efficiency
a)	Air atomized spray (waterborne coating)	0.39
b)	Air atomized spray (solventborne coating)	0.50
c)	Manual electrostatic spray	0.75
d)	Automatic electrostatic spray	0.95
e)	Electrodeposition	1.00

The values in the table above represent an overall system efficiency which includes a total capture of purge. If a spray system uses line purging after each vehicle and does not collect any of the purge material, the following table shall be used:

Table 2 - Transfer Efficiencies

Application method	Transfer efficiency
a)	Air atomized spray (waterborne coating) .	0.30
b)	Air atomized spray (solventborne coating)	0.40
c)	Manual electrostatic spray	0.62
d)	Automatic electrostatic spray	0.75

Note: Under 40 CFR 60.393(c) (1) (i) (C), if the owner or operator can justify to the administrator's satisfaction that other values for transfer efficiencies are appropriate, the administrator will approve their use on a case-by-case basis.

j) When more than one application method (l) is used on an individual surface coating operation, the owner or operator shall perform an analysis to determine an average transfer efficiency by the following equation where "n" is the total number of coatings used and "p" is the total number of application methods:

See PDF for diagram

4) Calculate the volume weighted average mass of VOC per volume of applied coating solids (G) during each calendar month for each affected facility by the following equation:

See PDF for diagram

b. If the volume weighted average mass of VOC per volume of applied coating solids (G), calculated on a calendar month basis, is less than or equal to the applicable emission limit specified in sub. (3), the affected facility is in compliance. Each monthly calculation is a performance test for the purpose of this section.

2. The owner or operator shall use the following procedures for each affected facility which uses a capture system and a control device that destroys VOC (e.g., incinerator) to comply with the applicable emission limit specified under sub. (3).

a. Calculate the volume weighted average mass of VOC per volume of applied coating solids (G) during each calendar month for each affected facility as described under subd. 1. a.

b. Calculate the volume weighted average mass of VOC per volume of applied solids emitted after the control device, by the following equation:

See PDF for diagram

1) Determine the fraction of total VOC which is emitted by an affected facility that enters the control device by using the following equation where "n" is the total number of stacks entering the control device and "p" is the total number of stacks not connected to the control device:

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If the owner can justify to the department's satisfaction that another method will give comparable results, the department shall approve its use on a case-by-case basis.

a) In subsequent months, the owner or operator shall use the most recently determined capture fraction for the performance test.

2) Determine the destruction efficiency of the control device using values of the volumetric flow rate of the gas streams and the VOC content (as carbon) of each of the gas streams in and out of the device by the following equation where "n" is the total number of stacks entering the control device and "m" is the total number of stacks leaving the control device:

See PDF for diagram

a) In subsequent months, the owner or operator shall use the most recently determined VOC destruction efficiency for the performance test.

3) If an emission control device controls the emissions from more than one affected facility, the owner or operator shall measure the VOC concentration (Cbi) in the effluent gas entering the control device (in parts per million by volume) and the volumetric flow rate (Qbi) of the effluent gas (in dry standard cubic meters per hour) entering the device through each stack. The destruction or removal efficiency determined using these data shall be applied to each affected facility served by the control device.

c. If the volume weighted average mass of VOC per volume of applied solids emitted after the control device (N) calculated on a calendar month basis is less than or equal to the applicable emission limit specified in sub. (3), the affected facility is in compliance. Each monthly calculation is a performance test for the purposes of this section.

3. The owner or operator shall use the following procedures for each affected facility which uses a capture system and a control device that recovers the VOC (e.g., carbon adsorber) to comply with the applicable emission limit specified under sub. (3).

a. Calculate the mass of VOC (Mo + Md) used during each calendar month for each affected facility as described under subd. 1. a.

b. Calculate the total volume of coating solids (Ls) used in each calendar month for each affected facility as described under subd. 1. a.

c. Calculate the mass of VOC recovered (Mr) each calendar month for each affected facility by the following equation: Mr = LrDr

d. Calculate the volume weighted average mass of VOC per volume of applied coating solids emitted after the control device during a calendar month by the following equation:

N = Mo + Md- Mr/LsT

e. If the volume weighted average mass of VOC per volume of applied solids emitted after the control device (N) calculated on a calendar month basis is less than or equal to the applicable emission limit specified in sub. (3), the affected facility is in compliance. Each monthly calculation is a performance test for the purposes of this section.

(5) MONITORING OF EMISSIONS AND OPERATIONS. The owner or operator of an affected facility which uses an incinerator to comply with the emission limits specified under sub. (3) shall install, calibrate, maintain and operate temperature measurement devices as prescribed below:

(a) Where thermal incineration is used, a temperature measurement device shall be installed in the firebox. Where catalytic incineration is used, a temperature measurement device shall be installed in the gas stream immediately before and after the catalyst bed.

(b) Each temperature measurement device shall be installed, calibrated and maintained according to accepted practice and the manufacturer's specifications. The device shall have an accuracy of the greater of " 0.75% of the temperature being measured expressed in degrees Celsius or "2.5°C.

(c) Each temperature measurement device shall be equipped with a recording device so that a permanent record is produced.

(6) REPORTING AND RECORDKEEPING REQUIREMENTS.

(a) Each owner or operator of an affected facility shall include the data outlined in subds. 1. and 2. in the initial compliance report required by s. NR 440.08.

1. The owner or operator shall report the volume weighted average mass of VOC per volume of applied coating solids for each affected facility.

2. Where compliance is achieved through the use of incineration, the owner or operator shall include the following additional data in the control device initial performance test required by s. NR 440.08(1) or subsequent performance tests at which destruction efficiency is determined: the combustion temperature (or the gas temperature upstream and downstream of the catalyst bed), the total mass of VOC per volume of applied coating solids before and after the incinerator, capture efficiency, the destruction efficiency of the incinerator used to attain compliance with the applicable emission limit specified in sub. (3), and a description of the method used to establish the fraction of VOC captured and sent to the control device.

(b) Following the initial performance test, the owner or operator of an affected facility shall identify, record and submit a written report to the department every calendar quarter of each instance in which the volume-weighted average of the total mass of VOCs emitted to the atmosphere per volume of applied coating solids (N) is greater than the limit specified under sub. (3). If no instances have occurred during a particular quarter, a report stating this shall be submitted to the department semiannually. Where compliance is achieved through the use of a capture system and control device, the volume-weighted average after the control device shall be reported.

(c) Where compliance with sub. (3) is achieved through the use of incineration, the owner or operator shall continuously record the incinerator combustion temperature during coating operations for thermal incineration or the gas temperature upstream and downstream of the incinerator catalyst bed during coating operations for catalytic incineration. The owner or operator shall submit a written report at the frequency specified in s. NR 440.07(3) and as defined as follows:

1. For thermal incinerators, every 3-hour period shall be reported during which the average temperature measured is more than 28°C less than the average temperature during the most recent control device performance test at which the destruction efficiency was determined as specified under sub. (4).

2. For catalytic incinerators, every 3-hour period shall be reported during which the average temperature immediately before the catalyst bed, when the coating system is operational, is more than 28°C less than the average temperature immediately before the catalyst bed during the most recent control device performance test at which destruction efficiency was determined as specified under sub. (4). In addition, every 3-hour period shall be reported each quarter during which the average temperature difference across the catalyst bed when the coating system is operational is less than 80% of the average temperature difference of the device during the most recent control device performance test at which destruction efficiency was determined as specified under sub. (4).

3. For thermal and catalytic incinerators, if no such periods occur, the owner or operator shall submit a negative report.

(d) The owner or operator shall notify the department 30 days in advance of any test by Method 25 of 40 CFR part 60, Appendix A, incorporated by reference in s. NR 440.17(1).

(7) REFERENCE METHODS AND PROCEDURES.

(a) The reference methods in 40 CFR part 60, Appendix A, incorporated by reference in s. NR 440.17, except as provided in s. NR 440.08 shall be used to conduct performance tests.

1. Method 24 or an equivalent or alternative method approved by the administrator shall be used for the determination of the data used in the calculation of the VOC content of the coatings used for each affected facility. Manufacturer's formulation data is approved by the administrator as an alternative method to Method 24. In the event of dispute, Method 24 shall be the referee method.

2. Method 25 or an equivalent or alternative method approved by the administrator shall be used for the determination of the VOC concentration in the effluent gas entering and leaving the emission control device for each stack equipped with an emission control device and in the effluent gas leaving each stack not equipped with a control device.

3. The following methods shall be used to determine the volumetric flow rate in the effluent gas in a stack:

a. Method 1 for sample and velocity traverses,

b. Method 2 for velocity and volumetric flow rate,

c. Method 3 for gas analysis, and

d. Method 4 for stack gas moisture.

(b) For Method 24 of 40 CFR part 60, Appendix A, incorporated by reference in s. NR 440.17(1), the coating sample shall be a one-liter sample taken in a one-liter container.

(c) For Method 25 of 40 CFR part 60, Appendix A, incorporated by reference in s. NR 440.17(1), the sampling time for each of 3 runs shall be at least one hour. The minimum sample 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. The department shall approve the sampling of representative stacks on a case-by-case basis if the owner or operator can demonstrate to the satisfaction of the department that the testing of representative stacks would yield results comparable to those that would be obtained by testing all stacks.

(8) MODIFICATIONS. For purposes of this chapter, the following physical or operational changes are not, by themselves, considered modifications of existing facilities described in sub. (1) (a):

(a) Changes as a result of model year changeovers or switches to larger cars.

(b) Changes in the application of the coatings to increase coating film thickness.