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Electronic Code of Federal Regulations

e-CFR Data is current as of October 30, 2014

Title 40Chapter ISubchapter CPart 63 → Subpart NNN


Title 40: Protection of Environment
PART 63—NATIONAL EMISSION STANDARDS FOR HAZARDOUS AIR POLLUTANTS FOR SOURCE CATEGORIES (CONTINUED)


Subpart NNN—National Emission Standards for Hazardous Air Pollutants for Wool Fiberglass Manufacturing


Contents
§63.1380   Applicability.
§63.1381   Definitions.
§63.1382   Emission standards.
§63.1383   Monitoring requirements.
§63.1384   Performance test requirements.
§63.1385   Test methods and procedures.
§63.1386   Notification, recordkeeping, and reporting requirements.
§63.1387   Compliance dates.
§63.1388   Implementation and enforcement.
§§63.1389-63.1399   [Reserved]
Table 1 to Subpart NNN of Part 63—Applicability of General Provisions (40 CFR Part 63, Subpart A) to Subpart NNN
Appendix A to Subpart NNN of Part 63—Method for the Determination of LOI
Appendix B to Subpart NNN of Part 63—Free Formaldehyde Analysis of Insulation Resins by Hydroxylamine Hydrochloride
Appendix C to Subpart NNN of Part 63—Method for the Determination of Product Density

Source: 64 FR 31709, June 14, 1999, unless otherwise noted.

§63.1380   Applicability.

(a) Except as provided in paragraphs (b) and (c) of this section, the requirements of this subpart apply to the owner or operator of each wool fiberglass manufacturing facility that is a major source or is located at a facility that is a major source.

(b) The requirements of this subpart apply to emissions of hazardous air pollutants (HAPs), as measured according to the methods and procedures in this subpart, emitted from the following new and existing sources at a wool fiberglass manufacturing facility subject to this subpart:

(1) Each new and existing glass-melting furnace located at a wool fiberglass manufacturing facility;

(2) Each new and existing rotary spin wool fiberglass manufacturing line producing a bonded wool fiberglass building insulation product; and

(3) Each new and existing flame attenuation wool fiberglass manufacturing line producing a bonded pipe product and each new flame attenuation wool fiberglass manufacturing line producing a bonded heavy-density product.

(c) The requirements of this subpart do not apply to a wool fiberglass manufacturing facility that the owner or operator demonstrates to the Administrator is not a major source as defined in §63.2.

(d) The provisions of this part 63, subpart A that apply and those that do not apply to this subpart are specified in Table 1 of this subpart.

§63.1381   Definitions.

Terms used in this subpart are defined in the Clean Air Act, in §63.2, or in this section as follows:

Bag leak detection system means systems that include, but are not limited to, devices using triboelectric, light scattering, and other effects to monitor relative or absolute particulate matter (PM) emissions.

Bonded means wool fiberglass to which a phenol-formaldehyde binder has been applied.

Building insulation means bonded wool fiberglass insulation, having a loss on ignition of less than 8 percent and a density of less than 32 kilograms per cubic meter (kg/m3) (2 pounds per cubic foot [lb/ft3]).

Cold top electric furnace means an all-electric glass-melting furnace that operates with a temperature of 120 °C (250 °F) or less as measured at a location 46 to 61 centimeters (18 to 24 inches) above the molten glass surface.

Flame attenuation means a process used to produce wool fiberglass where molten glass flows by gravity from melting furnaces, or pots, to form filaments that are drawn down and attenuated by passing in front of a high-velocity gas burner flame.

Glass-melting furnace means a unit comprising a refractory vessel in which raw materials are charged, melted at high temperature, refined, and conditioned to produce molten glass. The unit includes foundations, superstructure and retaining walls, raw material charger systems, heat exchangers, melter cooling system, exhaust system, refractory brick work, fuel supply and electrical boosting equipment, integral control systems and instrumentation, and appendages for conditioning and distributing molten glass to forming processes. The forming apparatus, including flow channels, is not considered part of the glass-melting furnace.

Glass pull rate means the mass of molten glass that is produced by a single glass-melting furnace or that is used in the manufacture of wool fiberglass at a single manufacturing line in a specified time period.

Hazardous Air Pollutant (HAP) means any air pollutant listed in or pursuant to section 112(b) of the Clean Air Act.

Heavy-density product means bonded wool fiberglass insulation manufactured on a flame attenuation manufacturing line and having a loss on ignition of 11 to 25 percent and a density of 8 to 48 kg/m3 (0.5 to 3 lb/ft3).

Incinerator means an enclosed air pollution control device that uses controlled flame combustion to convert combustible materials to noncombustible gases.

Loss on ignition (LOI) means the percent decrease in weight of wool fiberglass after it has been ignited. The LOI is used to monitor the weight percent of binder in wool fiberglass.

Manufacturing line means the manufacturing equipment for the production of wool fiberglass that consists of a forming section where molten glass is fiberized and a fiberglass mat is formed and which may include a curing section where binder resin in the mat is thermally set and a cooling section where the mat is cooled.

New source means any affected source the construction or reconstruction of which is commenced after March 31, 1997.

Pipe product means bonded wool fiberglass insulation manufactured on a flame attenuation manufacturing line and having a loss on ignition of 8 to 14 percent and a density of 48 to 96 kg/m3 (3 to 6 lb/ft3).

Rotary spin means a process used to produce wool fiberglass building insulation by forcing molten glass through numerous small orifices in the side wall of a spinner to form continuous glass fibers that are then broken into discrete lengths by high-velocity air flow. Any process used to produce bonded wool fiberglass building insulation by a process other than flame attenuation is considered rotary spin.

Wool fiberglass means insulation materials composed of glass fibers made from glass produced or melted at the same facility where the manufacturing line is located.

Wool fiberglass manufacturing facility means any facility manufacturing wool fiberglass on a rotary spin manufacturing line or on a flame attenuation manufacturing line.

§63.1382   Emission standards.

(a) Emission limits—(1) Glass-melting furnaces. On and after the date the initial performance test is completed or required to be completed under §63.7 of this part, whichever date is earlier, the owner or operator shall not discharge or cause to be discharged into the atmosphere in excess of 0.25 kilogram (kg) of particulate matter (PM) per megagram (Mg) (0.5 pound [lb] of PM per ton) of glass pulled for each new or existing glass-melting furnace.

(2) Rotary spin manufacturing lines. On and after the date the initial performance test is completed or required to be completed under §63.7 of this part, whichever date is earlier, the owner or operator shall not discharge or cause to be discharged into the atmosphere in excess of:

(i) 0.6 kg of formaldehyde per megagram (1.2 lb of formaldehyde per ton) of glass pulled for each existing rotary spin manufacturing line; and

(ii) 0.4 kg of formaldehyde per megagram (0.8 lb of formaldehyde per ton) of glass pulled for each new rotary spin manufacturing line.

(3) Flame attenuation manufacturing lines. On and after the date the initial performance test is completed or required to be completed under §63.7 of this part, whichever date is earlier, the owner or operator shall not discharge or cause to be discharged into the atmosphere in excess of:

(i) 3.9 kg of formaldehyde per megagram (7.8 lb of formaldehyde per ton) of glass pulled for each new flame attenuation manufacturing line that produces heavy-density wool fiberglass; and

(ii) 3.4 kg of formaldehyde per megagram (6.8 lb of formaldehyde per ton) of glass pulled from each existing or new flame attenuation manufacturing line that produces pipe product wool fiberglass.

(b) Operating limits. On and after the date on which the performance test required to be conducted by §§63.7 and 63.1384 is completed, the owner or operator must operate all affected control equipment and processes according to the following requirements.

(1)(i) The owner or operator must initiate corrective action within 1 hour of an alarm from a bag leak detection system and complete corrective actions in a timely manner according to the procedures in the operations, maintenance, and monitoring plan.

(ii) The owner or operator must implement a Quality Improvement Plan (QIP) consistent with the compliance assurance monitoring provisions of 40 CFR part 64, subpart D when the bag leak detection system alarm is sounded for more than 5 percent of the total operating time in a 6-month block reporting period.

(2)(i) The owner or operator must initiate corrective action within 1 hour when any 3-hour block average of the monitored electrostatic precipitator (ESP) parameter is outside the limit(s) established during the performance test as specified in §63.1384 and complete corrective actions in a timely manner according to the procedures in the operations, maintenance, and monitoring plan.

(ii) The owner or operator must implement a QIP consistent with the compliance assurance monitoring provisions of 40 CFR part 64 subpart D when the monitored ESP parameter is outside the limit(s) established during the performance test as specified in §63.1384 for more than 5 percent of the total operating time in a 6-month block reporting period.

(iii) The owner or operator must operate the ESP such that the monitored ESP parameter is not outside the limit(s) established during the performance test as specified in §63.1384 for more than 10 percent of the total operating time in a 6-month block reporting period.

(3)(i) The owner or operator must initiate corrective action within 1 hour when any 3-hour block average temperature of a cold top electric furnace as measured at a location 46 to 61 centimeters (18 to 24 inches) above the molten glass surface, exceeds 120 °C (250 °F) and complete corrective actions in a timely manner according to the procedures in the operations, maintenance, and monitoring plan.

(ii) The owner or operator of a cold top electric furnace must implement a QIP consistent with the compliance assurance monitoring provisions of 40 CFR part 64, subpart D when the temperature, as measured at a location 46 to 61 centimeters (18 to 24 inches) above the molten glass surface, exceeds 120 °C (250 °F) for more than 5 percent of the total operating time in a 6-month block reporting period.

(iii) The owner or operator must operate the cold top electric furnace such that the temperature does not exceed 120 °C (250 °F) as measured at a location 46 to 61 centimeters (18 to 24 inches) above the molten glass surface, for more than 10 percent of the total operating time in a 6-month reporting period.

(4)(i) The owner or operator must initiate corrective action within 1 hour when any 3-hour block average value for the monitored parameter(s) for a glass-melting furnace, which uses no add-on controls and which is not a cold top electric furnace, is outside the limit(s) established during the performance test as specified in §63.1384 and complete corrective actions in a timely manner according to the procedures in the operations, maintenance, and monitoring plan.

(ii) The owner or operator must implement a QIP consistent with the compliance assurance monitoring provisions of 40 CFR part 64 subpart D when the monitored parameter(s) is outside the limit(s) established during the performance test as specified in §63.1384 for more than 5 percent of the total operating time in a 6-month block reporting period.

(iii) The owner or operator must operate a glass-melting furnace, which uses no add-on controls and which is not a cold top electric furnace, such that the monitored parameter(s) is not outside the limit(s) established during the performance test as specified in §63.1384 for more than 10 percent of the total operating time in a 6-month block reporting period.

(5)(i) The owner or operator must initiate corrective action within 1 hour when the average glass pull rate of any 4-hour block period for glass melting furnaces equipped with continuous glass pull rate monitors, or daily glass pull rate for glass melting furnaces not so equipped, exceeds the average glass pull rate established during the performance test as specified in §63.1384, by greater than 20 percent and complete corrective actions in a timely manner according to the procedures in the operations, maintenance, and monitoring plan.

(ii) The owner or operator must implement a QIP consistent with the compliance assurance monitoring provisions of 40 CFR part 64, subpart D when the glass pull rate exceeds, by more than 20 percent, the average glass pull rate established during the performance test as specified in §63.1384 for more than 5 percent of the total operating time in a 6-month block reporting period.

(iii) The owner or operator must operate each glass-melting furnace such that the glass pull rate does not exceed, by more than 20 percent, the average glass pull rate established during the performance test as specified in §63.1384 for more than 10 percent of the total operating time in a 6-month block reporting period.

(6) The owner or operator must operate each incinerator used to control formaldehyde emissions from forming or curing such that any 3-hour block average temperature in the firebox does not fall below the average established during the performance test as specified in §63.1384.

(7)(i) The owner or operator must initiate corrective action within 1 hour when the average pressure drop, liquid flow rate, or chemical feed rate for any 3-hour block period is outside the limits established during the performance tests as specified in §63.1384 for each wet scrubbing control device and complete corrective actions in a timely manner according to the procedures in the operations, maintenance, and monitoring plan.

(ii) The owner or operator must implement a QIP consistent with the compliance assurance monitoring provisions of 40 CFR part 64, subpart D when any scrubber parameter is outside the limit(s) established during the performance test as specified in §63.1384 for more than 5 percent of the total operating time in a 6-month block reporting period.

(iii) The owner or operator must operate each scrubber such that each monitored parameter is not outside the limit(s) established during the performance test as specified in §63.1384 for more than 10 percent of the total operating time in a 6-month block reporting period.

(8)(i) The owner or operator must initiate corrective action within 1 hour when the monitored process parameter level(s) is outside the limit(s) established during the performance test as specified in §63.1384 for the process modification(s) used to control formaldehyde emissions and complete corrective actions in a timely manner according to the procedures in the operations, maintenance, and monitoring plan.

(ii) The owner or operator must implement a QIP consistent with the compliance assurance monitoring provisions of 40 CFR part 64, subpart D when the process parameter(s) is outside the limit(s) established during the performance test as specified in §63.1384 for more than 5 percent of the total operating time in a 6-month block reporting period.

(iii) The owner or operator must operate the process modifications such that the monitored process parameter(s) is not outside the limit(s) established during the performance test as specified in §63.1384 for more than 10 percent of the total operating time in a 6-month block reporting period.

(9) The owner or operator must use a resin in the formulation of binder such that the free-formaldehyde content of the resin used does not exceed the free-formaldehyde range contained in the specification for the resin used during the performance test as specified in §63.1384.

(10) The owner or operator must use a binder formulation that does not vary from the specification and operating range established and used during the performance test as specified in §63.1384. For the purposes of this standard, adding or increasing the quantity of urea and/or lignin in the binder formulation does not constitute a change in the binder formulation.

§63.1383   Monitoring requirements.

On and after the date on which the performance test required to be conducted by §§63.7 and 63.1384 is completed, the owner or operator must monitor all affected control equipment and processes according to the following requirements.

(a) The owner or operator of each wool fiberglass manufacturing facility must prepare for each glass-melting furnace, rotary spin manufacturing line, and flame attenuation manufacturing line subject to the provisions of this subpart, a written operations, maintenance, and monitoring plan. The plan must be submitted to the Administrator for review and approval as part of the application for a part 70 permit. The plan must include the following information:

(1) Procedures for the proper operation and maintenance of process modifications and add-on control devices used to meet the emission limits in §63.1382;

(2) Procedures for the proper operation and maintenance of monitoring devices used to determine compliance, including quarterly calibration and certification of accuracy of each monitoring device according to the manufacturers's instructions; and

(3) Corrective actions to be taken when process parameters or add-on control device parameters deviate from the limit(s) established during initial performance tests.

(b)(1) Where a baghouse is used to control PM emissions from a glass-melting furnace, the owner or operator shall install, calibrate, maintain, and continuously operate a bag leak detection system.

(i) The bag leak detection system must be certified by the manufacturer to be capable of detecting PM emissions at concentrations of 10 milligrams per actual cubic meter (0.0044 grains per actual cubic foot) or less.

(ii) The bag leak detection system sensor must produce output of relative PM emissions.

(iii) The bag leak detection system must be equipped with an alarm system that will sound automatically when an increase in relative PM emissions over a preset level is detected and the alarm must be located such that it can be heard by the appropriate plant personnel.

(iv) For positive pressure fabric filter systems, a bag leak detection system must be installed in each baghouse compartment or cell. If a negative pressure or induced air baghouse is used, the bag leak detection system must be installed downstream of the baghouse. Where multiple bag leak detection systems are required (for either type of baghouse), the system instrumentation and alarm may be shared among the monitors.

(v) A triboelectric bag leak detection system shall be installed, operated, adjusted, and maintained in a manner consistent with the U.S. Environmental Protection Agency guidance, “Fabric Filter Bag Leak Detection Guidance” (EPA-454/R-98-015, September 1997). Other bag leak detection systems shall be installed, operated, adjusted, and maintained in a manner consistent with the manufacturer's written specifications and recommendations.

(vi) Initial adjustment of the system shall, at a minimum, consist of establishing the baseline output by adjusting the range and the averaging period of the device and establishing the alarm set points and the alarm delay time.

(vii) Following the initial adjustment, the owner or operator shall not adjust the range, averaging period, alarm setpoints, or alarm delay time except as detailed in the approved operations, maintenance, and monitoring plan required under paragraph (a) of this section. In no event shall the range be increased by more than 100 percent or decreased more than 50 percent over a 365-day period unless a responsible official as defined in §63.2 of the general provisions in subpart A of this part certifies that the baghouse has been inspected and found to be in good operating condition.

(2) The operations, maintenance, and monitoring plan required by paragraph (a) of this section must specify corrective actions to be followed in the event of a bag leak detection system alarm. Example corrective actions that may be included in the plan include the following:

(i) Inspecting the baghouse for air leaks, torn or broken bags or filter media, or any other conditions that may cause an increase in emissions.

(ii) Sealing off defective bags or filter media.

(iii) Replacing defective bags or filter media, or otherwise repairing the control device.

(iv) Sealing off a defective baghouse compartment.

(v) Cleaning the bag leak detection system probe, or otherwise repairing the bag leak detection system.

(vi) Shutting down the process producing the particulate emissions.

(c)(1) Where an ESP is used to control PM emissions from a glass-melting furnace, the owner or operator must monitor the ESP according to the procedures in the operations, maintenance, and monitoring plan. (2)The operations, maintenance, and monitoring plan for the ESP must contain the following information:

(i) The ESP operating parameter(s), such as secondary voltage of each electrical field, to be monitored and the minimum and/or maximum value(s) that will be used to identify any operational problems;

(ii) A schedule for monitoring the ESP operating parameter(s);

(iii) Recordkeeping procedures, consistent with the recordkeeping requirements of §63.1386, to show that the ESP operating parameter(s) is within the limit(s) established during the performance test; and

(iv) Procedures for the proper operation and maintenance of the ESP.

(d) The owner or operator must measure and record at least once per shift the temperature 46 to 61 centimeters (18 to 24 inches) above the surface of the molten glass in a cold top electric furnace that does not use any add-on controls to control PM emissions.

(e)(1) Where a glass-melting furnace is operated without an add-on control device to control PM emissions, the owner or operator must monitor the glass-melting furnace according to the procedures in the operations, maintenance, and monitoring plan.

(2) The operations, maintenance, and monitoring plan for the glass-melting furnace must contain the following information:

(i) The operating parameter(s) to be monitored and the minimum and/or maximum value(s) that will be used to identify any operational problems;

(ii) A schedule for monitoring the operating parameter(s) of the glass-melting furnace;

(iii) Recordkeeping procedures, consistent with the recordkeeping requirements of §63.1386, to show that the glass-melting furnace parameter(s) is within the limit(s) established during the performance test; and

(iv) Procedures for the proper operation and maintenance of the glass-melting furnace.

(f)(1) The owner or operator of an existing glass-melting furnace equipped with continuous glass pull rate monitors must monitor and record the glass pull rate on an hourly basis. For glass-melting furnaces that are not equipped with continuous glass pull rate monitors, the glass pull rate must be monitored and recorded once per day.

(2) On any new glass-melting furnace, the owner or operator must install, calibrate, and maintain a continuous glass pull rate monitor that monitors and records on an hourly basis the glass pull rate.

(g)(1) The owner or operator who uses an incinerator to control formaldehyde emissions from forming or curing shall install, calibrate, maintain, and operate a monitoring device that continuously measures and records the operating temperature in the firebox of each incinerator.

(2) The owner or operator must inspect each incinerator at least once per year according to the procedures in the operations, maintenance, and monitoring plan. At a minimum, an inspection must include the following:

(i) Inspect all burners, pilot assemblies, and pilot sensing devices for proper operation and clean pilot sensor, as necessary;

(ii) Ensure proper adjustment of combustion air and adjust, as necessary;

(iii) Inspect, when possible, internal structures, for example, baffles, to ensure structural integrity per the design specifications;

(iv) Inspect dampers, fans, and blowers for proper operation;

(v) Inspect for proper sealing;

(vi) Inspect motors for proper operation;

(vii) Inspect combustion chamber refractory lining and clean and repair/replace lining, as necessary;

(viii) Inspect incinerator shell for corrosion and/or hot spots;

(ix) For the burn cycle that follows the inspection, document that the incinerator is operating properly and make any necessary adjustments; and

(x) Generally observe that the equipment is maintained in good operating condition.

(xi) Complete all necessary repairs as soon as practicable.

(h) The owner or operator who uses a wet scrubbing control device to control formaldehyde emissions must install, calibrate, maintain, and operate monitoring devices that continuously monitor and record the gas pressure drop across each scrubber and scrubbing liquid flow rate to each scrubber according to the procedures in the operations, maintenance, and monitoring plan. The pressure drop monitor is to be certified by its manufacturer to be accurate within ±250 pascals (±1 inch water gauge) over its operating range, and the flow rate monitor is to be certified by its manufacturer to be accurate within ±5 percent over its operating range. The owner or operator must also continuously monitor and record the feed rate of any chemical(s) added to the scrubbing liquid.

(i)(1) The owner or operator who uses process modifications to control formaldehyde emissions must establish a correlation between formaldehyde emissions and a process parameter(s) to be monitored.

(2) The owner or operator must monitor the established parameter(s) according to the procedures in the operations, maintenance, and monitoring plan.

(3) The owner or operator must include as part of their operations, maintenance, and monitoring plan the following information:

(i) Procedures for the proper operation and maintenance of the process;

(ii) Process parameter(s) to be monitored to demonstrate compliance with the applicable emission limits in §63.1382. Examples of process parameters include LOI, binder solids content, and binder application rate;

(iii) Correlation(s) between process parameter(s) to be monitored and formaldehyde emissions;

(iv) A schedule for monitoring the process parameter(s); and

(v) Recordkeeping procedures, consistent with the recordkeeping requirements of §63.1386, to show that the process parameter value(s) established during the performance test is not exceeded.

(j) The owner or operator must monitor and record the free-formaldehyde content of each resin shipment received and used in the formulation of binder.

(k) The owner or operator must monitor and record the formulation of each batch of binder used.

(l) The owner or operator must monitor and record at least once every 8 hours, the product LOI and product density of each bonded wool fiberglass product manufactured.

(m) For all control device and process operating parameters measured during the initial performance tests, the owners or operators of glass-melting furnaces, rotary spin manufacturing lines or flame attenuation manufacturing lines subject to this subpart may change the limits established during the initial performance tests if additional performance testing is conducted to verify that, at the new control device or process parameter levels, they comply with the applicable emission limits in §63.1382. The owner or operator shall conduct all additional performance tests according to the procedures in this part 63, subpart A and in §63.1384.

§63.1384   Performance test requirements.

(a) The owner or operator subject to the provisions of this subpart shall conduct a performance test to demonstrate compliance with the applicable emission limits in §63.1382. Compliance is demonstrated when the emission rate of the pollutant is equal to or less than each of the applicable emission limits in §63.1382. The owner or operator shall conduct the performance test according to the procedures in 40 CFR part 63, subpart A and in this section.

(1) All monitoring systems and equipment must be installed, operational, and calibrated prior to the performance test.

(2) Unless a different frequency is specified in this section, the owner or operator must monitor and record process and/or add-on control device parameters at least every 15 minutes during the performance tests. The arithmetic average for each parameter must be calculated using all of the recorded measurements for the parameter.

(3) During each performance test, the owner or operator must monitor and record the glass pull rate for each glass-melting furnace and, if different, the glass pull rate for each rotary spin manufacturing line and flame attenuation manufacturing line. Record the glass pull rate every 15 minutes during any performance test required by this subpart and determine the arithmetic average of the recorded measurements for each test run and calculate the average of the three test runs.

(4) The owner or operator shall conduct a performance test for each existing and new glass-melting furnace.

(5) During the performance test, the owner or operator of a glass-melting furnace controlled by an ESP shall monitor and record the ESP parameter level(s), as specified in the operations, maintenance, and monitoring plan, and establish the minimum and/or maximum value(s) that will be used to demonstrate compliance after the initial performance test.

(6) During the performance test, the owner or operator of a cold top electric furnace that is not equipped with an add-on control device for PM emissions control, must monitor and record the temperature 46 to 61 centimeters (18 to 24 inches) above the molten glass surface to ensure that the maximum temperature does not exceed 120 °C (250 °F).

(7) During the performance test, the owner or operator of a glass melting furnace (other than a cold top electric furnace) that is not equipped with an add-on control device for PM emissions control, must monitor and record the furnace parameter level, and establish the minimum and/or maximum value(s) that will be used to demonstrate compliance after the initial performance test.

(8) The owner or operator must conduct a performance test for each rotary spin manufacturing line, subject to this subpart, while producing the building insulation with the highest LOI expected to be produced on that line; and for each flame attenuation manufacturing line, subject to this subpart, while producing the heavy-density product or pipe product with the highest LOI expected to be produced on the affected line.

(9) The owner or operator of each rotary spin manufacturing line and flame attenuation manufacturing line regulated by this subpart must conduct performance tests using the resin with the highest free-formaldehyde content. During the performance test of each rotary spin manufacturing line and flame attenuation manufacturing line regulated by this subpart, the owner or operator shall monitor and record the free-formaldehyde content of the resin, the binder formulation used, and the product LOI and density.

(10) During the performance test, the owner or operator of a rotary spin manufacturing line or flame attenuation manufacturing line who plans to use process modifications to comply with the emission limits in §63.1382 must monitor and record the process parameter level(s), as specified in the operations, maintenance, and monitoring plan, which will be used to demonstrate compliance after the initial performance test.

(11) During the performance test, the owner or operator of a rotary spin manufacturing line or flame attenuation manufacturing line who plans to use a wet scrubbing control device to comply with the emission limits in §63.1382 must continuously monitor and record the pressure drop across the scrubber, the scrubbing liquid flow rate, and addition of any chemical to the scrubber, including the chemical feed rate, and establish the minimum and/or maximum value(s) that will be used to determine compliance after the initial performance test.

(12) During the performance test, the owner or operator of a rotary spin manufacturing line or affected flame attenuation manufacturing line shall continuously record the operating temperature of each incinerator and record the average during each 1-hour test; the average operating temperature of the three 1-hour tests shall be used to monitor compliance.

(13) Unless disapproved by the Administrator, an owner or operator of a rotary spin or flame attenuation manufacturing line regulated by this subpart may conduct short-term experimental production runs using binder formulations or other process modifications where the process parameter values would be outside those established during performance tests without first conducting performance tests. Such runs must not exceed 1 week in duration unless the Administrator approves a longer period. The owner or operator must notify the Administrator and postmark or deliver the notification at least 15 days prior to commencement of the short-term experimental production runs. The Administrator must inform the owner or operator of a decision to disapprove or must request additional information prior to the date of the short-term experimental production runs. Notification of intent to perform an experimental short-term production run shall include the following information:

(i) The purpose of the experimental production run;

(ii) The affected line;

(iii) How the established process parameters will deviate from previously approved levels;

(iv) The duration of the experimental production run;

(v) The date and time of the experimental production run; and

(vi) A description of any emission testing to be performed during the experimental production run.

(b) To determine compliance with the PM emission limit for glass-melting furnaces, use the following equation:

eCFR graphic er14jn99.040.gif

View or download PDF

Where:

E = Emission rate of PM, kg/Mg (lb/ton) of glass pulled;

C = Concentration of PM, g/dscm (gr/dscf);

Q = Volumetric flow rate of exhaust gases, dscm/h (dscf/h);

K1 = Conversion factor, 1 kg/1,000 g (1 lb/7,000 gr); and

P = Average glass pull rate, Mg/h (tons/h).

(c) To determine compliance with the emission limit for formaldehyde for rotary spin manufacturing lines and flame attenuation forming processes, use the following equation:

eCFR graphic er14jn99.041.gif

View or download PDF

Where:

E = Emission rate of formaldehyde, kg/Mg (lb/ton) of glass pulled;

C = Measured volume fraction of formaldehyde, ppm;

MW = Molecular weight of formaldehyde, 30.03 g/g-mol;

Q = Volumetric flow rate of exhaust gases, dscm/h (dscf/h);

K1 = Conversion factor, 1 kg/1,000 g (1 lb/453.6 g);

K2 = Conversion factor, 1,000 L/m3 (28.3 L/ft3);

K3 = Conversion factor, 24.45 L/g-mol; and

P = Average glass pull rate, Mg/h (tons/h).

§63.1385   Test methods and procedures.

(a) The owner or operator shall use the following methods to determine compliance with the applicable emission limits:

(1) Method 1 (40 CFR part 60, appendix A) for the selection of the sampling port location and number of sampling ports;

(2) Method 2 (40 CFR part 60, appendix A) for volumetric flow rate;

(3) Method 3 or 3A (40 CFR part 60, appendix A) for O2 and CO2 for diluent measurements needed to correct the concentration measurements to a standard basis;

(4) Method 4 (40 CFR part 60, appendix A) for moisture content of the stack gas;

(5) Method 5 (40 CFR part 60, appendix A) for the concentration of PM. Each run shall consist of a minimum run time of 2 hours and a minimum sample volume of 60 dry standard cubic feet (dscf). The probe and filter holder heating system may be set to provide a gas temperature no greater than 177 ±14 °C (350 ±25 °F);

(6) Method 316 or Method 318 (appendix A of this part) for the concentration of formaldehyde. Each run shall consist of a minimum run time of 1 hour;

(7) Method contained in appendix A of this subpart for the determination of product LOI;

(8) Method contained in appendix B of this subpart for the determination of the free-formaldehyde content of resin;

(9) Method contained in appendix C of this subpart for the determination of product density;

(10) An alternative method, subject to approval by the Administrator.

(b) Each performance test shall consist of 3 runs. The owner or operator shall use the average of the three runs in the applicable equation for determining compliance.

§63.1386   Notification, recordkeeping, and reporting requirements.

(a) Notifications. As required by §63.9(b) through (h) of this part, the owner or operator shall submit the following written initial notifications to the Administrator:

(1) Notification for an area source that subsequently increases its emissions such that the source is a major source subject to the standard;

(2) Notification that a source is subject to the standard, where the initial startup is before June 14, 2002.

(3) Notification that a source is subject to the standard, where the source is new or has been reconstructed, the initial startup is after June 14, 2002, and for which an application for approval of construction or reconstruction is not required;

(4) Notification of intention to construct a new major source or reconstruct a major source; of the date construction or reconstruction commenced; of the anticipated date of startup; of the actual date of startup, where the initial startup of a new or reconstructed source occurs after June 14, 2002, and for which an application for approval or construction or reconstruction is required (See §63.9(b)(4) and (5) of this part);

(5) Notification of special compliance obligations;

(6) Notification of performance test; and (7) Notification of compliance status.

(b) Performance test report. As required by §63.10(d)(2) of the general provisions, the owner or operator shall report the results of the initial performance test as part of the notification of compliance status required in paragraph (a)(7) of this section.

(c) Startup, shutdown, and malfunction plan and reports. (1) The owner or operator shall develop a written plan as described in §63.6(e)(3) that contains specific procedures to be followed for operating the source and maintaining the source during periods of startup, shutdown, and malfunction and a program of corrective action for malfunctioning process modifications and control systems used to comply with the standards. In addition to the information required in §63.6(e)(3), the plan shall include:

(i) Procedures to determine and record the cause of the malfunction and the time the malfunction began and ended;

(ii) Corrective actions to be taken in the event of a malfunction of a control device or process modification, including procedures for recording the actions taken to correct the malfunction or minimize emissions; and

(iii) A maintenance schedule for each control device and process modification that is consistent with the manufacturer's instructions and recommendations for routine and long-term maintenance.

(2) The owner or operator shall also keep records of each event as required by §63.10(b) of this part and record and report if an action taken during a startup, shutdown, or malfunction is not consistent with the procedures in the plan as described in §63.10(e)(3)(iv) of this part.

(d) Recordkeeping. (1) As required by §63.10(b) of this part, the owner or operator shall maintain files of all information (including all reports and notifications) required by the general provisions and this subpart:

(i) The owner or operator must retain each record for at least 5 years following the date of each occurrence, measurement, maintenance, corrective action, report, or record. The most recent 2 years of records must be retained at the facility. The remaining 3 years of records may be retained off site;

(ii) The owner or operator may retain records on microfilm, on a computer, on computer disks, on magnetic tape, or on microfiche; and

(iii) The owner or operator may report required information on paper or on a labeled computer disk using commonly available and EPA-compatible computer software.

(2) In addition to the general records required by §63.10(b)(2) of this part, the owner or operator shall maintain records of the following information:

(i) Any bag leak detection system alarms, including the date and time of the alarm, when corrective actions were initiated, the cause of the alarm, an explanation of the corrective actions taken, and when the cause of the alarm was corrected;

(ii) ESP parameter value(s) used to monitor ESP performance, including any period when the value(s) deviated from the established limit(s), the date and time of the deviation, when corrective actions were initiated, the cause of the deviation, an explanation of the corrective actions taken, and when the cause of the deviation was corrected;

(iii) Air temperature above the molten glass in an uncontrolled cold top electric furnace, including any period when the temperature exceeded 120 °C (250 °F) at a location 46 to 61 centimeters (18 to 24 inches) above the molten glass surface, the date and time of the exceedance, when corrective actions were initiated, the cause of the exceedance, an explanation of the corrective actions taken, and when the cause of the exceedance was corrected;

(iv) Uncontrolled glass-melting furnace (that is not a cold top electric furnace) parameter value(s) used to monitor furnace performance, including any period when the value(s) exceeded the established limit(s), the date and time of the exceedance, when corrective actions were initiated, the cause of the exceedance, an explanation of the corrective actions taken, and when the cause of the exceedance was corrected;

(v) The formulation of each binder batch and the LOI and density for each product manufactured on a rotary spin manufacturing line or flame attenuation manufacturing line subject to the provisions of this subpart, and the free formaldehyde content of each resin shipment received and used in the binder formulation;

(vi) Process parameter level(s) for RS and FA manufacturing lines that use process modifications to comply with the emission limits, including any period when the parameter level(s) deviated from the established limit(s), the date and time of the deviation, when corrective actions were initiated, the cause of the deviation, an explanation of the corrective actions taken, and when the cause of the deviation was corrected;

(vii) Scrubber pressure drop, scrubbing liquid flow rate, and any chemical additive (including chemical feed rate to the scrubber), including any period when a parameter level(s) deviated from the established limit(s), the date and time of the deviation, when corrective actions were initiated, the cause of the deviation, an explanation of the corrective actions taken, and when the cause of the deviation was corrected;

(viii) Incinerator operating temperature and results of periodic inspection of incinerator components, including any period when the temperature fell below the established average or the inspection identified problems with the incinerator, the date and time of the problem, when corrective actions were initiated, the cause of the problem, an explanation of the corrective actions taken, and when the cause of the problem was corrected;

(ix) Glass pull rate, including any period when the pull rate exceeded the average pull rate established during the performance test by more than 20 percent, the date and time of the exceedance, when corrective actions were initiated, the cause of the exceedance, an explanation of the corrective actions taken, and when the cause of the exceedance was corrected.

(e) Excess emissions report. As required by §63.10(e)(3)(v) of this part, the owner or operator shall report semiannually if measured emissions are in excess of the applicable standard or a monitored parameter deviates from the levels established during the performance test. The report shall contain the information specified in §63.10(c) of this part as well as the additional records required by the recordkeeping requirements of paragraph (d) of this section. When no deviations have occurred, the owner or operator shall submit a report stating that no excess emissions occurred during the reporting period.

[64 FR 31709, June 14, 1999, as amended at 71 FR 20460, Apr. 20, 2006]

§63.1387   Compliance dates.

(a) Compliance dates. The owner or operator subject to the provisions of this subpart shall demonstrate compliance with the requirements of this subpart by no later than:

(1) June 14, 2002, for an existing glass-melting furnace, rotary spin manufacturing line, or flame attenuation manufacturing line; or

(2) Upon startup for a new glass-melting furnace, rotary spin manufacturing line, or flame attenuation manufacturing line.

(b) Compliance extension. The owner or operator of an existing source subject to this subpart may request from the Administrator an extension of the compliance date for the emission standards for one additional year if such additional period is necessary for the installation of controls. The owner or operator shall submit a request for an extension according to the procedures in §63.6(i)(3) of this part.

§63.1388   Implementation and enforcement.

(a) This subpart can be implemented and enforced by the U.S. EPA, or a delegated authority such as the applicable State, local, or Tribal agency. If the U.S. EPA Administrator has delegated authority to a State, local, or Tribal agency, then that agency, in addition to the U.S. EPA, has the authority to implement and enforce this subpart. Contact the applicable U.S. EPA Regional Office to find out if implementation and enforcement of this subpart is delegated to a State, local, or Tribal agency.

(b) In delegating implementation and enforcement authority of this subpart to a State, local, or Tribal agency under subpart E of this part, the authorities contained in paragraph (c) of this section are retained by the Administrator of U.S. EPA and cannot be transferred to the State, local, or Tribal agency.

(c) The authorities that cannot be delegated to State, local, or Tribal agencies are as specified in paragraphs (c)(1) through (4) of this section.

(1) Approval of alternatives to the requirements in §§63.1380, 63., and 63.1387.

(2) Approval of major alternatives to test methods under §63.7(e)(2)(ii) and (f), as defined in §63.90, and as required in this subpart.

(3) Approval of major alternatives to monitoring under §63.8(f), as defined in §63.90, and as required in this subpart.

(4) Approval of major alternatives to recordkeeping and reporting under §63.10(f), as defined in §63.90, and as required in this subpart.

[68 FR 37358, June 23, 2003]

§§63.1389-63.1399   [Reserved]

Table 1 to Subpart NNN of Part 63—Applicability of General Provisions (40 CFR Part 63, Subpart A) to Subpart NNN

General provisions citationRequirementApplies to
subpart NNN
Explanation
63.1(a)(1)-(a)(4)ApplicabilityYes.
63.1(a)(5)No[Reserved].
63.1(a)(6)-(a)(8)Yes.
63.1(a)(9)No[Reserved].
63.1(a)(10)-(a)(14)Yes.
63.1(b)(1)-(b)(3)Initial Applicability DeterminationYes.
63.1(c)(1)-(c)(2)Applicability After Standard EstablishedYes.
63.1(c)(3)No[Reserved].
63.1(c)(4)-(c)(5)Yes.
63.1(d)No[Reserved].
63.1(e)Applicability of Permit ProgramYes.
63.2DefinitionsYesAdditional definitions in §63.1381.
63.3(a)-(c)Units and AbbreviationsYes.
63.4(a)(1)-(a)(3)Prohibited ActivitiesYes.
63.4(a)(4)No[Reserved].
63.4(a)(5)Yes.
63.4(b)-(c)Yes.
63.5(a)(1)-(a)(2)Construction/ReconstructionYes.
63.5(b)(1)Existing, New, ReconstructedYes.
63.5(b)(2)No[Reserved].
63.5(b)(3)-(b)(6)Yes.
63.5(c)No[Reserved].
63.5(d)Approval of Construction/ReconstructionYes.
63.5(e)Yes.
63.5(f)Yes.
63.6(a)Compliance with Standards and Maintenance RequirementsYes.
63.6(b)(1)-(b)(5)Yes.
63.6(b)(6)No[Reserved].
63.6(b)(7)Yes.
63.6(c)(1)Compliance Date for Existing SourcesYes§63.1387 specifies compliance dates.
63.6(c)(2)Yes.
63.6(c)(3)-(c)(4)No[Reserved].
63.6(c)(5)Yes.
63.6(d)No[Reserved].
63.6(e)(1)-(e)(2)Operation & MaintenanceYes§63.1383 specifies operations/maintenance plan.
63.6(e)(3)Startup, Shutdown Malfunction PlanYes.
63.6(f)(1)-(f)(3)Compliance with Nonopacity Emission StandardsYes.
63.6(g)(1)-(g)(3)Alternative Nonopacity StandardYes.
63.6(h)Opacity/VE StandardsNoSubpart NNN-no COMS, VE or opacity standards.
63.6(i)(1)-(i)(14)Extension of ComplianceYes.
63.6(i)(15)No[Reserved].
63.6(i)(16)Yes.
63.6(j)Exemption from ComplianceYes.
63.7(a)Performance Testing RequirementsYes§63.1384 has specific requirements.
63.7(b)NotificationYes.
63.7(c)Quality Assurance Program/Test PlanYes.
63.7(d)Performance Testing FacilitiesYes.
63.7(e)(1)-(e)(4)Conduct of Performance TestsYes.
63.7(f)Alternative Test MethodYes.
63.7(g)Data AnalysisYes.
63.7(h)Waiver of Performance TestsYes.
63.8(a)(1)-(a)(2)Monitoring RequirementsYes.
63.8(a)(3)No[Reserved].
63.8(a)(4)Yes.
63.8(b)Conduct of MonitoringYes.
63.8(c)CMS Operation/MaintenanceYes.
63.8(d)Quality Control ProgramYes.
63.8(e)Performance Evaluation for CMSYes.
63.8(f)Alternative Monitoring MethodYes.
63.8(g)Reduction of Monitoring DataYes.
63.9(a)Notification RequirementsYes.
63.9(b)Initial NotificationsYes.
63.9(c)Request for Compliance ExtensionYes.
63.9(d)New Source Notification for Special Compliance RequirementsYes.
63.9(e)Notification of Performance TestYes.
63.9(f)Notification of VE/Opacity TestNoOpacity/VE tests not required.
63.9(g)Additional CMS NotificationsYes.
63.9(h)(1)-(h)(3)Notification of Compliance StatusYes.
63.9(h)(4)No[Reserved].
63.9(h)(5)-(h)(6)Yes.
63.9(i)Adjustment of DeadlinesYes.
63.9(j)Change in Previous InformationYes.
63.10(a)Recordkeeping/ReportingYes.
63.10(b)General RequirementsYes.
63.10(c)(1)Additional CMS RecordkeepingYes.
63.10(c)(2)-(c)(4)No[Reserved].
63.10(c)(5)-(c)(8)Yes.
63.10(c)(9)No[Reserved].
63.10(c)(10)-(15)Yes.
63.10(d)(1)General Reporting RequirementsYes.
63.10(d)(2)Performance Test ResultsYes.
63.10(d)(3)Opacity or VE ObservationsNoNo limits for VE/opacity.
63.10(d)(4)Progress ReportsYes.
63.10(d)(5)Startup, Shutdown, Malfunction ReportsYes.
63.10(e)(1)-(e)(3)Additional CMS ReportsYes.
63.10(e)(4)Reporting COM DataNoCOM not required.
63.10(f)Waiver of Recordkeeping/ReportingYes.
63.11(a)Control Device RequirementsYes.
63.11(b)FlaresNoFlares not applicable.
63.12State Authority and DelegationsYes.
63.13State/Regional AddressesYes.
63.14Incorporation by ReferenceNo
63.15Availability of InformationYes.

Appendix A to Subpart NNN of Part 63—Method for the Determination of LOI

1. Purpose

The purpose of this test is to determine the LOI of cured blanket insulation. The method is applicable to all cured board and blanket products.

2. Equipment

2.1   Scale sensitive to 0.1 gram.

2.2   Furnace designed to heat to at least 540 °C (1,000 °F) and controllable to ±10 °C (50 °F).

2.3   Wire tray for holding specimen while in furnace.

3. Procedure

3.1   Cut a strip along the entire width of the product that will weigh at least 10.0 grams. Sample should be free of dirt or foreign matter.

Note: Remove all facing from sample.

3.2   Cut the sample into pieces approximately 12 inches long, weigh to the nearest 0.1 gram and record. Place in wire tray. Sample should not be compressed or overhang on tray edges.

Note: On air duct products, remove shiplaps and overspray.

3.3   Place specimen in furnace at 540 °C (1,000 °F), ±10 °C (50 °F) for 15 to 20 minutes to insure complete oxidation. After ignition, fibers should be white and should not be fused together.

3.4   Remove specimen from the furnace and cool to room temperature.

3.5   Weigh cooled specimen and wire tray to the nearest 0.1 gram. Deduct the weight of the wire tray and then calculate the loss in weight as a percent of the original specimen weight.

Appendix B to Subpart NNN of Part 63—Free Formaldehyde Analysis of Insulation Resins by Hydroxylamine Hydrochloride

1. Scope

This method was specifically developed for water-soluble phenolic resins that have a relatively high free-formaldehyde (FF) content such as insulation resins. It may also be suitable for other phenolic resins, especially those with a high FF content.

2. Principle

2.1   a. The basis for this method is the titration of the hydrochloric acid that is liberated when hydroxylamine hydrochloride reacts with formaldehyde to form formaldoxine:

HCHO + NH2OH:HCl → CH2:NOH + H2O + HCl

b. Free formaldehyde in phenolic resins is present as monomeric formaldehyde, hemiformals, polyoxymethylene hemiformals, and polyoxymethylene glycols. Monomeric formaldehyde and hemiformals react rapidly with hydroxylamine hydrochloride, but the polymeric forms of formaldehyde must hydrolyze to the monomeric state before they can react. The greater the concentration of free formaldehyde in a resin, the more of that formaldehyde will be in the polymeric form. The hydrolysis of these polymers is catalyzed by hydrogen ions.

2.2   The resin sample being analyzed must contain enough free formaldehyde so that the initial reaction with hydroxylamine hydrochloride will produce sufficient hydrogen ions to catalyze the depolymerization of the polymeric formaldehyde within the time limits of the test method. The sample should contain approximately 0.3 grams free formaldehyde to ensure complete reaction within 5 minutes.

3. Apparatus

3.1   Balance, readable to 0.01 g or better.

3.2   pH meter, standardized to pH 4.0 with pH 4.0 buffer and pH 7 with pH 7.0 buffer.

3.3   50-mL burette for 1.0 N sodium hydroxide.

3.4   Magnetic stirrer and stir bars.

3.5   250-mL beaker.

3.6   50-mL graduated cylinder.

3.7   100-mL graduated cylinder.

3.8   Timer.

4. Reagents

4.1   Standardized 1.0 N sodium hydroxide solution.

4.2   Hydroxylamine hydrochloride solution, 100 grams per liter, pH adjusted to 4.00.

4.3   Hydrochloric acid solution, 1.0 N and 0.1 N.

4.4   Sodium hydroxide solution, 0.1 N.

4.5   50/50 v/v mixture of distilled water and methyl alcohol.

5. Procedure

5.1   Determine the sample size as follows:

a. If the expected FF is greater than 2 percent, go to Part A to determine sample size.

b. If the expected FF is less than 2 percent, go to Part B to determine sample size.

c. Part A: Expected FF ≥2 percent.

Grams resin = 60/expected percent FF

i. The following table shows example levels:

Expected % free formaldehydeSample size, grams
230.0
512.0
87.5
106.0
125.0
154.0

ii. It is very important to the accuracy of the results that the sample size be chosen correctly. If the milliliters of titrant are less than 15 mL or greater than 30 mL, reestimate the needed sample size and repeat the tests.

d. Part B: Expected FF <2 percent

Grams resin = 30/expected percent FF

i. The following table shows example levels:

Expected % free formaldehydeSample size, grams
215
130
0.560

ii. If the milliliters of titrant are less than 5 mL or greater than 30 mL, reestimate the needed sample size and repeat the tests.

5.2   Weigh the resin sample to the nearest 0.01 grams into a 250-mL beaker. Record sample weight.

5.3   Add 100 mL of the methanol/water mixture and stir on a magnetic stirrer. Confirm that the resin has dissolved.

5.4   Adjust the resin/solvent solution to pH 4.0, using the prestandardized pH meter, 1.0 N hydrochloric acid, 0.1 N hydrochloric acid, and 0.1 N sodium hydroxide.

5.5   Add 50 mL of the hydroxylamine hydrochloride solution, measured with a graduated cylinder. Start the timer.

5.6   Stir for 5 minutes. Titrate to pH 4.0 with standardized 1.0 N sodium hydroxide. Record the milliliters of titrant and the normality.

6. Calculations

eCFR graphic er14jn99.042.gif

View or download PDF

7. Method Precision and Accuracy

Test values should conform to the following statistical precision:

Variance = 0.005

Standard deviation = 0.07

95% Confidence Interval, for a single determination = 0.2

8. Author

This method was prepared by K. K. Tutin and M. L. Foster, Tacoma R&D Laboratory, Georgia-Pacific Resins, Inc. (Principle written by R. R. Conner.)

9. References

9.1   GPAM 2221.2.

9.2   PR&C TM 2.035.

9.3   Project Report, Comparison of Free Formaldehyde Procedures, January 1990, K. K. Tutin.

Appendix C to Subpart NNN of Part 63—Method for the Determination of Product Density

1. Purpose

The purpose of this test is to determine the product density of cured blanket insulation. The method is applicable to all cured board and blanket products.

2. Equipment

One square foot (12 in. by 12 in.) template, or templates that are multiples of one square foot, for use in cutting insulation samples.

3. Procedure

3.1   Obtain a sample at least 30 in. long across the machine width. Sample should be free of dirt or foreign matter.

3.2   Lay out the cutting pattern according to the plant's written procedure for the designated product.

3.2   Cut samples using one square foot (or multiples of one square foot) template.

3.3   Weigh product and obtain area weight (lb/ft2).

3.4   Measure sample thickness.

3.5   Calculate the product density:

Density (lb/ft3) = area weight (lb/ft2)/thickness (ft)



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