United States
         Environmental Protection
         Agency
           Office of Air Quality
           Planning and Standards
           Washington DC 20460
EPA 340/1-90-010
Apri 11991
         Stationary Source Compliance Series
xvEPA
Regulatory and
Inspection Manual for
Nonmetallic Mineral
Processing  Plants

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Regulatory and Inspection  Manual for
Nonmetallic Mineral Processing  Plant
                          by

                  IT Environmental Programs, Inc.
                     11499 Chester Road
                     Cincinnati, Ohio 45246

                    Contract No. 68-02-4466
                   Work Assignment No. 91-74

                 EPA Project Officer: Aaron R. Martin
            EPA Work Assignment Manager: Karen A. Randolph
             U.S. ENVIRONMENTAL PROTECTION AGENCY
               Office of Air Quality Planning and Standards
                Stationary Source Compliance Division
                     Washington DC 20460

                        April 1991

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                                 DISCLAIMER
      This manual was prepared for the U.S. Environmental Protection Agency by IT
Environmental Programs, Inc., Durham, North Carolina, under Contract No. 68-02-
4466, Work Assignment No. 91-74.  The contents of this report are reproduced herein
as received from the contractor.  The opinions, findings, and conclusions expressed
are those of the author and not necessarily those of the U.S.  Environmental Protection
Agency.

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                                  CONTENTS
Figures                                                                        x
Tables                                                                        xiii
Acknowledgment                                                              xiv

      1.      Introduction                                                        1

             1.1    Scope and Content                                           2
             1.2    Intended use of the Manual                                   3
             1.3    Industry Overview                                            4

                   1.3.1  General                                               4
                   1.3.2  General process description                             6

      2.      Process Equipment Emissions and Particulate Matter Controls         12

             2.1    Crushers                                                   13

                   2.1.1  Jaw crushers                                         14
                   2.1.2  Gyratory crushers                                     16
                   2.1.3  Roll crushers                                          18
                   2.1.4  Impact crushers                                      18
                   2.1.5  Sources of emissions                                  20

             2.2    Grinding Mills                                               22

                   2.2.1  Hammermills                                          23
                   2.2.2  Roller mill                                             24
                   2.2.3  Rod mill                                              24
                   2.2.4  Pebble and ball mills                                  25
                   2.2.5  Fluid energy mills                                      25
                   2.2.6  Separating and classifying                              27
                                       in

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                CONTENTS (Continued)


2.3    Emission Controls for Crushers and Grinding Mills              27

       2.3.1  Wet dust suppression                                  28
       2.3.2  Dust collection systems                                31

2.4    Screening Operations                                        33

       2.4.1  Grizzlies                                              33
       2.4.2  Shaking screens                                       35
       2.4.3  Vibrating screens                                      35
       2.4.4  Revolving screens                                     37
       2.4.5  Emission controls for screening operations              37

2.5    Storage  Bins                                                39

       2.5.1  Emission controls for storage bins                      39

2.6    Bucket Elevators                                            41

       2.6.1  Emission controls for bucket elevators                  44

2.7    Belt Conveyors                                              44

       2.7.1  Emission controls for belt conveyor transfer points       44

2.8    Bagging  Operations                                         48

       2.8.1  Emission controls for bagging operations                48

2.9    Enclosed Truck or Railcar Loading Operations                 50

       2.9.1  Emission controls for enclosed truck or railcar
             loading  stations                                      50
                           IV

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                      CONTENTS (Continued)


3.     Regulatory Requirements and Their Application                       52

      3.1   Applicability and Designation of Affected Facility - §60.670       52

            3.1.1  General applicability and affected
                    facilities - §60.670(a)                                  52
            3.1.2  Facilities subject to other NSPS - §60.670(b)             53
            3.1.3  Facilities exempted by plant type/capacity -
                    §60.670(c)                                           54
            3.1.4  Exemption by replacement with facilities of equal
                    or smaller size - §60.670(d)                            54
            3.1.5  Designation of affected facility by date of
                    construction, reconstruction, or modification -
                    §60.670(e)                                           55

      3.2   Definitions - §60.671                                         56

      3.3   Standard for Particulate Matter - §60.672                       66

            3.3.1  Stack emissions standard - §60.672(a)                   66
            3.3.2  Fugitive emissions standards - §60.672(b) & (c)          67
            3.3.3  Exemption for truck dumping - §60.672(d)               68
            3.3.4  Affected facilities enclosed in buildings                   68

      3.4   Reconstruction - §60.673(a)                                   69

            3.4.1  Fixed capital cost exemptions -  §60.673(a)               69
            3.4.2  Continuous programs of component replacement -
                    §60.673 (b)                                           70

      3.5   Monitoring of Operations (Wet Scrubbers) - §60.674            71

      3.6   Test Methods and Procedures - §60.675                       72

            3.6.1  General requirements for performance tests  -
                    §60.675(a)                                           72
            3.6.2  Test methods and procedures for stack emissions -
                    §60.675(b)                                           73
                                 v

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                      CONTENTS (Continued)
             3.6.3  Test methods and procedures for fugitive emissions -
                    §60.675(c)                                          73
             3.6.4  Determining the presence of fugitive emissions from
                    buildings - §60.675(d)                                74
             3.6.5  Approved alternatives to the test procedures for
                    fugitive emissions - §60.675(e)                         75
             3.6.6  Wet scrubber monitoring compliance - §60.675(f)         76

      3.7    Reporting and Recordkeeping - §60.676                       76

             3.7.1  Reporting requirements for equal or smaller size
                    replacements - §60.676(a)                            76
             3.7.2  Special reporting requirements for equal or smaller
                    size replacements - §60.676(b)                        77
             3.7.3  Wet scrubber requirements - §60.676(c)(d) & (e)          77
             3.7.4  Performance test reporting requirements - §60.676(f)      78
             3.7.5  Requirements under delegated enforcement  authority -
                    §60.676(g)                                          79

4.     Compliance Determination (Level II Inspection)                        80

      4.1    Pre-lnspection Preparation                                    81

             4.1.1  Review of facility background                           81
             4.1.2  Development of an inspection plan                      83
             4.1.3  Notification  of facility and responsible agency            84
             4.1.4  Equipment preparation                                 86

      4.2    Pre-Entry Observations                                      87

             4.2.1  Plant surroundings observation                          88
             4.2.2  Visible emissions observation                           88

      4.3    Plant Entry                                                  88

             4.3.1  Authority                                              89
             4.3.2  Arrival                                                89
             4.3.3  Credentials                                            89
                                 VI

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                CONTENTS (Continued)
      4.3.4 Consent                                              90
      4.3.5 Uncredentialed persons accompanying an inspector      90
      4.3.6 Waivers, releases, and sign-in logs                      91
      4.3.7 Nondisclosure statements                              91

4.4   Opening Conference                                         91

4.5   Inspection Documentation                                    93

      4.5.1 Inspector's field notebook and field notes                94
      4.5.2 Visible emission observation form                       95
      4.5.3 Drawings and maps                                    98
      4.5.4 Copies of records                                     98
      4.5.5 Printed matter                                         99
      4.5.6 Photographs                                         100

4.6   Verification of Facility Records                               101

4.7   Means of Determining Compliance with the Standard for
        Particulate Matter                                          104

      4.7.1 Determining compliance with  opacity during
              the inspection                                       105
      4.7.2 Determining compliance with  opacity during the
              initial performance test                               107

4.8   Field Inspection Procedures for Affected Facilities              108

      4.8.1 Crushers                                            109
      4.8.2 Grinding mills                                        113
      4.8.3 Screening operations                                 115
      4.8.4 Storage bins                                         119
      4.8.5 Bucket elevators                                      119
      4.8.6 Belt conveyors                                       119
      4.8.7 Bagging operations                                   123
      4.8.8 Enclosed truck or railcar loading operations             123
                           VII

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                            CONTENTS (Continued)


            4.9   Field Inspection Procedures for Air Pollution Control
                    Equipment                                             127

                4.9.1    Operating pulse jet baghouses                       127
                4.9.2    Operating shaker and reverse air baghouses          128
                4.9.3    Nonoperating pulse jet baghouses                    129
                4.9.4    Nonoperating shaker and reverse air baghouses       131
                4.9.5    Spray tower scrubbers                              133
                4.9.6    Mechannically aided scrubbers                       134
                4.9.7    Gas-atomized scrubbers                            136
                4.9.8    Large diameter cyclones                            137
                4.9.9    Multiple cyclone collectors                           139
                4.9.10   Wet suppression systems                            140

            4.10  Post-Inspection  Conference                               141

            4.11  Report Preparation and Tracking                            142

                4.11.1   Computer data base updates                         143
                4.11.2   Agency file  updates                                 143
                4.11.3   Report preparation                                  144

Appendices

      A.    40 CFR  60, Subpart OOO With February 14, 1989 Revision          A-1

      B.    40 CFR  60, Subpart A  General  Provisions (Abbreviated)             B-1

      C.    EPA Method 9 - Visual Determination of Emissions From
             Stationary Sources                                            C-1

      D.    EPA Method 22 - Visual Determination of Fugitive  Emissions
             From Material Sources and Smoke Emissions From Flares         D-1

      E.    Sample  Inspection Forms                                       E-1

      F.    Sample  Inspection Report                                       F-1
                                     VIII

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                    CONTENTS (Continued)
G.    State Agencies to which Authority has been Delegated for
      40 CFR 60, Subpart OOO                                    G-1

H.    Compilation of EPA Policy Memoranda Concerning 40 CFR 60,
      Subpart OOO                                              H-1
                             IX

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                                   FIGURES



Number                                                                    Page



1-1         Flowsheet of a typical aggregate crushing plant                       7



1-2         General schematic of a nonmetallic mineral processing plant          10



2-1         Double-toggle jaw crusher                                         15



2-2         Single-toggle jaw crusher                                          15



2-3         The pivoted spindle gyratory                                       17



2-4         Cone crusher                                                    17



2-5         Double-roll crusher                                                19



2-6         Single-roll crusher                                                19



2-7         Hammermill                                                      21



2-8         Impact crusher                                                   21



2-9         Fluid energy mill                                                  26



2-10        Spray nozzle arrangement above primary crusher throat              29



2-11        Dust suppression application at crusher discharge                   30



2-12        Hood configuration used to control a cone crusher                   32



2-13        Stationary grizzly                                                 34



2-14        Vibrating screen                                                  36



2-15        Hood configuration for vibrating screen                             38



2-16        Baghouse atop a storage bin                                       40

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                             FIGURES (Continued)

Number                                                                    Page

2-17        Cyclones and baghouses serving storage bins                       42

2-18        Bucket elevator types                                             43

2-19        Conveyor belts and transfer point                                   45

2-20        Hood configuration for conveyor transfer, less than 0.91
              meter (3-foot) fall                                                46

2-21        Hood configuration for a chute-to-belt or conveyor transfer,
              greater than 0.91 meter (3-foot) fall                                47

2-22        Exhaust configuration at bin or hopper                              47

2-23        Bag filling vent system                                            49

2-24        Combination enclosed truck and railcar loading station               51

4-1         EPA Method 9 Visible Emission Observation Form                   96

4-2         EPA Method 22 Field  Data Sheet for Outdoor Location               97

4-3         Fugitive emissions from a jaw crusher                              110

4-4         Feed inlet of cone crusher with feed skirts                         111

4-5         Open feed inlet of cone crusher                                   112

4-6         Portable jaw crusher                                             114

4-7         Deck-type screen with fugitive emissions                           116

4-8         Screen hood showing open cleanout emitting fugitive dust           117

4-9         Enclosed screen hood showing external fugitive dust buildup         118

4-10        Bucket elevator with fugitive emissions                             120
                                       XI

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                              FIGURES (Continued)



Number                                                                     Page



4-11         Uncontrolled belt-to-belt transfer point                              121



4-12         Belt-to-belt transfer point with capture hood                         122



4-13         Nonenclosed truck loading station                                 124



4-14         Enclosed railcar loading station with fugitive emissions               125



4-15         Enclosed truck loading station with flexible feed tube                 126
                                       XII

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                                 TABLES



Number                                                               Page



1-1          Major uses of the Nonmetallic Minerals                             5



2-1          Relative Crushing Mechanisms                                   14



4-1          Recommended Inspection and Safety Equipment                   87
                                    XIII

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                            ACKNOWLEDGMENT
      This report was prepared for the U.S. Environmental Protection Agency,
Stationary Source Compliance Division, by IT Environmental Programs, Inc. (ITEP),
Durham, North Carolina.  The project was directed by Mr. Steven H. Kopp and
managed by Mr. Craig Mann. The principal author is Mr. Craig Mann.  ITEP would
like to acknowledge Ms. Karen  A. Randolph, the U.S. Environmental Protection
Agency Work Assignment Manager, and Mr. Paul Reinermann for their overall
guidance and direction in preparing this manual.
                                     XIV

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                                  SECTION 1
                                INTRODUCTION

      New Source Performance Standards (NSPS), are promulgated under 40 CFR
Part 60. The general provisions for all NSPS were promulgated in the Federal Register
on December 16, 1975 (40 FR 58416) as Subpart A.  Specific standards applicable to
nonmetallic mineral processing plants were initially proposed on August 31, 1983
(48 FR 39566).  The NSPS for nonmetallic mineral processing plants was promulgated
as Subpart OOO on August 1, 1985 (50 FR 31337) and revised on February 14, 1989
(54 FR 6680).
      The NSPS for nonmetallic mineral processing plants provides 1) rules for
applicability of the standards and designation of affected facilities, 2) standards for
particulate matter emitted from affected facilities, 3) monitoring, reporting, and
recordkeeping requirements, and 4) test methods and procedures for determining
compliance with the emissions standards. The regulatory standards limit particulate
matter emissions from crushers, grinding mills (including air separators, classifiers,  and
conveyors), screens, bucket elevators, bagging operations, storage bins, enclosed
truck and railcar loading operations, and  transfer points on belt conveyors. Unit
operations not included are drilling, blasting, loading at the mine,  hauling, drying,
stockpiling, conveying (other than at transfer points), and windblown dust from
stockpiles, roads and plant yards.
      Subpart OOO designates affected facilities as individual pieces of operating
equipment (i.e., screens, storage bins, crushers, etc.) manufactured, modified or
reconstructed after August 31, 1983.
      Recordkeeping requirements of the NSPS general provisions as well as those of
Subpart OOO require data to be recorded and notifications issued for individual
operating units.

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       The regulatory standards limit both fugitive emissions and stack emissions from
 affected facilities. Stack emissions are limited to 0.05 g/dscm (0.02 gr/dscf) and an
 opacity of 7 percent, unless a wet scrubbing device is employed to control emissions.
 Fugitive emissions are limited to an opacity of 10 percent, except crushers without
 capture systems are limited to an opacity of 15 percent.

 1.1    Scope and Content
       Section 1 describes the content of the manual, its intended use, and gives an
 overview of the nonmetallic mineral processing industry including the types of minerals
 processed and the general equipment types employed.
       Section 2 describes the specific equipment types covered by the standard.
 Coverage includes theory of operation, what quantities and types of particulate matter
 emissions are expected, and control  options most frequently employed in  nonmetallic
 mineral processing plants.  Photographs and/or schematic drawings are reproduced
 to facilitate a better understanding of the mechanics behind the operation  of these
 equipment types and control of their  emissions.
       Section 3 details the requirements of the regulations including the general
 provisions of Subpart A applicable to the nonmetallic mineral processing plants, as
 well as the specific requirements of Subpart OOO.  Individual sections or paragraphs
 of the  regulations are cited followed by a clarification.  The clarification explains the
 intent and application of the preceding citation. Section 3 attempts to clarify the
 multitude of questions regarding interpretation of the regulations that have emerged
 since the standards were first proposed.
       Section 4 describes the steps  necessary to conduct a Level II compliance
 inspection of a facility subject to the NSPS standards. This section discusses file
 review, plant  entry procedures and preinspection interviews, safety and inspection
 equipment, report writing and tracking of affected facilities, and detailed inspection
techniques for determining compliance with the standards.  Photographs and
 illustrations are used to acquaint-the reader with typical compliance situations that may

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be encountered.  In addition, checklists are included to aid the inspector in compliance
determinations and tracking of affected facilities.
      The appendices include the Subpart OOO final rule (51 FR 31337) and revision
(54 FR 6680) incorporated into one document (Appendix A),  Sections of Subpart A
that directly affect the requirements contained in Subpart OOO (Appendix B), EPA
Reference Method 9 - Determining the Opacity of Emissions from Stationary Sources
(Appendix C), EPA Reference Method 22 for determining fugitive emissions from
material sources (Appendix D), sample compliance determination and tracking forms
(Appendix E), a typical inspection report for nonmetallic mineral processing plants
(Appendix F), a list of State agencies with delegated authority for the nonmetallic
mineral processing NSPS (Appendix G), and a complilation of EPA policy memoranda
concerning 40 CFR  60, Subpart OOO (Appendix H).
1.2   Intended use of the Manual
      The intended audience of this manual is not only EPA, State and local
compliance inspectors but the nonmetallic mineral processing industry as well as other
involved parties. The manual attempts to attain several objectives:  1) present the
latest guidance for applying the regulations and standards to the affected industries, 2)
present field tested techniques for determining compliance of affected facilities, and 3)
answer some of the most frequently asked questions concerning the nonmetallic
mineral processing NSPS.
      The manual is written in such a way as to offer guidance on applying the
regulations in the field and for reporting and tracking compliance of affected facilities.
No degree of prescriptiveness, however,  can be effective in all situations.  In the last
analysis, correct use of these guidelines and procedures must be coupled with a
thorough knowledge of site-specific conditions to ensure correct application of the
regulations.

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1.3   Industry Overview
1.3.1  General
      There are many nonmetallic minerals that are individually produced in a wide
range of quantities. For the purpose of the nonmetallic mineral processing  NSPS, the
EPA studied 18 minerals based upon Bureau of Mines classifications, which are the
highest mined production segment of the industry involving crushing and grinding
operations, excluding  coal,  phosphate rock, and asbestos. The 18 nonmetallic
minerals affected by the NSPS are:
            Crushed and Broken Stone                  °     Boron
            Sand and Gravel                           °     Barite
            Clay                                      °     Fluorspar
            Rock Salt                                  °     Feldspar
            Gypsum                                   °     Diatomite
            Sodium Compounds                        °     Perlite
            Pumice                                    °     Vermiculite
o
o
o
o
      Gilsonite                                   °      Mica
0     Talc and Pyrophyllite                        °      Kyanite
      Geographically, the industry is highly dispersed, with all States reporting
production of at least one of these 18 nonmetallic minerals.  The industry is also
extremely diverse in terms of production capacities per facility (from 5 to several
thousand tons per hour) and end product uses.
      Crushed stone and gravel are by far the largest segments of the industry.
From 1985 to 1986 figures, there were approximately 4323 processing plants in the
sand and gravel industry and approximately 3557 quarries worked  in the crushed
stone industry.  Each of the other industries had less than 100 processing plants,
except for the clay industry which had approximately 120 plants.
      Table 1-1 lists the major uses of  each individual mineral.  Generally, the uses of
nonmetallic minerals can  be classified as either aggregate for the construction
industry; minerals for the chemical and  fertilizer industries; or clay,  ceramic, refractory,
and miscellaneous minerals. Minerals generally used  for construction are crushed and
broken stone, sand and gravel, gypsum, gilsonite, perlite, pumice, vermiculite, and

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             TABLE
         Mineral
1-1.   MAJOR USES OF THE NONMETALLIC MINERALS
                                               Major  uses
Crushed and broken
Sand and gravel
Clay
Rock salt
Gypsum
Sodium compounds
Pumice
Gilsonite
Talc
Boron
Barite
Fluorspar
Feldspar
Diatomite
Perlite
Vermiculite
Mica
Kyanite
stone   Construction,  lime manufacturing,  erosion control
        Construction
        Bricks,  cement,  refractory,  paper
        Highway  use, chlorine
        Wallboard,  plaster,  cement,  agriculture
        Glass, chemicals,  paper
        Road construction, concrete
        Asphalt  paving
        Ceramics,  paint,  toilet preparations
        Glass, soaps,  fertilizer
        Drilling mud,  chemicals
        Hydrofluoric acid, iron and  steel,  glass
        Glass, ceramics
        Filtration,  filters
        Insulation,  filter aid, plaster aggregate
        Concrete
        Paint, joint cement,  roofing
        Refractories,  ceramics

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mica.  Minerals generally used in the chemical and fertilizer industries are barite,
fluorspar, boron,  rock salt, and sodium compounds.  Clay, feldspar, kyanite, talc, and
diatomite can be  generally classified as clay, ceramic, refractory, and miscellaneous
minerals.
1.3.2 General Process Description
       General industry processing involves extracting from the ground; loading,
unloading, and dumping, conveying, crushing, screening, milling, and classifying.
Some minerals processing also includes washing, drying, calcining, or flotation
operations. The operations performed depend on the ore type and the desired
product.
      The mining techniques used for the extraction  of nonmetallic minerals vary with
the particular mineral, the nature of the deposit, and the location of the deposit.
Mining is carried out both underground and in open pits. Some  minerals require
blasting while others can be removed by excavator, loader, bulldozer, dragline, or
dredging operations alone.
      The nonmetallic minerals are normally delivered to the processing plant by truck
and are dumped  into a hoppered feeder, usually a vibrating grizzly type,  or onto
screens, as illustrated in Figure 1-1. These screens separate or scalp the larger
boulders from the finer rocks that do not require primary crushing, thus minimizing the
load to the primary  crusher. Jaw or gyratory  crushers are usually used for  initial
reduction, although impact crushers are gaining favor for crushing low-abrasion rock,
such as limestones and talc where high  reduction ratios are desired.  The crusher
product, normally 7.5 to 30 centimeters (3 to 12 inches) in size,  and the grizzly
throughs (undersize material) are discharged onto a belt conveyor and normally
transported to either secondary screens and a crusher, or to a surge pile or silo for
temporary storage.

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                                                                FINISHING
                                                                 SCREENS
Figure 1-1.  Flowsheet of a typical aggregate crushing plant.

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      The secondary screens separate the process flow into generally two fractions
(oversize and throughs) prior to the secondary crusher. The oversize is discharged to
the secondary crusher for further reduction.  The undersize, which require no further
reduction at this stage, normally  by-pass the secondary crusher.  A third fraction, the
throughs, is separated when processing some minerals.  Throughs contain unwanted
fines that are usually removed from the crushing process flow and processed as fine
aggregate.  For secondary crushing, gyratory or cone crushers are most commonly
used, although impact crushers are used at some installations.
      The product from the secondary crushing stage, usually 5.0 centimeters or less
in size, is normally transported to a secondary screen for further sizing.  Sized material
from this screen is either discharged directly to a tertiary crushing stage or conveyed
to classifying screens or to a fine-ore bin, which supplies the milling stage.  Cone
crushers or hammermills are normally used for tertiary crushing.  Rod mills, ball mills,
and hammermills are normally used in the milling stage. The product from the tertiary
crusher or  the mill is usually conveyed to a type of classifier such as a dry vibrating
screen system, a wash screen, an  air separator, or a wet rake or spiral system (if wet
grinding was employed),  which also dewaters the material.  The oversize is returned to
the tertiary crusher or mill for further size reduction.  At this point, some mineral end
products of the desired grade are conveyed directly to finished product bins, or are
stockpiled in open areas  by conveyors or trucks.  Other minerals such as talc or barite
may require air classification to obtain the required mesh size, and treatment by
flotation to  obtain the necessary chemical purity and color.
      Most nonmetallic minerals require additional processing depending on the rock
type and consumer requirements.  In certain cases, especially in the crushed stone
and sand and gravel industry, washing may be required to meet particular end product
specifications or  demands such as for concrete aggregate.  Some minerals, especially
certain lightweight aggregates, are  washed and dried, sintered, or treated prior to
primary crushing.  Others are dried following secondary crushing or milling.  Sand and
                                       8

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gravel, crushed and broken stone, and most lightweight aggregates normally are not
milled and are screened and shipped to the consumer after secondary or tertiary
crushing.  Figures 1-1 and 1-2 show simplified diagrams of the typical process steps
required for some nonmetallic mineral processing facilities.
      In general, the factors that affect emissions from most mineral processing
operations  include: the type of ore processed, the type of  equipment and operating
practices employed, the moisture content of the ore, the amount of ore processed,
and a variety of geographical and seasonal factors.  These factors, discussed in more
detailed below, apply to both fugitive  and stack emission sources associated with
processing plant operations.
      The  type of ore processed is important.  Soft  rocks can produce a higher
percentage of fine-grained material than do hard rocks because of their greater
friability and lower resistance to fracture.  Thus,  it is concluded that the processing of
soft rocks results in a greater potential for uncontrolled emissions than the processing
of hard rock.  Minerals arranged in order of increasing hardness are:  talc, clay,
gypsum, barite, limestone and dolomite,  perlite,  feldspar, and quartz.  Thus,  talc could
be expected to exhibit the highest uncontrolled emissions and quartz the least.
      The  type of equipment and operating practices employed also affect emissions.
In general,  emissions from process equipment such  as crushers, screens, grinders,
and conveyors depend on the size distribution of the material, the  moisture content,
and the velocity that is mechanically imparted to the  material.
      The  inherent moisture content  or wetness of the ore processed can have a
substantial  effect on emissions. This is especially evident during mining, initial material
handling, and  initial plant process operation such as primary crushing.  Surface
wetness causes fine particles to agglomerate or adhere to the faces of larger stones
with a resultant dust suppression effect.  However, as new fine particles are  created by
crushing and attrition, and as the moisture content is reduced by evaporation,  this

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COARSE
  ORE
  BIN.
   GRIZZLY
     OR
   SCREEN
PRIMARY
CRUSHER
                                                        SECONDARY
                                                        CRUSHER
                                                      SIZE
                                                      CLASSIFIER
              STOCKPILE
              OR BIN
              13
                      STOCKPILE
                      OR BIN
                      #4
 Figure 1-2.  General schematic for nonmetallic minerals processing.
                              10

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suppressive effect diminishes and may even disappear.  Depending on the
geographical and seasonal factors, the primary variables affecting uncontrolled
particulate matter emissions  are wind parameters and moisture content of the material.
Wind parameters will vary with geographical location and season and it can certainly
be expected that the level of emissions from sources that are not enclosed  (principally
fugitive dust sources) will be greater during periods of high winds than periods of low
winds.  The moisture content of the material will also vary with geographical location
and season.  It can, therefore, be expected that the level of uncontrolled emissions
from fugitive emission sources will be greater in arid regions of the country  than in
temperate ones and greater  during the summer months due to a higher evaporation
rate. The effect of equipment type on uncontrolled emissions from all sources will be
more fully discussed in Section 2.
                                       11

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                                  SECTION 2
                    PROCESS EQUIPMENT EMISSIONS AND
                      PARTICULATE MATTER CONTROLS
      Affected facilities under 40 CFR Part 60, Subpart OOO include only the following
process equipment types: crushers, grinding  mills, screening operations, bucket
elevators, belt conveyors, bagging operations, storage bins, and enclosed truck or
railcar loading stations. This section discusses the most common of these equipment
types encountered in the industry, their principles of operation, and the emission
controls most frequently employed. Because of the diversity of processes and
process equipment used  in the nonmetallic mineral processing industry, the inspector
requires a fundamental knowledge of  the emission sources likely encountered in the
field.  Many times an operating plant may appear to be a confusing array of
equipment, sometimes spread over a  large area, other times compacted into confined
spaces or enclosed within buildings. The inspector may be required  to recognize
subtle differences in equipment and processes to verify that affected facilities are
onsite and are operated within permitted  conditions.
      When conducting a compliance inspection of a nonmetallic mineral processing
plant, it is usually best to  start at the beginning of the process operations and end the
inspection at the finished  product loading station(s). This is especially true of the initial
plant visit when the inspector is becoming acquainted with the particular processes
and equipment types employed at the facility. A beginning-to-end approach allows the
inspector to understand the logic of plant processes as well as trace  the flow of
materials.  For this reason, the types of process equipment defined as affected
facilities under Subpart OOO are presented in this section in the process order most
frequently found  in the industry.
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2.1   Crushers
      Subpart OOO affected facilities begin with the first crushing or grinding
operation at the plant.  Plants that do not employ crushing or grinding are, by
definition, not considered nonmetallic mineral processing plants and are thus not
subject to the nonmetallic mineral processing NSPS.
      After blasting, ripping, or breaking is completed in the quarry, the initial size
reduction of the raw material is usually accomplished in the primary crusher.
Generally, crushing is size reduction in the  coarse range and grinding  in the fine
range. Crushing is usually accomplished in machines having crushing or ore  contact
surfaces which are mechanically  held apart. In grinders, the grinding surfaces will rub
on one another if material is not present.
      The mechanical stress applied to rock fragments during crushing may be
accomplished by either compression or impaction. In impaction, the breaking force is
applied very rapidly, while in compression,  the rock is slowly squeezed and forced to
fracture.  All types  of crushers are both compression and impaction to varying
degrees, and in all cases there is some reduction due to rubbing of stone on  stone or
on metal surfaces.   Generally, compression-type crushers produce less fines and
impart less kinetic energy to particles than  do impaction crushers.  Table  2-1 ranks
crushers according to their predominant crushing mechanism (from top to bottom,
compression to impaction).
      Because the size reduction achievable by one machine is limited, reduction in
stages is frequently required.  The various stages include primary, secondary, and
perhaps tertiary crushing. Basically, the crushers used in the nonmetallic minerals
industry are: jaw, gyratory, roll, and impact crushers.
                                       13

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                    TABLE 2-1.  RELATIVE CRUSHING MECHANISMS
               Compression
                Impaction
Double roll crusher
Jaw crusher
Gyratory crusher
Single roll crusher
Rod mill (low speed)
Ball mill
Rod mill (high speed)
Hammermill  (low speed)
Impact breaker
Hammermill  (high speed)
2.1.1  Jaw Crushers
      Jaw crushers consist of a vertical fixed jaw and a moving inclined jaw that is
operated by a single toggle or a pair of toggles. Rock is crushed by compression as
a result of the opening and closing action of the moveable jaw against the fixed jaw.
Their principal application in the industry is for primary crushing.
      The most commonly used jaw crusher is the Blake or double-toggle type. As
illustrated in Figure 2-1, an eccentric shaft drives a Pitman arm that raises and lowers
a pair of toggle plates to open and close the moving jaw which is suspended from a
fixed shaft.  In a single-toggle jaw crusher, the moving jaw is itself suspended from an
eccentric shaft and the lower part of the jaw supported by a rolling toggle plate (Figure
2-2). Rotation of the eccentric shaft produces a circular motion at the  upper end of
the jaw and an elliptical motion at the lower end. Other types, such  as the Dodge and
overhead eccentric are used on a limited scale.
      A jaw crusher can be categorized by its feed opening dimensions and may
range from approximately 15x30 centimeters to 213x168 centimeters (6x12 inches to
84x66 inches).  The size reduction obtainable may  range from 3:1 to 10:1  depending
on the nature of the rock.  Capacities are quite variable depending on  the unit and its
discharge setting.
                                       14

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                          MOVEABLE JAW
FIXED JAW
ECCENTRIC
                                                              PITMAN ARM
                  DISCHARGE
                     Figure 2-1.  Double-toggle jaw crusher.
                     MOVEABLE JAW

                        FEED
                FIXED
                 JAW
                          DISCHARGE
                                         TOGGLE
                     Figure 2-2. Single-toggle jaw crusher.
                                    15

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2.1.2  Gyratory Crushers
      Simply, a gyratory crusher may be considered to be a jaw crusher with circular
jaws between which the material flows and is crushed. However, a gyratory crusher
has a much greater capacity than a jaw crusher with an equivalent feed opening.
      There are basically three types of gyratory crushers, the pivoted spindle, fixed
spindle, and cone.  The fixed and pivoted spindle gyratories are used for primary and
secondary crushing, and cone crushers for secondary and tertiary crushing.  The
larger gyratories are grouped according to feed opening and the smaller units by cone
diameters.
      The pivoted spindle gyratory (Figure 2-3) has the crushing head mounted on a
shaft that is suspended from above and free to pivot. The bottom of the shaft is
seated in an eccentric sleeve which revolves, thus causing the crusher head to gyrate
in a circular path within a stationary concave circular chamber.  The crushing action is
similar to that of a jaw crusher in that the crusher element reciprocates to and from a
fixed crushing plate. Because some part of the crusher head is working at all times,
the discharge from the gyratory is continuous rather than intermittent as in a jaw
crusher.  The  crusher setting is determined  by the wide-side opening at the discharge
end and  is adjusted by raising or lowering the crusher head.
      Unlike the pivoted spindle gyratory, the fixed spindle gyratory has its crushing
head mounted on an eccentric sleeve fitted  over a fixed shaft. This produces a
uniform crushing stroke from the top to the  bottom of the crushing chamber.
      For fine crushing, the gyratory is equipped with flatter heads  and converted to a
cone crusher (Figure 2-4).  Commonly, in the  lower section a parallel zone exists.
This results in a larger discharge-to-feed area  ratio which makes it extremely suitable
for fine crushing at high capacity. Also,  unlike regular gyratories, the cone crusher
sizes at the closed side setting and not the open side (wide-side) setting. This
assures that the material discharge will have been crushed at least once at the closed
                                       16

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                FEED
          FIXED
         THROAT

CRUSHING SURFACE
         ECCENTRIC
                                                      DRIVE
                DISCHARGE
                  Figure 2-3.  The pivoted spindle gyratory.
                       FEED
          CRUSHING
          SURFACES
                 DISCHARGE
                                                      DRIVE
                                              ECCENTRIC
                        Figure 2-4.  Cone crusher.
                                 17

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side setting.  Cone crushers yield an elongated product and a high percentage of fines
due to interparticle crushing.  They are the most commonly used crusher in the
industry for secondary and tertiary reduction.
2.1.3  Roll Crushers
      These machines are used primarily at intermediate or final reduction stages and
are often used at portable plants. There are essentially two types,  the single-roll  and
the double-roll. As illustrated in Figure 2-5, the double-roll crusher  consists of two
heavy parallel rolls which are turned toward each other at the same speed.  Roll
speeds range from 50 to 300 rpm. Usually, one roll is fixed and the other set by
springs.  Typically, roll diameters range from 61 to 198 centimeters (24 to 78 inches)
and have narrow face widths, about half the roll diameter.  Rock particles are caught
between  the rolls and crushed almost totally by compression.  Reduction ratios are
limited and range from 3 to 4 to 1. These units produce few fines and no oversize.
They  are used especially for reducing hard stone to a final product ranging from  1 /4
inch to 20 mesh.
      The  working elements of a single-roll crusher include a toothed or knobbed roll
and a curved crushing plate that may be corrugated or smooth. The crushing plate is
generally hinged at the top and its setting is held  by a spring at the bottom.  A
toothed-roll crusher is depicted in Figure 2-6.  The feed caught between the roll and
crushing  plate is broken by a combination of compression, impact, and shear.  These
units may accept feed sizes up to 51  centimeters (20 inches) and have capacities up
to 454 megagrams per hour (500 tons/h).  In  contrast with the double-roll, the single-
roll crusher is principally used for reducing soft materials such  as limestones.
2.1.4   Impact Crushers
      Impact crushers, including hammermills and impactors,  use the force of fast
rotating massive impellers or hammers to strike and shatter free falling rock particles.
These units have extremely high reduction ratios and produce  a cubical  product
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                FEED
                   DISCHARGE
ADJUSTABLE
  ROLLS
              Figure 2-5.  Double-roll crusher.
                  FEED
        TOOTH
ROLL
       CRUSHING
          PLATE
              Figure 2-6. Single-roll crusher.
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spread over a wide range of particle sizes with a large proportion of fines, thus making
their application in industry segments such as cement manufacturing and agstone
production extremely cost effective by reducing the need for subsequent grinding
machines.
      A hammermill consists of a high speed horizontal rotor with several rotor discs
to which sets of swing hammers are attached (Figure 2-7).  As rock particles are fed
into the crushing chamber, they are impacted and shattered by the hammers which
attain tangential speeds as high as 76 meters (250 feet) per second. The shattered
rock then collides with a steel breaker plate and is fragmented  even further. A
cylindrical grating or screen positioned at the discharge opening restrains oversize
material until it is reduced to a size small enough to  pass between the grate bars.
Rotor speeds range from 250 to 1800 rpm  and  capacities to over 907 megagrams per
hour (1,000 tons/h). Product size is controlled  by the rotor speed, the spacing
between the grate bars, and by hammer length.
      An impact breaker (Figure 2-8) is similar to a hammermill except that it has no
grate or screen to act as a restraining member. Feed is broken by impact  alone.
Adjustable breaker bars are used instead of plates to reflect material back into the
path of the impellers.  Primary-reduction units are available that can reduce quarry run
material at over 907 megagrams per hour (1,000 tons/h) capacity to approximately 2.5
centimeters (1  inch). These units are not appropriate for hard abrasive materials, but
are ideal for soft rocks like limestone.
2.1.5  Sources of Emissions
      The generation of particulate emissions is inherent in the crushing  process.
Emissions are  most apparent at crusher feed and discharge points.  Emissions are
influenced predominantly by the type  of rock  processed, the moisture content of the
rock, and the type of crusher used.
      The most important element influencing emissions from crushing equipment is
the type of rock and the moisture content of the mineral being crushed.  The crushing
                                      20

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                FEED
                   \
BREAKER
 PLATE
                                       SWING
                                       HAMMERS
                                    — GRATE BARS
              Figure 2-7.  Hammermill.
 BREAKER
  PLATE
BREAKER
   BARS

    FEED
                                ROTOR
                   DISCHARGE
             Figure 2-8. Impact crusher.
                       21

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mechanism employed has a substantial affect on the size reduction that a machine
can achieve; the particle size distribution of the product, especially the proportion of
fines produced; and the amount of mechanically induced energy that is imparted to
fines.
      Crushing units using impaction rather than compression produce a larger
proportion of fines as noted above.  In addition to generating more fines, impaction
crushers also impart higher velocity to the particles as a result of the fan-like action
produced by the fast rotating hammers.  Because of this and the high proportion of
fines produced, impaction crushers generate larger quantities of uncontrolled
particulate emissions per ton of material processed than any other crusher type.
      The level of uncontrolled emissions from jaw, gyratory, cone and roll crushers
closely parallels the reduction stage to which they are applied. Emissions increase
progressively from primary to secondary to tertiary crushing.  Factors other than  the
type of crushing mechanism (compression, impaction) also affect emissions.  In all
likelihood, primary jaw crushers produce greater emissions than comparable gyratory
crushers because  of the bellows effect of the jaw and because gyratory crushers are
usually choke fed to minimize the open spaces from which  dust may be emitted.  For
subsequent reduction stages, cone crushers produce more fines as a result of attrition
and consequently generate more dust.
2.2   Grinding Mills
      Grinding is a further step in the reduction of material to particle sizes smaller
than those attainable by crushers.  Because the material to be treated has already
been reduced to small sizes, and the force to be applied to each particle is
comparatively small, the machines used in grinding are of a different type, and may
operate on a different principle from those used in more coarse crushing.  The
Subpart OOO definition of a "grinding mill" does not distinguish between wet and  dry
crushing and also includes the air conveying  system, air separator, or air classifier
associated with the grinding operation where it is  employed.
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      As with crushers, the most important element influencing emissions from
grinding  mills is the reduction mechanism employed, compression, or impaction.
Grinding  mills generally use impaction rather than compression.  Reduction by
impaction will produce a larger proportion of fines.  Particulate emissions are
generated from grinding mills at the grinder's inlet and outlet.  Gravity type grinding
mills accept feed from a conveyor and discharge product into a screen or classifier or
onto a conveyor.  These transfer points are the source of particulate emissions.  The
outlet has the highest emissions potential because of the finer material. Air-swept mills
include an air conveying system and an air separator, a classifier, or both.  The air
separator and classifier are generally cyclone collectors.  In some systems, the air just
conveys  the material to a separator for deposit into a storage bin with  the conveying
air escaping via the cyclone vent. In other grinding systems, the air is continuously
recirculated.  Maintaining this circulating air system under suction keeps the mill
dustless  in  operation, and any surplus air drawn into the system due to the suction
created by  the fan is released through a vent.  In both cases the vent  gases will
contain a certain amount of particulate matter.
      Many types of grinding mills are manufactured for use by various industries.
The principal types of mills used are:  1) hammer, 2)  roller, 3) rod, 4) pebble and ball,
and 5) fluid energy.  Each of these types of mills is discussed separately below.
2.2.7   Hammermills
      A  hammermill consists of a high speed horizontal  rotor with several rotor discs
to which  sets of swing hammers are attached.  As rock particles are fed into the
grinding  chamber, they are impacted and shattered by the hammers, which  attain
peripheral speeds greater than 76 meters (250 feet) per second.  The  shattered rock
then collides with a steel breaker plate and is fragmented even further. A cylindrical
grate or screen positioned at the discharge opening restrains oversize material until it
is reduced to a size small  enough to pass  between the grate bars.  Product size is
                                       23

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controlled by the rotor speed, the spacing between the grate bars, and by hammer
length.  These mills are used for nonabrasive materials and can accomplish a size
reduction of up to 12:1.
2.2.2  Roller Mill
      The roller mill, also known as a Raymond Roller Mill, with its integral whizzer
separator can produce ground material ranging from 20 mesh to 325 mesh or finer.
The material is ground by rollers that travel along the inside of a horizontal stationary
ring.  The rollers swing outward by  centrifugal force, and trap the material between
them and the  ring.  The material is swept out of the mill by a stream of air to a whizzer
separator, located directly on top of the mill.  Here the oversize  is separated and
dropped back for further grinding while the desired fines pass up through the whizzer
blades into the duct leading to the air separator (cyclone).
2.2.3  Rod Mill
      The rod mill is generally considered as a granular grinding unit, principally for
handling a maximum feed size of 2  to 4 centimeters (1 to 2 inches), and grinding to a
maximum of 65 mesh.  It is normally used in a closed circuit with a sizing device, such
as classifiers or screens, and for wet or dry grinding.  It will grind with the minimum of
the finer sizes, such as 100 or 200 mesh, and will handle relatively higher moisture
material without packing.
      The mill in its general form consists of a horizontal,  slow-speed, rotating,
cylindrical drum. The grinding media consists of a charge of steel rods, slightly
shorter than the mill's inside length  and from 5 to 13 centimeters (2 to 5 inches) in
diameter.  The rods roll freely inside the drum during its rotation to provide the
grinding action desired.
                                       24

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2.2.4  Pebble and Ball Mills
      The simplest form of a ball mill is cylindrical, horizontal, slow-speed rotating
drum containing a mass  of balls as grinding media. When other types of grinding
media such as a flint or various ceramic pebbles are used, it is known as a pebble
mill.  The  ball mill uses steel, flint, porcelain, or cast iron balls.
      The diameter of balls or pebbles as the initial charge in a mill is determined by
the size of the feed material and the desired fineness of the product.  Usually the
larger diameter ranges are used for preliminary grinding and the smaller for final
grinding.  Ball mills reduce the size of the feed mostly by impaction.  These grinders •
normally have a speed of 10 to 40 revolutions per minute. If the shell rotates too fast,
centrifugal force keeps the balls against the shell and minimal grinding occurs.
2.2.5  Fluid Energy Mills
      When the desired  material size is in the range of 1 to 20 microns, an ultrafine
grinder such as the fluid  energy mill is required.  A typical fluid energy mill is shown in
Figure 2-9.  In this type of mill, the particles are suspended and conveyed by a high
velocity gas stream in a circular or elliptical path.  Size reduction is caused by
impaction and rubbing against mill walls, and by interparticle attrition.  Classification of
the particles takes place  at the  upper bend of the loop.  Internal  classification occurs
because the smaller particles are carried through the outlet by the gas stream while
the larger particles are thrown against the outer wall by centrifugal force. Product size
can be varied by changing the gas velocity through the grinder.
      Fluid energy mills  can normally reduce up to 0.91 megagrams/h (1 ton/h) of
solids from 0.149 mm (100 mesh) to particles averaging 1.2 to 10 microns in  diameter.
Typical gas requirements are 0.45  and 1.8  kg (1 to 4 pounds) of steam or 2.7 to 4.1
                                       25

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Figure 2-9.  Fluid energy mill.
             26

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kg (6 to 9 pounds) of air admitted at approximately 6.8 atm (100 psig) per 0.45 kg (1
pound) of product. The grinding chambers are typically about 2.5 to 20 cm (1 to 8
inches) in diameter.
2.2.6  Separating and Classifying
       Mechanical air separators of the centrifugal type cover a distinct field and find
wide acceptance for the classification of dry materials in a relatively fine state of
subdivision.  In commercial practice the separator may be said to begin where the
impact of vibrating screens leave off, extending from 40 to 60 mesh  down.
       Briefly stated, the selective action of the centrifugal separator  is the result of an
ascending  air current generated within the machine by  means of a fan, such current
tends to  lift the finer particles against the combined effect of centrifugal force and
gravity. In operation, the feed opening allows the material to drop on the lower or
distributing plate where it is spread and  thrown off by centrifugal force, the larger and
heavier particles being projected against an inner casing, while the small and lighter
particles  are picked up by the ascending air current created by the fan.  These fines
are carried over into an outer cone and  deposited. Concurrently, the rejected  coarse
material drops into the inner cone,  passes out through  a spout and  is recycled back to
the grinding mill.
      The  air, after dropping the major portion of its burden, is either recirculated
back to the grinding mill or vented.  In the case of the recirculated air, a small  amount
of extraneous air is entrained in the feed and frequently builds  up pressure in the
separator,  in  which case the excess air may be vented  off.  Both vent gases are a
source of particulate matter.
2.3    Emission Controls for Crushers and  Grinding Mills
      Generally, particulate matter emission control for crushers and grinding  mills
involve one of two techniques:  1) wet dust suppression, and/or 2) dust collection by
a capture and conveying system to a control device. Wet dust suppression consists
of introducing water or amended water into the material flow, causing the fine
                                       27

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participate matter to be confined and remain with the material flow rather than
becoming airborne. Dust collection involves hooding and enclosing dust-producing
emission points and exhausting emissions to a collection device.
2.3.1  Wet Dust Suppression
      Wet dust suppression of dry crushing usually involves water sprays both above
and  below the crusher throat.  The objective of the water sprays is not to fog the
emission source with a fine mist to capture PM emissions,  but rather to prevent
emissions by keeping the material moist during the crushing process.  Enough
moisture must be added to progressively wet the ore surfaces as reduction proceeds.
The  water spray nozzles above the crusher throat may be  positioned close to the
receiving end of the throat or positioned some distance above the throat to assist in
dust suppression  from truck or feeder dumping of the ore.  Figure 2-10 shows a spray
nozzle arrangement above the throat of a primary jaw crusher.  Note that the wide
spray pattern assists in reducing truck dump emissions as well as emissions  from the
crusher throat.  In determining compliance with the Subpart OOO emission standards
for crushers, however, emissions from truck dumping of material directly or indirectly
into a crusher, grinding mill, screening operation or feed hopper is exempt from the
standards and must be separated from emissions originating directly from the affected
facility.
      In addition  to water sprays above the crusher throat, spray  nozzles are normally
required below the throat where new dry surfaces and dust are generated by the
fracture of the ore. Figure 2-11 shows a typical arrangement for the control of
emissions at the crusher discharge.
      When plain or untreated water is used, because of its unusually high surface
tension, the addition of 5 to 8 percent moisture (by weight), or greater, may be
required to adequately suppress dust. In some installations, this may not be  optimum
because the excess moisture may cause downstream screen blinding or result in the
coating of mineral surfaces yielding a marginal or nonspecification product.
                                       28

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Figure 2-10.  Spray nozzle arrangement above primary crusher throat.
                             29

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                                              SUPPRESSANT
                    CRUSHER
SPRAY HEADER
         \
                                                           FILTER
                                                           CONTROL
                                                          *~  VALVE
                                                    RUBBER
                                                    SHIELD
                                                      BELT
                                                      IDLERS
  Figure 2-11. Dust suppression application at crusher discharge.
                          30

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To counteract this effect, small quantities of wetting agents or surfactants may be
added to the water to reduce its surface tension and improve it wetting efficiency.
2.3.2 Dust Collection Systems
      Hooding and air volume requirements for the control of crusher and grinder
emissions are quite variable depending  upon the size and shape of the emission
source,  the hood's position relative to the points of emission, and the velocity, nature,
and  quantity of the released particles. The only established criterion is that a minimum
indraft velocity of 61 meters per minute  (200 fpm) be maintained through all open
hood areas.  To achieve this, capture velocities in excess of 150  meters per minute
(500 fpm) may be necessary to overcome induced air motion, resulting from the
material feed and discharge velocities and the  mechanically induced velocity (fan
action) of a particular  equipment type.  To achieve effective emission control,
ventilation should be applied at both the upper portion, or feed end, of the equipment
and  at the discharge point. An exception to this would be at primary jaw or gyratory
crushers because of the necessity to have ready access to get at and dislodge large
rocks that may get stuck in the crusher feed opening.  Where access to a device is
required for maintenance, removable hood sections may  be used.
      In general, the  upper portion of the crusher or grinder should be enclosed as
completely as possible.  The exhaust rate varies considerably depending on crusher
type. For impact crushers or grinders, exhaust volumes may range from  110 to 230
m3/nnin  (4,000 to 8,000 cfm).  For compression type crushers, an exhaust rate of 46
m3/min  per meter (500 cfm per foot) of discharge opening should be sufficient.  The
width of the discharge opening will approximate the width of the receiving conveyor.
For either impact crushers or compression type crushers, pick-up should be applied
downstream of the crusher for a distance of at least 3.5 times the width of the
receiving conveyor. A typical hood configuration used  to control particulate emissions
from a cone crusher is depicted in Figure 2-12.
                                       31

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CO
IV)
                    FEED

                    BELT
                              -.
                                         INSPECTION
                                         -  DOOR
  CONE _.
CRUSHER
              CRUSHER
              DISCHARGED*
COLLECTION
  HOODS
                                                                                                CONTROL
                                                                                                DEVICE
                                                                                                   DUST
                                                                                                    BIN
                                                                                                                EXHAUST
                                                                                                                   A
                                                                                                                      FAN
                                   Figure 2-12. Hood configuration used to control a cone crusher.

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      Grinding or milling circuits which employ air conveying systems operate at
slightly negative pressure to prevent the escape of air containing the ground rock.
Because the system is not airtight, some air is drawn into the system and must be
vented.  This vent stream can be controlled by discharging it through a control device.
2.4   Screening Operations
      Screening is  the process by which a mixture of stones is  separated according
to size.  In screening, material  is dropped onto a mesh  surface with openings  of
desired  size and separated into two fractions, undersize which passes through the
screen opening and oversize which is retained on the screen surface.  When material
is passed over and  through  multiple screening surfaces, it is separated  into fractions
of known particle size distribution.  Screening surfaces may be constructed of metal
bars, perforated or  slotted metal plates, woven wire cloth, or polyurethane  materials.
      The capacity or size of a screen is primarily determined by the open area of the
screening surface and the physical characteristics of the feed.  It is usually expressed
in tons of material per hour per square foot of screen area.  Although screening may
be performed wet or dry, dry screening is the more common in  crushing circuits.
Screening equipment commonly used in the nonmetallic minerals industry includes
grizzlies, shaking screens, vibrating screens, and revolving screens.
2.4.1 Grizzlies
      Grizzlies consist of a set of uniformly spaced bars, rods, or rails. The bars may
be horizontal or inclined and are usually wider in cross section at the top than the
bottom.  This  prevents the clogging or wedging of stone particles between bars.  The
spacing between the bars ranges from 5 to 20 centimeters (2 to 8 inches).  Bars are
usually constructed of manganese steel or other highly  abrasion-resistant material.
      Grizzlies are  primarily used to prevent oversize material from entering the
crusher, thus reducing the load. Grizzlies may be stationary (Figure 2-13),
cantilevered (fixed at one end with the discharge end free to vibrate), or mechanically
                                       33

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Figure 2-13. Stationary grizzly.
              34

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vibrated. Vibrated grizzlies are simple bar grizzlies mounted on eccentrics. The entire
assembly is moved forward and backward at approximately 100 strokes a minute,
resulting in better flow through and across the grizzly surface.
2.4.2   Shaking Screens
      The  shaking screen consists of a rectangular frame with perforated plate or wire
cloth screening surfaces, usually suspended by rods or cables and inclined at an
angle of 14 degrees. The screens are mechanically shaken parallel to the plane of
material flow at speeds ranging from  60 to 800 strokes per minute and at amplitudes
ranging from 2 to 23 centimeters (3/4 to 9 inches). Generally, they are used for
screening coarse material, 1.3 centimeters (1/2-inch)  or larger.
2.4.3   Vibrating Screens
      Where large capacity and  high efficiency are desired, the vibrating screen has
practically replaced all other screen types. It is by far the most commonly used
screen type in the nonmetallic minerals industry.  A vibrating screen (Figure 2-14)
essentially  consists of a inclined flat or slightly convex screening surface which is
rapidly vibrated in  a plane normal or  nearly normal to the screen surface.  The
screening motion is of small amplitude but high frequency, normally in excess of 3,000
cycles per  minute.  The vibrations may be generated either mechanically by means  of
an eccentric shaft, unbalanced fly wheel, cam and tappet assembly, or electrically by
means of an electromagnet.
      Mechanically-vibrated units are operated at approximately 1,200 to 1,800 rpm
and at amplitudes  of approximately 0.3 to 1.3 centimeters (1/8 to 1/2 inch).
Electrically  vibrated screens are available in standard sizes from 30 to 180 centimeters
(12 inches  to 6 feet) wide and 0.76 to 6.1 meters (2-1/2 to 20 feet) long. A complete
screening unit may have one  or more decks.
                                       35

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Figure 2-14.  Vibrating screen.
            36

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2.4.4   Revolving Screens
      This screen type consists of an inclined cylindrical frame around which is
wrapped a screening surface of wire cloth or perforated plate.  Feed material is
delivered at the upper end and, as the screen is rotated, undersized material passes
through the screen openings while the oversized is discharged at the lower end.
Revolving screens are available up to 1.2 meters (4 feet) in diameter and usually run at
15 to 200 rpm.
2.4.5   Emission Controls for Screening Operations
      Dust is emitted from screening operations as a result of the agitation of dry
material. The level of uncontrolled emissions depends on the quantity of fine particles
contained in the material, the moisture content of the material and the type of
screening equipment. Generally, dry  screening of fines produces higher emissions
than the screening of coarse materials.  Also, screens agitated at large amplitudes and
high frequency  emit more dust than those operated at small amplitudes and low
frequencies.
      As with crushers and grinding mills, particulate  matter emission control may be
accomplished by either wet dust suppression when the addition of moisture is not
deleterious to the process, or by dust collection and conveyance to a control device.
A full coverage  hood, as depicted  in Figure 2-15, is generally used to control
emissions generated at actual screening surfaces.  Required exhaust volumes vary
with the surface area of the screen and the amount of open area around the periphery
of the enclosure.  A well-designed enclosure should have a space of no more than 5
to 10 centimeters (2 to 4  inches) around the periphery of the screen.  A minimum
exhaust rate of  15 m3/min per square meter (50 cfm per square foot) of screen area is
commonly  used with no increase for multiple decks.
                                      37

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                      TO CONTROL
                        DEVICE
FEED
                                           COMPLETE
                                          ENCLOSURE

                                               SCREEN
                            THROUGHS
     Figure 2-15. Hood configuration for vibrating screen.
                          38

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      As was previously discussed in Section 2.4, screening may be performed either
wet or dry. When the object of wet screening is to remove unwanted material from the
product (e.g., silt, clay, grit, etc.) and not to separate product by size, the operation is
termed washing. Washers are not affected facilities under Subpart OOO (see the
definition of screening operation in Section 3.2).
      It should be noted, however, that some washers such as deck-type screens
with spray bars can be modified for dry screening by removing the sprays.  If a
washer is modified and used for dry screening, and the washer was manufactured
after August 31, 1983, the modified washer constitutes a screening operation  as
defined in §60.671  and therefore becomes an affected facility under Subpart OOO.
2.5   Storage Bins
      Storage bins for raw materials, intermediates, and final products  may be
charged and unloaded by gravity, mechanically or by pneumatic conveying and
loading systems.  Charging and unloading may also occur continuously or
intermittently. Particulate matter emissions may occur during charging  as the air head
space in  the bin is displaced by product. This air head space is either  discharged to
the atmosphere without controls through vents, or is collected and conveyed  to a
control device.
2.5.1  Emission Controls for Storage Bins
      The amount of uncontrolled particulate matter emissions generated during
storage bin charging is dependent on the material size, charging rate, moisture
content and the charging mechanism employed.  Top loading of a storage  bin
involving  free-falling material is expected to generate the greatest emissions.
      The most frequently employed control devices used on storage bins are fabric
dust collectors (baghouse) or air pollution control cyclones. The baghouse may be
positioned atop the storage bin (Figure 2-16) or may  be  positioned some distance
away.  If  a cyclone is employed, however, it is positioned above  the bin charging port.
                                      39

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Figure 2-16. Baghouse atop a storage bin.
                  40

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Cyclones with low circumference-to-height ratios are designed as air separators and
are not efficient in reducing fine particulate matter emissions. Figure 2-17 shows two
cyclones, each serving a storage bin and acting as air separators during charging.
Also note that between the cyclones are two baghouses which control emissions from
the exits of each cyclone and also serve as controls on bin venting.
2.6    Bucket Elevators
       Bucket elevators are used where substantial elevation is required within a
limited space. They consist of a head and foot assembly which supports and drives
an endless single or double strand chain or belt to which buckets are attached.
Figure 2-18 depicts the three types most commonly used: the high-speed centrifugal-
discharge, the slow speed positive or perfect-discharge, and the continuous-bucket
elevator.
       The centrifugal-discharge elevator has a single strand  of chain or belt to which
the spaced buckets are attached. As the buckets round the tail pulley, which is
housed within a suitable curved boot, the buckets scoop up  their load and elevate it to
the point of discharge. The buckets are so spaced so that at discharge, the material
is thrown out by the centrifugal action of the bucket rounding the head pulley. The
positive-discharge type also uses spaced buckets but differs from the centrifugal type
in that it has a double-strand chain and a different discharge mechanism. An
additional sprocket, set below the head pulley, effectively bends the strands back
under the pulley, which causes the bucket to be totally  inverted resulting in a positive
discharge.
       The continuous-bucket elevator uses closely spaced buckets attached to a
single or double strand belt or chain. Material is loaded directly into the  buckets
during ascent and is discharged gently as a result of using the back of the precluding
bucket as a discharge chute.
                                       41

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Figure 2-17.  Cyclones and baghouses serving storage bins.
                          42

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                 (b)
                 (c)
                        LEGEND
                  (a) centrifugal discharge
                  (b) positive discharge
                  (c) continuous discharge
Figure 2-18. Bucket elevator types.
            43

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2.6.1  Emission Controls for Bucket Elevators
       Particulate matter emissions generated by bucket elevators are dependent on
the particle size distribution of the material, freefall distance, moisture content, and the
speed of the elevator belt or chain.  Emission control is applied at the top of the
elevator at the point of bucket discharge using a dust capture and conveying system
to a control device, usually a baghouse. The angle of the capture system duct
penetration into the elevator enclosure is important to avoid duct pluggage.  The
penetration angle should be above or below perpendicular to the elevator.  The fan
draft of the capture system should be enough to capture the fines within the
enclosure, but not high  enough to capture product.
2.7    Belt Conveyors
       Belt conveyors are the most widely  used means of transporting, elevating,  and
handling materials in the nonmetallic minerals industry.  As illustrated in Figure 2-19,
belt conveyors consist of an endless belt that is carried on a series of idlers usually
arranged so that the belt forms a trough. The belt is stretched between a drive or
head pulley and a tail pulley.  Although belts may be constructed of other material,
reinforced rubber is the  most commonly used.  Belt widths may range from  36 to 152
centimeters (14 to 60 inches) with 76 to 91 centimeter (24 to 36 inch) belts the most
common.  Normal operating speeds may range from 60  to 120 meters per minute
(200 to 400 feet/minute).  Depending on the belt speed,  belt width and rock density,
load capacities  may be in excess of 1360 megagrams (1,500 tons) per hour.
       Subpart OOO only regulates particulate matter emissions from transfer points to
and from affected facility belt conveyors (except transfer  points to stockpiles).
2.7.1  Emission Controls for Belt Conveyor Transfer Points
       Particulate  matter emissions from belt conveyor transfer points are dependent
on the particle size distribution of the material conveyed, moisture content, belt speed,
wind speed, and free-fall distance.  Emission control is usually applied by hooding,
                                       44

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                       HEAD
                       PULLEY
                 IDLER
O
o   o   u
                                0
                                            o
                                                             TAIL
                                                             PULLEY
                     Figure 2-19.  Conveyor belts and transfer point.
capturing, and conveying to a control device or by wet suppression. Fugitive
emissions are possible, however, from the return portion of the belt (bottom) if the
load material is not completely discharged and adheres to the belt surface. Belt
cleaning is usually accomplished immediately below the head pulley by scrapers,
brushes or vibrators.
      At belt-to-belt conveyor transfer points, hoods should be designed to enclose
both the head pulley of the upper belt and the tail pulley of the lower belt as
completely as possible. With careful design, the open area should be reduced to
approximately 0.15 square meters per meter (0.5 square feet per foot) of belt width.
Factors affecting the air volume to be exhausted include the conveyor belt speed  and
the free-fall distance to which the material is subjected.  Recommended exhaust rates
are 33 m3 per min per  meter (350 cfm per foot) of belt width for belt speeds less than
61 meters/min (200 fpm) and 150 m3/min (500 cfm) for belt speeds exceeding 61
meters/min (200 fpm).  For a belt-to-belt transfer with less than a 0.91 meter (three
foot) fall, the enclosure illustrated in Figure 2-20 is commonly used.
                                       45

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                                                           2" CLEARANCE FOR LOAD
                                                                on BELT
                                                      or KLT ot>cmuc
          CONVEYOR TRANSFER LESS THAM
          3* FALL Km MEATEM PALL
          FNOVIDE ADDITIONAL KXMAUST AT
          LOWE* KLT SEE DETAIL AT fflCMT
               Figure 2-20. Hood configuration for conveyor transfer, less than
                                0.91 meter (3-foot) fall.
       For belt-to-belt transfers with a free-fall distance greater than 0.91 meters (three
feet) and for chute-to-belt transfers, an arrangement similar to that depicted in Figure
2-21 is commonly used. The exhaust connection should be made as far downstream
as possible to maximize dust fallout and thus minimize needless dust entrainment.  For
material containing a high percentage of fines, additional exhaust air may be required
at the tail  pulley of the receiving belt.  Recommended air volumes are 20 m3/min (700
cfm) for belts 0.91 meters (three feet) wide and less, and 28 m3/min (1,000 cfm) for
belts wider than 0.91 meters (three feet).
       Belt or chute-to-bin transfer points differ from the  usual transfer operation in that
there is no open area downstream of the transfer point.  Thus, emissions are emitted
only at the loading point. As illustrated in  Figure 2-22, the exhaust connection is
normally located at some point remote from the loading  point and exhausted at a
minimum rate of 61 m3/rnin per square meter (200 cfm per square foot) of open area.
                                        46

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FROM CHUTE
 OR BELT
                                       ,.	> TO  CONTROL
                                       [        DEVICE
  ADDITIONAL tt
  EXHAUST
                                           RUBBER
                                             SKIRT
                          CONVEYOR BELT
Figure 2-21. Hood configuration for a chute-to-belt or conveyor transfer,
                greater than 0.91 meter (3-foot) fall.
      BELT
                              LOADING
                               POINT
                               BIN
                               OR
                              HOPPER
                                                TO CONTROL
                                                  DEVICE
        Figure 2-22.  Exhaust configuration at bin or hopper.
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2.8    Bagging Operations
       In the nonmetallic minerals industry the valve type paper bag, either sewn or
pasted together, is widely used for shipping fine materials. The valve bag is "factory
closed," that is, the top and bottom are closed either by sewing or by pasting, and a
single  small opening is left on one corner. Materials are discharged into the bag
through the valve.  The valve closes automatically due to the internal pressure of the
contents of the bag as soon as it is filled.
       The valve type bag is filled by means of a packing machine designed
specifically for this purpose.  The material enters the bag through a nozzle inserted in
the valve opening, and the valve  closes automatically when the filling is completed.
       Bagging operations are  a  source of particulate emissions.  Dust is emitted
during the final stages of filing when dust laden air is forced out of the bag. The
fugitive emissions due to bagging operations are generally localized  in the area of the
bagging machine.
2.8.1   Emission Controls for Bagging Operations
       Bagging operations are controlled by local exhaust systems and vented to a
baghouse for product recovery.  Hood face velocities on the order of 150 meters (500
feet) per minute should be used.   An automatic bag filling operation  and vent system
is shown in Figure 2-23.
       It should be noted that if the baghouse serving the NSPS bagging operation
also serves other process equipment, whether or not they  are Subpart OOO affected
facilities, the baghouse emissions will be subject to the Subpart OOO particulate
emission standards unless already covered by other NSPS standards (e.g., Subpart I).
For certain conditions, the Subpart OOO particulate standard may be prorated with
another applicable particulate standard (Section 4.8.2).
                                      48

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                          Hood attached to bin
                               Principal dust source
                      Bag
Figure 2-23. Bag filling vent system.
             49

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2.9    Enclosed Truck or Railcar Loading Operations
       Product materials that are not bagged for shipment may be either bulk loaded
into trucks or railroad cars.  The usual method of loading is gravity feeding through
plastic or fabric sleeves. Bulk loading of fine material is a source of particulate
emissions because, as in the bagging operation, dust laden air is forced out of the
truck or railroad car during the loading operation.
       Subpart OOO defines an enclosed truck or railcar loading station as "that
portion of a nonmetallic mineral processing plant where nonmetallic minerals are
loaded by an enclosed conveying system into enclosed trucks or railcars." This
means that the conveying system must be enclosed as well as the truck or railcar.  An
enclosed  conveying system includes the enclosed apparatus that directly discharges
into the truck or railcar.  To determine the termination of the enclosed conveying
system, the system should be traced from the transfer point at the truck or railcar
countercurrent to material flow to the first transfer point.  Any particulate matter
emissions between these two transfer points are emissions from the enclosed
conveying system.
       Finally, the definition of enclosed truck or railcar loading station stipulates that
the truck or railcar be enclosed. Enclosure may be here defined as a hood or cover,
integral or attached to the truck or railcar, through which penetrations are afforded for
loading and displacement of air.
2.9.1  Emission Controls for Enclosed Truck or Railcar Loading Stations
       Particulate emissions from enclosed truck and railcar loading of coarse material
can  be minimized by eliminating any breaks in the enclosed conveying system.
Shrouds, telescoping feed tubes, and windbreaks can further reduce the fugitive
emissions from this intermittent source.  Particulate emissions from loading of fine
material into either trucks or railroad cars can be controlled by an exhaust system
vented to  a baghouse.  The material is fed through one of the vehicle's  openings and
the exhaust connection is normally at another opening.  The system should be
                                       50

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designed with a minimum amount of open area around the periphery of the feed chute
and the exhaust duct.  Figure 2-24 shows both an enclosed truck and railcar loading
station.  In this example, product material is directly loaded by gravity from storage
bins through enclosed feed tubes.  Note that both the truck and railcar are also
separately enclosed systems.
             Figure 2-24.  Combination enclosed truck and railcar loading station.

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                                    SECTION 3
            REGULATORY REQUIREMENTS AND THEIR APPLICATION

       Regulatory requirements for the nonmetallic mineral processing NSPS are
contained in 40 CFR Part 60, Subpart OOO as well as in the general provisions of 40
CFR Part 60, Subpart A.  This section details these requirements and provides an
explanation of the definitions, rules, and standards contained in Subpart OOO and
those requirements in Subpart A that directly affect the nonmetallic mineral processing
NSPS.  In addition, this section provides guidance on the application of the NSPS
requirements.
       To facilitate a better understanding of the regulations and their application, the
specific requirements of Subpart OOO are presented in their entirety.   Each section of
the subpart is arranged in numerical order and is divided  into individual subsections or
paragraphs.  Each subsection  or paragraph is presented  as it appears in the Federal
Register followed by a more detailed explanation of its content  as well as notes on its
application. Where applicable, the provisions  of Subpart A which directly affect each
subsection or paragraph are included.  Finally, cross-sectional  references are provided
to better explain each subsection or paragraph in the overall context of the
regulations.
       Although this section should be read in its entirety, it may also be used as a
reference when questions arise during actual application of the regulations.
3.1    Applicability and Designation of Affected Facility - §60.670
3.1.1   General Applicability and Affected Facilities - §60.670 (a)
       (a) Except as provided in paragraphs, (b) [subject to Subpart F or I], (c) [plants
       exempted by capacity] and (d) [replacement of equipment of equal  or smaller size] of
       this section, the provisions of this subpart are applicable to the following affected
       facilities in fixed or portable nonmetallic mineral processing plants; each crusher,
       grinding mill, screening operation, bucket elevator, belt conveyor, bagging operation,
       storage bin, enclosed truck or railcar loading station.
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Explanation /Application:

      Paragraphs (b), (c), and (d) will be more fully explained separately in this
section.  Also, each type of affected facility (i.e., crusher, grinding mill, belt conveyor,
etc.) will  be covered individually in Section 3.2. The key term is "affected facility."  In
determining the appropriate designation of "affected facility" for this NSPS, EPA found
that a narrow designation was most appropriate to minimize  emissions by application
of best demonstrated control technology. Under this narrow designation, affected
facilities are individual pieces of operating equipment, not entire plants.

See also:
             Appendix B, §60.2 "Affected Facility"
             Section 3.1.2,3.1.3, and 3. 1 .4
             Section 3.2, §60.671  "Crusher," "Grinding Mill," "Belt
                   Conveyor,""Screening Operation," "Bucket Elevator," "Bagging
                   Operation," "Storage Bin,"  "Enclosed Truck or Railcar Loading
                   Station," and "Nonmetallic Mineral Processing Plants"

3. 1.2  Facilities Subject to Other NSPS - §60.670 (b)

       (b) An affected facility that is subject to the provisions of Subpart F or I or that follows in
       the plant process any facility subject to the provisions of Subpart F or I of this part is
       not subject to the provisions of this subpart.

Explanation/Application:

       Subpart F is the NSPS for portland cement plants while Subpart I is the NSPS
for asphalt concrete plants.  At these types of facilities, the nonmetallic mineral
processing NSPS will apply to affected facilities that precede equipment covered  by
Subparts F or I.  For example, onsite crushing operations at asphalt concrete plants
will  be subject to the nonmetallic mineral processing NSPS.  Once the crushed stone
is entered as a raw material into the asphalt concrete process, however, equipment for
handling it is covered under Subpart I.
See also:
             Appendix H, memorandum from John B. Rasnic to Bernard E.
             Turlinski, November 8, 1990.
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3.1.3  Facilities Exempted by Plant Type/Capacity - §60.670 (c)

       (c) Facilities at the following plants are not subject to the provisions of this subpart:

              (1) Fixed sand and gravel plants and crushed stone plants with capacities, as
              defined in §60.671, of 23 megagrams per hour (25 tons per hour) or less

              (2) Portable sand and gravel plants and crushed stone plants with capacities, as
              defined in §60.671, of 136 megagrams per hour (150 tons per hour) or less

              (3) Common clay plants and pumice plants with capacities, as defined in
              §60.671, of 9 megagrams per hour (10 tons per hour) or less.

Explanation/Application:

       Economic and environmental  impacts analysis conducted by EPA indicated that
at these types of facilities operating at these capacities, emissions reductions might be
unreasonably costly for the environmental benefits received.

       In order to accurately identify these plant types, the definitions of "fixed plant,"
"portable plant," "capacity," and "initial crusher" must be accurately applied.

See also:

              Section 3.2, §60.671 "Fixed  Plant," "Portable Plant," "Capacity," and "Initial
              Crusher"

3.1.4  Exemption by Replacement with Facilities of Equal or Smaller Size - §60.670 (d)

       (d)(1) When an existing facility is replaced by a piece of equipment of equal or smaller
       size, as defined in §60.671, having the same function as the existing facility, the new
       facility is exempt from the provisions of §§60.672, 60.674 and 60.675 except as provided
       in paragraph (d)(3) of this section.

       (2) An owner or operator seeking to comply with this paragraph shall comply with the
       reporting requirements of §60.676 (a) and (b).

       (3) An owner or operator replacing all existing facilities in a production line with new
       facilities does not qualify for the exemption described in paragraph (d)(1)  of this section
       and must comply with the provisions of §§60.672, 60.674, and 60.675.

Explanation/Application:

       The key point in paragraph (d)(1) is the term "size."  For crushers, grinding
mills, bucket elevators, bagging operations, and enclosed truck or railcar loading
stations, size is defined as the rated capacity in tons per hour.  Rated capacity  is the
manufacturer's highest rated capacity.  To ensure that the replacement equipment is
indeed of equal or smaller size, the manufacturer's highest rated capacities of both the
existing equipment  and the replacement equipment should be based on the same
                                          54

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operating criteria.  For example, the size (rated capacity) of an existing crusher may
be based on the crusher efficiency index number (CEIN) method involving variables
such as the test material work index, feed size, product size, open circuit capacities for
each closed side setting, and maximum horsepower. Regardless of rating
methodology, identical or like criteria and methods should be used to rate the capacity
of replacement equipment.

      It should be noted that if this exemption is applicable, the owner or operator is
only exempt from §§60.672, 60.674, and 60.675; all other requirements of the Subpart
are applicable.

      Paragraph (d)(3)  stipulates that if an entire production line is replaced with
equipment  of equal or smaller size, the exemptions from the particulate matter
standards (§60.672), wet scrubber monitoring requirements (§60.674), and
performance test (§60.675) do not apply.  This also means that if the equipment is
replaced one or more pieces at a time, the entire production line retains  the
exemptions until the last piece of equipment is replaced.

      §60.671 defines "production line" as all  affected facilities which are directly
connected  together by a conveying system.  Although the definition  of "conveying
system" is not limited to feeders, belt conveyors,  bucket elevators and pneumatic
systems, movable equipment (i.e., trucks, frontend loaders, etc.)  are not to be
included in the definition of "conveying system" as it applies to the definition of
"production line" because movable equipment do not directly connect the affected
facilities.

See also:

            Section 3.2, §60.671 "Size"  and "Production Line"

3.1.5  Designation of Affected Facility by Date of Construction, Reconstruction, or
      Modification - §60.670 (e)

      (e) An affected facility under paragraph (a) of this section that commences construction,
      reconstruction, or modification after August 31, 1983 is subject to the requirements of
      this part.

Explanation/Application:

      As defined in  §60.2 of Subpart A, "commenced" means that an owner or
operator has undertaken a continuous program of construction (or reconstruction) or
modification or has entered into a contractural obligation to undertake and complete
such a program.
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       §60.2 also defines "construction" as fabrication, erection, or installation of an
affected facility.  Because of the narrow designation of affected facility under Subpart
OOO, construction means the date of fabrication or manufacture of the affected facility.
For example, a crusher manufactured before August 31,  1983 but erected or installed
after this date would not be designated an affected facility under Subpart OOO.

       Finally, §60.2 defines "modification" as any physical change in, or change in the
method of operation of, an existing facility which increases the amount of any air
pollutant (to which a standard applies) from that facility or results in the emission of a
pollutant not previously emitted.  EPA does  not, however, anticipate that the
modification provisions will be triggered except on rare occassions. Most
modifications to existing facilities will fall within the  provisions of §60.14(e) of Subpart A
which, by themselves, are not considered modifications.  These provisions  include: 1)
routine maintenance,  repair and replacement within the IRS annual asset guideline
repair allowance (presently 6.5 percent), 2) An increase in production rate without  a
capital expenditure on a facility, 3) an increase in the hours of operation,  4) use of
alternative raw materials if the facility was designed to accommodate them before the
date of the NSPS  proposal (August 31,  1983), 5) the addition or use of an air pollution
control device, and 6) relocation or change  in ownership. Not meeting the provisions
of §60.14(e) (2), an increase in production rate involving  a capital expenditure, is
probably the most likely way a modification would  cause  an  existing facility to become
subject to the NSPS requirements (see the definition of "capital expenditure" in
Appendix B, §60.2).

       For a detailed explanation of reconstruction, see Section 3.4.

See also:

       0      Appendix B, §60.2 "Commenced," "Construction," "Modification," and
             §60.14
             Sections 3.7.1, 3.7.2

3.2    Definitions - §60.671

       Definitions contained  in §60.671 are presented here in alphabetical order as
they appear in the regulations.

Bagging Operation

       "Bagging operation" means the mechanical process by which bags are filled with
       nonmetallic minerals.
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Explanation/Application:

       By definition, only operations which mechanically fill "bags" are designated as
affected facilities.  This does not include similar operations that fill boxes, drums, or
other containers.

Belt Conveyor

       "Belt conveyor" means a conveying device that transports material from one location to
       another by means of an endless belt that is carried on a series of idlers and routed
       around a pulley at each end.

Explanation/Application:

       Although belt conveyors are listed in §60.670 (a) as affected facilities, only
transfer points to and from belt conveyors manufactured after August 31, 1983 are
subject to the requirements of Subpart OOO (except transfer points to stockpiles).
Bucket Elevator

       "Bucket elevator" means a conveying device of nonmetallic minerals consisting of a head
       and foot assembly which supports and drives an endless single or double strand chain
       or belt to which buckets are attached.

Explanation/Application:   None
Building

       "Building" means any frame structure with a roof.

 Explanation/Application:

       There is no requirement that the building be enclosed on any side except the
top (roof). The roof may be any solid structure with the sole purpose of weatherizing
whatever is covered by the roof.  The  key point is that the roof must be constructed
solely  as a weather barrier.  For example, a truck loading station beneath a silo
supported by framing members does not constitute a building because the silo was
not constructed solely as a weather barrier for the loading station.


Capacity

       "Capacity" means the cumulative rated capacity of all initial crushers that are part of the
       plant.

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Explanation/Application:

       Capacity is defined here as plant capacity.  Therefore, plant capacity is the
cumulative total manufacturer's rated capacity of all the initial crushers that are onsite
whether or not the crushers are in service. See Section 3.1, §60.670(d) for a more
detailed clarification of "rated capacity."  Also, see the definition of "initial crusher"  in
this section.
Capture System

       "Capture system" means the equipment (including enclosures, hoods, ducts, fans,
       dampers, etc.) used to capture and transport paniculate matter generated by one or
       more process operations to a control device.

Explanation/Application:

       None
Control Device

       "Control device" means the air pollution control equipment used to reduce paniculate
       matter emissions released to the atmosphere from one or more process operations at a
       nonmetallic mineral processing unit.

Explanation/Application:

       Control devices include, but are not limited to the following:  baghouses, wet
scrubbers, cyclones, multiple cyclones, and  wet dust suppression systems.
Conveying System

       "Conveying system" means a device for transporting materials from one piece of
       equipment or location to another location within a plant. Conveying systems include,
       but are not limited, to the following: feeders, belt conveyors, bucket elevators,
       pneumatic systems, screw conveyors, etc.
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Explanation/Application:

      Conveying system is here defined as it relates to the definition of "production
line."  In this context, movable equipment (i.e., trucks frontend loaders, etc.) is not
considered  part of a conveying system.  See the definition of "production line" in this
section.  Also see Section 3.1, §60.670(d) (3).
Crusher

      "Crusher" means a machine used to crush any nonmetallic minerals, and includes, but is
      not limited to, the following types: jaw, gyratory, cone, roll, rod mill, hammermill, and
      impactor.

Explanation/Application:   See Section 2.1
Enclosed Truck or Railcar Loading Station

      "Enclosed truck or railcar loading station" means that portion of a nonmetallic mineral
      processing plant where nonmetallic minerals are loaded by an enclosed conveying
      system into enclosed trucks or railcars.

Explanation/Application:

      Subpart OOO defines an enclosed truck or railcar loading station as "that
portion of a nonmetallic mineral processing plant where nonmetallic minerals are
loaded by an enclosed conveying system into enclosed trucks or railcars." This
means that the conveying system must be enclosed as well as the truck or railcar.  An
enclosed conveying system includes the  enclosed  apparatus that directly discharges
into the truck or railcar.  To determine the termination of the enclosed conveying
system, the system  should be traced from the transfer point at the truck or railcar
countercurrent to  material flow to the first transfer point. Any particulate matter
emissions between these two transfer points are emissions from the enclosed
conveying system.

      Finally, the  definition of enclosed truck or railcar loading station stipulates that
the truck or railcar be enclosed. Enclosure may be here defined as a hood or cover,
integral or attached  to the truck or railcar, through  which penetrations are afforded for
loading of material and displacement of air.
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Fixed Plant

       "Fixed plant" means any nonmetallic mineral processing plant at which the processing
       equipment specified in §60.670(a) is attached by a cable, chain, turnbuckle, bolt or other
       means (except electrical connections) to any anchor, slab, or structure including
       bedrock.

Explanation/Application:

       The definition of a fixed plant relates to the exemptions granted fixed sand and
gravel plants and crushed stone plants with capacities of 23 megagrams per hour  (25
tons  per hour) or less, and fixed or portable common clay plants and pumice plants
with capacities of 9 megagrams per hour (10 tons per hour) or less.  The exception for
electrical connections in the definition includes both power  connections and grounding
connections.
Fugitive Emission

       "Fugitive emission" means paniculate matter that is not collected by a capture system
       and is released to the atmosphere at the point of generation.

Explanation/Application:

       Fugitive emissions are those particulate matter emissions not released through
a stack or vent (powered).  For the purposes of this definition, a release to the
atmosphere at the point of generation includes release to the atmosphere within a
building as well as a release to the outside atmosphere at the point at which the
particulate matter is first produced.
Grinding Mill

       "Grinding mill" means a machine used for the wet or dry fine crushing of any nonmetallic
       mineral. Grinding mills include, but are not limited to, the following types:  hammer,
       roller, rod, pebble and ball, and fluid energy.  The grinding mill includes the air
       conveying system, air separator, or air classifier, where  such systems are used.

Explanation/Application:

       As defined, Subpart OOO does not distinguish between wet and dry grinding.
Therefore, wet grinding operations are not exempt from the particulate matter
standards, wet scrubber  monitoring  requirements, or the  performance test
requirements of the regulations.  In determining compliance with the standards, all
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emission points in the total grinding system, including the air conveying system, air
separator and/or air classifier, are subject to all the NSPS requirements.
Initial Crusher

       "Initial crusher" means any crusher into which nonmetallic minerals can be fed without
       prior crushing in the plant.

Explanation/Application:

       An  initial crusher is the first piece of crushing equipment employed after quarry
reduction  (i.e., blasting, cracking, or breaking) is achieved.  The location of the initial
crusher(s) may be in the quarry or at the plant.  Also, note that this definition is not
conditional as to whether or not a crusher is operating at any given time..." into which
nonmetallic minerals can be fed..."  Therefore, if a crusher is onsite, whether or not
operating, its rated capacity must be included in the cumulative total of all  initial
crushers for the purpose of establishing plant capacity. See the  definitions of
"capacity"  and "crusher" in this section.  Also see section 3.1, §60.670(c).
Nonmetallic Mineral

       "Nonmetallic mineral" means any of the following minerals or any mixture of which the
       majority is any of the following minerals.

       (a)     Crushed and broken stone, including limestone, dolomite, granite, traprock,
              sandstone, quartz, quartzite, marl, marble, slate, shale, oil shale, and shell.

       (b)     Sand and  gravel
       (c)     Clay including kaolin, fireclay, bentonite, fuller's earth, ball clay, and common
              clay

       (d)     Rock salt

       (e)     Gypsum

       (f)      Sodium compounds, including sodium carbonate, sodium chloride,  and sodium
              sulfate

       (g)     Pumice

       (h)     Gilsonite

       (i)      Talc and pyrophyllite

       (j)      Boron, including borax, kernite, and colemanite
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       (k)     Barite
       (I)      Fluorospar

       (m)    Feldspar

       (n)     Diatomite

       (o)     Perlite

       (p)     Vermlcuiite
       (q)     Mica
       (r)      Kyanite, including andalusite, sillimanite, topaz, and dumortierite.

Explanation/Application:

       A nonmetallic  mineral, by definition, includes any one or any  mixture of the
listed minerals which comprises over half of the raw material processed.



Nonmetallic Mineral Processing Plant

       "Nonmetallic mineral processing plant" means any combination of equipment that is
       used to crush or grind any nonmetallic mineral wherever located, including lime plants,
       power plants, steel mills,  asphalt concrete plants, portland cement plants, or any other
       facility processing nonmetallic minerals except as provided in §60.670(b) and (c).

Explanation/Application:

       To be designated as a nonmetallic mineral  processing plant,  a facility must
employ crushing or grinding processes.  Without crushing or grinding processes, the
entire plant is exempt from the NSPS requirements. If, for example, the  crusher is
located at the quarry and the  quarry is located on the same property as the
processing plant, then the crushing operation would be included and all  affected
facilities would be subject to the NSPS requirements.



Portable Plant

       "Portable plant" means any nonmetallic mineral processing plant that is mounted on any
       chassis or skids and may be moved by the application of a lifting or pulling force.  In
       addition, there shall be no cable, chain, turnbuckle, bolt or other means (except
       electrical connections) by which any piece of equipment is attached or clamped to any
       anchor, slab,  or structure, including bedrock that must be removed prior to the
       application of a lifting or pulling force for the purpose of transporting the unit.
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Explanation/Application:

       Although the definition of a portable plant is self-explanatory, the performance
tests required of affected facilities is somewhat different than for fixed plants.
Performance tests for portable plants are required only at the first site and not at
subsequent sites to which the plant is moved with two exceptions.  First, if a new
affected facility is added, a new performance test is required.  The second exception is
that if a portable plant is moved across State lines, the new State may require a
performance test.
Production Line

       "Production line" means all affected facilities (crushers, grinding mills, screening
       operations, bucket elevators, belt conveyors, bagging operations, storage bins, and
       enclosed truck and railcar loading stations) which are directly connected or are
       connected together by a conveying system.

Explanation/Application:

       Production line is defined here as it relates to a replacement of an  existing
facility with one of equal or smaller size.  §60.670(d) (3)  provides no exemption from
the particulate matter standards, wet scrubber monitoring provisions, or performance
tests if the owner operator replaces all existing facilities in a production line with new
affected facilities.  The definition of production line requires that the affected facilities
be directly connected or connected by a conveying system.  Although the definition of
conveying system is not  limited to explicit pieces of equipment, movable equipment
(i.e., trucks, frontend loaders, etc.) is  not included as part of a conveying system.
Replacement of all facilities in the production line simultaneously or the replacement of
the last facility in the production line will cause all the affected facilities in the
production line to be subject to all the requirements of Subpart OOO.
Screening Operation

       "Screening operation" means a device for separating material according to size by
       passing undersize material through one or more mesh surfaces (screens) in series, and
       retaining oversize material on the mesh surfaces (screens).
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 Explanation/Application:

       Screens include grizzlies, rotating screens and deck-type screens.  Care should
 be taken not to confuse a screen with a washer.  Washers are designed principally to
 remove fines from sized aggregate.  As with screens, washers may employ a
 separating surface that rotates or a deck-type surface. Wash water may be sprayed
 onto the aggregate or slurried with the aggregate across the separating surface.  The
 key  distinction is that washers are designed to remove unwanted or unnecessary
 material  from the  product (e.g., grit, fines, clay, etc.) whereas screens are designed to
 separate product  by size. Washers are not affected facilities under Subpart OOO
 (Section 2.4).
Size

       "Size" means the rated capacity in tons per hour of a crusher, grinding mill, bucket
       elevator, bagging operation, or enclosed truck or railcar loading station; the total surface
       area of the top screen of a screening operation; the width of a conveyor belt; and the
       rated capacity in tons of a storage bin.

Explanation/Application:

       Size is defined here in relation to the exemptions for replacement of existing
facilities with new facilities of equal or smaller size. Rated capacities are
manufacturer's rated capacities for crushers,  grinding mills, bucket elevators, bagging
operations, and enclosed truck or  railcar loading stations.  For screening operations,
size is determined by the total surface area of the top screen because screen type
and mesh may be changed in most designs.  For transfer points on belt conveyors,
size is determined by belt width, while storage bins are sized by rated storage capacity
in tons.

       For purposes of applying the equal or  smaller size exemption, rated capacity for
crushers, grinding mills, bucket elevators, bagging operations, enclosed truck or
railcar loading stations, and storage bins should be based on equal or like rating
criteria.  See Section 3.1, §60.670(d)  (1).
Stack Emission

      "Stack emission" means the paniculate matter that is released to the atmosphere from a
      capture system.
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Explanation/Application:

       As defined, stack emissions requires the application of a capture system.  The
definition of a capture system, in turn, requires the application of a control device.
Storage Bin

       "Storage bin" means a facility for storage (including surge bins) of nonmetallic minerals
       prior to further processing or loading.

Explanation/Application:   None
Transfer Point

       'Transfer point" means a point in a conveying operation where the nonmetallic mineral is
       transferred to or from a belt conveyor except where the nonmetallic mineral is being
       transferred to a stockpile.

Explanation/Application:

       By definition, only transfer  points to or from belt conveyors are so defined.
Such transfer points (except those to a stockpile) on belt conveyors manufactured
after August 31, 1983  are subject to the NSPS requirements.
Truck Dumping

       "Truck dumping" means the unloading of nonmetallic minerals from movable vehicles
       designed to transport nonmetallic minerals from one location to another.  Movable
       vehicles include but are not limited to: trucks, frontend loaders, skip hoists, and railcars.
Explanation/Application:

       Truck dumping is here defined in relation to §60.672(d) which exempts
emissions from truck dumping of nonmetallic minerals into any screening operation,
feed hopper,  crusher, or stock pile.
Vent
       "Vent" means an opening through which there is mechanically induced air flow for the
       purpose of exhausting from a building air carrying paniculate matter emissions from one
       or more affected facilities.
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Explanation/Application:

       Vent is here defined in relation to §60.672(e) (2) which limits vent emissions to
0.05 g/dscm (0.02 gr/dscf) and 7 percent opacity where vents are used to exhaust
buildings containing one or more affected facilities.  Note that this definition requires
that air flow through the vent be mechanically induced.  Unpowered  vent emissions
are therefore deemed fugitive emissions.

3.3    Standard for Paniculate Matter - §60.672

3.3.1   Stack Emissions Standard - §60.672(a)

       (a) On and after the date on which the performance test required to be conducted by
       §60.8 is completed, no owner or operator subject to the provisions of this subpart shall
       cause to be discharged into the atmosphere from any transfer point on belt conveyors
       or from any other affected facility any stack emissions which:  1) Contain paniculate
       matter in excess of 0.05  g/dscm, or 2) Exhibit greater than 7 percent opacity, unless the
       stack emissions are discharged from an affected facility using a wet scrubbing control
       device. Facilities using a wet scrubber must comply with the reporting provisions of
       §60.676(c), (d), and (e).

Explanation/Application:

       §60.8 (a) of Subpart A requires performance tests to be  conducted within 60
days after  achieving the maximum production rate at which the facility will be operated,
but no later than 180 days  after initial startup of such facility.  The maximum
production rate at which the affected facility will be operated is  the maximum
achievable capacity based on  representative performance of the affected facility.
Because an affected facility has been designated  for this NSPS as an individual piece
of operating equipment, the maximum production rate is the maximum process rate at
which the individual piece of equipment is expected to operate  considering the
maximum plant capacity.  This may or may not be equivalent to the manufacturer's
rated capacity.

       §60.2 of Subpart A defines startup as the "setting in operation of an affected
facility  for any purpose." Startup, therefore, is the first time the affected facility is
operated for any reason.  This includes such operations as short process runs of raw
material for a determination of product quality or specification as well as full production
runs.

      The stack particulate matter standard is in the form of a  concentration (0.05
g/dscm).  Unless a wet scrubbing control device  is used, an opacity limit of 7 percent
is also applicable.  In lieu of an opacity standard for wet scrubber control devices,
surrogate indicators of compliance were chosen involving monitoring of the scrubber
pressure drop and scrubbing liquid flow rate (Sections 3.5 and  3.7).
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       Finally, it should be noted that the regulations specify that the emissions
standards take effect on and after the date on which the performance test(s) is
completed.   §60.11 (d) of Subpart A, however, does require that the owner or  operator
maintain and operate, at all times, any affected facility and associated control
equipment "in a manner  consistent with  good air pollution control practice for
minimizing emissions."  In addition, any  applicable State or  local emission standards
remain in force.
See also:
             Appendix B, §§60.8 and 60.11  (d)
             Sections 3.5 and 3.7
3.3.2  Fugitive Emissions Standards - §60.672 (b) & (c)

       (b) On and after the sixtieth day after achieving the maximum production rate at which
       the affected facility will be operated, but not later than 180 days after initial startup, no
       owner or operator subject to the provisions of this subpart shall cause to be discharged
       into the atmosphere from any transfer point on belt conveyors or from any other
       affected facility any fugitive emissions which exhibit greater than 10 percent opacity,
       except as provided in paragraphs (c), (d), and (e) of this section.
       (c) On and after the sixtieth day after achieving the maximum production rate at which
       the affected facility will be operated, but no later than 180 days after initial startup, no
       owner or operator shall cause to be discharged into the atmosphere from any crusher,
       at which a capture system is not used, fugitive emissions which exhibit greater than 15
       percent opacity.

Explanation/Application:

       All of the provisions of paragraphs 1,  2, and 4 contained in the
"Explanation/Application" of Section 3.3.1 apply to fugitive emissions  as well as stack
emissions.

       In some situations it may be difficult to distinguish  the equipment performing the
initial reduction at the plant as  a crusher or a grinding mill.  Jaw crushers, gyratory
crushers, and cone crushers are used for coarse reduction only.  Roll crushers,
hammermills and impactors may be used as either crushers or grinding mills in that
they may be designed and operated for coarse or fine reduction.  Some quarry
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material may be sufficiently small in size that grinding mills may be employed for initial
size reduction in the plant.  If a hammermill, impactor, or roll mill are installed as initial
reduction equipment, a determination may be necessary as to whether the equipment
is designated as a crusher or grinding mill for the purposes of applying the 15 percent
opacity standard for crushers without capture systems.  As a guide, grinding mills
generally reduce the feed material to a 40 mesh or less.

See also:

              Section 2.1 and 2.2
3.3.3  Exemption for Truck Dumping - §60.672 (d)

       (d) Truck dumping of nonmetallic minerals into any screening operation, feed hopper, or
       crusher is exempt from the requirements of this section.

Explanation/Application:

       Care must be taken during opacity compliance determinations to separate
emissions from the affected facility from those of any truck dumping operation.  If the
emissions cannot be  separated during a Method 9 compliance test,  do not interrupt
recording opacity observations, but note which observations occurred during the truck
dumping.  When determining average opacity, observations during these events
cannot be used in any 24-observation (6-minute) set.

See also:

Appendix C, Section 2.4 and 2.5
3.3.4  Affected Facilities Enclosed in Buildings - §60.672(e)

       (e) If any transfer point on a conveyor belt or any other affected facility is enclosed in a
       building, then each enclosed affected facility must comply with the emission limits in
       paragraphs (a), (b), and (c) of this section, or the building enclosing the affected facility
       or facilities must comply with the following emission limits:

       (1) No owner or operator shall cause to be discharged into the atmosphere from any
       building enclosing any transfer point on a conveyor belt or any other affected facility any
       visible fugitive emissions except  emissions from a vent as defined in §60.671.

       (2) No owner or operator shall cause to be discharged into the atmosphere from any
       vent of any building enclosing any transfer point on a conveyor beii or any other
       affected facility emissions which  exceed the stack emissions limits in paragraph (a) of
       this section.
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Explanation/Application:

      Affected facilities enclosed in buildings must comply with either §60.672(a), (b),
or (c), or exhibit no visible emissions from the building as determined by EPA Method
22.  If visible emissions from the building are so detected, EPA Method 9 should be
employed inside the building to determine the opacity of the emissions from the
affected facility or facilities.

See also:

             Sections 3.6.4 and 4.7.1
3.4    Reconstruction - §60.673

3.4.1  Fixed Capital Cost Exemptions - §60.673 (a)

       (a) The cost of replacement of ore-contact surfaces on processing equipment shall not
       be considered in calculating either the "fixed capital cost of the new components" or the
       "fixed capital cost that would be required to construct a comparable new facility" under
       §60.15. Ore-contact surfaces are crushing surfaces, screen meshes, bars, and plates,
       conveyor belts, and elevator buckets.

Explanation/Application:

       As set forth in §60.15 of Subpart A, reconstruction of an existing facility (e.g.,
screen, bucket elevator, crusher, etc.) means the replacement of components to such
an extent that the fixed capital cost of the new components exceeds 50 percent of the
fixed capital cost to construct a comparable new facility, and it is technologically and
economically feasible to meet the applicable standards. "Fixed capital cost" is also
defined as "the capital needed to provide all the  depreciable components."

       Under the provisions of Subpart OOO, ore-contact surfaces of both the existing
facility and a comparable new facility are not  included in calculating the fixed capital
costs. The ore-contact surfaces cited in  §60.673 (a) are the only ore-contact surfaces
to be exempted from calculating the fixed capital costs.

       Some confusion may result when  replacing components as to whether the
replacements are covered under the routine maintenance, repair, and replacement
provisions of §60.14 (e) (modifications) or under the provisions of §60.15
(reconstruction).  If the replacement components are ore-contact surfaces as defined
in §60.673 (a), unlimited monies may be  expended for their replacement without
triggering either the modification or reconstruction provisions.  If the replacement
components  are not ore-contact surfaces, are considered routine replacements, and
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the cost of the replacements do not exceed the IRS annual asset guideline repair
allowance, the modification provisions do not apply. If the replacements are not
considered routine and do not include ore-contact surfaces, the reconstruction
provisions will apply, but only depreciable components would be included in
calculating fixed capital costs.
See also:
             Appendix B, §60.2 "Capital expenditure," §§60.14 and 60.15
             Section 3.15.
3.4.2  Continuous Programs of Component Replacement - §60.673 (b)

       (b) Under §60.15, the "fixed capital cost of the new components" includes the fixed
       capital cost of all depreciable components (except components specified in paragraph
       (a) of this section) which are or will be replaced pursuant to all continuous programs of
       component replacement commenced within any 2-year period following August 31,
       1983.

Explanation/Application:

       A 2-year period begins each time the owner or operator commences  a
reconstruction. "Commenced" is defined in the general provisions (§60.2) as meaning
that an owner or operator has undertaken a continuous program of construction or
modification or that an owner or operator has entered into a contractual obligation to
undertake or complete,  within a reasonable time, a continuous program of
construction or modification.

       There is not a single 2-year  period that begins on any specified date.   Rather,
EPA will aggregate any  continuous programs  of component replacement that begin
within any 2-year period in determining whether "the fixed  capital cost of the new
components exceeds 50 percent of the fixed capital cost that would be required to
construct a comparable entirely new facility..." [§60.15(b)(1)] (the "50 percent test.")
For example, suppose that an owner or operator of an existing facility begins program
A of component replacement in month 1, program B in month 40,  program C in month
60, and program D  in month  80, and that programs B and C,  considered together,
meet the 50 percent test in §60.15(b)(1).  Since programs B and C commenced within
a 2-year period (20  months apart),  the 50 percent test would be satisfied (regardless
of programs A and  D, and regardless of when programs B and C are finished).

      The  affected facility for the purpose of determining the 50 percent reconstructed
threshold is the individual piece of equipment  (e.g., crusher, grinding mill,  etc.) as
defined in §60.670 and §60.671, not the entire plant. However, replacement of an
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existing affected facility with a new facility of equal or smaller size as described in
§60.670(d) is exempt from compliance with emission limits, but is subject to the
reporting and recordkeeping  requirements in §60.676.
See also:
             Appendix B, §60.2 "Commenced," "Construction," and "Modification"
             Section 3.1.4.
3.5    Monitoring of Operations (Wet Scrubbers) - §60.674

       The owner or operator of any affected facility subject to the provisions of this subpart
       which uses a wet scrubber to control emissions shall install, calibrate, maintain and
       operate the following monitoring devices:
       (a) A device for the continuous measurement of the pressure loss of the gas stream
       through the scrubber. The monitoring device must be certified by the manufacturer to
       be accurate within _+. 250 pascals _+. 1 inch water gauge pressure and must be
       calibrated on an annual basis in accordance with manufacturer's instructions.
       (b) A device for the continuous measurement of the scrubbing liquid flow rate to the wet
       scrubber.  The monitoring device must be certified  by the manufacturer
       to be accurate within _+. 5 percent of design scrubbing liquid flow rate
       and must be calibrated on an annual basis in accordance with manufacturer's
       instructions.

Explanation/Application:

       The principle of  operation of a  wet scrubbing device involves contacting dust
particles with liquid droplets in some way and then having the wetted and unwetted
particles impinge upon a collecting surface where they can be separated and
removed. The major types of wet scrubbers are  wet cyclones,  mechanical, spray,  self-
induced spray,  and venturi  scrubbers.

       The standards do not include opacity requirements for wet scrubbers.  In order
to verify proper operation and maintenance of wet scrubbers, the standards  require
the installation,  calibration, and recording of the pressure drop across the scrubber
including any type of mist eliminator; and installation, calibration, and recording of the
flow rate of the  scrubbing liquid. These surrogate indicators of scrubber performance
can be used to isolate  typical performance problems (i.e., throat wear or pluggage,
decreased liquid-to-gas ratio, decreased pressure drop,  etc.).  See Section 3.7 for
recordkeeping and notification requirements.

       "Monitoring device" is defined in §60.2 of Subpart A as "the total equipment,
required under the monitoring of operations sections in applicable  subparts,  used to
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 measure and record (if applicable) process parameters."  "Continuous" measurement
 of the data is required under §60.674 and recording of the data is required under
 §60.676.
See also:
             Appendix B, §60.2 "Monitoring device," §§60.7(d) and 60.13(b)
             Sections 3.5, 3.6.6, and 3.7.3
3.6    Test Methods and Procedures - §60.675

3.6.1  General Requirements for Performance Tests - §60.675(a)

       (a) In conducting the performance tests required in §60.8, the owner or operator shall
       use as reference methods and procedures the test methods in Appendix A of this part or
       other methods and procedures as specified in this section, except as provided in
       §60.8(b). Acceptable alternative methods and procedures are given in paragraph (e) of
       this section.

Explanation /Application:

       §60.8 of Subpart A provides the general performance test requirements for this
and  all other NSPS.  These requirements include notification requirements, initial
performance test requirements, test methods and exceptions, requirements for
operating conditions during testing, and sampling facility requirements.  §60.8 of
Subpart A also specifies the number  of test runs (3), and that compliance is based on
the average of the three test runs unless otherwise specified  in the applicable Subpart.

       Appendix A of 40 CFR Part 60 contains  the reference methods for determining
compliance with all NSPS.  Methods applicable to the nonmetallic mineral processing
NSPS  include Methods 1 through 5, 9, 17, and 22.

       §60.8(b) provides authority for the  Administrator (or his representative) to
specify or approve 1) equivalent methods, 2) alternative methods, 3) minor changes  in
the methodology of the reference methods, 4)  waivers of performance test
requirements, or 5) reduced sampling times  or sampling volumes.  Approved
alternative procedures for this NSPS are provided in paragraph (e) of this section.
Alternative methods and procedures beyond those given in paragraph (e) may  be
specified by the  Administrator or submitted by  the source and approved by the
Administrator as he deems adequate to determine that the  source is in compliance.

See also:

             Section 3.7.3

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3.6.2  Tesf Methods and Procedures for Stack Emissions - §60.675(b)

       (b) The owner or operator shall determine compliance with the paniculate matter
       standards in §60.272(a) as follows: 1) Method 5 or Method 17 shall be used to
       determine the paniculate matter concentration.  The sample volume shall be at least
       1.70 dscm (60 dscf). For Method 5, if the gas stream being sampled is at ambient
       temperature, the sampling probe and filter may be operated without heaters. If the gas
       stream is above ambient temperature, the sampling probe and filter may be operated at
       a temperature high enough, but no higher than 121° C (250° F), to prevent water
       condensation on the filter, and 2)  Method 9 and the procedures in §60.11  shall be used
       to determine opacity.

Explanation/Application:

       As explained  in the preface  of 40 CFR 60,  Appendix A, a "Test Methods and
Procedures" section is included within the  respective subpart for each NSPS. The
purpose of  §60.675(b) is to 1) identify the applicable test method(s), and 2) identify
any special instructions or conditions to be followed such as sampling rates, volumes,
or temperatures.  Paragraph (b)(1) above  provides  these special instructions and
conditions for this NSPS.

       Paragraph  (b)(2) above specifies Method 9 for determining compliance with the
opacity standards of this subpart.  §60.11 (b) of Subpart A requires that initial
compliance be determined using a minimum total time of observation for each affected
facility of 3 hours  (30-6 minute averages) unless  an alternate method is approved by
the Administrator, or the Administrator waives the associated performance test.

       §60.11 (e)(1) of Subpart A requires that an  opacity compliance determination be
made concurrently with the performance test (stack test) unless: 1) no performance
test is required, or 2) visibility or other conditions prevent concurrent observations.
Under such conditions, see §60.11(e)(1) for scheduling or rescheduling instructions for
initial opacity determinations.  §60.11 also  provides  other compliance and maintenance
standards for performance tests and compliance  determinations.
See also:
             Appendix B, §§60.8 and 60.11
             Appendix C, Sections 2.1  through 2.5
             Sections 3.3, 3.6.1, and 3.7.3
3.6.3  Test Methods and Procedures for Fugitive Emissions - §60.675(c)

       (c) In determining compliance with the paniculate matter standards in §60.672(b) and
       (c), the owner or operator shall use Method 9 and the procedures in  §60.11, with the
       following additions:


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       1.      The minimum distance between the observer and the emission source shall be
              4.57 meters (15 ft).
       2.      The observer shall, when possible, select a position that minimizes interference
              from other fugitive emission sources (e.g., road dust). The required observer
              position relative to the sun (Method 9, Section 2.1) must be followed.
       3.      For affected facilities using wet dust suppression for paniculate matter control, a
              visible mist is sometimes generated by the spray. The water mist must not be
              confused with paniculate matter emissions and is not to be considered a visible
              emission.  When a water mist of this nature is present, the observation of
              emissions is to be made at a point in the plume where the mist is no longer
              visible.

Explanation/Application:

       Paragraph (c)(1) emphasizes a minimum distance of 15 feet  from the emission
source so that opacity observations are not attempted while the  observer is in the
plume.

       Paragraph (c)(2) emphasizes selecting a position  to minimize interferences from
other sources while  maintaining the required observer-to-sun angle  sector of 140°.

       Finally, paragraph (c)(3) emphasizes that water mists from wet suppression
system must not be confused with source emissions.  In some situations, a wet
suppression system may be activated intermittently.  In such  cases, two options are
possible.   First, choose a point  in the plume beyond which the water mist disappears.
Second, choose the point in the plume of greatest  opacity when the wet dust
suppression system is not being operated and begin the Method 9  observations.
When  the wet dust suppression system is operated, continue to  record opacity at this
point but note all such observations on the data sheet.   During data reduction,
eliminate any such observations from any 24-observation (6-minute) set.
See also:
             Appendix B, §§60.8 and 60.11
             Appendix C, Sections 2.1 through 2.5
             Sections 3.3.2, 3.6.1, and 3.6.2
3.6.4  Determining the Presence of Fugitive Emissions From Buildings - §60.675(d)

       (d) In determining compliance with §60.672(e), the owner or operator shall use Method
       22 to determine fugitive emissions. The performance test shall be conducted while all
       affected facilities inside the building are operating. The performance test for each
       building shall be at least 75 minutes in duration, with each side of the building and the
       roof being observed for at least 15 minutes.
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Explanation/Application:

       The 75 minute duration (15 minutes per side and the roof) using Method 22 is
applicable for the initial performance test.

See also:

       0      Appendix D, Sections 1 through 6
              Section 3.3.4
3.6.5  Approved Alternatives to the Test Procedures for Fugitive Emissions - §60.675(e)

       (e) The owner or operator may use the following as alternatives to the reference
       methods and procedures specified in this section:

       (1) For the method and procedure of paragraph (c) of this section, if emissions from two
       or more facilities continuously interfere so that the  opacity of fugitive emissions from an
       individual affected facility cannot be read, either of the following procedures may be
       used:

       (i) Use for the combined emission stream the highest fugitive opacity standard
       applicable to any of the individual affected facilities contributing to the emissions stream.
       (ii) Separate the emissions so that the opacity of emissions from each affected facility
       can be read.

Explanation/Application:

       The "highest fugitive opacity standard" cited  in paragraph (e)(1)(i) must  be
Federally enforceable.   In addition, any Method 9 opacity observations  must use the
point of  highest opacity whether from a single or combined plume.

       Separation of emissions, as cited in  paragraph (e)(1)(ii),  may be accomplished
by construction of a physical barrier or by shutting  down the interfering facility if the
maximum achievable production rate (capacity) of the affected  facility being tested is
not altered or the shutting down of the interfering facility does not cause operational
problems.
See also:
             Appendix C, Sections 2.1 through 2.5
             Sections 3.6.1, 3.6.3, and 4.7.2
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3.6.6  Wet Scrubber Monitoring Compliance - §60.675(9

       (f) To comply with §60.676(d), the owner or operator shall record the measurements as
       required in §60.676(c) using the monitoring devices in §60.674(a) and (b) during each
       paniculate matter run and shall determine the averages.

Explanation/Application:

       To comply with the semi-annual wet scrubber monitoring notification
requirements of the standards (Section 3.7.3), the owner or operator shall record daily
any changes in scrubber pressure drop and scrubbing liquid flow rate.  Pressure drop
and liquid flow  rate is to be monitored using the equipment described in Section 3.5.
These measurements are to also be recorded during each run of the performance test
[§60.676(c)] and included in the report required by §60.676(f).

See also:

              Sections 3.5, 3.7.3,  3.7.4, and 3.7.5
3.7    Reporting and Recordkeeping - §60.676

3.7.1  Reporting Requirements for Equal or Smaller Size Replacements - §60.676(a)

       (a) Each owner or operator seeking to comply with §60.670(d) shall submit to the
       Administrator the following information about the existing facility being replaced and the
       replacement piece of equipment.
       (1) For a crusher, grinding mill,  bucket elevator, bagging operation, or enclosed truck or
       railcar loading station:

       (i) The rated capacity in tons per hour of the existing facility being replaced and (ii) The
       rated capacity in tons per hour  of the replacement equipment.

       (2) For a screening operation:

       (i) The total surface area of the  top screen of the existing screening operation being
       replaced and (ii) The total surface area of the top screen of the replacement screening
       operation.

       (3) For a conveyor belt:
       (i) The width of the existing belt being replaced and (ii) The width of the replacement
       conveyor belt.

       (4) For a storage bin:

       (i) The rated capacity in tons of the existing storage bin being replaced and (ii) The
       rated capacity in tons of replacement storage bins.
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Explanation/Application:

       The information above, plus the information required under paragraph (b) of
§60.676, is to be forwarded to the Administrator when requesting the exemption for
replacement of existing facilities with facilities of equal or smaller size.  The information
is to be postmarked 60 days or as soon as practicable before the change is
commenced [§60.7(a)(4)].
See also:
             Appendix B, §60.7(a)(4)
             Sections 3.1.4 and 3.7.2
3.7.2  Special Reporting Requirements for Equal or Smaller Size Replacements -
       §60.676(b)

       (b) Each owner or operator seeking to comply with §60.670(d) shall submit the following
       data to the Director of the Emission Standards, (MD-13), U.S. Environmental Protection
       Agency, Research Triangle Park, North Carolina, 27711.
       (1) The information described in §60.676(a).
       (2) A description of the control device used to reduce paniculate matter emissions from
       the existing facility and a list of all other pieces of equipment controlled by the same
       control device; and
       (3) The estimated age of the existing facility.

Explanation/Application:

       In addition to the reporting requirements in Section 3.7.1, special reporting is
required to the Office of Air Quality Planning and Standards, Emission Standards
Division in Research Triangle Park, North Carolina. This information is to be used for
the purpose of reviewing the standard. As with the time requirements described in
Section 3.7.1, these data are to be postmarked 60 days or as soon as practicable
before the change is commenced.

See also:

             Appendix B, §60.7(a)(4)
             Sections 3.1.4 and 3.7.1

3.7.3  Wet Scrubber Requirements - §60.676(c)(d) & (e)

       (c)  During the initial performance test of a wet scrubber, and daily thereafter, the owner
       or operator shall record the measurements of both the change in pressure of the gas
       stream across the scrubber and the scrubbing liquid flow rate.

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      (d) After the initial performance test of a wet scrubber, the owner or operator shall
      submit semiannual reports to the Administrator of occurrences when the measurements
      of the scrubber pressure loss (or gain) and liquid flow rate differ by more than _+_ 30
      percent from the averaged determined during the most recent performance test.
      (e) The reports required under paragraph (d) shall be postmarked within 30 days
      following the end of the second and fourth calendar quarters.

Explanation/Application:

      Changes in pressure drop of the gas stream across the scrubber and the
scrubbing liquid flow rate are to be measured according to the procedures described
in Section 3.5.  The section above requires that all "occurrences" of pressure drop and
liquid flow rate that differ by more than _+_ 30 percent from the average during the most
recent performance test be submitted to the Administrator.  Because the requirements
described in Section 3.5 call for "continuous" measurements of the scrubber pressure
drop and liquid flow rate, and because  paragraph (d)  of this section requires reporting
of all occurrences of the specified changes in operating parameters, it would follow
that some type of continuous recording equipment is  required to identify these
occurrences on a continuous basis.  Because such occurrences may be
instantaneous or represent prolonged events, noncontinuous recording of the data is
not appropriate given the reporting requirements of this Subpart.

      Finally, it should be recognized that the intent of the measurement and
reporting requirements of this section is to substitute these parameters as surrogate
indicators of opacity.  Therefore, to avoid unnecessary reporting of occurrences due to
instrument noise or other nonrepresentative factors, only occurrences  of 6 minutes or
greater  (minimum observation time for EPA Method 9) need be reported.

See also:

             Appendix B, §60.13(b)
             Sections 3.5 and 3.6.6

3.7.4 Performance Test Reporting Requirements - §60.676(1)

      (f) The owner or operator of any affected  facility shall submit written reports of the
      results of all performance tests conducted to demonstrate compliance with the
      standards set forth in §60.672, including reports of opacity observations made using
      Method 9 to demonstrate compliance with §60.672 (b) and (c) and reports of
      observations using Method 22 to demonstrate compliance with §60.672(e).
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Explanation/Application:

       The written reports referred to in this paragraph are due within the same time
requirements found in Subpart A, §60.8(a)  (i.e., within 60 days after achieving the
maximum production rate at which the facility will be operated, but no later than 180
days after initial startup).

See also:

             Appendix B, §§60.8 and 60.11


3.7.5  Requirements Under Delegated Enforcement Authority - §60.676(g)

       (g) The requirements of this paragraph remain in force until and unless the Agency, in delegating
       enforcement authority to a State under section 111 (c) of the Act, approves reporting
       requirements or an alternative means of compliance surveillance adopted by such States.  In
       that event, affected sources within the State will be  relieved of the obligation to comply with
       paragraphs (a), (c), (d), (e), and (f) of this section, provided that they comply with requirements
       established by the State. Compliance with paragraph (b) of this section will still be required.

Explanation/Application:

       Enforcement authority  can be delegated  to a State, provided the reporting and
recordkeeping requirements of the State are at least as stringent as the  reporting and
recordkeeping requirements of this Subpart.  Once enforcement authority  is approved
by EPA,  the owner or operator is relieved of the following  reporting and  recordkeeping
requirements.

       1.     Equal or smaller size replacement data (Section 3.7.1)
       2.     Wet scrubber requirements (Section 3.7.3)
       3.     Performance test requirements (Section 3.7.4).

       Even under delegated authority to the State, however, the special reporting
requirements for replacements of equal or smaller size (Section 3.7.2) remain in force.

See also:

             Section 3.7
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                                  SECTION 4
                        COMPLIANCE DETERMINATION
                            (LEVEL II INSPECTION)

      The purpose of this section is to provide the inspector with a logical and
sequential methodology for determining the compliance status of affected facilities
subject to 40 CFR 60, Subpart OOO.  This methodology is consistent with a Level II
compliance inspection as outlined in the Air Compliance Manual. EPA-340/1-85-020,
September 1985, but cannot be employed as a substitute for the initial performance
test requirements described in Subparts A and OOO.  A Level II inspection
incorporates the following activities:
      0     "Walkthrough" evaluation of emission sources and/or devices
      0     Visible emission observations
      0     Data collection from and evaluation of process and control device
            instrumentation
      0     Checks (from outside) of internal conditions of control devices (if shut
            down)
      0     Routine check of continuous emission monitor (GEM) data
      0     Check of source-maintained records
      0     Annual determination of continued operation and process throughput of
            sources that do not operate control equipment.
      General procedures for a Level II inspection include the following sequential
steps:
      1.    Pre-inspection  preparation
      2.    Pre-entry observations
      3.    Entry
      4.    Opening conference with source personnel
      5.    Source records verification
      6.    Field inspection procedures
      7.    Post-inspection conference
      8.    Reporting and tracking.
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The remainder of this section will cover each of these Level II inspection procedures
as they specifically apply to the nonmetallic mineral processing NSPS.
4.1   Pre-lnspection Preparation
      Pre-inspection preparation is always necessary to ensure effective use of the
inspector's time and the facility's time, and to ensure that the inspection is properly
focused on collecting  relevant data and information.  This preparation involves:
      0      Review of facility background
      0      Development of an inspection plan
      0      Notifications
      0      Equipment preparation.
4.1.1   Review of Plant Background
      A review of the available background information on the plant to be inspected is
essential to the overall success of the inspection. The review should enable the
inspector to become familiar with the plant's process and emission characteristics;
conduct the inspection in a timely manner; minimize inconvenience to the plant by not
requesting unnecessary data such as that previously provided to the EPA or another
agency; conduct an efficient,  but thorough inspection; clarify technical and legal issues
before entry;  and prepare a useful inspection report. The following types of
information should be reviewed.
Basic Plant Information
      0      Names, titles, and phone numbers of plant representatives
      0      Maps showing plant location and geographic relationship to residences,
             etc. potentially impacted by emissions
      0      Process  and production information
      0      Flowsheets identifying affected facilities, control devices,  monitors, and
             other points of interest
      0      Safety equipment requirements.
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Pollution Control Equipment and Other Relevant Equipment Data

      0      Description and design data for control devices and relevant process
             equipment

      0      Sources and characterization of emissions

      0      Previous inspection checklists (and reports)

      0      Baseline performance data and control equipment.

Regulations. Requirements, and Limitations

      0      Most recent permits (construction and/or operating) for affected facilities
             subject to the NSPS

      0      Location and description of all affected facilities subject to the NSPS
             standard for particulate matter and the locations of affected facility
             emission points (also included in  final report)

      0      Location and description of all affected facilities subject to the NSPS
             recordkeeping/reporting requirements only

      °      Special exemptions and waivers,  if any (e.g., affected facilities previously
             waived from initial compliance testing and any waiver conditions)

      0      Acceptable plant operating conditions (e.g., maximum permitted
             throughput or process weight rates,  etc.)

      0      Total top screen surface areas of all affected facility screens and belt
             widths of all affected facility conveyor belts (for onsite verification)

      0      Average scrubber pressure drop  and scrubbing liquid flow rate from
             most recent compliance test (if applicable)

      0      Schedules for replacement of existing facilities with  new facilities of equal
             or smaller size (if any)

             Other applicable emission limits or opacity limits of affected facilities more
             restrictive than NSPS limits (i.e., PSD, State  regulations, etc.).
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Facility Compliance and Enforcement History
      0     Previous inspection reports
      0     Complaint history and reports
      0     Past conditions of noncompliance
      0     Previous enforcement actions
      °     Pending enforcement actions, compliance schedules and/or variances
      0     Continuous monitoring system reports
      0     Startup, shutdown and malfunction reports.
4.1.2 Development of an Inspection Plan
      Based on the review of the plant background information, the inspector should
develop an inspection plan addressing the following items.
      0     Inspection objectives
      0     Tasks sequence
      0     Procedures
      0     Resources
      0     Schedule
      Although the main objective of the inspection is to determine source compliance
with the NSPS provisions, the plant operating schedule or the sheer number of
sources may not be conducive to covering  the entire plant in one inspection.  Portions
of the plant or particular production lines may need to be covered separately or during
different inspections.  This may be due to intermittent production or scheduling of
maximum operating conditions for different  production lines. If necessary, the
inspector should divide the affected facilities to be inspected into manageable groups.
      Once the inspector has determined which affected facilities and what plant
records are to  be inspected, each individual task necessary to meet the inspection
objectives should be identified and procedures reviewed for accomplishing each task.
      All inspection tasks should also be arranged in a logical and chronological
sequence that  takes into account the inspection objectives as well as possible
constraints that are anticipated at the plant.  The task sequence, however, should
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include the flexibility for change if onsite conditions are not as expected or if plant
operations change during the inspection.
      Finally, the resources required to complete the inspection should be reviewed.
Resources include personnel, inspection equipment, and safety equipment required at
the site.
      Appendix E provides sample inspection forms that may be used to construct
the task sequence list for an  inspection plan.
4.1.3  Notification of Plant and Responsible Agency
      EPA Regional Offices and State and local agencies vary in their exact policies
concerning giving a plant advance notification of an inspection.  In a recent EPA policy
memo entitled Final Guidance on Use of Unannounced Inspections, however, the
Stationary Source Compliance Division recommends that all  Regional inspection
programs incorporate unannounced inspections as part of their overall inspection
approach.  The advantages of the unannounced inspection are:  1) the opportunity to
observe the source under normal operating conditions, because the source does not
have time to prepare for the inspection, 2) detection of visible emissions and O&M-
type problems and violations, 3) creation of an increased level of attention by a source
to its compliance status, and 4) projection of a serious attitude toward surveillance by
the Agency.
      The potential negative aspects of performing unannounced inspections are 1)
the source may not be  operating or key plant personnel may not be available, and 2)
there could be an adverse impact on Agency source relations. However, it has been
demonstrated by the Regional Offices who already use the unannounced inspections
that, in the majority of cases, these drawbacks can be overcome.
      When using the unannounced inspection, an alternative to arriving at the source
totally unannounced is to contact the source shortly before the scheduled inspection
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time. This is left to the discretion of the Regional Office and/or the inspector and must
be done so as not to alter the representativeness of the source operation. The
amount of advanced notice given should be noted in the inspection report.

      Announced inspections are performed by EPA and its authorized
representatives when some specific purpose is served  by providing such notice.
Situations where announced inspections are appropriate are:

      0      When specific information is being sought which must be  prepared by
             the source, or where the source must make significant accommodations
             for the inspector to gather the information

      0      When the assistance of specific plant personnel is necessary for the
             successful performance of the inspections, i.e., the information they
             provide cannot be obtained from other on-duty plant personnel or by a
             follow-up information request

      0      When inspecting government facilities or sources operating under
             government contract where entry is restricted due to classified
             operations.

      When the inspection is announced in advance, a lead time of five working days
is generally appropriate.  Notification may be by telephone or letter and it may or may
not include the exact date and time of the inspection.  Instances where written
notification (instead of oral) is appropriate are:

      0     When requested by the State/local agency or by the source

      0     When extensive or specific records are being sought

      0     When the inspection is to be performed solely by an EPA  or State/local
            contractor

      0     When inspecting government facilities with classified operations or
            otherwise restricted entry

      0     Special-purpose inspections, e.g., to establish conditions for a source-
            specific SIP revision.

      The  plant representative notified should have the authority to release data and

samples and to arrange for access to specific processes.  In addition, when notifying  a

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plant of an inspection, information should be requested in regard to onsite safety
regulations. This will avoid problems concerning safety equipment at the time of the
inspection.
      State and/or local agencies should be given a minimum of five working days
advance notice of unannounced or announced inspections to be conducted within
their jurisdiction. In the case of an announced inspection, this notification should
precede that given to the source.
      Notification can be written or oral, in any case, a record should be  kept. The
notification and record thereof should include the following items:
      0     Name and location of subject facility
      0     Date and approximate time of the activity
      0     Regional Office contact (phone number, etc.)
      0     Reason for the inspection
      0     Name of the State contact
      0     Date and time of notification.
      State/EPA Memorandums of Agreements should be consulted for further
information on notification procedures.
4.1.4   Equipment Preparation
      Part of the pre-inspection preparation involves obtaining and preparing
inspection and safety equipment.  A general list of inspection and safety equipment for
a Level II compliance inspection of nonmetallic mineral processing facilities is included
in Table 4-1.  All safety equipment should meet Mine Safety and Health  Administration
(MSHA) requirements.
      All equipment should be checked before use.  The inspector is responsible for
seeing that all equipment necessary to conduct an inspection is brought to the
inspection site.
      Safety equipment required for a facility is based on the plant's response to the
inspection announcement or on the safety requirements for that facility previously
recorded in the agency files. Safety requirements must be met, not only for safety
reasons, but to ensure that the inspector is not denied entry to the plant.

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 	TABLE 4-1.  RECOMMENDED  INSPECTION AND SAFETY  EQUIPMENT	

 	Inspection  equipment	Safety equipment	

 Tape  measure                     Respirator with appropriate cartridge(s)
 Flashlight                       Hardhat
 Stopwatch                        Safety glasses or goggles
 Duct  tape                        Gloves
 Sample bottles                   Coveralls
                                  Safety shoes
                                  Ear protection
 	NIOSH/OSHA Pocket Guide to Chemical Hazards
      Before or after equipment preparation, the inspector must also consider what

written materials, forms, documents, etc. he/she will require during the inspection.

These should also be gathered and organized before the inspection.  These materials

may include any or all from the following list:

            Maps
      0     Flowcharts
            Plant layout
      0     Applicable regulations
      0     Inspection checklists
      0     Field notebook
      0     Reference materials
      0     Visible emission observation forms (Method 9 and 22 as applicable)
      0     Inspection plan or agenda
      0     Agency credentials
      0     Baseline data
      0     Information requested by facility.

4.2   Pre-Entry Observations

      Two types of observations, conducted prior to plant entry, have been shown to

be valuable in determination of facility compliance.  These are the  observation of the

plant surroundings and the  visible emission observations.
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4.2.1  Plant Surroundings Observation
       Observations of areas surrounding the plant before entry may reveal a variety of
signs of operational practices and pollutant emissions which can aid in the pre-entry
evaluation.  These include:
       0      Obvious vegetation damage near the plant
             Deposits on cars parked close by
       0      Conditions around product and waste piles
       0      Heavy dusting of standing trees or buildings
       0      Proximity of sources to potential receptors.
4.2.2  Visible Emissions Observations
       In addition to observing the plant surroundings prior to entry, the  inspector may
also perform visible emission observations at that time. Visible emission observations
can  be performed on both stack and fugitive sources using both Method 9 and 22 as
long as the provisions of the references methods  and the provisions of §§60.11 and
60.675(c) are met.
       Although it is likely that not all emission points will  be visible from  a location
outside the plant property lines, elevated emission points (e.g., stacks, elevated
buildings, silos,  bucket elevators,  conveyor belt transfer points, etc.) may be easily
read.  Extreme care should  be taken, however, to ensure that the emission point is
correctly identified at the time of observation. Verification of the emission points that
were observed should be sought  during the onsite inspection.  Visible emission
observation procedures are detailed in  Section 4.7.
4.3    Plant Entry
       This section  details the accepted procedures under the Clean Air  Act (CAA or
the Act) for entry to a facility to conduct onsite inspections.  As such, these
procedures are  applicable to EPA inspectors and  may or may not be applicable or
compatible with State or local procedures.  This section does not provide procedures
for obtaining an inspection warrant in the case of  refusal  of entry which are covered in
detail in other publications.
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4.3.1  Authority
       The Clean Air Act authorizes plant entry for the purposes of inspection.  In
specific, Section 114 of the Act states:
       "	the Administrator or his authorized representative, upon presentation
       of his credentials shall have a right of entry to, upon or through any
       premises of such person or in which any records required to be
       maintained	are located, and may at reasonable times have access to
       and copy any records, inspect any monitoring equipment or methods	,
       and sample any emissions which such person is required to sample	"
4.3.2  Arrival
       Arrival at the facility must be during normal working hours.  Entry through the
main gate is recommended unless the inspector has been previously instructed
otherwise.  As soon as the inspector arrives on the premises, he should locate a
responsible plant official usually the plant owner, manager, or chief environmental
engineer.  In  the case of an announced inspection, this person would most probably
be the official to whom notification was made.  The inspector should note  the name
and title of this plant representative.
4.3.3  Credentials
       Upon meeting the appropriate plant official, the inspector should introduce
himself or herself as an  EPA inspector and present the official with the proper  EPA
credentials and state the reason for requesting entry.  The credentials provide the
plant official with the assurance that the  inspector is a lawful representative of the
Agency.  Each office of the EPA issues its own credentials; most include the
inspector's photograph, signature, his physical description (age, height, weight, color
of hair and eyes), and the  authority for the inspection. Credentials must be presented
whether or not identification is requested. After facility officials have examined the
credentials, they may telephone the appropriate EPA Office for verification of the
inspector's identification. Credentials should never leave the sight of the inspector.
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4.3.4  Consent
      Consent to inspect the premises must be given by the owner, operator, or his
representative at the time of the inspection.  As long as the inspector is allowed to
enter, entry is considered voluntary and consensual, unless the inspector is expressly
told to leave the premises.  Express consent is not necessary; absence of an express
denial constitutes consent.
      If there is difficulty in gaining consent to enter, inspectors should tactfully probe
the reasons and work with officials to overcome the obstacles.  Care should be taken,
however, to avoid threats of any kind,  inflammatory discussions, or deepening of
misunderstandings.  Whenever the situation is beyond the authority or  ability of the
inspector, he or she should contact their supervisor for  guidance.
      If the inspector is asked to  leave the premises after the inspection has begun,
the inspector should 1) tactfully discuss the reason for denial, 2) avoid  any situation
that might be construed as threatening or inflammatory, 3) withdraw from the premises
and contact his or her supervisor, 4) note the facility name, address, and the name
and title of the plant official(s) approached and the authority of the person issuing the
denial, and 5) note the date, time, and reason for the denial as well as  facility
appearance and any reasonable suspicion why entry was denied.  These procedures
also apply if the inspector is denied entry to certain parts of the facility. After
withdrawal from the premises, the inspector should always contact the  appropriate
Agency office for further instructions including a determination of whether a warrant
should be obtained to inspect the facility.
4.3.5  Uncredentialed Persons Accompanying an Inspector
      The consent of the owner or agent in charge must be  obtained for the entry of
persons accompanying an inspector to a site if they do not have specific authorization.
If consent is not given voluntarily,  these persons may not enter the premises.  If
consent is given, these persons may not view confidential business information unless
officially authorized for access.
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4.3.6  Waivers, Releases, and Sign-In Logs
       When the facility provides a blank sign-in sheet, log, or visitor register, it is
acceptable for inspectors to sign it. Under no circumstances should EPA employees
sign any type of "waiver" or "visitor release" that would relieve the facility of
responsibility for injury or which would limit the rights of the Agency to use data
obtained from the facility.
       If such a waiver or release is presented, the inspector should politely  explain
he/she cannot sign and  request a blank sign-in sheet.  If an inspector is refused entry
because they do  not sign such release, they should leave and immediately report all
pertinent facts to  the appropriate supervisory and/or legal staff.  All events
surrounding the refused entry should be fully documented.  Problems should be
discussed cordially and professionally.
4.3.7  Nondisclosure Statements
       Inspectors have, in the past, occasionally been asked to sign nondisclosure
statements or agreements.  These agreements vary  slightly in content from one to
another, but generally require that confidential information,  disclosed to an inspector
during the course of an inspection, be handled thereafter in a specified manner.  An
inspector should not sign such agreements since Federal Regulations (40 CFR Part 2,
as amended) on the confidentiality of business information  already protect the
business from disclosure of confidential information.
4.4    Opening Conference
       Once legal entry has been established, the inspector should proceed  with a vital
part of every inspection, the opening conference.  The purpose of the opening
conference is to inform the  facility official(s) of the purpose  of the inspection, the
authorities under which it will  be  conducted, and the procedures to be followed.  The
opening conference also  offers the inspector the opportunity to strengthen Agency -
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industry relations through a positive attitude and provide relevant information and other
assistance.  The effective execution of the opening conference on the inspector's part

often facilitates the remainder of the inspection.
      During the opening conference, the inspector is responsible for covering the

following items:

      0     Inspection Objectives - An outline of inspection objectives will inform
            facility officials of the purpose and scope of the inspection and may help
            avoid misunderstandings.

      0     Inspection Agenda - Discussion of the sequence and content of the
            inspection including operations and control equipment to be inspected
            and their current operating status.  This  will help eliminate wasted time by
            allowing officials time to make  any preparations necessary.  The types of
            measurements to be made and the samples to be  collected (if any)
            should also be addressed.

      0     Facility Information Verification - The inspector should verify or collect the
            following information:

                   Correct name and address of facility
                   Correct names of plant  management and officials
                   Principal product(s) and production rates
                   Affected facilities  and emission points.

      0     List of Records - A list of records (NSPS or permit  requirements) to be
            inspected will allow officials to  gather and make them available to the
            inspector.

      0     Accompaniment - It is imperative that a facility official accompany the
            inspector during the inspection, not only to describe the plant and its
            principal operating characteristics, but also to identify confidential data
            and for safety and liability considerations.

      0     Safety Requirements - The inspector should  determine what facility safety
            regulations including safety equipment requirements will be involved in
            the inspection, and should be  prepared  to meet these requirements.  The
            inspector should also inquire about emergency warning signals and
            procedures.
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       0      Meeting Schedules - A schedule of meetings with key personnel (if
             necessary) will allow them to allocate a clear time to spend with the
             inspector.

       0      Closing Conference - A post-inspection meeting should be scheduled
             with the appropriate officials to provide a final opportunity to gather
             information, answer questions, and make confidentiality declarations.

       0      New Requirements - The inspector should discuss any new rules and
             regulations that might affect the facility and answer questions pertaining
             to them. If the inspector is aware of proposed  rules that might affect the
             facility, he  or she may wish to encourage facility officials to obtain a copy.

             Duplicate Samples and/or Simultaneous Measurements - Facility officials
             should be  informed of their right to receive a duplicate of any physical
             sample collected for laboratory analysis or to conduct simultaneous
             measurements such as visible emission observations.

       0      Confidentiality Claims - Company officials should be advised of their right
             to request  confidential treatment of trade secret information.

       0      Photographs - If necessary,  the inspector should request permission to
             take photographs  during the inspection.

4.5    Inspection Documentation

       The air compliance inspection  is generally conducted to achieve one or more of
three main objectives.

       1.      To provide data and other information for making a compliance
             determination.

       2.      To provide evidentiary support for some type of enforcement action.

       3.      To gather the data required for other agency functions.

Taking physical samples, reviewing records, and documenting facility operations are

the methods  used by the inspector to develop the documentary support required to

accomplish these objectives.  The documentation from the inspection establishes the
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actual conditions existing at the time of the inspection so that the evidence of these
conditions may be objectively examined at a later time in the course of an enforcement
proceeding or other compliance related activity.
      Documentation is a general term referring to all print and mechanical media
produced, copied, or taken by an inspector to provide evidence of facilities status.
Types of documentation include the field notebook, field notes and checklists, visible
emission observation forms, drawings, flowsheets, maps, lab analyses of samples,
chain of custody records, statements, copies of records, printed matter,  and
photographs.  Any documentation gathered or produced during the inspection may
eventually become part of an  enforcement proceeding.  It is the inspector's
responsibility to recognize this possibility and ensure that all documentation can pass
later legal scrutiny.
4.5.1  Inspector's Field Notebook and Field Notes
      The core of all documentation relating to an inspection is the  inspector's field
notebook or field  notes, which provide accurate and  inclusive documentation of all field
activities.  Even where certain data or other documentation is not actually included in
the notebook or notes, reference should be made in the notebook or notes to  the
additional data or documentation such that it  is completely identified and it is clear how
it fits into the inspection scheme.
      The field notebook and/or notes form the basis for both the inspection report
and the evidence  package and should contain only facts and pertinent observations.
Language should  be objective, factual, and free of personal feelings or terminology
that might prove inappropriate.
      Because the inspector  may eventually be called upon to testify in  an
enforcement proceeding, or his/her field data may be entered into evidence, it is
imperative that he/she keep detailed records of inspections, investigations, samples
collected, and related inspection functions. The types of information that should be
entered into the field notebook or notes include:
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       0      Observations - All conditions, practices, and other observations relevant
             to the inspection objectives or that will contribute to valid evidence
             should be recorded.

       0      Procedures - Inspectors should list or reference all procedures followed
             during the inspection such as those for entry, sampling, records
             inspection, and document preparation.  Such information could help
             avoid damage to case proceedings on procedural grounds.

       0      Unusual Conditions and Problems - Unusual conditions and problems
             should be recorded and described in detail.

       0      Documents  and Photographs - All documents taken or prepared by the
             inspector should be noted and related to specific inspection activities.
             (For example, photographs taken should be listed, described, and
             related to the subject photographed.)

       0      General Information - Names and titles of facility personnel and the
             activities they perform should be listed along with other general
             information.  Pertinent statements made by these people should be
             recorded. Information  about a facility's recordkeeping  procedures may
             be useful in later inspections.

4.5.2  Visible Emission Observation Form

       Because visible emission (VE) observations are such a frequently used

enforcement tool, a separate form has been developed for recording data from the VE

observation using EPA Method 9 (Figure 4-1). This form has been designed to

include all the supporting documentation necessary, in most cases, for VE observation

data to be accepted as evidence of a violation. Thus, it is recommended that the

inspector use this form for recording opacity observations; an appropriate reference

should be made to the form  in the field notebook or notes.  In addition, a separate

form is used to record the presence and duration of fugitive emissions from  buildings

enclosing NSPS affected facilities.  This is the EPA Method 22 Field Data Sheet for

Outdoor Locations (Figure 4-2).
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               VISIBLE EMISSION OBSERVATION FORM
                                                       No.
COMPANY NAME
STREET ADDRESS

CITY

PHONE (KEY CONTACT)

PROCESS EQUIPMENT

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DESCRIBE EMISSIONS
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Figure 4-1. EPA Method 9 Visible Emission Observation Form.
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                      FUGITIVE OR SMOKE EMISSION INSPECTION
                                OUTDOOR LOCATION
 Company
 Location .
 Company reprasantativa
ObMivar .
Affiliation
Ottt	
 Sky Condition*
 Precipitation _
Wind diractlon
Wlndspaad	
 Industry
Procass unit
 Skatch procaar unit: indieata obtarvar position ralativa to sourca and tun: Indfeate potamial
 •mission points and/or actual amission points.
OBSERVATIONS
Baojn Obsarvation
                                           Clock
                                           time
             Obsarvation
               pariod
              duration.
               min:sac
Accumulated
  •mission
   tima.
  min:sac
End observation
     Figure 4-2.  EPA Method 22 Field Data Sheet for Outdoor Location.
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4.5.3 Drawings and Maps

      Schematic drawings, flowsheets, maps, charts, and other graphic records can
be useful as supporting documentation. They can provide graphic clarification of

emission source location relative to the overall facility, relative height and size of
objects, and other information which, in combination with samples, photographs, and

other documentation, can produce an accurate, complete, evidence package.

      Drawings and maps should be simple and free of extraneous details. Basic

measurements and  compass points should be included, if necessary, to provide a

scale for interpretation.

4.5.4 Copies of Records

      A facility's records and files may be stored  in a variety of information retrieval

systems, including written or printed materials,  computer or electronic systems, or

visual systems such as microfilm  and microfiche.
      When copies of records are necessary for an inspection report, storage and

retrieval methods must be taken into consideration:

      0     Written or printed records can generally be photocopied onsite. Portable
            photocopy machines may be available to inspectors  through the
            Regional Office.  When necessary, inspectors are authorized to pay a
            facility a  "reasonable" price for the use of facility copying equipment. All
            copies made for or by the inspector  should  be initialed and dated for
            identification purposes.

      0     Computer or electronic records may require the generation of "hard"
            copies for inspection purposes.  Arrangements should be made during
            the opening conference, if possible, for these copies. (Photographs of
            computer screens may possibly provide adequate copies of records if
            other means are impossible.)

      0     Visual  systems (microfilm, microfiche) usually have photocopying
            capacity built into the viewing machine, which  can be used to generate
            copies.  (Photographs of the viewing screen may provide adequate
            copies of records if  other means are impossible.)
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       Immediate and adequate identification of records reviewed is essential to ensure

the ability to identify records throughout the Agency custody process and to ensure
their admissibility in court.  When inspectors are called to testify in court, they must be

able to positively identify each particular document and state its source and the reason

for its collection.  Initial, date, number, and record the facility's name on each record,

and reference these items in the field notebook or notes.

       0      Initialing/Dating - The inspector should develop a unique system for
             initialing  and dating records and copies of records so that he/she can
             easily verify their validity. This can be done by initialing each document
             in a similar position, or by another method, at the time of collection.
             Both the original and copy should be initialed. All record identification
             notations should be made on the  back of the document.

       0      Numbering - Each document or set of documents substantiating a
             suspected violation or violations should be assigned an identifying
             number unique to that document.  The number should be recorded on
             each document and in the field notebook.

      0      Logging  - Documents obtained during the inspection should be entered
             in the field notebook or notes according to some logical system.  The
             system should include the following information:

                   Identifying number
                   Date
                   The reason for copying the material
                   The source of the record
                   The manner of collection.

4.5.5   Printed Matter

      Brochures, literature, labels, and other printed matter may provide important

information regarding a facility's condition and operations.  These materials may be

collected as documentation if, in the inspector's judgment, they are relevant.  All

printed matter should be identified with the date, inspector's initials, and related

sample numbers.  Reference to these materials should  be  made  in  the field notebook
or notes.
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4.5.6  Photographs
      The documentary value of photographs ranks high as admissible evidence;
clear photos of relevant subjects, taken in proper light and at proper lens settings,
provide an objective record of conditions at the time of inspection.  The use of
photographic documentation, however, often elicits a negative reaction from plant
officials, thus, it is recommended that photographic  documentation be used only
sparingly and only when necessary to document an inspection finding.
      When a situation arises that dictates the use of photographs, the inspector
should obtain the company's permission  to take photographs.  This is most
conveniently accomplished during the opening conference.  The inspector may offer to
provide the official with duplicates of all photographs taken.  As with other business
data collected, during and/or at the conclusion of the inspection, the  inspector should
ascertain whether any of the photographs taken contain proprietary information and if
the company wishes to designate any as confidential.  Photographs taken employing a
Polaroid-type instant camera allow an immediate confidentiality review and the
opportunity for the inspector to readily provide the company with duplicate shots.
Photographs may always be taken form areas of public access (e.g.,  outside the
fence, from the road, from a parking lot, etc.).
      A photographic log  should be maintained in the inspector's field notes for all
photographs taken during  an inspection,  and the entries are to be made at the time
the photograph is taken.  These entries are to be numerically identified so that after
the film is developed the prints can be serially numbered corresponding to the log
book descriptions and, if necessary, pertinent information can be easily transferred to
the back of the photograph.
      Polaroid-type instant photos should be immediately identified on the back after
shooting with the corresponding photo ID number; photographs that  require
developing and printing should be numbered as soon as possible.  One
recommendation which will ensure that all prints and negatives can be positively
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identified is that prints and negatives be left uncut and the photographic log be
photographed at the beginning and end of each roll of film.  Photographs of a
confidential nature must be developed by an authorized contractor.
4.6   Verification of Facility Records
      40 CFR 60,  Subpart A and Subpart OOO require that the source maintain a
permanent file of required notifications, reports,  measurements, and records for review
by the Administrator or authorized representative.  Pursuant to §60.7(d) of Subpart A,
this permanent file is to be retained by the source for at least two years.  Integral to
the compliance inspection, these notifications and records must be verified by the
inspector.
      A complete  records check should be accomplished before the inspector leaves
the plant.  However, §60.7(d) does not specify that the owner or operator must locate
this permanent file at the facility to be inspected. If required records are located
elsewhere (main or central corporate office), provisions should be made for the
records to be made available during the inspection.  This is best accomplished during
the inspection notification to the facility.  If the inspection is unannounced, the
inspector should make definite arrangements with the source during the opening
conference to have the records made available on specified dates.
      The following is a list of records required  to be kept by the owner or operator  of
the source under the provisions of the nonmetallic mineral processing NSPS.  Each
item on  the list  is accompanied by its regulatory citation.
Written Notifications to the Administrator
      1.    The date of construction or reconstruction of any affected facility -
            §60.7(a)(1).
      2.    The date of anticipated startup of any affected facility - §60.7(a) (2).
      3.    The date of actual startup of any affected facility -  §60.7(a)(3).
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4.    Any physical or operational change to an existing facility which may
      increase the emissions rate of any air pollutant to which a standard
      applies, unless that change is specifically exempted under an applicable
      subpart or in §60.14(e).

      §60.14(e) exemptions:

      0      Routine maintenance, repair and replacement within
             the IRS annual asset guideline repair allowance

             An increase in production rate of an existing facility
             without a capital expense on that facility

      0      An increase in the hours of operation

      0      Use of an alternative fuel or raw material if the
             existing facility was designed to accommodate same
             before August 31, 1983

      0      The addition or use of any air pollution  control device
             or  system except when such a device or system is
             removed or replaced by a system which is less
             environmentally beneficial

      0      Relocation or change in ownership  of an existing
             facility.

5.    The date  that initial performance test opacity observations are anticipated
      - §60.7(a)(6).

6.    Rescheduled dates for initial performance  test opacity observations if
      visibility or other conditions prevent opacity observations from being
      performed concurrently with the  initial performance test - §60.11(e)(1).

7.    Proposed "reconstructions" of existing facilities - §60.15(d) (See §60.15(d)
      for information required in the notification).

8.    30 day advance notification of any performance test of an affected facility
      - §60.8(d).

9.    Proposed replacements of existing facilities with facilities of equal or
      smaller size - §60.676(a) (See §60.676(a) for information required in the
      notification).
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Written Reports to the Administrator

       1.     Initial performance test results of all affected facilities - §60.8(a).

       2.     Initial performance test opacity results of all affected facilities -
             §60.11 (e)(2).

       3.     The results of all performance tests of affected facilities to demonstrate
             compliance including opacity observation results (Method 9) and/or
             Method 22 observation results - §60.676(f).

       4.     Semiannual reports of occurrences when scrubber pressure drop and
             liquid flow rate differ from the average of the last performance test by
             ±30 percent - §60.676(d).

Records On File

       1.     Startup, shutdown, and malfunction occurrences and their durations for
             all affected facilities; malfunctions of air pollution control equipment
             serving affected facilities;  and any periods during which continuous
             monitoring systems or monitoring devices (i.e., scrubber  pressure drop
             and liquid  flow rate measurement devices) are inoperative - §60.7(b).

       2.     All measurements of monitoring devices, calibration checks, and all
             adjustments and maintenance performed on these devices  - §60.7(d).

             To include:

             0      Daily continuous measurements of scrubber pressure
                   drop and liquid flow rate - §60.676(c)

             0      Scrubber monitoring device annual calibration checks
                   - §60.674.

       It should be remembered that §60.7(d) of Subpart A requires the owner or

operator of the affected facility to maintain these notifications, reports, records, and
measurements for at least two years.  Therefore, the inspector should  be familiar with
the chronological  history of the affected facilities to determine whether the records of
the owner or operator are current and acceptable.  Accurate agency files and tracking

of affected facilities, their dates of construction, and dates of performance tests are

vital for a complete and accurate check of source records.


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4.7   Means of Determining Compliance with the Standard for Paniculate
      Matter
      The standard for paniculate matter for the nonmetallic mineral processing NSPS
is found in §60.672 and includes a mass emission limit of 0.5 g/dscm (0.02 gr/dscf)
for point sources (i.e., stacks and powered vents) and a point source opacity limit of 7
percent, as well as an opacity limit of 10 percent for all fugitive emission sources
except 15 percent for crushers without capture systems  (see definition of "capture
system" in Section 3.2).  It should be noted that wet suppression is not considered a
capture system.  In addition, §60.672(e) limits emissions from affected facilities
enclosed in buildings to 10 or 15 percent opacity as applicable, or limits the building to
no visible  emissions.
      Determining compliance of each affected facility and/or emission point may
therefore involve visible emission observations using EPA Method 9 or Method 22 as
applicable (Sections 3.6.3 and 3.6.4). In the case of wet scrubbers, a compliance
determination with the monitoring provisions of §60.674 necessarily involves checking
scrubber pressure drop and liquid flow rate data from the continuous monitoring
devices.
      Although the only way to determine the compliance status of stacks or powered
vents with the mass emission limit is a stack test, surrogate indicators of compliance
may be used by the inspector to make logical decisions based on engineering
principals  as  to the likelihood of compliance.  Use of surrogate indicators of
compliance is not appropriate for the initial performance test or any other compliance
determination requiring a stack test,  but can be used as an indicator of compliance
during inspections. Such surrogate  indicators of compliance may include significant
variations  in process  variables or pollution control equipment variables that are outside
of the range recorded during the most recent compliance test or outside of the range
of good engineering practice (e.g., broken or inoperable baghouse cleaning systems;
bypassed  or  isolated sections of capture systems; increased process rates of
nonaffected sources co-vented to APC equipment serving NSPS  affected facilities,
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etc.).  If these surrogate indicators of compliance strongly suggest that the source is
not in compliance with the mass emission limit, a stack test should be required under
the same or similar operating conditions unless it is determined that the operating

conditions constituted a startup, shutdown or malfunction event.

4.7.1  Determining Compliance with Opacity During the Inspection

      While §60.11(b) of Subpart A requires a minimum time of observation using EPA

Method 9 of 3 hours (thirty 6-minute averages) to determine compliance with the
NSPS opacity limits for  the initial performance test,  the inspector is not required to
duplicate these visible emission observation  requirements during a compliance
inspection.  In the case of  affected facilities enclosed in buildings, §60.675(d) of
Subpart OOO similarly requires a minimum observation time using EPA Method 22 of

75 minutes (15 minutes per side and top)  during  the initial performance test. As with
EPA Method 9, the inspector is not required  to duplicate this  requirement during a
compliance inspection.
      The following are acceptable guidelines that  may be used for performing EPA

Method 9 or Method 22 observations during a compliance inspection:

      0     Continuous operating/emitting  sources -  Minimum observation time using
            EPA Method 9 should be 18  minutes  (three 6-minute observation sets).
            When using EPA Method 22  for buildings, minimum observation time
            should be 20 minutes  (5 minutes per side and top).

      0     Intermittent operating/emitting sources - Intermittent sources should be
            observed for at least two or three cycles of operation.  Observations
            should end at the end of the  process  cycle and noted on the visible
            emission observation form. Observations should be continued when the
            next cycle begins.  A least two  6-minute observation sets should be
            recorded.

      0     Affected facilities inside buildings - If affected facilities are enclosed in
            buildings and the  inspector has determined through EPA Method 22 that
            fugitive emissions are emitted from the building, the following are
            acceptable minor  changes to the reference  method pursuant to §60.8(b)
            for applying EPA Method 9 inside the  building:
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             1.     Assume a position at least 4.57 meters (15 ft) from the source of
                   emissions.

             2.     Without available and proper sunlight, use portable directional
                   lights positioned within the 140° sector to the observer's back.

             3.     If background color is sufficiently similar to emission color, artificial
                   backgrounds are permissible to promote color and luminescence
                   contrast.

      0      Unaccessible affected facilities inside buildings - If affected facilities alone,
             or existing and affected facilities are  enclosed in buildings and the
             inspector, after a positive EPA Method 22 reading, cannot gain building
             access to perform EPA Method 9 observations, Method 9 observations
             may be performed on the entire building.  Because the inspector cannot
             confirm individual facility opacities from inside the building, the most
             restrictive opacity limit is applicable for the entire building (see Appendix
             H, memorandum from John S. Seitz to Winston A. Smith,  not dated).

      0      Wet processes - If, in the opinion of the inspector, the process material
             moisture content is sufficiently high to prevent the airborne suspension of
             paniculate matter, or if the process material is wetted to the same extent,
             or immersed in water, visible emission observations are not necessary
             and the affected facility can be considered in compliance with the
             standard.

      It should be noted that EPA policy is to allow no measurement error allowance

for conducting EPA Method 9. Thus, EPA policy prohibits dropping from

consideration marginal opacity exceedances solely because of possible reader

measurement error (see Appendix H, memorandum from John S. Seitz to Roger O.

Pfaff, March 3, 1989).

      The preferred approach for accounting for  measurement error is to follow the

procedures for conducting Method 9 observations described in the "Quality Assurance

Handbook for Air Pollution Measurement Systems" (EPA-600/4-77-027b, 1977) and to
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conduct followup investigation whenever opacity exceedances are observed.  The
Method 9 guidance materials suggest various ways to augment the visible emission
observation if opacity values are in excess of the standard.
       For example, in marginal violation situation, additional sets of readings over
longer time periods or even on different days may be appropriate for ensuring that the
opacity exceedances documented truly reflect noncompliance.  Finally, enforcement
officials must exercise their technical judgement carefully in the final determination of
an enforceable violation, which may be based on additional factors such as the plant
operating history and extent  and duration of excessive emissions.
4.7.2  Determining Compliance with Opacity During the Initial Performance Test
       The observation duration requirements for determining compliance with the
performance test opacity standards of §60.672 are found in §60.11 (b) of Subpart A
(i.e., 3 hours of observations per affected facility or emission point). This requirement
can only be changed pursuant to §60.8(b) which allows the Administrator to 1) specify
or approve,  in specific cases, the use of a reference method with minor changes in
methodology, 2) approve the use of an alternative method the results of which he has
determined to be adequate for indicating compliance, 3) approve the use of an
equivalent method, 4) waive the requirement for a performance test because the
owner or operator has demonstrated to the Administrator's satisfaction that the
affected facility is in compliance with the standard, or 5) approve shorter sampling
times and smaller sample volumes when necessitated by process variables or other
factors.
      Any and all requests for changes in the performance test requirements pursuant
to §60.8(b) must be submitted to the appropriate EPA Regional Office.  Requests
include those from the owner or operator of an affected facility and from States,
whether or not the State has received from EPA delegated  authority for 40 CFR 60,
Subparts A or OOO or both.
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4.8   Field Inspection Procedures for Affected Facilities
      The field inspection procedures herein include those tasks to be performed in
determining the compliance status of affected facilities with the NSPS standard for
particulate matter (§60.672)  and, if applicable, the provisions for monitoring of wet
scrubber operations (§60.674).
      As was discussed in  Section 2, it is usually best to start the inspection at the
beginning of the facility process operations and end the inspection at the finished
product loading station(s).   If, however, from pre-entry observations the inspector has
discovered possible violations at specific plant areas (e.g., excessive stack opacity or
fugitive emissions) it is usually best to begin the field inspection at these areas to
document any violations in a timely manner.
      To aid the inspector in keeping track of the number and type of affected
facilities at the source and the opacity and  mass emission limits applicable to each
affected facility, a master list containing this information should be carried  into the field.
Appendix E contains a sample form that can be used for this purpose.  In addition to
affected facilities, existing facilities should be included as potentially affected facilities in
the master list.  With this information, the inspector can verify that existing facilities
have not been replaced with new facilities that have not yet been permitted under the
NSPS provisions or modified in such a way as to  increase emissions.
      In addition to the master list of potentially affected and affected facilities,
Appendix E includes a Field Inspection Sheet that may be used to document
compliance data for individual affected facilities. The Field Inspection Sheet includes
the specific  items to be inspected and serves as compliance documentation for
individual affected facilities and emission points.
      Finally, Appendix E contains  an example Initial Performance Test Field Sheet for
affected facilities. Similar to the Field Inspection Sheet, this form includes  space to
illustrate the applicable affected facility or transfer point. The  Initial Performance Test
Field Sheet may subsequently be used as a file reference  document to be reviewed as
necessary before future inspections.
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       The following inspection techniques are specific to individual affected facilities
 (e.g., crushers, bagging operations, enclosed truck or railcar loading stations, etc.)
 and individual ARC systems (e.g., wet scrubbers, baghouses, wet suppression, etc.).
 4.8.1  Crushers
       Fugitive emissions from crushers are most apparent at crusher feed and
 discharge points.  Care must be taken to separate fugitive emission opacity from water
 mists generated by wet suppression systems. The inspector should position
 himself/herself at least 4.57 meters (15 ft) from the emission source and in
 accordance with the provisions of EPA Method 9.  Both the crusher inlet and
 discharge outlet should be observed.  Previously, there has been some confusion as
 to whether emissions  at the crusher discharge onto a belt conveyor should be
 considered crusher emissions or belt conveyor transfer point emissions.  For the
 purposes of determining compliance with the provisions of Subpart OOO, these
 emissions should be considered as crusher emissions.  Therefore, if a crusher is an
 affected facility and the crusher is not  served by a capture system, emissions at both
 the inlet and discharge of the crusher  are limited to 15 percent opacity. Crusher
 discharge emissions onto a belt conveyor that is also an affected facility are not
 considered belt conveyor transfer point emissions which are limited to 10 percent
 opacity.  Figure 4-3 shows  excessive fugitive emissions from the discharge of a
 primary jaw crusher.
      The inspector must  exercise caution when observing crusher emissions,
 especially at the crusher feed inlet, due to the possibility of ore fragments being
violently ejected from the crusher. Figures 4-4 and 4-5 show the inlets of two
 secondary cone crushers with and without skirting,  respectively.  Note the waterspray
supply hose around the diameter of the crusher casing in Figure 4-4.  The inspector
should also maintain a safe distance from any mobile equipment hauling ore to or
from the crusher.
                                      109

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Figure 4-3.  Fugitive emissions from a jaw crusher.
                     110

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                                                                    —,-rrtl
Figure 4-4.  Feed inlet of cone crusher with feed skirts.
                        111

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Figure 4-5.  Open feed inlet of cone crusher.
                  112

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      In distinguishing whether a crusher (or any other equipment) is portable or fixed
as it applies to the exemption provisions of §60.670(c), the equipment must be
mounted on a movable chassis or skid and must not be attached to any anchor slab,
or structure by any means other than electric cabling.  Figure 4-6 shows a portable
primary crusher mounted on a wheeled chassis.
4.8.2  Grinding Mills
      As with crushers, fugitive emissions are generated at the grinder's inlet and
outlet with the majority of emissions at the outlet after reduction of raw material  (i.e.,
more fines).  Because the definition  of grinding mill found in §60.671 includes the air
conveying system, air separator, or  air classifier, the inspector should  also inspect the
entire length of these systems for any fugitive emissions as well as the emission points
for mill sweep air.  Both closed-loop and open-circuit systems  are common.  In  the
closed-loop system, dryer flue gases may be added to the mill sweep air and an
equivalent amount of air bled from the system to discharge moisture.  In an open-
circuit system, the dryer gases and/or mill sweep air are not recirculated.  Typically,
these types of systems use roller or ball type mills.
      Normally, when an affected facility is vented to the same ARC equipment and
stack as nonaffected facilities, the emission point is subject to the NSPS standard.  In
such cases, performance tests of the affected facility are conducted while the
nonaffected facilities are not operating.  When dryer flue gases are vented  to the
sweep air of an affected facility grinding mill, however, the dryer usually cannot be shut
down during a performance test.  Dryer heat is normally required to prevent the
material being reduced from clogging the grinding mill.  For these types of situations it
is acceptable to prorate emissions between the dryer and  the grinding mill using the
following equation:
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Figure 4-6.  Portable jaw crusher.
              114

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                            0.5 x
                                       000
P x
where       Ep  =  Prorated emission standard, g/dscm
           0.05  =  Subpart OOO emission standard, g/dscm
      (QSTD)OOO  =  Volumetric flow rate from Subpart OOO source(s), dscfm
         (QSTD)T  =  (QsioJoop +  (QSTD)D = total volumetric flow rate, dscfm
             )D  =  volumetric flow rate from dryer, dscfm
              p  =  Dryer emission standard, g/dscm.
This prorating process requires measurement of both the volumetric flow rate from the
dryer and from the Subpart OOO source (mill).  In addition, the test protocol must
include dryer firing rates that are commensurate with representative operating
conditions.
4.8.3  Screening Operations
     Affected facility screens may be controlled  for fugitive emissions by wet
suppression systems or with hooded capture systems.  Figure 4-7 shows a vibrating
deck-type screen releasing excessive fugitive emissions (uncontrolled). Opacity
observations should be made at the point of maximum opacity in the plume.
     Hooded screens  should be checked for signs of ill-fitting seals or gaps in hood
integrity.  Figure  4-8 illustrates a hooded screen with a capture system off-take at the
top of the screen.  Note that the cleanout of the evacuation system pipe at the top of
the off-take is open allowing fugitive dust to escape.
     If the screen is not operating during the inspection, the inspector should observe
the immediate area of the screen for signs of excess emissions during  operation.
Dust buildup is not presumptive evidence of noncompliance since the time for the dust
accumulation is likely to be unknown.  However, excessive dust buildup may indicate
that the nonoperating  affected facility should be reinspected when operating.  Figure 4-
9 shows a considerable dust buildup on the capture system hood and  the walls of the
enclosing building around a nonoperating screen.

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Figure 4-7.  Deck-type screen with fugitive emissions.
                       116

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Figure 4-8.  Screen hood showing open cleanout emitting fugitive dust.
                              117

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Figure 4-9. Enclosed screen hood showing external fugitive dust buildup.
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4.8.4  Storage Bins
     Venting of storage bins during loading or unloading constitutes the emission
potential for these affected facilities.  Vents may be controlled or uncontrolled.  Typical
ARC equipment involves cyclones, baghouses or wet suppression.
     The inspector should observe the vent discharge points during at least one cycle
(loading or unloading).  In addition, the inspector should observe the area around the
vent.  Accumulations of dust indicate releases of particulate matter.  Absence of
opacity does not necessarily equate with no particulate emissions.  Large diameter
particles which do not readily scatter light can be emitted in significant mass without
appreciable opacity. Because these large and heavier particles will fallout quickly,
heavy deposits close to the point of emissions may be readily apparent.
4.8.5  Bucket Elevators
     Bucket elevators are normally controlled by a capture system at the top of the
elevator at the point of bucket discharge.  Fugitive dust is pneumatically conveyed to
an ARC system, usually a baghouse. The inspector should observe the entire length
of the elevator enclosure. If emissions are present, they are usually emitted at the
capture system atop the elevator as in Figure 4-10, or at the access door(s) to the
elevator interior which may be opened to allow for infiltration of makeup  air.
4.8.6  Belt Conveyors
     Subpart OOO applies only to transfer points to and from affected facility belt
conveyors except transfer points to storage piles.  Although wet suppression is the
most frequently used method for emission control, hooding, capture, and conveying to
a control device are  also used.  Figure 4-11 shows a belt-to-belt transfer point without
controls.  If the moisture content of the material being transferred is sufficient to
prevent the material from becoming airborne, visible emission observation can  be
waived for determining compliance during the inspection.  Belt conveyor transfer
points after process  drying are more likely to result in airborne emissions and are
normally controlled with hooded  capture systems as illustrated in Figure  4-12.
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Figure 4-10. Bucket elevator with fugitive emissions.
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Figure 4-11.  Uncontrolled belt-to-belt transfer point.
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Figure 4-12.  Belt-to-belt transfer point with capture hood.
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     As with other affected facilities, nonoperating belt conveyors should be examined
at transfer points for evidence of excessive emissions (heavy dusting). Visible
emission observations should be scheduled during operation of the affected facility.
4.8.7  Bagging Operations
     Fugitive emissions from  bagging operations are generally localized in the area of
the bagging machine(s).  Bagging operations are almost always enclosed in buildings
to protect these operations from the weather. In such cases, the inspector may
perform EPA Method 22 observations of the building.  If Method 22 observations are
positive for visible emissions,  the inspector should perform EPA Method 9
observations of the affected facilities inside of the building.  If powered vents are
employed, Method 9 observations of the vent(s) should be made.
4.8.8  Enclosed Truck or Railcar Loading Operations
     As with storage bins, truck and railcar loading is an intermittent operation. Visible
emission observations should be made during at least one cycle of operation.
     The inspector should completely understand the definition of an enclosed truck or
railcar loading station, which requires that both the conveying system as well as the
truck or railcar be enclosed.  Figure 4-13 is an example of a nonenclosed truck
loading station. This type of facility is not covered by the nonmetallic mineral
processing NSPS. Figure 4-14, however, illustrates one type of enclosed station
subject to the  NSPS.  Note the enclosed feed tube and the three air vents on the
dome of the enclosed railcar.   Also note the fugitive emissions from the loading
operation  approaching 100 percent opacity immediately above the transfer point.
     Figure 4-15 illustrates another type of enclosed truck loading station showing
some visible emissions as the air is displaced from the truck. In this case, loadout
emissions are  not controlled because the evacuation system is not connected to the
off-take port at the base of the flexible feed tube (small black square at the top of the
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Figure 4-13.  Nonenclosed truck loading station.
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Figure 4-14.  Enclosed railcar loading station with fugitive emissions.
                              125

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Figure 4-15.  Enclosed truck loading station with flexible feed tube.
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4.9  Field Inspection Procedures for Air Pollution Control Equipment

     The following are Level II inspection procedures for APC systems typically found

at nonmetallic mineral processing facilities.

4.9.1  Operating Pulse Jet Baghouses

Inspection Steps

     0    Method 9 observation of fabric filter discharge

     0    Method 9 observation of fugitive emissions from solids handling operation (if
         reentrainment is occurring)

     0    Method 9 observation of fugitive emissions from process equipment

     °    Counterflow checks of audible air infiltration into fan, baghouse (solids
         discharge valve, access doors, shell), and ductwork; check physical
         condition and location of hoods

     0    Check static pressure drop across baghouse using onsite gauge; compare
         with baseline data

     0    Compare compressed air pressures at reservoir with baseline values; check
         for audible leaks of compressed air at fittings; check operation of diaphragm
         valves, record number of valves that do not appear to be working properly

     0    Check inlet gas temperatures using onsite gauge

     0    Observe and describe corrosion of fabric filter shell and hoppers

     0    Evaluate bag failure records, gas inlet temperature records, pressure drop
         data, and other maintenance information.
Evaluation
         Visible emissions greater than the standard (7 percent opacity) indicate poor
         performance; inspection should include: evaluation of bag problems,
         including but not limited to abrasion, chemical attack, high temperature
         damage, and improper cleaning; if conditions appear to be severe, a Level
         III inspection (primary clean side checks) is recommended
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         Fugitive emissions from all process sources should be carefully
         documented; reasons for poor capture should be investigated, and include
         air infiltration, poor hood condition or location, fan  belt slippage (listen for
         squeal), fabric blinding, and poor cleaning effectiveness

     0    Static pressure drop data and cleaning system performance checks
         (compressed air pressures, conditions of diaphragm valves, and frequency
         of cleaning) are very important

     0    Check of the entire system for air infiltration is very important, because it can
         lead to severe problems.

Safety Considerations

     0    Level II inspection involves some climbing and close contact with the pulse
         jet baghouse; check the integrity of all supports and ladders; climb ladders
         properly; avoid contact with hot ducts and  roofs; avoid downward point gas
         discharge

     0    Because the inspector must enter the facility to conduct a Level  II inspection,
         all facility and agency  safety precautions apply.

4.9.2 Operating Shaker and Reverse Air Baghouses

Inspection Steps

     °    Method 9 observation of fabric filter stack or individual compartment
         discharge points

     0    Method 9 observation of fugitive emissions from solids handling  operation  (if
         reentrainment is occurring)

         Method 9 observation of fugitive emissions from process equipment

     0    Counterflow checks of audible air infiltration into fan, baghouse (solids
         discharge valve, access doors, shell), and ductwork; check physical
         condition and location of hoods

         Check static pressure drop across collector using  onsite gauges

     0    Check static pressure drop across each compartment during cleaning;
         values should be zero for shaker collectors
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         Confirm that reverse air fan or shaker motor is operating

         Check inlet gas temperatures using onsite gauges

         Observe and describe corrosion of fabric filter shell and hoppers

         Evaluate bag failure records, gas inlet temperature records, pressure drop
         data, and other records.
Evaluation
     0    Visible emissions >5 percent indicate poor performance; inspections should
         include:  evaluation of bag problems, including abrasion, chemical attack,
         high temperature damage, and excessive cleaning intensities; if conditions
         appear severe, a Level III inspection is recommended

     0    Fugitive emissions from all process sources should be carefully documented

     0    Static pressure drop data and cleaning system performance checks
         (compartment static pressure drops during cleaning, operation of reverse air
         fan) are very useful for determining if the problem is due to the unit

     0    Counterflow inspection of the entire system for air infiltration is very
         important because it can gradually lead to severe bag damage, and reduced
         capture effectiveness at the process.

Safety Considerations

     0    Level II inspection involves some climbing and close contact with the unit;
         check the integrity of all supports and ladders; climb ladders properly; avoid
         contact with hot ducts and roofs; avoid poorly ventilated areas under
         hoppers and between compartments

     0    All plant and agency safety procedures for onsite inspections apply.

4.9.3 Nonoperating Pulse Jet Baghouses

Inspection Steps

     0    Confirm that unit is out-of-service and will not be brought on line during
         period of inspection
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    0    Request plant personnel to open one or more access hatches on the clean
         side of unit; evaluate quantity and pattern of clean side deposits

    0    Check orientation of blow tubes (and extension nipples, if present)

         Check for obvious poorly  seated bags and gaps in tube sheet welds

    0    Request that plant personnel open side access hatches if available

    0    Check for bag abrasion against side flanges, internal walkways, and other
         bags; check for bowed and bent bag/cage assemblies

    0    Check the condition of any deflector plates on the gas inlet

    0    Check for obvious erosion of ductwork leading to baghouse

    0    Check operation of bag cleaning equipment.

Evaluation

    0    Presence of clean side deposits (enough to make a footprint) indicates poor
         performance; inspection should include an evaluation of bag failure problems
         due to abrasion, excessive cleaning intensities, improper blow tube
         alignment, chemical attack, and high temperature damage;  potential for
         leakage around top of bag and tube sheet should also be checked

    0    Potential for bag-to-bag abrasion at bottom and for damage of the fabric
         against side flanges and internal walkways can be seen from side access
         hatches

    0    Deflector serves to protect the bags from abrasive materials

    0    Erosion of these plates could contribute to premature failures; eroded
         ductwork could lead to reduced pollutant capture at the generation source
         and operating temperatures below the acid dewpoint for combustion
         sources.

Safety Considerations

    0    Hatches located on hoppers should never be opened during an inspection
         because there is often dangerous accumulations of hot, free flowing solids
         behind the door
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     0    Inspector should never stick his or her head into the clean air plenum
         because this poorly ventilated area may contain asphyxiants and/or toxic
         gases

     0    All hatches must be opened carefully to prevent hand injuries.

Special Notes

     0    Presence of clean side deposits or other abnormal conditions cannot be
         used alone as a basis for a Notice of Violation (NOV)

     0    Baghouses should be opened only with consent of plant management
         personnel.

4.9.4 Nonoperating Shaker and Reverse Air Baghouses

Inspection Steps

     0    Confirm that unit or individual compartment is out-of-service and will not be
         brought on line during period of inspection

     0    Request that plant personnel open access hatch of compartments isolated;
         use the hatch just above the elevation of the tube sheet; evaluate quantity
         and pattern of clean side deposits

     0    Observe bag tension throughout the portion of the compartment that is
         visible from access hatch; check tension of bags that can be  reached
         without entering compartment

     0    Check  for leaks around thimble connections or snap ring connections

     0    Check  for obvious bag abrasion on internal flanges

         Check  for obvious tube sheet weld failures

     0    Note any holes or tears in bags visible from access hatch.

Evaluation

     0    Presence of clean side deposits (enough to make a footprint) indicates poor
         performance; inspection should include an evaluation of bag failure problems
         due to  abrasion, excessive cleaning intensities, chemical attack, and high
         temperature attack
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         Bag tension is critical; in both reverse air and shaker collectors bags must
         not sag at bottom; the reverse air bags are kept under 40 to 120 pounds
         tension; shaker bags are normally hung with no measurable tension

         Spatial pattern of clean side deposits can be used to indicate dust emission
         problems; however, once deposits exceed several inches in depth,
         diagnostic signs are essentially buried

         Gaps in tube sheet welds are usually visible because the high velocity gas
         stream passing through gap moves the dust deposits away from that portion
         of tube sheet.
Safety Considerations
         Hatches located on hoppers should never be opened during inspection
         because there is often dangerous accumulations of hot, free flowing solids
         behind door

         Side access hatches for each compartment should also be opened carefully
         because hot clean side deposits ranging from several inches to several feet
         in depth may be behind door

         Under no circumstances should inspector enter the compartment

         Even compartments properly isolated may have high concentrations of toxic
         gases, toxic particulate,  and asphyxiants; the gas temperature inside can be
         quite hot due to radiation and conduction from adjacent compartments still
         operating

         Respirators should be worn whenever observing conditions through an open
         hatch.
Special Notes
         Presence of clean side deposits or other abnormal conditions cannot be
         used alone as a basis for a NOV

         Unit should be opened only with consent of plant management.
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4.9.5  Spray Tower Scrubbers

Inspection Steps

    0    Method 9 observation of stack for a period of not less than 6 minutes;
         calculate average opacity and describe cycles in the average opacity

    0    Method 9 observation of all bypass stacks and vents and any fugitive
         emissions from process equipment

    0    Presence of rainout close to the stack or mud lips at the discharge point

    0    Presence of fan vibration

    0    Liquor flow rate and pressure drop indicated  by onsite monitors (compare
         wih average of last compliance test)

         Pump discharge pressure and motor current  indicated by onsite gauges

    0    Audible pump cavitation

    0    Nozzle header pressure indicated  by onsite gauge

    0    Physical condition of shell and ductwork

    0    Recirculation pond layout and pump intake position

    0    Physical condition of nozzles observed through access hatch

    0    Note means used to dispose of purged liquor.

Evaluation

    0    A shift in the average opacity may be due to a decrease in the particle size
         distribution of the inlet gas stream; a co-current inspection of the process
         operation is often advisable

    0    Anything that affects the nozzles will reduce performance; liquor turbidity is
         related to the vulnerability to nozzle pluggage and erosion

    0    Shell and ductwork corrosion is often caused by operation at pH levels that
         are lower than desirable; measure the liquor pH using in-plant instruments, if
         available
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     0    Performance of a spray tower scrubber is dependent on the liquor flow rate;
         any problems that potentially reduce the flow rate should be fully examined.

Safety Considerations

     0    Check all ladders and platforms before use; safe climbing and walking
         practices are important, especially in cold weather

     0    Avoid poorly ventilated areas

     0    Avoid hot duct and pipes

     0    Terminate inspection if a severely vibrating fan is noted in the vicinity of the
         scrubber

     0    Under no circumstances should inspector attempt to look inside an
         operating wet scrubber

     0    Visible emission observations should be made only in secure areas.

Special Notes

     0    Observations and data do not provide conclusive evidence of
         noncompliance with mass emission standards (requires stack test); these
         can be used only as surrogate indicators of compliance.

4.9.6 Mechanically Aided Scrubbers

Inspection Steps

     0    Method 9 observation of the stack for a period of not less than 6 minutes;
         calculate average opacity

     0    Method 9 observation of all bypass stacks and vents and any fugitive
         emissions from process equipment

     0    Presence of rainout close to the stack or mud lips at the discharge point

     0    Presence of fan vibration

     0    Pump discharge pressure and motor current indicated by onsite gauges

     0    Audible pump cavitation
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         Nozzle header pressure indicated by onsite gauge

         Physical condition of shell and ductwork

         Recirculation pond layout and pump intake position

         Note means used to dispose of purged liquor

         Static pressure increase across scrubber and liquor flow rate monitored by
         onsite gauges (compare with average of last  compliance test).
Evaluation
         Shift in the average opacity may be due to a decrease in the particle size
         distribution of the inlet gas stream; a co-current inspection of the process
         operation is often advisable

         Liquor turbidity is related to the vulnerability of the fan blades to erosion
         damage

         Shell and ductwork corrosion is often caused by operation at pH levels
         which are lower than desirable; measure liquor pH using in-plant
         instruments, if available

         Performance of a mechanically aided scrubber is dependent on liquor flow
         rate; any problems which potentially reduce the flow rate should be fully
         examined; indirect indications of liquor flow rate include pump discharge
         pressure, nozzle header pressure, pump motor currents, and audible pump
         cavitation.
Safety Considerations
         Check all ladders and platforms before use; safe climbing and walking
         practices are important at all times

         Avoid poorly ventilated areas

         Avoid hot ducts and pipes

         Terminate inspection if the fan is vibrating severely

         under no circumstances should inspector attempt to look inside an
         operating wet scrubber
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     0    Visible emission observations should be made only in secure areas.

Special Notes

     0    Inspection data and observations do not provide conclusive evidence of
         violation of mass emission standards (requires stack test); these can be
         used only as surrogate indicators of compliance.

4.9.7 Gas-Atomized Scrubbers

Inspection Steps

     0    Method 9 observation of stack for a period of not less than 6 minutes;
         calculate average opacity

     0    Method 9 observation of all bypass stacks and vents and any fugitive
         emissions from process equipment

     0    Presence of rainout close to the stack or mud lips at the discharge

     0    Presence of fan vibration

         Static pressure drop across the  scrubber and  liquor flow rate indicated  by
         onsite gauges (compare with average of last compliance test)

     0    Pump discharge pressure and motor current indicated by onsite gauges

     0    Audible pump cavitation

     0    Nozzle header pressure indicated by onsite  gauge

     0    Physical condition of shell and ductwork

     0    Recirculation pond layout and pump intake position

     0    Physical condition of nozzles observed through access hatch

     0    Means used to dispose of purged liquor should be noted.

Evaluation

     0    Shift in the average opacity may be due to a decrease in  particle size
         distribution of the inlet gas stream; a co-current inspection of the process
         operation is often advisable


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     0    Anything which affects the nozzles will reduce performance; liquor turbidity is
         related to the vulnerability to nozzle pluggage and erosion

     0    Shell and ductwork corrosion is often caused by operation at pH levels
         which are lower than desirable; measure liquor pH using in-plant
         instruments,  if available

     0    Performance of a gas-atomized scrubber is partially dependent on the liquor
         flow rate; any problems which potentially reduce the flow  rate should be fully
         examined

     0    Overall performance of a gas-atomized wet scrubber is related to the static
         pressure drop except in cases where there is a particle size shift, a change
         in the liquor surface tension, or gas-liquor  maldistribution  problems.

Safety  Considerations

     0    Check all ladders and  platforms before use; safe climbing and walking
         practices are important at all times

     0    Avoid poorly ventilated areas

     0    Avoid hot ducts and pipes

     0    Terminate inspection if a severely vibrating fan is noted in the general vicinity
         of the scrubber

     0    Under no circumstances should inspector  attempt to look inside an
         operating wet scrubber

     0    Visible emission observations should be made only in secure areas.

Special Notes

     0    Inspection data and observations do not provide conclusive evidence of
         violation of mass emission standards (requires stack test); these can be
         used only as surrogate indicators of compliance

4.9.8  Large Diameter Cyclones

Inspection Steps

     0    Method 9 observation of stack for a sufficient period to fully characterize
         conditions during normal process cycles


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     0    Method 9 observation of any fugitive emissions from process equipment,
         and material handling operations

     0    Presence of accumulated dust in the vicinity of the stack

     0    Presence of obvious holes and dents in cyclone shell

     0    Air infiltration sites on cyclone shell, cyclone hopper, solids discharge valve,
         and inlet ductwork

     0    Obvious corrosion of cyclone

     °    Static pressure drop across the cyclone as indicated by onsite gauge.

Evaluation

     0    If the visible emissions have increased more than 5 percent since the
         baseline period or if the visible emissions  are within 5 percent of the
         regulatory limit, a more detailed inspection is recommended

     0    Accumulated solids near the stack generally imply high mass emissions
         composed of large particles which do not scatter light  effectively

     0    Fugitive emissions from the process area can be at least partially due to air
         infiltration into ductwork or collector; check process area and ductwork

     0    Holes and dents in shell can disrupt the gas vortex, causing some
         particulate reentrainment and emissions

     0    Static pressure provides an indication of the flow rate;  removal efficiency
         generally increases with the static pressure.

Safety Considerations

     0    Positions selected for the Method 9 observations should be secure from
         moving vehicles such as cars,  trains, and moving machinery

     0    Footing must be secure; stockpiles are not acceptable

     0    All climbing  and walking safety procedures are very important; some
         horizontal structures may not be able to withstand the  load of accumulated
         solids and several people

     0    Avoid contact with hot surfaces


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     0    Some fugitive leaks from the cyclone body and the cyclone discharge vents
         may contain high velocity materials which could cause eye injuries; avoid
         potential areas of exposure.

Special Notes

     0    Inspection data and observations do not provide conclusive evidence of
         violation of mass emission standards (requires stack test); these can be
         used only as surrogate indicators of compliance.

4.9.9  Multiple Cyclone Collectors

Inspection Steps

     0    Method 9 observation of stack for a sufficient period to fully characterize
         conditions during normal process cycles

     0    Method 9 observation of any fugitive emissions from process  equipment,
         and material handling operations

     0    Air infiltration sites on collector shell, hopper, solids  discharge valve, and
         inlet ductwork

     0    Static pressure drop across collector as indicated by onsite gauge

     0    Inlet gas temperature as indicated by onsite gauge.

Evaluation

     0    If the visible emissions have increased more than  5  percent since the
         baseline period or if the visible emissions are within  5 percent of the
         regulatory limit, a more detailed inspection is recommended

     0    Fugitive emissions from the process area can be at  least partially due to air
         infiltration into ductwork or collector; check process area and ductwork

     0    Static pressure provides an indication of the flow rate and the resistance to
         gas flow; static pressure should  be checked against baseline  static pressure
         drops for similar process operating rates;  if the present value  is higher, then
         pluggage is possible; if it is lower,  erosion of outlet tubes and gasket
         problems are likely.
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Safety Considerations
     0    Positions selected for the Method 9 observations should be secure from
         moving vehicles such as cars, trains, and moving machinery

     0    Footing must be secure; stockpiles are not acceptable

     0    All climbing and walking safety procedures are very important; some
         horizontal structures may not be able to withstand the load of accumulated
         solids and  several people

     0    Avoid contact with hot surfaces

     0    Many multicyclone collectors are located in hot areas; avoid heat stress by
         limiting the time spent in the area (moderate heat conditions) or by not
         entering the area (high heat areas)

Special Notes

     °    Inspection  data and observations do not provide conclusive evidence of
         violation of mass emission standards (requires stack test); these can be
         used only as surrogate indicators of compliance.

4.9.10  Wet Suppression Systems

Inspection Steps

     0    Check the  condition  of spray nozzles and spray patterns

     0    Check nozzle header pressure with baseline data or last compliance test

     0    Check timing cycle and actuators for intermittent operation

     0    Check for use of wetting agents/surfactants

     0    Are wetting agents/surfactants used at manufacturer's specifications or at
         similar rates of  last compliance test

     0    Location of sprays versus file information

     0    Check to see if antifreeze is used in winter (if required).
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Evaluation
     0    Spray towers and nozzles should be located for maximum dust suppression.
         Spray nozzles should emit an adequate spray pattern.  Water added to
         crusher inlets should be adequate to wet reduced ore size

     0    Surfactants and wetting agents should be used at or near manufacturer's
         specifications or at rates similar to the last compliance test

     0    Manually operated system actuators allow for nonoperation due to human
         error

     0    High water turbidity may cause increased nozzle pluggage if water is
         recycled.

Safety Considerations

     0    Level II inspections involve some climbing and proximity to heavy equipment,
         puleys, drive belts and moving vehicles; avoid close proximity to equipment
         inlets and outlets where reduction fragments may be ejected; do not touch
         operating or nonoperating nozzles.

4.10     Post-Inspection Conference

     The closing conference with facility officials enables the inspector to "wrap up" the

inspection including answering any questions the company may have, filling in any

gaps in the data collected, and identifying information  considered confidential. Thus,

the following elements generally constitute the closing conference.

     0    Review of Inspection Data - At this point, the inspector can identify and fill in
         any gaps  in the information collected and ensure that there is general
         agreement on the technical facts.

     0    Inspection Follow-up Discussion - The inspector should be willing to answer
         inspection related questions from facility officials, but should  only state
         matters of fact.  Under no circumstances should the inspector make
         judgments or conclusions concerning the facility's compliance status, legal
         effects, or enforcement consequences.
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     0    Declaration of Confidential Business Information - Plant officials authorized to
          make business confidentiality claims should be given the opportunity to
          make a claim of confidentiality by noting such claim  on documentary material
          provided to EPA.  The inspector should note all information claimed
          confidential and handle materials accordingly, even if a written declaration is
          not made at this time.

     0    Preparation of Receipts - The inspector should provide receipts for any
          samples or records taken to a responsible plant individual.

     Since EPA and State inspectors are often the only direct contact between the

regulatory agency and the regulated industry, the inspector should always be aware of

opportunities to improve industry-agency relations.  The closing conference provides

an ideal opportunity to offer various kinds of assistance to facility officials.  At this

point, the inspector has first-hand  knowledge of questions, problems, and possible

solutions to problems. The  inspector should consider:

     0    Answering all questions within his ability and authority.

     0    Referral of questions  and problems to other Agency personnel when
          necessary.

     0    Discussion of problems and tactful suggestion of possible solutions and
          assistance.

     0    Tactful probing of problem areas uncovered during the inspection.

     0    Offering or suggesting available resources such as technical publications,
          special services available to industry,  etc.

     It is very important that the inspector follow up all referrals and offers to  help.  A

letter, phone call, or repeat visit will indicate to facility officials a genuine interest on the

part  of the agency and aid the agency's industry relations.

4.11       Report Preparation and Tracking

     During the inspection, the  inspector collects and substantiates inspection data

which may later be used as  evidence in an enforcement proceeding.  When  he/she

returns to the office it is his/her responsibility to see that this data is organized and
                                       142

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arranged so that other agency personnel may make maximum use of it.  Thus, the file
update and inspection report preparation are an important part of the inspection
process. These should both be done as soon as possible after the inspection to
ensure that all events of the inspection are still fresh in the inspector's memory.
He/she must be able to confirm during a later enforcement proceeding that the
information contained in the inspection report is true.
4.11.1   Computer Data Base Updates
     Both the EPA and State agencies use several types of "files" for facility information
storage, which include computer data bases. State agencies may use different
variations of an Emissions Inventory System (EIS) while EPA uses  data from the
Aerometric Information Retrieval System (AIRS). States with delegation and
enforcement authority for the nonmetallic mineral processing NSPS should enter the
results of compliance inspections of affected facilities into the AIRS Facility Subsystem
as well as into their respective computer data bases.
     The inspector should check to see if any required information is missing or  has
changed since the last update and then work within the office  system to use the data
he/she has collected to update the appropriate data base.
4.11.2  Agency File Updates
     The agency files usually contain the hard copies of all information,
correspondence, reports,  etc.  relevant to a particular facility.  Examples of such items
are listed below:
     0    General  Facility  Information
     0    Correspondence to Facility
     0    Correspondence from Facility
     0    Permit Applications
     0    Permits
         Facility Layout
     0    Flowcharts
     0    Raw Data from  Inspections
     0    Inspection Reports
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         Source Test Reports
         Excess Emission Reports
         Case Emission Reports
         Agency Notes, etc. on Compliance Actions.
    The inspector's data should be used to update the general facility information
including plant contact, correct address, changes in production rates, new flowcharts,
layouts, etc. and of course, the inspector's raw data and inspection report will be
added to the file.
4.11.3  Report Preparation
    The inspector's inspection report serves two very important purposes in agency
operations:  1) it provides other agency personnel with easy access to the inspection
information because it has been organized into a comprehensive, usable document;
and 2) it constitutes a major part of the evidence package on the inspection which will
be available for subsequent enforcement  proceedings and/or other types of
compliance-related follow-up activities.
    Although specific information contained in the  inspection report will vary
depending on the requirements of the agency, the  basic format includes a narrative
report and documentary support. A typical report format is outlined below.
General Inspection Information
    0     Inspection objectives
    0     Facility selection scheme
    0     Inspection facts (date, time, location, plant official, etc.)
Summary of Findings
    0     Factual compliance findings (include problem areas)
    0    Compliance status with applicable  regulations
    0    Administrative problems (as with entry, withdrawal of consent, etc.)
    0     Recommended future action (if  appropriate)
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Facility Information

     0    Process information
     0    Raw materials, production rates
     0    Control equipment
     0    Applicable regulations
     0    Enforcement history

Inspection Procedures and Detail of Findings

     0    Refer to standard procedures used
     0    Describe nonroutine procedures used
     0    Reference inspection data attached
     0    Note and reference any statements taken
     0    Reference photographs, if relevant
     0    Reference any drawings, charts, etc. made
     0    Reference visible emission observation forms
     0    List records reviewed and  address inadequacies

Sampling

     0    Refer to methods used
     0    Reference analytical results attached

Attachments

     0    List of all documentary support attached

     Documentary support is all evidence referred to in the inspection report. It will

include:

     0    Inspector's field notes, forms, checklists
     0    Drawings, charts,  etc
     0    Photographs
     0    Analysis results of samples collected
     0    Statements taken
     °    Visible emission observation forms.
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     Appendix F contains a typical inspection report for a nonmetallic mineral
processing facility.  The inspection and the final inspection report should document
whether the inspection objectives were attained, the compliance status of the affected
facilities, and the need for any follow-on activities required as a result of the inspection.
                                       146

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       APPENDIX A

40 CFR 60, SUBPART 000 WITH
FEBRUARY 14, 1989 REVISION
           A-1

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Subpart OOO—Standards of
Performance for Nonmetallic Mineral
Processing Plants
[Subpart OOO added by 50 FR 31337.
August 1,  1985]

§60.670 Applicability and designation
of affected facility.
  (a) Except as provided in paragraphs
(b), (c) and (d) of this section, the
provisions of this subpart are
applicable to the following affected
facilities in fixed or portable
nonmetallic  mineral processing plants:
each crusher, grinding mill, screening
operation, bucket elevator, belt
conveyor,  bagging operation, storage
bin, enclosed truck or railcar loading
station.
  (b) An affected facility that is subject
to the provisions of Subpart F or I or
that follows  in the plant process any
facility subject to the provisions of
Subparts F or I of this part is not
subject to  the provisions of this
subpart.
  (c) Facilities at the following plants
are not subject to the provisions of this
subpart:
  (1) Fixed sand and gravel plants and
crushed stone plants with capacities, as
defined  in §60.671, of 23 megagrams
per hour (25 tons per hour) or less;
  (2) Portable sand and gravel plants
and crushed stone plants with
capacities, as defined in §60.671, of 136
megagrams per hour (150 tons per hou>)
or less; and
  (3) Common clay plants and pumice
plants with capacities, as defined  in
§60.671, of 9 megagrams per hour (10
tons per hour) or less.
  (d)(l) When an existing facility is
replaced by  a piece of equipment of
equal or smaller size, as defined in
§60.671, having the same function as
the existing facility, the new facility is
exempt from the provisions of
§§60.672, 60.674, and 60.675 except as
provided for in paragraph (d)(3) of this
section.
  (2) An owner or operator seeking to
comply with this paragraph shall
comply with the reporting
requirements of §60.676(a) and (b).
  (3) An owner or operator replacing
a!! existing facilities in 3 production
line with new  facilities does not
qualify for the exemption described in
paragraph (d)(l) of this section and
must comply with the provisions of
§§60.672, 60.674 and 60.675.
  (e) An affected  facility under
paragraph (a) of this section that
commences construction.
reconstruction,  or modification after
August 31.1983 is subject to the
requirements of this part.

§60.671 Definitions.
 All terms used in this subpart. but not
specifically defined in this section,
shall have the meaning given them in
the Act and in  Subpart  A of this part.
  "Bagging operation" means the
mechanical process by which bags are
filled with nonmetallic minerals.
  "Belt conveyor" means a conveying
device that transports material from
one location to another by means of an
endless belt that  is carried on a series
of idlers and routed around a pulley at
each end.
  "Bucket elevator" means a
conveying device of nonmetallic
minerals consisting of a head and foot
assembly  which supports and drives an
endless single or  double strand chain
or belt to  which buckets are attached.
  "Building" means any frame
structure with a roof.
  "Capacity" means the cumulative
rated capacity of all initial  crushers
that are part of the plant.
   "Capture system" means the
equipment (including enclosures,
hoods, ducts, fans, dampers, etc.) used
to capture and transport particulate
matter generated by one or more
process operations to a  control  device.
   "Control device" means  the air
pollution  control equipment used to
reduce particulate matter emissions
released to the atmosphere from one or
more process operations at a
nonmetallic mineral processing plant.
  "Conveying system" means a device
for transporting materials from one
piece of equipment or location  to
another location  within a plant.
Conveying systems include but are not
limited to the following: Feeders, belt
conveyors, bucket elevators and
pneumatic systems.
  "Crusher" means a machine  used to
crush any nonmetaiiic minerals, and
includes,  but is not limited to, the
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following types: jaw, gyratory, cone,
roll, rod mill, hammermill, and
impactor.
  "Enclosed truck or railcar loadir.g
station" means that portion  of a
nonmetallic mineral processing plant
were nonmetallic minerals are loaded
by an enclosed conveying system into
enclosed trucks or railcars.
  "Fixed plant" means any
nonmetallic mineral processing plant
at which the processing equipment
specified in §60.670(a) is attached by a
cable, chain, turnbucket, bolt or other
means (except electrical connections)
to any anchor, slab, or structure
including bedrock.
  "Fugitive emission "means particulate
matter that is not collected by a
capture system and is released to the
atmosphere at the point of generation.
  "Grinding mill" means a machine
used for the wet or dry fine crushing
of any nonmetallic mineral. Grinding
mills include, but are not limited to,
the  following types: hammer, roller,
rod, pebble and ball, and fluid energy.
The grinding mill includes  the air
conveying system, air separator,  or air
classifier, where such systems are
used.
  "Initial crusher"  means any crusher
into which nonmetallic minerals can
be fed without prior crushing in the
plant.
  "Nonmetallic mineral" means any of
the  following minerals or any mixture
of which the majority is any of the
following minerals:
  (a) Crushed and Broken Stone,
including Limestone, Dolomite,
Granite, Traprock, Sandstone, Quartz,
Quartzite, Marl, Marble, Slate, Shale
Oil Shale, and Shell.
  (b) Sand and Gravel.
  (c) Clay including Kaolin, Fireclay,
Bentonite, Fuller's Earth, Ball Clay,
and Common Clay.
  (d) Rock Salt.
  (e) Gypsum.
  (f)  Sodium  Compounds, including
Sodium  Carbonate, Sodium Chloride,
and Sodium Sulf ate.
  (g) Pumice.
  (h) Gilsonite.
  (i) Talc and Pyrophyllite.
  (j) Boron,  including Borax, Kernite,
and Colemanite.
  (k) Barite.
  (1) Fluorospar.
  (m) Feldspar.
  (n) Diatomite.
  (o) Perlite.
  (p) Vermiculite.
  (q) Mica.
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  (r)  Kyanite,  including  Andalusite,
Sillimanite, Topaz, and Dumortierite.
  "Nonmetallic   mineral   processing
plant"  means  any  combination  of
equipment that is used  to crush or
grind any nonmetallic mineral wherev-
er  located,  including  lime  plants,
power plants, steel mills, asphalt con-
crete plants, Portland cement plants,
or any other facility processing non-
metallic minerals except as provided in
f 60.670 (b) and (c).
  "Portable plant" means any nonme-
tallic mineral processing plant that is
mounted  on any chassis or skids and
may be moved by the application of a
lifting or  pulling force.  In addition,
there  shall be no cable, chain,  turn-
buckle, bolt or  other means (except
electrical  connections) by which any
piece  of  equipment  is attached  or
clamped to any  anchor, slab, or struc-
ture,  including bedrock  that must be
removed prior to the application of a
lifting or pulling force for the purpose
of transporting the unit.
  "Production line" means all affected
facilities  (crushers,   grinding  mills,
screening  operations, bucket elevators,
belt   conveyors,  bagging  operations,
storage bins, and enclosed truck and
railcar loading stations) which are di-
rectly connected or  are connected  to-
gether by  a conveying system.
  "Screening  operation"   means   a
device for separating material accord-
ing to size by passing undersize materi-
al through one or more mesh surfaces
(screens) in series, and retaining over-
size  material on  the mesh surfaces
(screens).
  "Size" means  the  rated  capacity in
tons per hour of a  crusher, grinding
mill,  bucket elevator,  bagging  oper-
ation, or enclosed truck or railcar load-
ing station; the  total surface area of
the top screen  of a  screening  oper-
ation;  the width of  a conveyor belt;
and  the rated capacity in tons of a
storage bin.
  "Stack emission" means the particu-
late matter that is released to the at-
mosphere  from a capture system.
  "Storage bin" means a  facility for
storage (including surge bins) or non-
metallic  minerals  prior  to  further
processing or loading.

  "Transfer point" means a point in a
conveying operation  where the nonme-
tallic mineral is  transferred to or from
a belt conveyor except where the non-
metallic mineral is  being  transferred
to a stockpile.
  "Truck dumping" means the unload-
ing of nonmetallic minerals from mov-
able  vehicles designed  to  transport
nonmetallic minerals from  one  loca-
tion to another.  Movable vehicles  in-
clude but are not limited to:  trucks,
front end loaders, skip hoists, and rail-
cars.
  "Vent" means  an opening through
which there is mechanically  induced
air flow for the purpose of exhausting
from a building  air carrying  particu-
late matter emissions  from  one  or
more affected facilities.

§ 60.672  Standard for participate matter.
  (a)  On and after the date on which
the performance  test required  to  be
conducted  by § 60.8 is completed,  no
owner or operator subject to the provi-
sions of this subpart shall cause  to be
discharged into the atmosphere  from
any transfer point on belt  conveyors
or from any other affected facility any
stack emissions which:
  (1)  Contain  particulate matter  in
excess of 0.05 g/dscm; or
  (2)  Exhibit greater than  7  percent
opacity, unless the stack  emissions are
discharged  from  an  affected facility
using a wet scrubbing control  device.
Facilities using a wet scrubber  must
comply with the reporting  provisions
of 5 60.676 (c), (d), and (e).
  (b)  On and after the  sixtieth day
after  achieving the maximum produc-
tion rate at which the affected facility
will be  operated,  but not later  than
180 days after initial startup, no owner
or operator subject to the  provisions
of this subpart shall  cause  to be dis-
charged into the atmosphere from any
transfer  point  on belt conveyors  or
from  any other affected  facility any
fugitive emissions which exhibit great-
er than 10  percent opacity,  except  as
provided in paragraphs (c), (d) and (e)
of this section.
  (c)  On and after  the  sixtieth day
after achieving the maximum  produc-
tion rate at which the affected facility
will be  operated,  but not later  than
180 days after initial startup, no owner
or  operator shall cause to  be dis-
charged into the atmosphere from any
crusher, at which  a capture system is
not used, fugitive emissions  which ex-
hibit greater than 15 percent opacity.

  (d)  Truck dumping of  nonmetallic
minerals into any screening operation,
feed hopper,  or   crusher  is  exempt
from the requirements of this section.
  (e) If any transfer point on a convey-
or belt or any other affected facility is
enclosed in a building, then each en-
closed affected facility must comply
with the emission limits in paragraphs
(a), (b) and (c) of this section, or the
building enclosing the affected facility
or facilities must comply with the fol-
lowing emission limits:
  (1) No owner or operator shall cause
to be discharged into the atmosphere
from any building enclosing any trans-
fer point on  a' conveyor belt or  any
other affected facility any visible fugi-
tive emissions except emissions from a
vent as defined in § 60.671.
  (2) No owner or operator shall cause
to be discharged  into the atmosphere
from any vent of any building enclos-
ing any  transfer  point on a conveyor
belt or  any  other  affected facility
emissions  which  exceed  the  stack
emissions limits  in  paragraph (a) of
this section.

§ 60.673 Reconstruction.
  (a) The cost of  replacement of  ore-
contact surfaces on processing equip-
ment shall not be considered in calcu-
lating  either the "fixed capital cost of
the new  components" or the "fixed
capital cost that would be required to
construct a comparable new facility"
under  $ 60.15. Ore-contact surfaces are
crushing surfaces; screen meshes, bars,
and plates; conveyor belts; and  eleva-
tor buckets.
  (b) Under § 60.15, the "fixed capital
cost of the new components" includes
the fixed capital cost  of all depreciable
components (except components speci-
fied in paragraph (a) of this section)
which  are or will be replaced pursuant
tc all continuous programs of compo-
nent replacement commenced within
any 2-year period following August 31,
1983.

§ 60.674  Monitoring of operations.
  The owner or operator of any affect-
ed facility subject to  the provisions of
this subpart which uses a wet scrubber
to control emissions shall install, cali-
brate,  maintain and  operate the  fol-
lowing monitoring devices:
  (a)  A  device  for  the  continuous
measurement of  the pressure loss of
the gas stream through the scrubber.
The monitoring device must be certi-
fied by the manufacturer to be accu-
rate within   ±250  pascals  ±1  inch
water gauge pressure and must be cali-
brated on an annual basis  in accord-
                                                       A-4

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 ance with manufacturer's Instructions.
   (b)   A  device  for  the  continuous
 measurement of the  scrubbing liquid
 flow  rate to  the  wet scrubber.  The
 monitoring device must be certified by
 the   manufacturer  to  be   accurate
 within ±5 percent of  design scrubbing
 liquid flow rate and must be calibrated
 on an annual basis in accordance with
 manufacturer's instructions.

6 60.675  Test methods and procedures.

[60.675 revised  by 54 FR 6662, February
14, 1989]

   (a) In conducting the performance
 tests required in { 60.8, the  owner or
 operator shall  use as reference methods
 and procedures the test  methods in
 Appendix A of mis part or other
 methods and procedures as specified in
 this section, except as provided in
 5 60.8(b). Acceptable alternative
 methods and procedures are given in
 paragraph (e) of this section.
   (b) The  owner or operator shall
 determine compliance with the
 particulate matter standards in
 S 60.272(a) as follows*.
   (1) Method 5 or Method 17 shall be
 used to determine the particulate matter
 concentration. The sample volume shall
 be at least 1.70 dscm (60 dscf). For
 Method 5, if the gas stream being
 sampled is at ambient temperature, the
 sampling probe and filter may be
 operated without heaters. If the gas
 stream is above ambient temperature,
 the sampling probe and  filter may be
 operated at a temperature high enough.
 but no higher than 121 *C (250 T). to
 prevent water  condensation on the filter.
   (2) Method 9 and the procedures in
 § 60.11 shall be used to determine
 opacity.
   (c) In determining compliance with the
 particulate matter standards in § 60.672
 (b) and (c), the owner or operator shall
 use Method 9 and the procedures in
 5 60.11. with the following additions:
   (1) The minimum distance between
 the observer and the emission source
 shall be 4.57 meters (15 feet).
   (2) The observer shall, when possible.
 select a position that minimizes
 interference from other fugitive emission
 sources (e.g.. road dust). The required
 observer position relative to the sun
 (Method 9. Section 2.1) must be
 followed.
   (3) For affected facilities using wet
 dust suppression for particulate matter
 control, a visible mist is sometimes
 generated by the spray. The water mist
 must not be confused with particulate
 matter emissions and is not to be
 considered a visible emission. When a
 water mist of this nature is present, the
 observation of emissions is to be made
 at a point in the plume where the mist is
 no longer visible.
   (d) In determining compliance with
 $ 60.672(e). the owner or operator shall
 use Method 22 to determine fugitive
 emissions. The performance test shall be
 conducted while all affected facilities
 inside the building are operating. The
 performance test for each building shall
 be at least 75 minutes in duration, with
 each side of the building and the roof
 being observed for at least 15 minutes.
  (e) The owner or operator may use the
 following as alternatives to the
 reference methods and procedures
 specified in this section:
  (1) For the method and procedure of
 paragraph (c) of this section, if
 emissions from two or more facilities
 continuously interfere so that the
 opacity of fugitive emissions from an
 individual affected .facility cannot be
 read, either of the following procedures
 may be used:
  (i) Use for the combined emission
 stream the highest fugitive opacity
 standard applicable to any of the
 individual affected facilities contributing
 to the emissions stream.
  (ii) Separate the emissions so that the
 opacity of emissions from each affected
 facility can be read.
  (f) To comply with § 60.676(d). the
 owner or operator shall record the
 measurements as required § 60.676(c)
 using the monitoring devices in § 60.674
 (a) and (b) during each particulate
 matter run and shall determine the
 averages.
  §60.676 Reporting and recordkeeping.
  (a) Each owner or operator seeking to
comply with §60.670(d) shall submit to
the Administrator the following informa-
tion  about the existing facility being re-
placed and  the  replacement  piece  of
equipment.
  (1) For a crusher, grinding mill, bucket
elevator,  bagging  operation, or enclosed
truck or railcar loading station:
   (i) The rated capacity in tons per hour
of the existing facility being replaced and
   (ii) The rated capacity in tons per hour
of the replacement equipment.
   (2) For a screening operation:
   (i)  The total surface area of the top
screen of the existing screening operation
being replaced and
   (ii) The total surface area of the top
screen  of  the  replacement  screening
operation.
   (3) For a conveyor belt:
   (i) The width of the existing belt being
replaced and
   (ii) The width of the replacement con-
veyor belt.
   (4) For a storage bin:
   (i)  The rated capacity  in tons of the
existing storage bin being replaced and
   (ii) The rated  capacity in tons  of re-
placement storage bins.
   (b) Each owner or operator seeking to
comply with  §60.670(d) shall submit the
following data to the Director of the Emis-
sion Standards and Engineering Division,
(MD-13), U.S. Environmental Protection
Agency, Research Triangle Park, North
Carolina 27711.
   (1)   The  information   described  in
§60.676(a).
   (2) A description of the control device
used  to  reduce particulate matter emis-
sions from the existing facility and a list of
all other pieces of equipment controlled by
the same device; and
   (3) The estimated  age  of the existing
facility.
  (c)  During the initial performance test
of a wet scrubber, and daily thereafter, the
owner or operator shall  record the mea-
surements of both the change in pressure
of the gas stream across the scrubber and
the scrubbing liquid flow rate.
   (d) After the initial performance test of
a  wet scrubber, the  owner or operator
shall  submit semiannual  reports  to the
Administrator of occurrences  when  the
measurements of the scrubber pressure
loss (or gain) and liquid flow rate differ by
more than ± 30 percent from the average
determined during the most recent per-
formance test.
(60.676(d) amended by 54  FR 6662, Feb-
ruary  14, 1989]

  (e)  The reports required under para-
graph (d) shall be postmarked within 30
days  following end  of  the second and
fourth calendar quarters.
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  (0 The owner or operator of any affect-
ed facility shall submit written  reports of
the results of all  performance  tests con-
ducted  to demonstrate  compliance  with
the standards set forth in §60.672, includ-
ing reports of opacity observations  made
using Method 9 to  demonstrate compli-
ance with §60.672  (b) and (c) and reports
of observations using Method 22 to dem-
onstrate compliance with §60.672(e).
  (g) The requirements of this paragraph
remain in force until and unless the Agen-
cy, in delegating enforcement authority to
a State under Section lll(c) of the Act,
approves reporting requirements or  an al-
ternative  means of  compliance surveil-
lance adopted  by such  States.  In that
event,  affected sources  within  the  State
will be relieved of the obligation to comply
with paragraphs (a), (c), (d), (e), and (f)
of this subsection, provided that they com-
ply with requirements established by the
State. Compliance with paragraph (b) of
this section will still be required.
[Approved by the  Office of Management
and  Budget   under   control   number
2060-0050]
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          APPENDIX B

      40 CFR 60, SUBPART A
GENERAL PROVISIONS (ABBREVIATED)
              B-1

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   Subpart A—General Provisions
§ 60.1  Applicability.
  Except as provided  in Subparts  B
and C,  the provisions  of  this part
apply to the owner or operator of any
stationary source  which  contains  an
affected facility,  the construction or
modification of which  is commenced
after the date ol  publication in this
part of any standard  (or, if earlier, the
date of  publication  of  any proposed
standard) applicable to that facility.
§ 60.2  Definitions.
[60.2 amended by 54 FR 6662, February
14. 1989]
   The terms used in this part are de-
 fined  in the Act or  in  this section as
 follows:
   "Act" means the Clean Air Act (42
 U.S.C. 1857 et  seq.. as  amended  by
 Pub. L. 91-604, 84 Stat.  1676).
   "Administrator" means the Adminis-
 trator of the Environmental Protec-
 tion Agency or  his  authorized repre-
 sentative.
   "Affected  facility" means, with ref-
erence to a stationary source, any ap-
paratus to which a standard is applica-
ble.
   "Alternative  method"  means  any
 method of sampling and analyzing for
 an air pollutant which is not a refer-
ence or equivalent method but which
has been demonstrated to the Admin-
istrator's  satisfaction to, in  specific
cases, produce results adequate for his
determination of compliance.
  "Capital  expenditure" means an ex-
penditure for a physical or operational
change to  an existing facility which
exceeds the product  of the applicable
"annual  asset guideline repair allow-
ance   percentage" specified  in   the
latest  edition of  Internal  Revenue
Service (IRS) Publication 534 and the
existing facility's basis, as defined by
section 1012 of  the Internal Revenue
Code. However,  the total expenditure
for a physical or operational  change to
an existing facility must not  be re-
duced  by any "excluded additions" as
defined in  IRS Publication  534,  as
would be done for tax purposes.
   "Commenced" means; with respect to
the definition of "new source" in section
lll(a)(2) of the  Act, that an  o^ner or
operator  has undertaken  a continuous
program of construction or modification
or that an owner or operator has entered
into a contractual obligation to undertake
and complete,  within a reasonable time,
a continuous program of  construction
or modification.
  "Construction"   means  fabrication,
erection, or installation of an affected
facility.
  "Continuous   monitoring   system
means  the  total  equipment,  required
under  the emission monitoring sections
in applicable subparts, used to  sample
and condition (if applicable), to analyze,
and to provide a permanent  record of
emissions or process parameters.
  "Equivalent  method"   means   any
method of sampling and analyzing for an
air pollutant  which has  been  demon-
strated to the Administrator's satisfac-
tion  to 'have  a  consistent and quan-
titatively known relationship to the  ref-
erence method, under specified condi-
tions.
  "Existing facility"  means,  with  ref-
erence to a stationary source, any ap-
paratus of the type for which a standard
is promulgated in this  part, and the con-
struction or modification of which  was
commenced before the date of proposal
of that standard;  or any apparatus which
could be altered in such a way as to~5e of
that type.
  "Isokinetic  sampling"  means sam-
pling in which the linear velocity of the
gas entering the sampling nozzle is equal
to that of the undisturbed gas stream at
the sample point.
  "Malfunction" means any sudden  and
unavoidable failure of  air pollution con-
trol equipment or  process equipment
or of a process to operate in a normal or
usual manner. Failures that are caused
entirelv or in cart bv Door maintenance.
 careless operation, or any other prevent-
 able  upset  condition   or  preventable
 equipment breakdown shall not be con-
 sidered malfunctions.
   "Modification" means any physical
 change in, or change in the method of
 operation of, an existing facility  which
 increases the amount of any air  pollu-
 tant  (to which a  standard  applies)
 emitted into  the  atmosphere  by that
 facility or which results in the emission
 of any air pollutant (to which a standard
 applies) into the atmosphere not pre-
 viously emitted.
   "Monitoring device" means the total
 equipment, required under the monitor-
 ing of operations sections in applicable
 subparts, used to measure and record (if
 applicable) process parameters.

   "Nitrogen oxides" means all oxides of
 nitrogen  except  nitrous   oxide,  as
 measured by test methods set forth in
 this part.
   "One-hour  period"  means  any  .60-
 minute period commencing on the hour.
   "Opacity" means the degree to  which
 emissions  reduce  the  transmission of.
 light  and obscure the view of an object
 in the background.

  ' "Owner or operator"  means any per-
 son who owns, leases, operates, controls,
 or supervises an affected facility or a
 stationary source of which  an affected
facility is a part.
  "Particulate   matter"" means  any
finely divided solid or  liquid material.
 ,)ther  than  uncombined  water, as
measured  by the  reference methods
specified under each  applicable  sub-
part,  or an  equivalent or  alternative
method.

  "Proportional sampling" means sam-
pling at a rate that  produces a  con-
stant ration of  sampling rate to stack
gas flow rate.
  "Reference   method"  means  any
method of sampling and analyzing for
an air pollutant as specified in the applica-
ble subpart.
  "Run" means the net period of  time
during  which  an  emission sample is
collected. Unless otherwise specified, a
run may be either intermittent or con-
tinuous within the limits of good engi-
neering practice.
  "Shutdown" means  the cessation of
operation of  an affected facility for
any purpose.
  "Six-minute period"  means any one
of the  10 equal parts  of a  one-hour
period.
  "Standard" means a standard of per-
 formance  proposed  or promulgated
under this part.
  "Standard conditions" means  a tem-
perature of 293 K  (68°F) and a pres-
                                                          B-2

-------
 sure of 101.3 kilopascals (29.92 in Hg).

  "Startup" means the setting in oper-
 ation of an affected facility  for any
 purpose.

   "Volatile Organic  Compound"  means
 any organic compound which participates
 in  atmospheric  photochemical  reactions;
 or which is measured by a reference meth-
 od,  an equivalent method,  an alternative
 method, or which is determined by proce-
 dures specified under any subpart.

 i 60.3  Unit* and abbreviations.

  Used in this  part are abbreviations
 and symbols  of  units  of measure.
 These are defined as follows:
  (a) System International (SI)  units
 of measure:
 A—ampere
 g—gram
 Hz—hertz
 J—joule
 K-degree Kelvin
 kg—kilogram
 m—meter
 m'—cubic meter
mg—milligram—10'J gram
mm—millimeter—10"' meter
Mg—megagram—10' gram
mol—mole
N—newton
ng—nanogram—10~ • gram
run—nanometer—10" * meter
Pa—pascal
s—second
V—volt
W-watt
n—ohm
MB—microgram—10" * gram

  (b) Other units of measure:

3tu—British thermal unit
•C—degree Celsius (centigrade)
cal—calorie
cfm—cubic feet per minute
cu ft—cubic feet
dcf—dry cubic feet
dcm— dry cubic meter
dscf—dry cubic feet at standard conditions
dscm—dry cubic  meter at  standard condi-
  tions
eq—equivalent
•p—degree Fahrenheit
ft—feet
gal—gallon
gr—grain
g-eq—gram equivalent
hr—hour
in—inch
k—1,000
1—liter
1pm—liter per minute
Ib—pound
meq—milliequivalent
min—minute
ml—milliliter
mol. wt.—molecular weight
ppb—parts per billion
ppm—parts per million
psia—pounds per square inch absolute
psig—pounds per square inch gage
•R—degree Rankine
scf—cubic feet at standard conditions
scfh—cubic feet per hour at  standard condi-
  tions
scm—cubic meter at standard conditions
sec—second
sq ft—square feet
std—at standard conditions

  (c)  Chemical nomenclature:

CdS—cadmium sulfide
CO—carbon monoxide
CO,—carbon dioxide
HC1—hydrochloric acid
Hg—mercury
H,O—water
H^J—hydrogen sulfide
H^'O.-sulfuric acid
N,—nitrogen
NO—nitric oxide
NOi—nitrogen dioxide
NO.—nitrogen oxides
Oi—oxygen
SO,—sulfur dioxide
SO,—sulfur trioxide
SO.—sulfur oxides
  (d) Miscellaneous:
A.S.T.M.—American Society for Testing and
  Materials
                                                        B-3

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 § 60.5  Determination  of  construction or
    modification.
  (a) When requested to do so by an
 owner or operator, the Administrator
 will make a determination of whether
 action taken or intended to be taken
 by  such owner or operator constitutes
 construction  (including   reconstruc-
 tion)  or  modification  or  the  com-
 mencement thereof  within  the mean-
 ing of this part.

  (b) The Administrator  will respond
 to  any request  for  a  determination
 under paragraph (a) of  this  section
 within 30 days of receipt of such re-
 quest.
§ 60.6 Review of plans.
  (a) When requested to  do so by an
owner or operator, the Administrator
will review plans  for  construction or
modification for the purpose  of pro-
viding technical advice to the owner or
operator.
  (bXl)  A separate request shall be
submitted for  each construction or
modification project.

  (2) Each request shall  identify the
location  of such project, and be accom-
panied  by technical information  de-
scribing  the  proposed  nature, size,
design,  and  method of operation of
each affected facility involved  in such
project,  including  information  on any
equipment to  be  used for measure-
ment or control  of emissions.
  (c) Neither  a  request  for plans
review nor advice furnished by  the Ad-
ministrator in  response  to such  re-
quest shall (1) relieve an owner or op-
erator of legal responsibility for com-
pliance with any provision of this part
or of any applicable State or local re-
quirement, or (2) prevent the Adminis--
trator from implementing or enforcing
any provision of this part or taking
any other action  authorized  by  the
Act.


§ 60.7 Notification and record keeping.
  (a) Any owner or operator subject to
the provisions of this part shall fur-
nish the Administrator written notifi-
cation as follows:
  (PA notification of the date con-
struction (or reconstruction as defined
under § 60.15) of an affected facility is
commenced postmarked no later than
30 days after such date. This require-
ment shall not apply  in the case of
mass-produced   facilities   which  are
purchased  in completed form.
  (2) A notification of the anticipated
date  of initial  startup  of an  affected
facility postmarked not more than 60
days nor  less  than 30 days  prior to
such date.
  (3) A notification of the actual date
of initial startup of an affected facility
postmarked within 15 days after such
date.

  (4) A notification of any physical or
operational change to an existing fa-
cility which may increase the emission
rate of any air pollutant  to which  a
standard applies, unless that change is
specifically exempted under an  appli-
cable subpart  or in |60.14(e).  This
notice shall be  postmarked 60 days or
as  soon  as  practicable  before  the
change is  commenced  and  shall in-
clude information describing the pre-
c'se nature of the change, present and
proposed   emission  control systems,
productive capacity  of  the  facility
before and after the  change,  and the
expected   completion  date  of  the
change. The Administrator may re-
quest additional relevant information
subseauent to this notice.
  (5) A notification of  the  date upon
which demonstration of the continu-
ous  monitoring  system performance
commences  in   accordance   with
§ 60.13(c).  Notification  shall be  post-
marked not less than 30 days prior to
such date.

  (6) A notification of the anticipated
date for conducting the opacity obser-
vations required by §60.11(e)(l) of this
part. The notification shall also in-
clude, if appropriate, a request for the
Administrator to provide a visible
emissions reader during a performance
test. The notification shall be post-
marked not less  than 30 days prior to
such date.
(60.7(a)(6) added by 50 FR 53113, De-
cember 27,  1985]
  (7) A  notification that continuous
opacity monitoring system data results
will be used to determine compliance
with the applicable opacity standard
during a performance test required by
I 60.8 in lieu of Method 9 observation
data as allowed by { 60.11(e)(5) of this
part. This notification shall  be post-
marked not less than 30 days prior to
the date of the performance test.
[60.7(aK7) added by 52 FR 9781, March 26.
1987]

  (b) Any owner or operator subject to
the provisions of  this part shall main-
tain records of the occurrence and du-
ration of  any  startup, shutdown,  or
malfunction in  the operation of an af-
fected facility; any malfunction of the
air  pollution  control  equipment;  or
any periods during which a continuous
monitoring  system  or  monitoring
device is inoperative.
  (c) Each owner  or operator required
to  install  a continuous monitoring
system shall submit a written  report
of  excess emissions (as defined  in ap-
plicable subparts) to  the Administra-
tor  for  every  calendar  quarter.  Ali
quarterly reports  shall be postmarked
by  the 30th day following the  end  of
each calendar  quarter  and shall in-
clude the following information:
  (1) The  magnitude  of excess emis-
sions  computed in accordance with
§ 60.13(h),   any  conversion   factor(s)
used, and  the date and time of com-
mencement and completion  of each
time period of excess emissions.
  (2) Specific  identification  of each
period of excess emissions that  occurs
during startups, shutdowns, and mal-
functions of the affected facility. The
nature and cause of any malfunction
(if known), the corrective action taken
or preventative measures adopted.
  (3) The  date and time identifying
each period during which the continu-
ous monitoring system was inoperative
except for zero and span checks and
the nature of the system repairs or ad-
justments.
  (4)  When no  excess emissions have
occurred or the continuous monitoring
system(s) have  not been inoperative,
repaired, or adjusted,  such informa-
tion shall be stated in the report.
                                                       B-4

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  (d) Any owner or operator subject to
the provisions of this part shall main-
tain a file of all measurements, includ-
ing  continuous  monitoring  system,
monitoring  device,  and  performance
testing  measurements;  all  continuous
monitoring system  performance evalu-
ations;   all  continuous   monitoring
system  or monitoring  device calibra-
tion checks; adjustments and mainte-
nance performed on these  systems or
devices; and all other information re-
quired by this  part recorded in a per-
manent form suitable  for  inspection.
The file shall be retained for at least
two years following the  date of such
measurements, maintenance,  reports.
and records.
  (e) If notification substantially simi-
lar to that in paragraph (a) of this sec-
tion is required by any other State or
local agency, sending the Administra-
tor a copy of that notification will sat-
isfy the requirements of paragraph (a)
of this section.

  (f) Individual subparts of  this part
may include specific provisions which
clarify or make inapplicable  the provi-
sions set forth in this section.

[60.7(0  added by 48 FR 48335, October
18, 1983]

§ 60.8  Performance tests.
  (a) Within 60 days  after achieving
the  maximum  production  rate  at
which the affected facility will be op-
erated, but not later  than 180 days
after initial startup of such facility
and at  such other times as may be re-
quired by the Administrator under sec-
tion 114 of the Act, the owner or oper-
ator of such facility shall conduct per-
formance test(s) and furnish  the Ad-
ministrator a written report of the re-
sults of such performance test(s).
  (b) Performance tests shall be con-
ducted and data reduced in accordance
with the test methods and procedures
contained in each applicable subpart
unless  the  Administrator  (1) specifies
or approves, in specific cases, the  use
of a  reference method  with minor
changes in methodology, (2) approves
the use of an equivalent  method, (3)
approves the  use of an  alternative
method the results of which he has
determined to be adequate for indicat-
ing  whether a  specific source is  in
compliance,  (4) waives the  requirement
for performance tests because the owner
or operator of a source has demonstrated
 by other means  to the Administrator's
 satisfaction  that the affected facility is in
 compliance  with the standard. Nothing in
 this paragraph shall be construed to abro-
 gate the Administrator's authority to re-
 quire testing under section 114 of the Act,
 or (5) approves shorter sampling times
 and smaller sample volumes when necessi-
 tated by process variables or other factors.
 [60.8(b) amended by 54 FR 6662, Febru-
 ary 14, 1989]
  (c) Performance tests shall  be con-
ducted under such conditions as the
Administrator  shall  specify  to the
plant operator based on repres°ntative
performance of the  affected  facility.
The owner or  operator  shall  make
available to the  Administrator such
records as  may be necessary to deter-
mine  the conditions  of the perform-
ance tests. Operations during periods
of startup, shutdown, and malfunction
shall   not   constitute  representative
conditions  for the purpose  of a per-
formance test nor shall emissions  in
excess of the level of the applicable
emission limit during periods of start-
up, shutdown,  and  malfunction  be
considered  a violation of the applica-
ble emission  limit  unless  otherwise
specified in the applicable standard.
  (d) The owner or operator of an  af-
fected facility shall  provide the Ad-
ministrator at  least 30'  days  prior
notice of any performance test, except
as specified under other subparts,  to
afford the  Administrator the opportu-
nity to have an observer present.
  (e) The owner or operator of an af-
fected facility shall provide, or  cause
to  be  provided,  performance testing
facilities as follows:
  (1) Sampling ports adequate for test
 methods applicable to such facility. This
 includes (i)  constructing the air pollution
control system such that volumetric flow
rates and pollutant emission rates  can be
accurately determined by applicable test
 methods and procedures and (ii)  providing
a stack or duct free of cyclonic flow during
 performance tests, as demonstrated by ap-
 plicable test methods and procedures.
 [60.8(e)(l) revised by 54 FR 6662, Febru-
ary 14, 1989]
  (2) Safe sampling platform(s).
               access   to   sampling
  (3)   Safe
platform(s).
  (4) Utilities for sampling and testing
equipment.
                                       (f) Unless otherwise specified in the
                                     applicable subpart,  each performance
                                     test shall consist of three  separate
                                     runs using the applicable test method.
                                     Each run shall be conducted for the
                                     time  and under the conditions speci-
                                     fied in the  applicable  standard.  For
                                     the purpose  of determining  compli-
                                     ance  with an applicable standard, the
                                     arithmetic means of results of  the
                                     three runs shall  apply. In the event
                                     that  a  sample  is accidentally lost or
                                     conditions occur in  which one of the
                                     three runs must  be discontinued be-
                                     cause of  forced shutdown, failure of
                                     an irreplaceable portion of the sample
                                     train,  extreme meteorological condi-
                                     tions, or  other circumstances, beyond
                                     the owner or operator's control,  com-
                                     pliance may, upon the Administrator's
                                     approval,  be  determined  using  the
                                     arithmetic mean of the results of the
                                     two other runs.
                                      § 60.9  Availability of information.
                                        The availability to the public of in-
                                      formation  provided to, or otherwise
                                      obtained by, the Administrator under
                                      this Part shall be governed by Part 2
                                      of this chapter. (Information submit-
                                      ted voluntarily  to the Administrator
                                      for the purposes of §§ 60.5 and 60.6 is
                                      governed by $ 2.201  through § 2.213 of
                                      this chapter and not by § 2.301 of this
                                      chapter.)
                                      § 60.10  State authority.
                                        The provisions of this part shall not
                                      be  construed  in any manner  to pre-
                                      clude any State or political subdivision
                                      thereof from:
                                        (a)  Adopting  and  enforcing  any
                                      emission standard or limitation appli-
                                      cable to an affected facility, provided
                                      that such emission standard or limita-
                                      tion is not  less stringent than the
                                      standard applicable to such  facility.
                                        (b) Requiring the owner or operator
                                      of an affected  facility to obtain per-
                                      mits, licenses, or approvals prior to ini-
                                      tiating  construction, modification,  or
                                      operation of such facility.
§60.11  Compliance  with  standards and
    maintenance requirements.
  (a)  Compliance  with  standards  in
this part,  other than  opacity  stand-
ards, shall be determined only by per-
formance tests established  by i 60.8,
unless otherwise specified in  the appli-
cable standard.
                                                         B-5

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  (b) Compliance with opacity standards
in this part shall be determined  by con-
ducting observations in accordance  with
Reference Method 9 in Appendix A of this
part, any alternative method that is  ap-
proved by the Administrator, or as pro-
vided in paragraph (e)(5) of this section.
For purposes of determining initial com-
pliance, the minimum total time of ob-
servations shall be 3  hours  (30 6-minute
averages) for the performance test or
other set of observations (meaning those
fugitive-type emission sources  subject
only to an opacity standard.
(60.11(b) revised by 50 FR 53113, De-
cember 27, 1985; amended  by 52  FR
9781, March 26,  1987]
  (c)  The opacity standards set  forth
in this  part shall  apply at all  times
except during periods of startup, shut-
down, malfunction, and  as otherwise
provided in the applicable standard.
  (d) At all times,  including periods of
startup, shutdown,  and malfunction,
owners  and operators  shall,  to  the
extent practicable, maintain and oper-
ate any affected facility including as-
sociated air pollution  control  equip-
ment  in  a  manner  consistent with
good air pollution  control practice for
minimizing emissions.  Determination
of whether acceptable  operating  and
maintenance  procedures  are   being
used  will  be  based  on  information
available to  the Administrator which
may  include, but  is not  limited to,
monitoring results, opacity  observa-
tions, review of operating and mainte-
nance procedures,  and  inspection of
the source.

(60.11(e)(l) and  (2) revised, new (3) —
(5) added and former (3) and (4) redesig-
nated as (6) and (7) by  50  FR  53113,
December 27, 1985]
   (e)(l) For the purpose of demonstrating
 initial  compliance, opacity  observations
 shall be conducted concurrently with the
 initial performance test required in §60.8
 unless one of the following conditions ap-
 ply. If no performance test under §60.8 is
 required, then opacity observations shall
 be conducted within 60 days after achiev-
 ing  the  maximum  production rate  at
 which the affected facility will be operated
 but no  later than 180 days after initial
 startup of the facility. If visibility or other
 conditions  prevent the  opacity observa-
 tions from  being conducted  concurrently
with the initial performance test required
under §60.8, the source owner or operator
shall reschedule the opacity  observations
as soon after the initial performance t?«t
as possible,  but  not  later than jo u.i^
thereafter, and shall advise the Adminis-
trator of the rescheduled date. In these
cases, the 30-day prior notification to the
Administrator required  in  §60.7(a)(6)
shall be waived. The rescheduled opacity
observations 'shall  be conducted  (to  the
extent possible) under the same operating
conditions that existed during  the initial
performance test conducted under §60.8.
The visible emissions observer shall deter-
mine whether visibility or other conditions
prevent the opacity observations from be-
ing made concurrently with the  initial per-
formance test in accordance with proce-
dures contained in Reference Method.9 of
Appendix B  of this part.  Opacity readings
of portions of plumes which contain con-
densed, uncombined water vapor shall not
be used for purposes of determining com-
pliance with opacity standards.  The owner
or  operator  of an affected  facility  shall
make available, upon  request by  the Ad-
ministrator, such records as may be neces-
sary to determine the conditions under
which the visual observations were made
and shall provide evidence indicating proof
of current visible observer emission certifi-
cation. Except as  provided in-paragraph
(e)(5) of this section, the results of con-
tinuous  monitoring  by   transmissometer
which indicate that the opacity at the time
visual observations were made  was not in
excess  of the standard are probative but
not conclusive evidence of the actual opac-
ity  of an  emission,  provided  that  the
source shall meet  the burden  of proving
that the instrument  used meets (at  the
time of the alleged violation) Performance
Specification 1 in Appendix B of this part,
has been properly maintained and (at the
time of  the  alleged  violation) that  the
resulting data have not been altered in any
way.

(60.11(e)(l)  amended by 52  FR  9781,
March 26, 1987]

   (2)  Except as provided in  paragraph
 (3)(e) of this section, the owner or opera-
 tor  of an affected facility  to which  an
 opacity standard in this part applies shall
 conduct  opacity observations  in accord-
 ance with paragraph (b) of this section,
 shall record the  opacity of emissions, and
 shall report to the Administrator the opac-
ity  results  along  with the  results  of the
initial  performance  test required  under
§60.8. The inability of an owner or opera-
tor  to secure a visible emissions observer
shall not be considered a reason for not
conducting the opacity observations  con-
current with the initial performance test.
  (3) The owner  or operator of an affect-
ed facility to which an opacity standard in
this part applies may request the Adminis-
trator to determine and to record the opac-
ity  of emissions from the affected facility
during the initial  performance  test  and at
such times as may be required. The owner
or operator of the  affected facility shall
report  the opacity results. Any request to
the Administrator  to  determine and  to
record the opacity of emissions from  an
affected facility shall be included in the
notification required in §60.7(a)(6). If for
some reason, the Administrator cannot de-
termine and record  the opacity of emis-
sions from the affected facility during the
performance test, then the provisions of
paragraph  (e)(l) of  this  section shall
apply.
  (4) An owner or operator of an affected
facility using a continuous opacity monitor
[transmissometer] shall record the moni-
toring  data produced during  the initial
performance test required  by §60.8 and
shall furnish the  Administrator a written
report of the monitoring results along  with
Method 9 and §60.8  performance   test
results.
(60.11(e)(4) corrected by 51  FR 1790,
January 15, 1986]
    (5) An owner or operator of an af-
 fected facility subject to an opacity
 standard may submit, for compliance
 purposes, continuous opacity monitor-
 ing system (COM3] data  results pro-
 duced during any performance test re-
 quired under §60.8 in lieu of Method 9
 observation data. If an owner or opera-
 tor elects to submit COM3 data  for
 compliance with the opacity standard,
 he shall  notify the Administrator of
 that decision, in writing, at least 30
 days  before any performance  test  re-
 quired under §60.8 is conducted. Once
 the owner or operator of an affected
 facility has notified the Administrator
 to that effect, the COMS data results
 will be used to determine opacity  com-
 pliance during subsequent tests  re-
 quired under §60.8 until the owner or
 operator notifies the Administrator, in
 writing,  to the contrary. For the pur-
                                                             B-6

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pose of determining compliance with
the opacity standard during a perform-
ance test required under §60.8 using
COM3 data, the minimum total time of
COM3 data collection shall be aver-
ages of all 6-minute continuous periods
within the duration of the mass emis-
sion performance test. Results of the
COMS opacity determinations shall be
submitted along with the results of the
performance test required under §60.8.
The owner or operator of an affected
facility using a COMS for compliance
purposes is responsible for demonstrat-
ing that the COMS meets the require-
ments specified in §60.13(c) of this part,
that the COMS has been properly
maintained and operated, and that the
resulting data have not been altered in
any way. If COMS data results are
submitted for compliance with the
opacity standard for a period of time
during which Method 9 data indicates
noncompliance, the Method 9 data will
be used to determine opacity
compliance.

[New 60.11(e)(5) added by  52 FR 9781,
March 26, 1987]

   (6) Upon receipt from an owner or
 operator of the written reports of the
 results of the performance tests re-
 quired by §60.8, the opacity observa-
 tion results and observer certification
 required by §60.11(e)(l], and the
 COMS results, if applicable, the Ad-
 ministrator will make a finding con-
 cerning compliance with opacity and
 other applicable standards. If COMS
 data results are used to comply with
 an opacity standard, only  those results
 are required to be submitted along
 with the performance test results
 required by §60.8. If the Administrator
 finds that an affected facility is in com-
 pliance with all applicable standards
 for which performance tests are con-
 ducted in accordance with §60.8 of this
 part but during the time such perform-
 ance tests are being conducted fails to
 meet any applicable opacity standard,
 he shall notify the owner or operator
 and advise him that he may petition
 the Administrator within 10 days of re-
 ceipt of notification to make appropri-
ate adjustment to the opacity standard
for the affected facility.
[Former 60.11(e)(5) amended and rede-
signated as (6) by 52 FR 9781. March
26, 1987]
   (7)  The  Administrator  will  grant
such a petition upon a demonstration
by the owner or operator  that the af-
fected facility and associated air pollu-
tion control  equipment was  operated
and .maintained in a manner to mini-
mize the  opacity  of  emissions during
the performance  tests;  that  the per-
formance  tests were  performed under
the conditions established by the Ad-
ministrator; and that the  affected fa-
cility and  associated air pollution con-
trol  equipment   were   incapable  of
being adjusted or operated to  meet the
applicable opacity standard.

[Former 60.11(e)(6) and (7) redesignated
as (7) and  (8) by 52 FR 9781, March 26,
1987]

  (8)  The Administrator  will  establish
an opacity standard for the affected
facility meeting  the  above  require-
ments at  a level  at which the source
will be able, as indicated  by the per-
formance and opacity tests, to meet
the  opacity  standard  at all  times
during  which the source  is meeting
the  mass or concentration  emission
standard.  The Administrator will pro-
mulgate the new opacity  standard in
the FEDERAL REGISTER.

   (0 Special provisions set forth  under an
applicable  subpart of this part shall, super-
sede  any  conflicting provisions  of  this
section.

[60.1 l(f) added by 48 FR 48335, October
18, 1983]

§ 60.12 Circumvention.
   No owner or operator subject to the
provisions of this part  shall  build,
erect, install, or  use any article, ma-
chine, equipment  or process, the use of
which  conceals   an emission which
would otherwise  constitute a violation
of an applicable  standard. Such con-
cealment  includes, but is not limited
to.  the  use  of   gaseous  diluents  to
achieve compliance  with  an opacity
standard  or with a standard which is
based on the concentration of a pollut-
ant in the gases discharged to the at-
mosphere.
S 60.13  Monitoring requirements.

  (a) For the purposes of this section, all
continuous monitoring  systems required
under applicable subparts shall be subject
to the provisions of this section upon pro-
mulgation  of  performance specifications
for continuous monitoring systems under
Appendix B to this part and, if the con-
tinuous monitoring system is used to dem-
onstrate compliance with emission  limits
on a  continuous basis. Appendix F to this
part, unless otherwise specified in an ap-
plicable subpart or by the Administrator.
Appendix  F is  applicable December  4,
1987.

[60.13(a] amended by 48 FR 32986, July
20, 1983; revised by 52 FR 21007, June
4, 1987]


  (b) All continuous monitoring sys-
tems and monitoring devices shall be
installed and operational prior to con-
ducting   performance  tests  under
§ 60.8.  Verification   of  operational
status shall,  as a minimum,  include
completion of the manufacturer's writ-
ten requirements or  recommendations
for installation, operation, and calibra-
tion of the device.

[60.13(b)  revised by 48 FR 23610, May
25, 1983]

  (c) If the owner or  operator of an af-
fected facility elects  to submit  contin-
ous    opacity   monitoring    system
(COMS) data for compliance with the
opacity  standard as provided  under
§ 60.11(e)(5),  he shall conduct a per-
formance evaluation of the COMS as
specified in Performance Specification
1, Appendix B, of this part before the
performance test required under § 60.8
is conducted. Otherwise, the owner or
operator  of an affected facility shall
conduct a performance evaluation of
the  COMS  or  continuous  emission
monitoring system (CEMS) during any
performance test required under $ 60.8
or within 30 days thereafter In accord-
ance with the applicable performance
specification  in  Appendix B  of this
part. The owner or operator of an af-
fected facility shall conduct COMS or
CEMS  performance evaluations  at
such other times as  may  be  required
by  the  Administrator under  section
114 of the Act.
                                                         B-7

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   (1) The owner or operator of an af-
 fected facility using a COM3 to deter-
 mine opacity compliance during any
 performance test required under §60.8
 and as described in §60.11(e)(5) shall
 furnish the Administrator two or, upon
 request, more copies of a written re-
 port of the results of the COMS per-
 formance evaluation described in para-
 graph (c) of this section at least 10 days
 before the performance test required
 under §60.8 is conducted.
   (2) Except as provided in paragraph
 (c)(l) of this section, the owner or oper-
 ator of an affected facility shall furnish
 the Administrator within 60 days of
 completion two or, upon request, more
 copies of a written report of the results
 of the performance evaluation.
 (60.13(c) revised by 52 FR 9781. March 26,
 1987]
   (d)(l)  Owners and operators of all
 continuous emission monitoring sys-
 tems installed  in accordance with the
 provisions of this part shall check the
 zero ior low-level value between 0 and
 20 PI room of span value) and span (50
 to 100 percent of span value) calibra-
 tion drifts at least once daily  in ac-
 cordance with  a written  procedure.
 The zero and  span shall,  as a  mini-
 mum,  be adjusted whenever the 24-
 hour zero  drift or 24-hour span drift
 exceeds two times the limits of the ap-
 plicable performance specifications  in
 Appendix B. The system must  allow
 the  amount  of  excess zero and span
 drift measured at the 24-hour interval
 checks to be recorded and  quantified,
 whenever  specified.  For  continuous
 monitoring systems measuring opacity
 of emissions, the optical  surfaces ex-
 posed  to the effluent gases shall be
 cleaned prior to performing the  zero
 and span  drift adjustments  except
 that for systems using automatic zero
 adjustments.  The  optical surfaces
 shall be cleaned when the cumulative
 automatic zero  compensation exceeds
 4 percent opacity.
  (2) Unless otherwise approved by the
 Administrator,   the following proce-
 dures shall be followed for continuous
 monitoring systems measuring opacity
 of  emissions.  Minimum  procedures
 shall include a method for producing a
simulated zero opacity condition  and
an upscale  (span)  opacity condition
using a certified neutral density filter
or other related technique to produce
a  known obscuration  of  the   light
beam. Such procedures shall provide a
system check of the analyzer internal
optical surfaces and all electronic cir-
cuitry including the lamp and photo-
detector assembly.

[60.13(d) revised by 48 FR 23610, May
25, 1983]

(60.l3(e) revised by 48 FR 32986, July
20, 1983]
  (e) Except for system breakdowns
repairs,  calibration  checks, and  zero
and span adjustments required under
paragraph (d) of this section, all con-
tinuous monitoring systems shall be in
continuous operation and shall meet
minimum frequency of operation re-
quirements as follows:
  (1) All continuous monitoring sys-
tems referenced  by paragraph (c)  of
this section for measuring opacity  of
emissions shall complete  a  minimum
of one cycle of sampling and analyzing
for  each successive 10-second  period
and one cycle  of data recording for
each successive 6-minute period.

    (2)  All  continuous  monitoring sys-
tems referenced  by paragraph (c)  ol
this section for  measuring  emissions.
except opacity, shall complete a mini-
mum of one cycle  of operation (sam-
pling, analyzing, and data recording)
for each successive 15-minute period.
  (f) All  continuous monitoring sys-
tems or monitoring devices shall be in-
stalled such that representative  mea-
surements of emissions or process pa-
rameters from the affected facility are
obtained. Additional procedures for  lo-
cation  of continuous monitoring sys-
tems contained in the applicable Per-
formance Specifications of  Appendix
B of this part shall be used.

(60.l3(g) and  (h) revised  by 48  FR
13326, March 30, 1983]
  (g) When the effluents from a single
affected facility or two or more affect-
ed facilities subject to the same emis-
sion standards are combined  before
being released to the atmosphere, the
owner or operator may install applica-
ble continuous monitoring systems on
each effluent or  on the combined ef-
fluent. When the affected facilities are
not  subject  to  the same  emission
standards,  separate  continuous moni-
toring  systems shall be installed on
each effluent. When the effluent from
one affected facility is released to the
atomosphere through more  than one
 point, the owner or operator shall in-
 stall  an applicable continuous moni-
 toring system on  each separate efflu-
 ent  unless the installation of fewer
 systems is approved by the Adminis-
 trator.  When more than one continu-
 ous monitoring system is used to meas-
 ure  the emissions from one affected
 facility (e.g., multiple breechings, mul-
 tiple  outlets), the owner or  operator
 shall report the  results  as  required
 from   each  continous  monitoring
 system.

  (h) Owners or operators of all con-
 tinuous monitoring systems for meas-
 urement  of  opacity  shall reduce  all
 data to 6-minute averages and for con-
 tinuous   monitoring  systems  other
 than opacity to 1-hour  averages  for
 time periods as defined in § 60.2. Six-
 minute opacity  averages shall be cal-
 culated from 36 or more data  points
 equally  spaced over each  6-minute
 period.  For continuous monitoring sys-
 tems other than opacity, 1-hour aver-
 ages shall be computed from four or
 more data points  equally spaced over
 each  1-hour period. Data  recorder
 during periods of continuous monitor-
 ing system breakdowns,  repairs, cali-
 bration checks,  and zero and span  ad-
 justments shall  not be included in the
 data  averages  computed under  this
 paragraph. An arithmetic or integrat-
 ed average of all data  may be used.
 The data may be  recorded in reduced
 or nonreduced form (e.g., ppm pollut-
 ant and percent O, or ng/J of pollut-
 ant). All excess emissions shall be con-
 verted into units of the standard using
 the  applicable conversion procedures
 specified in subparts. After conversion
 into units of the standard, the data
 may be rounded to the same number
 of significant digits as used in the  ap-
 plicable subparts to specify the emis-
 sion limit (e.g., rounded to the nearest
 1 percent opacity).

  (i) After receipt and consideration of
written  application, the Administrator
may approve alternatives to any moni-
toring procedures  or requirements of
this part including, but not limited to
the following:

  (1)  Alternative  monitoring require-
 ments when installation of a continu-
 ous monitoring system or monitoring
 device specified  by this part would not
 provide accurate measurements  due to
 liquid  water or  other  interferences
 caused by substances with the effluent
 gases.
                                                      B-8

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  (2)  Alternative monitoring require-
ments when the affected facility is in-
frequently operated.
  (3)  Alternative monitoring require-
ments  to accommodate  continuous
monitoring systems that require addi-
tional measurements to  correct  for
stack moisture conditions.
  (4)  Alternative locations for install-
ing continuous monitoring systems or
monitoring devices when the owner or
operator can demonstrate that instal-
lation  at  alternate  locations  will
enable accurate  and   representative
measurements.
  (5)  Alternative methods of convert-
ing pollutant concentration measure-
ments to units of the standards.
  (6)  Alternative procedures for per-
forming daily checks of zero and span
drift  that do not involve  use of span
gases or test cells.
  (7)  Alternatives to  the A.S.T.M. test
methods or sampling procedures speci-
fied by any subpart.
  (8)  Alternative continuous monitor-
ing systems  that  do  not meet the
design or performance requirements in
Performance Specification 1,  Appen-
dix B, but adequately demonstrate a
definite  and consistent  relationship
between  its  measurements and  the
measurements of opacity  by a system
complying with  the requirements in
Performance Specification 1. The  Ad-
ministrator  may  require  that such
demonstration be performed for each
affected facility.
  (9)  Alternative monitoring  require-
ments when  the effluent from a single
affected facility or the combined efflu-
ent from two or more affected facili-
ties are  released to the  atmosphere
through more than one point.
[60.130) added by 52 FR 17555, May 11,
1987]
  (j)  An alternative to the relative ac-
curacy test  specified in Performance
Specification 2 of Appendix  B may be
requested as follows:
  (1)  An alternative to the reference
method tests for determining relative
accuracy is available for sources with
emission rates demonstrated to be  less
than  50  percent  of  the applicable
standard. A  source owner or operator
may  petition the Administrator  to
waive the relative accuracy test in  sec-
tion  7 of Performance Specification 2
 and  substitute the procedures in  sec-
 tion  10 if the results of a performance
test  conducted according to  the re-
quirements in § 60.8 of this subpart or
other tests  performed  following  the
criteria in I 60.8 demonstrate that the
emission rate of the pollutant of inter-
est in the  units of  the applicable
standard is less than 50 percent of the
applicable standard. For sources  sub-
ject to standards  expressed as control
efficiency levels, a source owner or op-
erator may petition the Administrator
to waive the relative  accurancy  test
and substitute  the  procedures in sec-
tion 10 of Performance Specification 2
if the control device exhaust emission
rate is less than 50 percent of the level
needed to meet the control efficiency
requirement.  The  alternative  proce-
dures do not apply if  the continuous
emission monitoring system is used to
determine  compliance  continuously
with the applicable standard. The pe-
tition to waive  the  relative accurancy
test shall  include a detailed descrip-
tion of the procedures to be applied.
Included shall be location and proce-
dure  for conducting  the alternative,
the concentration or response levels of
the alternative  RA  materials, and the
other equipment checks  included in
the alternative procedure. The Admin-
istrator will  review the  petition for
completeness and  applicability.  The
determination to grant a waiver will
depend on the intended use of  the
CEMS data (e.g., data collection  pur-
poses other than NSPS) and may re-
quire  specifications  more  stringent
than  in Performance  Specification  2
(e.g.,  the applicable emission limit is
more stringent than NSPS).
  (2) The  waiver  of a CEMS relative
accuracy test will  be reviewed and may
be rescinded at such  time following
successful  completion of  the alterna-
tive  RA  procedure  that the  CEMS
data indicate the  source emissions ap-
proaching the level of the applicable
standard. The criterion for reviewing
the waiver is the collection of CEMS
data showing that emissions have ex-
ceeded 70  percent  of the applicable
standard for seven, consecutive, aver-
aging periods as specified by the appli-
cable  regulation(s). For sources  sub-
ject to standards  expressed as control
efficiency  levels,  the criterion for re-
viewing the waiver is the collection of
CEMS data  showing  that  exhaust
emissons have exceeded 70 percent of
the level needed  to meet the control
efficiency  requirement for seven,  con-
secutive, averaging periods as specified
by the applicable regulation(s) (e.g..
560.45(g) (2)  and (3). § 60.73(e), and
§ 60.84(e)L It is the responsibility  of
the  source   operator   to  maintain
records and  determine  the level  of
emissions relative to the criterion on
the waiver of relative accuracy testing.
If this criterion is exceeded, the owner
or operator must notify the Adminis-
trator within 10 days of such occur-
rence and include a description of the
nature  and cause  of  the  increasing
emissions.  The  Administrator  will
review  the  notification  and may re-
scind  the waiver  and  require the
owner or operator to conduct a rela-
tive accuracy test of the  CEMS  as
specified in section 7 of Performance
Specification 2.

§ 60.14   Modification.
  (a) Except as provided under  para-
graphs (e) and (f) of this section, any
physical or operational  change to  an
existing facility which results  in an in-
crease in the emission  rate to the  at-
mosphere of any pollutant to which a
standard applies shall be considered a
modification  within  the meaning  of
section 111 of the Act. Upon modifica-
tion, an existing facility shall bc-come
an affected facility for each pollutant
to  which a standard  applies and  for
which there is an increase in the emis-
sion rate to the atmosphere.

  (b) Emission rate shall be expressed
as kg/hr of any pollutant  discharged
into  the  atmosphere   for which  a
standard  is applicable.  The Adminis-
trator shall use the following to deter-
mine emission rate:

  (1) Emission factors as specified in
the latest issue of "Compilation of Air
Pollutant  Emission  Factors,"   EPA
Publication No.  AP-42, or other  emis-
sion factors determined by the Admin-
istrator to be superior to AP-42  emis-
sion factors, in cases where utilization
of emission factors demonstrate that
the emission level resulting from the
physical or  operational  change will
either clearly increase  or clearly not
increase.

  (2)  Material  balances,  continuous
monitor data, or manual emission tests
in cases where utilization of emission
factors as referenced in paragraph (b)
(1)  of this  section does not  demon-
strate  to the Administrator's  satisfac-
tion whether the emission level result-
ing from  the physical  or operational
change will either clearly increase  or
                                                       B-9

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 clearly  not  increase,  or  where  an
 owner or operator demonstrates to the
 Administrator's satisfaction that there
 are reasonable grounds to dispute the
 result obtained by the Administrator
 utilizing emission factors  as referenced
 in  paragraph  (b)(l) of  this  section.
 When the emission rate is based on re-
 sults from manual  emission  tests or
 continuous  monitoring   systems,  the
 procedures specified in Appendix C of
 this part shall be used  to determine
 whether  an increase in  emission rate
 has occurred. Tests shall  be conducted
 under such conditions as  the Adminis-
 trator shall specify to the owner or op-
 erator  based  on  representative  per-
 formance of the facility. At least three
 valid test  runs  must  be  conducted
 before  and  at least  three  after  the
 physical or operational change. All op-
 erating parameters which may affect
 emissions must be held constant to the
 maximum feasible degree for all test
 runs.
  

   (5) An estimate of the fixed capital cost
of the replacements and of constructing a
comparable entirely new facility.

   (6) The  estimated life of the existing
facility after the replacements.

   (7) A discussion of any  economic or
technical limitations the facility may have
in complying with  the  applicable  stan-
dards of performance  after the proposed
replacements.

   (e) The Administrator will  determine,
within 30 days of the receipt of the notice
required by  paragraph (d) of this section
and  any additional information he may
reasonably require, whether the proposed
replacement constitutes reconstruction.

   (0 The Administrator's determination
under paragraph (e) shall be based on:

   (1) The fixed  capital cost of the replace-
ments in comparison to  the fixed capital
cost  that   would   be  requi"ed  to
construct  a comparable entirely new
facility;

  (2) The estimated life of  the facility
after the replacements compared to
the  life of a comparable entirely new
facility;

  (3) The extent to  which the compo-
nents being replaced cause  or contrib-
ute to the emissions from the facility;
and

   (4) Any economic  or technical limita-
i.ions on  compliance with applicable
standards  of  performance  which  are
inherent  in   the   proposed  replace-
ments.

   (g) Individual subparts of this part
 may include  specific provisions which
 refine and delimit  the concept of re-
 construction set forth in this section.
                                                          B-10

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             APPENDIX C

 EPA METHOD 9 - VISUAL DETERMINATION
OF EMISSIONS FROM STATIONARY SOURCES
                C-1

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          40 CFR Ch. I (7-1-88 Edition)
METHOD 9—VISUAL DETERMINATION or THE
    OPACITY or EMISSIONS FROM STATIONARY
    SOURCES

  Many stationary sources discharge visible
emissions into the atmosphere; these emis-
sions are usually in the shape of a plume.
This method involves the determination of
plume opacity by qualified observers. The
method includes procedures for the training
and certification of observers, and proce-
dures to be used in the field for determina-
tion of plume opacity. The appearance of a
plume as viewed by an  observer depends
upon a number of variables, some of which
may be controllable and some of which may
not be controllable  in  the field. Variables
which can be controlled to an  extent  to
which they no longer exert a significant iiu
fluence  upon plume  appearance include:
Angle of the observer with respect to the
plume; angle of the observer with respect to
the sun; point of observation of attached
and detached steam plume; and angle of the
observer with respect to a plume emitted
from a rectangular stack with a large length
to width ratio. The method includes specific
criteria applicable to these variables.
  Other variables which may not be control-
lable in the field are luminescence and color
contrast between the plume and  the  back-
ground against which the plume  is viewed.
These variables exert an influence upon the
appearance of a plume  as viewed  by an ob-
server, and can affect the ability  of the ob-
server to accurately assign opacity values to
the observed plume. Studies of the theory
of plume  opacity and field  studies  have
demonstrated that a plume is most visible
and presents the greatest apparent opacity
when  viewed  against  a contrasting  back-
ground.  It follows  from  this, and is  con-
firmed by field trials, that the opacity of a
plume,  viewed  under  conditions  where a
contrasting background is present can be as-
signed with the greatest degree of accuracy.
However, the potential for a positive error is
also the greatest when a plume  is viewed
under such contrasting conditions. Under
conditions presenting  a less contrasting
background,  the apparent opacity  of  a
plume is less and approaches zero as the
color and  luminescence contrast decrease
toward zero. As a result, significant negative
bias and negative errors can be made when
a plume is viewed under less contrasting
conditions. A negative bias decreases rather
than  increases the  possibility  that a  plant
operator will be cited for a violation of opac-
ity standards due to observer error.
  Studies have been undertaken  to deter-
mine the magnitude of positive errors which
can be made by qualified observers while
reading  plumes  under contrasting condi-
tions and using the procedures set forth  in
this  method. The results of these studies
                                           C-2

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Environmental Protection Agency

(field trials) which involve a total of 769 sets
of 25 readings each are as follows:
  (1) For black plumes (133 sets at a smoke
generator). 100 percent of the sets were read
with a positive error' of less than 7.5 per-
cent opacity;  99 percent were read with a
positive error  of less than 5 percent opacity.
  (2) For white plumes (170 sets at a smoke
generator,  168 sets at  a  coal-fired power
plant, 298 sets at a sulfurlc acid plant), 99
percent of the sets were read with a positive
error of less  than 7.5  percent opacity; 95
percent were  read  with a  positive error of
less than 5 percent opacity.
  The positive observational error associat-
ed with an average of twenty-five readings is
therefore established. The accuracy of the
method must be taken  into account when
determining possible violations of applicable
opacity standards.
1. Principle and Applicability
  1.1 Principle. The opacity of emissions
from stationary sources is  determined visu-
ally by a qualified observer.
  1.2 Applicability.  This method is applica-
ble for the determination of the opacity of
emissions from stationary sources  pursuant
to { 60.11(b) and for qualifying observers for
visually determining opacity of emissions.
2. Procedures
  The observer qualified in accordance with
paragraph  3 of this  method shall use  the
following procedures for visually determin-
ing the opacity of emissions:
  2.1 Position. The qualified observer shall
stand at a distance sufficient to provide a
clear view of the emissions  with the sun ori-
ented in the 140* sector to his back. Consist-
ent  with maintaining  the above require-
ment, the observer shall, as much as possi-
ble,  make his observations from a position
such that his line of vision  is approximately
perpendicular to the plume direction, and
when observing opacity of emissions from
rectangular outlets  (e.g.,   roof monitors,
open baghouses, noncircular  stacks),  ap-
proximately  perpendicular to  the  longer
axis of  the outlet. The observer's line of
sight should  not  include  more than one
plume at a time when multiple stacks are in-
volved, and in any case  the observer should
make his observations with his line of sight
perpendicular to the longer axis of such a
set of multiple stacks (e.g., stub stacks on
baghouses).
  2.2 Field  Records. The observer  shall
record the name of  the plant, emission loca-
tion, type facility, observer's name and af-
filiation, a sketch of the observer's position
relative  to the source,  and the date on  a
  * For a set, positive error = average opaci-
ty  determined by observers'  25 observa-
tions—average  opacity  determined  from
transmissometer's 25 recordings.
                Pt. 60, App. A, Meth. 9

field data sheet (Figure 9-1). The time, esti-
mated distance to the emission location, ap-
proximate wind  direction,  estimated wind
speed, description of  the  sky condition
(presence and color of clouds), and  plume
background are recorded on a field data
sheet at the time opacity readings are Initi-
ated and completed.
  2.3  Observations.  Opacity  observations
shall be made at the point of greatest opaci-
ty in that portion of the plume where con-
densed water vapor is not present. The ob-
server shall not  look continuously at the
plume, but instead shall observe the  plume
momentarily at 15-second intervals.
  2.3.1 Attached Steam Plumes. When con-
densed water vapor  is present within the
plume as  it emerges  from  the  emission
outlet, opacity observations shall be made
beyond the point in the plume at which con-
densed water vapor is no longer visible. The
observer shall record the approximate dis-
tance from the emission outlet to the point
in the plume at which the observations are
made.
  2.3.2 Detached Steam Plume. When water
vapor in the plume condenses and becomes
visible at a distinct distance from the emis-
sion outlet,  the opacity of emissions should
be evaluated at the emission outlet prior to
the condensation of water vapor and the
formation of the steam plume.
  2.4 Recording Observations. Opacity ob-
servations shall be recorded to the nearest 5
percent at 15-second intervals on an obser-
vational record sheet. (See Figure 9-2 for an
example.) A minimum of  24  observations
shall be recorded. Each momentary observa-
tion recorded shall be deemed to represent
the average opacity of emissions for a 15-
second period.
  2.5 Data Reduction. Opacity shall be de-
termined as an average of 24 consecutive ob-
servations recorded at  15-second intervals.
Divide the  observations recorded on the
record sheet into sets of 24 consecutive ob-
servations. A set is  composed of any 24 con-
secutive observations. Sets need not be con-
secutive in time and in no case shall two sets
overlap. For each set of 24 observations, cal-
culate  the average  by summing the opacity
of the 24 observations and dividing this sum
by 24. If an applicable standard specifies an
averaging time requiring more than 24 ob-
servations, calculate the average for all ob-
servations made during the specified time
period. Record the average opacity on  a
record sheet. (See Figure 9-1 for an  exam-
ple.)
3. Qualifications and Testing
  3.1 Certification Requirements. To receive
certification as a qualified observer, a candi-
date must be tested and demonstrate the
ability to  assign opacity readings in  5 per-
cent  increments  to  25  different  black
                                        C-3

-------
 Pt. 60, App. A, M«th. 9
          40 CFR Ch. I (7-1-88 Edition)
 plumes and 25 different white plumes, with
 an error not to exceed 15 percent opacity on
 any one reading and an average error not to
 exceed 7.5 percent opacity in each category.
 Candidates shall be tested according to the
 procedures described  in  paragraph  3.2.
 Smoke generators used pursuant  to para-
 graph 3.2  shall be equipped with  a smoke
 meter which meets the  requirements of
 paragraph 3.3.
  The certification shall be  valid for a
 period of 6 months, at which time the quali-
 fication procedure must be repeated by any
 observer in order to retain certification.
  3.2 Certification Procedure. The certifica-
 tion test consists of showing the candidate a
 complete run of 50 plumes—25 black plumes
 and 25 white plumes—generated by a smoke
 generator. Flumes within each set of 25
 black and  25 white runs shall be presented
 in random order. The candidate assigns an
 opacity value to each plume and records his
 observation on a suitable form. At the com-
 pletion of each run of 50 readings, the score
 of the candidate is determined. If a candi-
 date fails to qualify, the complete run of 50
 readings must be repeated  in  any  retest.
 The smoke test may be administered as part
 of a smoke school or training program, and
 may be preceded by training or familiariza-
 tion  runs  of  the smoke generator during
 which candidates are shown black and white
 plumes of known opacity.
- 3.3 Smoke Generator  Specifications. Any
 smoke generator used for the purposes of
 paragraph 3.2 shall be equipped  with a
 smoke meter  installed to measure opacity
 across the diameter of the smoke generator
 stack. The smoke meter output shall display
 instack opacity based  upon  a  pathlength
 equal to the stack exit diameter, on a full 0
 to 100  percent chart recorder scale. The
 smoke meter  optical design  and perform-
 ance shall meet the specifications shown in
 Table 9-1. The smoke meter shall  be cali-
 brated as prescribed in paragraph 3.3.1 prior
 to the conduct of each smoke reading test.
 At the completion of each test, the zero and
 span drift  shall be checked and if the drift
 exceeds  ±1 percent opacity,  the condition
 shall be corrected prior to conducting  any
 subsequent test runs.  The  smoke meter
 shall be demonstrated, at the time of instal-
 lation, to meet the specifications  listed in
Table 9-1. This demonstration shall be re-
peated following any subsequent repair or
replacement of the photocell or associated
electronic circuitry including the chart re-
corder or output meter, or every 6 months,
whichever occurs first.

   TABLE 9-1—SMOKE METER DESIGN AND
       PERFORMANCE SPECIFICATIONS
     Parameter
a. Light source	

b. Spectral response of
  photocell.

c. Angle of view	
d. Angle of projection—
e. Calibration error	
f. Zero and span drift —
g. Response time
       Specification
Incandescent lamp operated at
 nominal rated voltage.
Photopic (dayNght spectral re-
 sponse of the human eye-
 reference 4.3).
15* maximum total angle.
15* maximum total angle.
±3% opacity, maximum.
±1% opacity, 30 minutes
5 seconds.
  3.3.1 Calibration. The smoke meter is cali-
brated after allowing a minimum of 30 min-
utes warmup by alternately producing simu-
lated  opacity of 0 percent and 100 percent.
When stable response at 0 percent or  100
percent is noted, the smoke meter is adjust-
ed to  produce an output of 0 percent or 100
percent, as appropriate. This calibration
shall be repeated until stable 0 percent and
100 percent readings are produced  without
adjustment. Simulated 0 percent  and  100
percent opacity values may be produced by
alternately switching the power to the light
source on and off while the smoke generator
is not producing smoke.
  3.3.2 Smoke Meter Evaluation. The smoke
meter design and performance are to be
evaluated as follows:
  3.3.2.1 Light Source. Verify from manufac-
turer's data and from voltage measurements
made  at the lamp, as installed, that  the
lamp  is operated within  ±5 percent of  the
nominal rated voltage.
  3.3.2.2 Spectral  Response of Photocell.
Verify from manufacturer's data that  the
photocell has a photopic response;  i.e.,  the
spectral sensitivity of the cell shall closely
approximate the standard spectral-luminosi-
ty curve for photopic vision which  is refer-
enced in (b) of Table 9-1.
                                         C-4

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                                                                       FIQME f-1
                                                         KCOUD QP VtSQ*. DETERHINATION OF OPACITY
                    LOCATION	
                    TEST NUMBER.
                    DATE
                    TYPE FACILITY^
                    CO.ITROL oevice.
                                                                            HOURS OF OISCRWTIOH.
                                                                            08SCWCT	"
                                                                            OtStltVER CERTIFICATION MTC.
                                                                            OBSCTYEH AFFILIATION	
                                                                            POIKT OF CMISS10HS	
                                                                            HEIGHT OF OISCMME FOINT
O
cn
CLOCK TDK
OBSERVE* LOCATION
  Distance to Dfsctergt
  Direction fro* Discharge
  Height of Observation Point
BACKGROUND DESCRIPTION
NEATKER CONDITIONS
  Wind Direction
  Wind Speed
  Anbicnt Temperature
SKY CONDITIONS (clear.
  overcast. % clouds, etc.)
PLUME DESCRIPTION
  Color
  Distance Visible
 CTHCR INFOPJIATtON
                                                  nititl
                                                          Ftnal
SUMMARY OF AVERAGE OPACITY
Set
iMber










TtM
Start-End










Ooacity
SM










Average










                                                                                           Readings ranged fro*	to    ... I opacity
                                                                                           The source was/was not in conpllance vtth
                                                                                           the time evaluation Mas made.
                                                                                                                                                 S
                                                                                                                                                •o
                                                                                                                                                 •
                                                                                                                                                 «o

-------
Pt. 60, App. A, Moth. 9
          40 CFR Ch. I (7-1-88 Edition)
Company...
Location.....
TestNumbi
Date	
                            FIGURE 9-2—OBSERVATION RECORD
                                                      Page	of •
Observer	..................
Type facility	
Point of emissions—
Hr.






























Mia
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
Seconds
0






























15






























30






























45






























Steam plume (check if applicable)
Attached






























Detached






























Comments






























                                         C-6

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Environmental Protection Agency
                Pt. 60, App. A, Moth. 9
                    FIGURE 9-2—OBSERVATION RECORD—(CONTINUED)
                                                  Page	of	
Company.
Location..
Test Number..
Date.™
 Observer..
 Type facility	
 Point of emissions..
Hr.






























Min.
30
31
32
33
34
35
36
37
38
39
40
41
48
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
Seconds
0






























15






























30






























45






























Steam plume (check If applicable)
Attached






























Detached






























ConuviGnts






























  3.3.2.3 Angle of View. Check construction
geometry to ensure that the total angle of
view of the smoke plume, as seen  by the
photocell, does not exceed 15*. The  total
angle of view may be calculated from: 0= 2
tan~>d/2L, where 0=total angle of view;
d-the sum of the photocell diameter-t-the
diameter  of  the limiting  aperture;  and
                                        C-7

-------
 Pt. 60, App. A, Alt. M«th.

 L=the distance from the photocell to the
 limiting aperture. The limiting aperture is
 the point in the path between the photocell
 and the smoke plume where the angle of
 view is most restricted. In smoke generator
 smoke meters this  is normally an orifice
 plate.
   3.3.2.4 Angle  of Projection. Check con-
 struction geometry to ensure that the total
 angle of projection  of the lamp on the
 smoke plume does not exceed 15*. The total
 angle of projection may be calculated from:
 0=2 tan~ H1/2L, where 0= total angle of pro-
 jection; d= the sum of the length of the
 lamp filament + the diameter of the limit-
 ing aperture; and L— the distance from the
 lamp to the limiting aperture.
   3.3.2.5  Calibration  Error. Using neutral-
 density filters of known opacity, check the
 error between the actual response and the
 theoretical  linear response of  the smoke
 meter. This check is accomplished by first
 calibrating the smoke meter according to
 3.3.1  and then inserting a series of three
 neutral-density filters of nominal opacity of
 20, 50, and 75 percent in the smoke meter
 pathlength. Filters  calibrated  within ±2
 percent shall be used. Care should be taken
 when  inserting the filters to prevent stray
 light from affecting the meter. Make a total
 of five nonconsecutive readings for  each
 filter. The maximum error on any one read-
 ing shall be 3 percent opacity.
  3.3.2.6  Zero  and  Span Drift.  Determine
 the zero and span drift by  calibrating and
 operating the smoke generator in a normal
 manner over a 1-hour period. The drift is
 measured by checking the zero and span at
 the end of this period.
  3.3.2.7 Response Time. Determine the re-
 sponse time by producing the series of five
 simulated 0 percent and 100 percent opacity
 values and observing the time required to
 reach  stable response. Opacity values  of 0
 percent and 100 percent may be simulated
 by alternately switching the power to the
 light source off and oh while the smoke gen-
 erator is not operating.
 4. References.
  4.1 Air  Pollution Control District Rules
 and Regulations, Los  Angeles County Air
 Pollution Control  District,  Regulation IV,
Prohibitions, Rule 50.
  4.2 Weisburd, Melvin I., Field Operations
 and Enforcement Manual for Air, U.S. Envi-
ronmental Protection Agency, Research Tri-
angle Park,  NC. APTD-110G. August  1972.
pp. 4.1-4.36.
  4.3 Condon, E.U., and Odishaw, H.. Hand-
book  of  Physics.  McGraw-Hill  Co.,  New
York. NY. 1958. Table 3.1. p. 6-52.
                                       C-8

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              APPENDIX D

 EPA METHOD 22 - VISUAL DETERMINATION OF
FUGITIVE EMISSIONS FROM MATERIAL SOURCES
    AND SMOKE EMISSIONS FROM FLARES
                  D-1

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METHOD 22—VISUAL DETERMINATION OF FU-
    GITIVE   EMISSIONS   FROM   MATERIAL
    SOURCES  AND  SMOKE EMISSIONS FROM
    FLARES

1. Introduction
  This method Involves the visual determi-
nation of fugitive emissions, i.e., emissions
not emitted directly from a process stack or
duct. Fugitive emissions  include emissions
that (1) escape capture by process equip-
ment exhaust hoods; (2) are emitted during
material transfer; (3) are  emitted from
buildings housing material  processing or
handling equipment; and (4) are emitted di-
rectly from process equipment. This method
is used also to determine visible smoke emis-
sions from flares used for combustion of
waste process materials.
  This method determines the  amount of
time that any visible emissions occur during
the observation period, i.e.. the accumulated
emission time. This method does not require
that the opacity of emissions be determined.
Since this  procedure requires only the de-
termination of whether a visible emission
occurs and does not require the determina-
tion of opacity levels, observer certification
according to the procedures of Method 9 are
not required. However, it is necessary that
the observer is educated on the general pro-
cedures for determining the presence of visi-
ble emissions. As a m<"<"'""". the observer
must be trained and knowledgeable regard-
ing the effects on the visibility of emissions
caused  by  background  contrast, ambient
lighting, observer position relative to light-
Ing, wind, and the presence of uncombined
water (condensing water vapor). This train-
ing is to be obtained from written materials
found in References 7.1 and 7.2 or from the
lecture  portion of the Method  9 certifica-
tion course.
2. Applicability and Principle
  2.1  Applicability. This method applies to
the determination of the frequency of fugi-
tive emissions from stationary sources  (lo-
cated Indoors or outdoors) when specified as
the test method for determining compliance
with new source performance standards.
  This method also is applicable for the de-
termination of  the  frequency  of  visible
smoke emissions from flares.
  2.2  Principle.  Fugitive  emissions  pro-
duced during material processing, handling,
and transfer operations or smoke emissions
from  flares are visually determined by an
observer without the aid of Instruments.
3. Definitions
                                          D-2

-------
 Pt. 60, App. A, M«th. 22
          40 CFR Ch. I (7-1-88 Edition)
  3.1 Emission  Frequency. Percentage of
 time that emissions are visible during the
 observation period.
  3.2 Emission Time. Accumulated amount
 of time that emissions are visible during the
 observation period.
  3.3 Fugitive Emissions. Pollutant  gener-
 ated by an affected facility which is not col-
 lected by a capture system and Is released to
 the atmosphere.
  3.4 Smoke Emissions. Pollutant generat-
 ed by combustion in a  flare and occurring
 Immediately  downstream  of  the  flame.
 Smoke occurring within the flame, but not
 downstream of the flame, is not considered
 a smoke emission.
  3.5 Observation   Period.   Accumulated
 time period during which observations are
 conducted, not to be less than the  period
 specified in the applicable regulation.
 4. Equipment
  4.1 Stopwatches. Accumulative type with
 unit divisions of at least 0.5 seconds; two re-
 quired.
  4.2 Light Meter. Light meter capable of
 measuring Illuminance in the 50- to 200-lux
 range;  required  for indoor  observations
 only.
 5. Procedure
  5.1 Position. Survey the affected facility
 or building or structure  housing the process
 to be observed and determine  the locations
 of potential emissions. If the affected facili-
 ty is located inside a building, determine an
 observation location that is consistent with
 the requirements of the applicable regula-
 tion (Le., outside  observation  of  emissions
 escaping the building/structure or inside ob-
 servation of emissions directly  emitted from
 the  affected facility process  unit).  Then
 select a position that enables a clear view of
 the potential emission pointts)  of the  affect-
 ed facility or  of the building or structure
 housing the affected facility, as appropriate
 for the applicable subpart. A position at
 least 15 feet, but not more than 0.25 miles,
 from the emission source is recommended.
 For  outdoor  locations,  select a  position
 where the sun is not directly in the observ-
 er's eyes.
  5.2  Field Records.
  5.2.1  Outdoor Location.  Record the  fol-
 lowing Information on the field data sheet
 (Figure  22-1):  company name.  Industry,
 process unit, observer's name, observer's af-
 filiation, and date. Record also the estimat-
 ed wind speed, wind direction,  and sky con-
 dition. Sketch the process unit being ob-
served and note the observer location rela-
tive to the source and the sun. Indicate the
potential and actual emission points on the
sketch.
  5.2.2 Indoor Location. Record the follow-
ing Information on the field data  sheet
(Figure  22-2):  company  name,  industry.
process unit, observer's name, observer's af-
filiation,  and date. Record  as  appropriate
the type, location, and intensity of lighting
on the data sheet. Sketch the process unit
being  observed  and note observer location
relative to the source. Indicate the potential
and actual fugitive emission points on the
sketch.
  5.3  Indoor Lighting Requirements. For
Indoor locations, use a light meter to meas-
ure the level of illumination at a location as
close to the emission source(s) as is feasible.
An Illumination of greater than 100 lux (10
foot candles) is  considered  necessary for
proper application of this method.
  5.4  Observations. Record  the dock  time
when observations begin. Use one stopwatch
to monitor the duration of the observation
period; start this stopwatch when the obser-
vation  period begins.  If  the  observation
period is divided into two or more segments
by process  shutdowns or   observer  rest
breaks, stop the  stopwatch when a break
begins and restart It without resetting when
the break ends. Stop the stopwatch at the
end of the observation period. The accumu-
lated time indicated by this stopwatch Is the
duration  of the  observation period. When
the observation period is completed, record
the clock time.
  During the observation period, continous-
ly watch  the emission source. Upon observ-
ing an emission  (condensed  water vapor is
not considered  an  emission),  start  the
second accumulative stopwatch; stop the
watch  when the  emission stops. Continue
this procedure for the entire  observation
period. The accumulated elapsed time on
this stopwatch is the total  time emissions
were visible during the observation period.
i.e.. the emission time.
  5.4.1  Observation Period.  Choose an ob-
servation period of sufficient length to meet
the requirements for determining  compli-
ance with the emission regulation in the ap-
plicable subpart. When the length of the ob-
servation period is specifically stated in the
applicable subpart, it may not be necessary
to observe the source for this entire period
if the emission  time required  to Indicate
noncompliance (based on the specified ob-
servation period) is observed in a shorter
time period. In other words, if the  regula-
tion prohibits emissions for more  than 6
minutes In any hour, then observations may
(optional) be stopped after an emission time
of 6 minutes is  exceeded. Similarly, when
the regulation is  expressed as an emission
frequency  and   the regulation  prohibits
emissions for greater than 10 percent of the
time in any hour, then observations  may
(optional) be terminated after 6 minutes of
emissions are observed since  6 minutes Is 10
percent of an hour. In any case, the observa-
tion period shall  not be less than 6 minutes
In duration. In some cases, the process oper-
ation may be intermittent or cyclic. In such
                                       D-3

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Environmental Protection Agency

cases, it may be convenient for the observa-
tion period to coincide with the length of
the process cycle.                       x
  5.4.2  Observer Rest Breaks. Do not ob-
serve emissions continuously for a period of
more than IS to 20 minutes without taking
a rest break. For sources requiring observa-
tion periods of greater than 20 minutes, the
observer shall take a break of not less than
5 minutes and not more than  10 minutes
after every 15 to 20. minutes of observation.
If continuous observations are  desired for
extended time periods, two observers can al-
ternate between making  observations  and
taking breaks.
  5.4.3  Visual  Interference.  Occasionally,
fugitive emissions from sources other than
the  affected facility (e.g., road dust) may
prevent a clear view of the affected facility.
This may particularly be a problem during
periods of high wind. If the view of the po-
tential emission points is obscured to such a
degree that the observer questions the va-
lidity of continuing observations, then the
observations are terminated, and the observ-
er clearly notes this fact  on the data form.
  5.5 Recording Observations. Record the
accumulated time of the observation period
on the data sheet as the observation period
duration.  Record  the accumulated  time
               Pt. 60, App. A, Meth. 22

emissions were observed on the data sheet
as the emission time. Record the clock time
the observation period began and ended, as
well as the clock time any observer breaks
began and ended.
6. Calculations
  If the applicable subpart requires that the
emission rate be expressed as  an emission
frequency (in percent), determine this value
as follows: Divide the accumulated emission
time (in seconds) by  the duration of the ob-
servation period (in seconds) or by any mini-
mum observation period required in the ap-
plicable subpart. if  the acutal observation
period is less than the required period and
multiply this quotient by 100.
7. References.
  7.1  Missan. Robert  and  Arnold  Stein.
Guidelines for Evaluation of Visible Emis-
sions Certification, Field Procedures, Legal
Aspects, and Background  Material.  EPA
Publication  No.  EPA-340/1-75-007.  April
1975
  7.2  Wohlschlegel.  P. and D. E. Wagoner.
Guideline for Development of a Quality As-
surance Program: Volume  IX—Visual Deter-
mination of  Opacity Emissions From  Sta-
tionary Sources. EPA Publication No. EPA-
650/4-74-005-i. November 1975.
                                        D-4

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       APPENDIX E




SAMPLE INSPECTION FORMS
          E-1

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                        Nonmetallic Mineral Processing Plants
                                 - Plant Information -
Plant ID/permit number:

Plant name and address:
Name of plant contact:
Phone:  (    )                ext.
Plant mailing address
(if different from plant address):
Owner/operator name and address
(if different from plant name/address):
Owner/operator phone:  (    )               ext.
Nonmetalic minerals processed:
Plant portability:  D portable  D  nonportable

Cummulative rated capacity of all initial crushers:	tons/year

Plant exempt by plant type/capacity:   D  yes   D  no

Plant emission source type:      D Al              D A2            D B
(particulate matter)          (> 100 t/yr actual)      (>100t/yr potential)   (<100 t/yr actual & potential)

U.S. EPA plant ID number/s (as applicable):
       •  National Emissions Data System (NEDS)   	
         Aerometric Information Retrieval System (AIRS)
Attach a detailed flow diagram of the plant showing the locations of all potentially
affected and affected facilities under 40 CFR Pan 60, Subpart OOO.

-------
Plant ID:  	
Facilities list for crushers, grinding mills, bucket elevators, screening operations, conveyor belts,
bagging operations, storage bins, transfer points, and enclosed truck/rail loading stations.
                   Master List of
Potentially Affected and Affected Facilites
Sownqrpi
(ernibtr, bBdul
•bntor, ilc.)











D«criplkM/loc«lion
or ID nuinbir
(for tm»ltr pobk, IduUT; both
transfer indi - U, Iron ind la)











IUM*
ttpncHr











DnUof
manufacture
(for transfer points,
(InditHforMcli
trtmltr nd)











SubjMtta
40CFRW
SubpvUForl
(Y«Wo)











40CFR60
Sabpu-IOOO
>rrbk
opMitj
standard
(%op.cllr)











Applkibk
auas
itandard
(g/dscm)











* . tons ner hour for crushers, grinding mills, bucket elevators, bagging operations, and enclosed truck/rail loading stations,
  - square meters of top screen surface area for screening operations,
  - tons for storage bins.
  - meters of belt width for conveyor belts.
** - "Yes" response indicates exemption for replacement of existing facility with facility of equal or smaller size.

-------
                       Initial Performance Test Field Sheet
                                                                      Date:
 Affected facility:
 Source ID number:
                                             Sketch of Affected Facility or Transfer Point;
Description/location:
 Source enclosed:  pi yes       pi no
 Source controlled: Q yes       pi no
 If yes, type of control device: 	
 Scrubber AP	 inches W.G.
                                     ^
 Scrubber liquid flow rate 	 GPM

 VE method employed: Q Method 9     C
                                                   Comments:
                                      Method 22
Compliance status: CH compliance  EH noncompliance EH not determined (explain in comments)
Attach appropriate VE Observation Form     Signature: 	
                       Initial Performance Test Field Sheet
                                                                      Date:
Affected facility: _
Source ID number:
                                             Sketch of Affected Facility or Transfer Point;
Description/location:
                                no
Source enclosed:  pi yes
Source controlled: p| yes       pi no
If yes, type of control device: 	
Scrubber AP	 inches W.G.
Scrubber liquid flow rate 	 GPM

VE method employed: EH Method 9     E
                                                   Comments:
                                      Method 22
Compliance status: EH compliance EH noncompliance EH not determined (explain in comments)
Attach appropriate VE Observation Form     Signature:  	

-------
Affected facility:
        Field Inspection Sheet

       	           Date of inspection:
Source ID number:
                Comments:
Description/location:
Source enclosed: pi yes       pi no

Source controlled: Q yes       pi no

If yes, type of control device: 	

Scrubber AP	 inches W.G.
Scrubber liquid flow rate 	 GPM
Baghouse AP
inches W.G.
Bag cleaning: Q operative  Q inoperative

VE method employed:  CH Method 9  d Method 22   Attach appropriate VE Observation Form

Compliance status: [H comph'ance [H noncompliance Q  not determined (explain in comments)

                                Inspector's signature:  	
Affected facility:
        Field Inspection Sheet

       	           Date of inspection:
Source ID number:
                Comments:
Description/location:
Source enclosed:  pi yes       pi no

Source controlled: r~\ yes       pi no

If yes, type of control device:  	

Scrubber AP	 inches W.G.
Scrubber liquid flow rate 	 GPM
Baghouse AP
inches W.G.
Bag cleaning: Q operative  Q inoperative

VE method employed: Q Method 9 D Method 22    Attach appropriate VE Observation Form

Compliance status: D compliance  D noncompliance Q not determined (explain in comments)

                                Inspector's signature: 	

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       APPENDIX F




SAMPLE INSPECTION REPORT
           F-1

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                 LEVEL II COMPLIANCE INSPECTION OF
                  BREAKSTONE LIMESTONE COMPANY
                           ANYWHERE, USA
Inspection Date:   January 5, 1990
Inspector:    Joe Brown
Inspection Report Date:  January 10, 1990
                                 F-2

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                 INSPECTION PROCEDURES AND CONCLUSIONS

Procedures
     On January 5, 1990, an inspection was conducted at Breakstone Limestone Co.
for the purpose of determining compliance of the plant's affected facilities under 40
CFR 60, Subpart OOO.  The inspection was unannounced and one of several
inspections of nonmetallic mineral processing facilities in the State.
     Entry  into the plant was gained without difficulty at 9:00 a.m.   Mr. John Smith,
Environmental Manager, acted as the official plant representative and also served  as
plant escort for the inspection.
     Company records concerning the NSPS affected facilities at this site were
inspected.  The following written notifications to the EPA Administrator for each
affected facility were checked and found to meet all regulatory requirements:
     0    Date of construction
     0    Dates of anticipated and actual startup
     0    Date of anticipated initial performance test opacity observations
     0    Thirty day advance notice of all compliance tests
Notification for 1)  proposed replacements of existing facilities with facilities of equal or
smaller size, 2) proposed reconstructions of existing facilities, and 3) notifications of
modification of existing facilities pursuant to the provisions of §60.14(e) were not
applicable to any existing facility at the plant at the time of inspection.
     The following written reports to the EPA Administrator for each affected facility
were checked and found to meet all regulatory requirements:
     0    All performance test results and results of all performance test opacity
         observations
     The following  records on file at the plant were checked and found to meet all
regulatory requirements:
                                      F-3

-------
     0    Startup, shutdown and malfunction reports

     Because no affected facility at this plant is served by a wet scrubber, the
reporting and recordkeeping requirements for wet scrubbers pursuant to Subparts A
and OOO are not applicable.
     Because no emission problems were observed outside of the plant boundary
during pre-entry observations, the field inspection began at 10:00 a.m. at the primary
crusher and proceeded through the process flow to the two bagging machines.
During the inspection the plant was operating at a rate of 275 tons/h, which is below
the operating rate recorded for the last compliance test.  All existing facilities on the
master list were still operating on site.  No modifications to existing facilities were
observed and no new equipment was apparent.
NSPS Sources
     Both transfer points from belt conveyor No.  13 were observed.  Material
conveyed was of sufficient moisture to prevent visible emissions.  Therefore, these
transfer points were in compliance with the NSPS opacity limit.
     The Ty-Rock screen No. 20 was observed using EPA Method 9 for 18 minutes,
the highest average 6-minute observation period  opacity was 0 percent.  The No. 20
screen was in compliance with the NSPS opacity limit.
     The building enclosing the No. 25 Raymond mill was observed for 20 minutes
employing EPA Method 22 with no visible emissions observed.  The cyclone air
separator serving the No. 25 Raymond mill was observing using EPA Method 9 for 18
minutes. The highest average 6-minute observation period opacity was 0 percent.  No
fallout near the discharge of the cyclone was evident. The stack of the baghouse
serving the No. 25 Raymond mill was likewise observed using  EPA Method 9 for 18
minutes with a highest average 6-minute observation period opacity of 0 percent. The
pulse-jet baghouse was inspected externally; all diaphragm valves were operating and
air reservoir pressure was comparable to that of the last compliance test.  No
evidence of breaches in shell integrity were observed.  Pressure drop across the
baghouse was recorded at 4.0 in. W.G. indicating proper operation.
                                      F-4

-------
     Product storage bin No. 46 was observed during three unloading cycles. The
stack of the storage bin baghouse was observed for a total of 40 minutes with two
sets of consecutive 6 minute observations recorded during the two unloading cycles.
The highest average 6-minute observation period opacity was 25 percent.  During the
two unloading cycles, stack emissions were characterized by cyclic puffs indicating the
possibility of a hole(s) in bags. Pressure drop was recorded across the baghouse at
2.5 in. W.G. which is low for this type of pulse-jet baghouse and 2 in. W.G. below the
average pressure drop recorded during the last compliance test. Air reservoir
pressure was normal and all  diaphragm valves appeared to be operable.  No
breaches in shell integrity were observed.
Conclusions
     The following conclusions are drawn from the inspection:
     0    Transfer points on  the No. 13 belt conveyor were in compliance with the
         NSPS opacity standard
     0    The No. 20 Ty-Rock screen was in compliance with the NSPS opacity
         standard
     0    Emissions from the No. 25 Raymond mill building,  cyclone air separator, and
         baghouse were in compliance with the NSPS opacity standard
     0    Emissions from the baghouse  serving the No. 46 storage bin were not in
         compliance with the NSPS opacity standard
     0    All existing facilities on the master list were on site  and showed no
         indications of modifications that would increase particulate matter emissions
     0    No new equipment that would be subject to the NSPS were observed on the
         plant property
         All notifications, reports, and records required by the NSPS were available at
         the plant upon request and met all NSPS requirements.
                                      F-5

-------
                        Nonmetallic Mineral Processing Plants
                                  - Plant Information -
Plant ID/permit number:      f\ 0
Plant name and address:    [Bur A
                             /v
                                            oy
Name of plant contact:

Phone:
                              ext.
Plant mailing address
(if different from plant address):
Owner/operator name and address
(if different from plant name/address):
                                            h.  ~3 *
Owner/operator phone:  (    )
Nonmetalic minerals processed:
                                         ext.
Plant portability:  D portable  IS  nonportable

Cummulative rated capacity of all initial crushers:

Plant exempt by plant type/capacity:   D  yes
                                                   X 10    tons/year
                                                  no
Plant emission source type:      12 A 1
(paniculate matter)          (> 100 t/yr actual)
                                                  D A2            D B
                                           (> 100 t/yr potential)   (<100 t/yr actual & potential)
U.S. EPA plant ID number/s (as applicable):
       •  National Emissions Data System (NEDS)
         Aerometric Information Retrieval System (AIRS)
Attach a detailed flow diagram of the plant showing the locations of all potentially
affected and affected facilities under 40 CFR Part 60, Subpart OOO.

-------

-------
Plant ID:
Facilities list for crushers, grinding mills, bucket elevators, screening operations, conveyor belts,
bagging operations, storage bins, transfer points, and enclosed truck/rail loading stations.
                  Master List of
Potentially Affected and Affected Facilites
(crahtr.biicktt
•Itralor, tic.)

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* ~ tons P.GT hour
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orn>D«mb«r
(Tor truihr potato, ld.»ttlj both
InuihriBdi -U, fraud to)

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AS*. 10
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Pown^y
AJo. 01



At*. 62
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c*«clrr

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(forlmtfarpolak,
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If 70
SobjKtla
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SubpvtiForl
'c^rab
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A/
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Emk»loiK
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yes
f£~£> 0&
.A/0



w
Control
d«rlc«ljpi
Pfq>pllobl>)

AJ C? V^
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>P/5/J>"A fer- AfCr
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-------
Affected facility:  .

Source ID number:
                              Field Inspection Sheet

                              ^YO^          Date of inspection:
                      /Jo.
                                       Comments:
                                        Sn FT"''O-CA/T
Description/location:
                                         f xV>o i's S
       (J
Source enclosed:  r—i yes

Source controlled: |~] yes

If yes, type of control device:
                                no
                                no
Scrubber AP	 inches W.G.
Scrubber liquid flow rate 	  GPM
Baghouse AP
                      inches W.G.
Bag cleaning: Q operative  Q inoperative

VE method employed: £3 Method 9 C] Method 22   Attach appropriate VE Observation Form

Compliance status: E3 compliance  CD noncompliance CD not determined (explain in comments)
                                                         r     D
                                 Inspector's signature: 	$^
                              Field Inspection Sheet
Affected facility:  .

Source ID number:
                        .  / 3
                                             Date of inspection:	

                                       Comments:    /W/> /> r / *1
.;,/*
                                                                    c> i s rw »- €
Description/location:
                                                         !
                                                       AT
Source enclosed:  pi yes

Source controlled: Q yes

If yes, type of control device:
                                 no
                                 no
Scrubber AP	 inches W.G.
Scrubber liquid flow rate 	 GPM
Baghouse AP
                       inches W.G.
Bag cleaning: Q operative  Q inoperative

VE method employed: ^ Method 9  D Method 22   Attach appropriate VE Observation Form

Compliance status: S compliance  CD noncompliance Q not determined (explain in comments)

                                 Inspector's signature: _

-------
Affected facUity:
                      »> <> e
 Field Inspection Sheet

	           Date of inspection:
Source ID number:
                                       Comments:
Description/location:
Source enclosed:  r—i yes

Source controlled: r-j yes

If yes, type of control device:
                                 no
                                 no
Scrubber AP	 inches W.G.
Scrubber liquid flow rate 	 GPM
Baghouse AP
                       inches W.G.
Bag cleaning:  Q operative Q inoperative

VE method employed: 0 Method 9  Q Method 22   Affac/z appropriate VE Observation Form

Compliance status: 0 compliance CU noncompliance fZI not determined (explain in comments)

                                 Inspector's signature:
                              Field Inspection Sheet

                    ^/l-e^ tf,ll             Date of inspection:

Source ID number:     A/
-------
                              Field Inspection Sheet

Affected facility:   S/g>-/>«>e  o/>v             Date of inspection:

Source ID number:     /v         Comments:    Hi*f ^i~

Description/location:   p^t^^ei'	
                                                                          (g> -/
                                          A S
Source enclosed:  rn yes

Source controlled: tt yes

If yes, type of control device:
                                                    Cclic
                             Hno

                             D no
Scrubber AP	 inches W.G.        	
Scrubber liquid flow rate 	 GPM
Baghouse AP  2. »5"     inches W.G.
Bag cleaning: ^ operative  Q inoperative

VE method employed: H Method 9  Q Method 22    Attach appropriate VE Observation Form

Compliance status:  CH compliance IS noncompliance Q] not determined (explain in comments)

                                Inspector's signature: —
Affected facility:
                              Field Inspection Sheet

                              	          Date of inspection:
Source ID number:
                                       Comments:
Description/location:
Source enclosed:  r~i yes       rn  no

Source controlled: Q yes       rn  no

If yes, type of control device:  	

Scrubber AP	 inches W.G.
Scrubber liquid flow rate 	  GPM
Baghouse AP
                       inches W.G.
Bag cleaning: Q operative  Q] inoperative

VE method employed: [H Method 9 n Method 22   Attach appropriate VE Observation Form

Compliance status: d compliance  EH noncompliance D not determined (explain in comments)

                                 Inspector's signature: 	

-------
                              APPENDIX G

               STATE AGENCIES TO WHICH AUTHORITY HAS
             BEEN DELEGATED FOR 40 CFR 60, SUBPART OOO
 EPA
Region
State
Address
        Maine
        Connecticut
         Rhode Island
             Bureau of Air Quality Control
             Department of Environmental Protection
             State House
             Station 17
             Augusta, Maine  04333
             (207) 289-2437

             Connecticut Department of Environmental Protection
             Bureau of Air Management
             165 Capital Avenue, Room 144
             Hartford, Connecticut 06106
             (203) 566-4030

             Rhode Island Division of Air and Hazardous Materials
             291 Promenade Street
             Providence, Rhode Island 02908-5767
             (401) 277-2808
         New York
         Puerto Rico
              New York Department of Environmental Conservation
              Division of Air Resources
              50 Wolf Road
              Albany, New York 12223-3250
              (518) 457-7230

              Puerto Rico Environmental Quality Board
              Del Parque Street #204
              Corner Pumarada Street
              Santurce, Puerto Rico  00910
              (809) 725-5140 or (809) 722-0077
                                  G-1

-------
 EPA
Region
State
Address
         Pennsylvania
        Virginia
              Bureau of Air Quality Control/Department of
              Environmental Control
              101 South 2nd Avenue, Box 2357
              Harrisburg, Pennsylvania  17105-2357
              (717) 787-9702

              Bureau of Air Pollution  Control
              Allegheny County Health Department
              301 39th  Street
              Pittsburgh, Pennsylvania 15201
              (412)578-8111

              Air Management Services
              Philadelphia Department of Public Health
              500 South Broad Street
              Philadelphia, Pennsylvania  19146
              (215) 875-5623

              Department of Air Pollution Control
              Box 10089
              Richmond, Virginia
              (804) 786-2378
                                   G-2

-------
 EPA
Region
    State
             Address
  IV
Alabama
         Florida
         Georgia
         Mississippi
         North Carolina
         South Carolina
Alabama Department of Environmental Management
1751 Congressman William L Dickinson Drive
Montgomery, Alabama 36130
(205) 271-7861

Florida State Agency
Department of Environmental Regulation
Twin Towers Office Building
2600 Blair Stone Road
Tallahassee, Florida 32301
(904) 488-1344

Environmental Protection Division
Department of Natural Resources
Floyd Towers East
205 Butler Street, SE
Atlanta, Georgia 30334
(404) 656-4713

Mississippi Department of Environmental Quality
Bureau of Pollution Control
2380 Highway 80 West
Jackson, Mississippi 39204
(601) 961-5171

Division of Environmental Management
Post Office Box 27687
Raleigh, North Carolina  27611-7687
(919) 733-3340

South Carolina Department of Health and
 Environmental Control
Bureau of Air Quality Control
2600 Bull Street
Columbia, South Carolina 29201
(803) 734-4750
                                   G-3

-------
EPA
Region
V
































State
Indiana








Illinois





Michigan




Minnesota



Ohio



Wisconsin




Address
Indiana Department of Environmental Management
105 South Meridian Street
Post Office Box 6015
Indianapolis, Indiana 46206
(317) 232-8162
Indianapolis Air Pollution Control Division
2700 South Belmont Avenue
Indianapolis, Indiana 46221
(817) 633-5496
Illinois Environmental Protection Agency
Division of Air Pollution Control
2200 Churchill Road
Post Of ice Box 19276
Springfield, Illinois 62794-9276
(217) 782-7326
Air Quality Division
Michigan Department of Natural Resources
Post Office Box 30028
Lansing, Michigan 48909
(517) 373-7023
Minnesota Pollution Control Agency
520 Lafayette Road
St. Paul, Minnesota 55155
(612) 296-7301
Ohio Environmental Protection Agency
1800 Water Mark Drive
Columbus, Ohio 43266-0149
(614) 644-2270
Wisconsin Department of Natural Resources
Bureau of Air Management
Post Office Box 7921
Madison, Wisconsin 53707
(608) 266-7718
G-4

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EPA
Region
VI





State
Arkansas
Louisiana
New Mexico

Oklahoma
Texas
Address
Arkansas Department of Pollution Control
8001 National Drive
Little Rock, Arkansas 72209
(501) 562-7444
Department of Environmental Quality
Office of Air Quality and Nuclear Energy
625 N. Fourth Street
Baton Rouge, Louisiana 70804
(504) 342-1201
Environmental Improvement Division
Air Quality Bureau
1190 St. Francis Drive
Santa Fe, New Mexico 87503
(505) 827-0070
Albuquerque Environmental Health and Energy
Department
Post Office Box 1293
Albuquerque, New Mexico 87103
(505) 768-2600
Air Quality Service
1000 Northeast 10th Street
Post Office Box 53551
Oklahoma City, Oklahoma 73142
(405) 271-5220
Texas Air Control Board
6330 Highway 290 East
Austin, Texas 78723
(512) 340-5653
G-5

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 EPA
Region
    State
             Address
  VII
Iowa
         Kansas
         Nebraska
Iowa Department of Natural Resources
Henry A. Wallace Building
Des Moines, Iowa  50319
(515) 281-5145

Bureau of Air and Waste Management
Forbes Field,
Building 740
Topeka, Kansas 66620
(913) 296-1500

Department of Environmental Control
301 Centennial Mall South
Post Office Box 98922
Lincoln, Nebraska  68509
(402) 471-2189
                                   G-6

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 EPA
Region
    State
             Address
  VIII
Colorado
         Montana
         North Dakota
         South Dakota
         Utah
         Wyoming
Colorado Department of Health
Air Pollution Control Division
421OE. 11th Street
Denver, Colorado  80220
(303) 331-8500

Montana State Department of Health and
 Environmental Sciences
Air Quality Bureau
Cogswell Building
Helena, Montana 59620
(406) 444-3454

North Dakota State Department of Health
1200 Missouri Avenue
Bismarck, North Dakota 58502-5520
(701) 224-2348

Department of Water and Natural Resources
Division of Air Quality and Solid Waste
Joe Foss Building
Pierre, South Dakota 57501
(605) 773-3153

Utah Department of Health
Division of Environment
Bureau of Air Quality
150288 North 1460 West
Post Office Box 16690
Salt Lake City, Utah  94116
(801) 533-6108

Air Quality Division
Department of Environmental Quality
122 West 25th Street
Cheyenne, Wyoming 82002
(307) 777-7391
                                   G-7

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EPA
Region
IX







State
Nevada
Hawaii
Arizona
California




Address
Division of Environmental Protection
201 South Fall Street
Carson City, Nevada 89710
(702) 885-5065
Hawaii Department of Health
Clean Air Branch
500 Ala Moana Boulevard
Honolulu, Hawaii 96813
(808) 543-8200
Office of Air Quality
Department of Environmental Quality
2005 North Central Avenue
Phoenix, Arizona 85004
(602) 257-2308



Bay Area Air Quality Management District
939 Ellis Street
San Francisco, California 94109
(415) 771-6000
Fresno County Air Pollution Control District
1221 Fulton Mall
Fresno, California 73721
(209) 445-3239
Kern County Air Pollution Control District
2700 M Street, Suite 275
Bakersfield, California 93301
(805) 861-3682
Lake County Air Quality Management
883 Lakeport Boulevard
Lakeport, California 95453
(707) 263-7000
District
Mendocino County Air Pollution Control District
Courthouse Square
Ukiah, California 95482
(707) 463-4354
G-8

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 EPA
Region
    State
              Address
  IX
California (cont.)
Monterey Bay Unified Air Pollution Control District
1164 Monroe Street, Suite  10
Salinas, California 93906
(408)443-1135

North Coast Unified Air Quality Management District
5630 South Broadway
Eureka, California 95501
(707) 443-3093

Sacramento Metropolitan Air Quality Management
 District
A Division of Sacramento County Environmental
 Management Department
8475 Jackson Road, Suite  215
Sacramento, California  95826
(916) 386-6650

San Diego County Air Pollution Control District
9150 Chesapeake Drive
San Diego, California 92123-1095
(619) 694-3307

San Joaquin County Air Pollution Control District
1601 East Hazelton Avenue
Post Office Box 2009
Stockton, California  95201
(209) 468-3470

Santa Barbara County Air Pollution Control District
5540 Ekwill Street, Suite B
Santa Barbara, California  93111
(805) 681-5325

Siskiyou County Air Pollution Control District
525 South Foothill Drive
Yreka,  California 96097
(916) 842-3906

South Coast Air Quality Management
9150 Flair Drive
El Monte, California 91731
(818) 572-6200

Ventura County Air Pollution Control District
800 South Victoria Avenue
Ventura California 93009
(805) 654-2806
                                    G-9

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EPA
Region
IX
State
Guam and American
Samoa
Address
No information available
G-10

-------
            APPENDIX H

COMPILATION OF EPA POLICY MEMORANDA
  CONCERNING 40 CFR 60, SUBPART OOO
                H-1

-------
       \        UNITED STATES ENVIRONMENTAL PROTECTION AGENCY
       I                    WASHINGTON, D.C.  20460
                               NOV  8 1990
                                                            OFF ICE OF
                                                         AIR AND RADIATION
MEMORANDUM
SUBJECT:   Applicability of NSPS Subpart  F to Kilns and Clinker
           Coolers  Using a Common Exhaust Stack
FROM:      John  B.  Rasnic,  Acting Director
           Stationary Source Compliance  Division (EN-341)
           Office of Air Quality Planning and Standards

TO:        Bernard  E.  Turlinski,  Chief
           Air Enforcement  Branch
           Region III

     I have received  your  memorandum  of May  I,  1990,  requesting a
determination of applicability of Subpart F  (Portland Cement
Plants) to a single exhaust' stack used  by the kiln and clinker
cooler at a portland  cement  plant in  Virginia.  I have also
received your more recent  draft  letter,  addressing the same issue,
to the State of Virginia.   I apologize  for the  delay  in our
response to your earlier memorandum.

     Your  request  is  for a procedure  to determine compliance  with
New Source Performance  Standards  (NSPS)  from two NSPS facilities
with different opacity  standards, which have a  combined exhaust
stream.  The facts in your memoranda  state that the exhaust stream
from the affected facility with  the 10%  opacity standard  (the
clinker cooler)  is introduced into the  preheater of the affected
facility with the 20% opacity standard  (the kiln).  The combined
emissions are then routed  to the control device and then  released
into the atmosphere.

     Section 60.63 of the  Subpart requires each owner or  operator
to install, calibrate,  maintain, and  operate  (in accordance with
§ 60.13)  a Continuous Opacity Monitoring System (COMS)  to measure
opacity from any kiln or clinker cooler subject to the Subpart.
Section 60.13(g) of the General  Provisions requires two or more
affected facilities which  are not subject to the same emission
standard to install an  applicable continuous monitoring system on
each separate effluent, unless the installation of fewer  systems
is approved by the Administrator.
                                  H-2
                                                             Printed on Rfcyded Paper

-------
                                -2-

     Therefore, as  indicated in your draft letter to the State, a
COM3 would need to be installed on the ductwork leading from the
clinker cooler to the preheater.  That COM3 must show compliance
with the 10% standard.  Another COM3 installed on the kiln exhaust
would show compliance with the 20% opacity standard, as your draft
letter stated.

     If, however, due to the configuration of the ductwork or for
some other reason approved by the Administrator, installation of
separate COM3 is impossible, the owner or operator may install an
applicable COM3 on the stack to monitor the combined effluent.  If
this is done, our concern is that no circumvention of an
applicable opacity standard be permitted as a result of this
configuration.  Section 60.12 (Circumvention) of the General
Provisions explicitly prohibits "...the use of gaseous diluents to
achieve compliance with an opacity standard...."  To ensure that
the provisions of § 60.12 are complied with,  and that compliance
with the standard for clinker coolers is achieved (10% opacity),
this common stack must meet the more stringent opacity requirement
of 10%.  Whether the clinker cooler emissions are ducted directly
to the same stack as the kiln,  or to the preheater,  the 10%
standard still applies.

     Furthermore, § 60.13(i)(1-9) allows the Administrator to
consider approval of alternatives to any monitoring procedures or
requirements upon receipt of a written application from the
source.  This application may cite factors which interfere with
the accuracy of the monitoring system, may attempt to demonstrate
that the COM3 can be installed at an alternate location and still
provide accurate and representative measurements, or make an
argument for other alternative procedures, methods,  or
specifications.  Any such alternatives approved by the
Administrator for the COM3 on the clinker cooler must adequately
demonstrate compliance with the 10% standard for clinker coolers.

     Turning to a further point you made in your more recent
submittal, you believe that the effluent from the clinker cooler,
after entering the preheater, undergoes a physical and chemical
change, and therefore becomes part of the kiln effluent.  You feel
that, because of this transformation, effluent from the clinker
cooler becomes subject to the 20% opacity limit of the kiln, and
not the 10% opacity limit of the cooler.  As the above discussion
indicates, we do not agree with that interpretation, given, in
part, the need to ensure compliance with the clinker cooler
standard.  Please, note that the source may apply to EPA for an
alternative opacity limit under the provisions of § 60.11(e).
However, as noted above, the source should first explore
alternative monitoring methods which will enable direct monitoring
of the effluent from the clinker cooler prior to its introduction
into the preheater.

                                 H-3

-------
                                -3-

     To ensure consistency, this response has been reviewed by the
Emission Standards Division and the Office of Enforcement.  My
staff has also been in touch with your staff to discuss this
request.  I am also enclosing a copy of a 1989 letter from
Region IV which illustrates application of the COM3 requirements
in situations similar to this one.  Please contact Ken Malmberg of
my staff (FTS 382-2870) if you have any questions about this
memorandum.

Attachment

cc:  Roger Pfaff, Region IV
     Ed Buckner, Region VII
     Shirley Tabler, ISB, ESD  (MD-13)
     Ron Meyers, ISB, ESD  (MD-13)
     Justina Fugh, AED
     John Rudd, AED
     Peter Fontaine, AED
     Howard Wright, SSCD
                                  H-4

-------
                 UNITED STATES ENVIRONMENTAL PROTECTION AGENCY
                             WASHINGTON, D.C. 20460
                                 MAR  3-  1933
                                                                        OFFICE OF
                                                                     AIR AND RADIATION
MEMORANDUM

SUBJECT:   Guidance  for Utilization of Method 9 Data in Enforcement
           Activities

FROM:      John S. Seitz, Directed      _  _
           Stationary  Source Comp^i^ncST Divisiorf
           Office of Air Quality Manning and Stands

TO:        Roger 0.  Pfaff, Chief
           Air  Compliance Branch
           Air,  Pesticides and Toxics Management Division

     In a  July 28 letter to Region IV, North Carolina's Division of
Environmental  Management requested resolution of an apparent contradiction
between the preamble  for Method 9 that states "the accuracy of the method must
be taken into  account when determining possible violations of applicable
opacity standards"  and EPA's stated policy of not allowing or accreting an
error allowance when  documenting opacity violations.  This request was
forwarded  to SSCD attached to an October 27, 1988 Region IV memorandum that
provided three alternative options to EPA's present policy on error allowance.
In further discussions between our staffs, we were informed that this request
stems from an  enforcement action where a nonmetallic mineral processing plant,
during its performance test, exceeded the opacity standard established by the
NSPS Subpart 000.   Further investigation of the elevated levels of opacity
identified problems with the plant's sprayer system, which required corrective
action.

     A number  of different issues are raised by this case and need to be
addressed  one  by one. First, the NSPS standards are carefully developed from
a comprehensive program of research, source testing study, and analysis.
Establishing the opacity standard for Subpart 000 sources was typical of this
process.   OAQPS conducted a comprehensive study at nonmetallic mineral
processing plants to  determine the range of opacity readings during maximum
operation  using BDT.  The opacity levels at the tested plants were very low
and the resulting Subpart 000 opacity standard adequately takes into account
the observed variation in opacity readings.  Thus, even a marginal exceedance
of the standard is  a  strong indication of a control equipment, operation, or
maintenance problem which may require an enforcement remedy.  It should be
noted that opacity  standards are separately enforceable requirements and any
exceedance of  the standard can be the sole basis for an enforcement action.


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      In the, specific case of the North Carolina plant, according to  the
 information provided to SSCD,  it appears  the  process worked as  intended.  The
 performance test for the Subpart 000 source uncovered an opacity violation
 which,  on further investigation, showed equipment  failure which required
 correction, and an appropriate enforcement penalty.  Measurement error was not
 a  relevant issue in this case.

      The rationale for EPA's  basic policy of no automatic error allowance is
 underscored by the North Carolina case.   The  policy does not attempt to define
 exactly how to account for measurement error, but  states that adding
 measurement error to the standard is not  an appropriate method  for accounting
 for  error.   Further, arbitrarily eliminating  from  enforcement consideration
 all  marginal exceedances relaxes the standard without justification.  This
 brings  into question the original intent  of the standard, which is to require
 installation of properly designed,  well operated control equipment.  Clearly,
 this should not happen,  since  it undermines the standard and weakens our
 enforcement program.

      As for the three alternative policy  options proposed in your memorandum,
 they can not guarantee the elimination of measurement error.  Adopting any of
 them amounts to relaxing current opacity  standards.  Measurement error cannot
 be addressed by a blanket policy statement, but instead the opacity  observers
must conduct their duties in a systematic and reasonable way.

      The preferred approach  for accounting for measurement error is  to follow
 the  procedures for conducting  Method 9 observations described in the "Quality
 Assurance Handbook for Air Pollution Measurement Systems" (EPA-600/4-77-027b,
 1977) and to conduct followup  investigation whenever opacity exceedances are
 observed.   The Method 9  guidance materials suggest various ways to augment the
 visible emission observation if opacity values are in excess of the  standard.

      For example,  in marginal  violation situation, additional sets of readings
 over  longer time periods or  even on different days may be appropriate for
ensuring that the opacity exceedances  documented truly reflect  noncompliance
 rather  than measurement  error.   Finally,  enforcement officials must  exercise
 their technical judgement carefully in the final determination  of an
enforceable violation, which may be based on additional factors such as the
plant operating history  and  extent  and duration of excessive emissions.

      In summary,  there is no conflict  between EPA's policy of no direct error
allowance and the requirement  to account  for error in Method 9  observations.
EPA's policy prohibits dropping frcm consideration marginal opacity
exceedances soley because there may be error.  However, EPA does support use
of QA procedures and followup  investigation as legitimate methods for
accounting  for measurement error.   If  additional clarification  of our policy
 is needed,  please contact Ken Malmberg at 382-2870.
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     \          UNITED STATES ENVIRONMENTAL PROTECTION AGENCY
     §                      WASHINGTON. D.C. 20460
                                                                       OFFICE OF
                                                                    AIK AND RADIATION
MEMORANDUM

SUBJECT:  Subpart 300 Determination

FROM:     John  S. Seitz, Director
          Stationary Source Compliance Division
          Office of Air Quality Planning and Standards

TO:       Winston A. Smith, Director
          Air,  Pesticides and Toxics Management Division
          Region IV

     This is  in response to your October 24, 1988 memorandum on enforcing 4fl
C.F.R. 60.672(e) of the NSPS for nontnetallic minerals.  I will address each of
the issues you  raised under the action portion of your memorandum, and as Ken
Malmberg of my  staff has clarified with Paul Reinnerman.

     Safety of  our inspectors is of paramount importance when inspecting
sources.  If  an inspector feels he is compromising his safety by entering a
building like you describe, then he must not enter it.  This is a guiding
premise of our  entire field inspection program.

     Your more  substantive concern is with enforcing 60.612(9), because "some
buildings at  Subpart 000 facilities preclude entry because of safety
problems."  Apparently there is such a facility in Kentucky.  All NSPS
standards are designed to require compliance with applicable standards at
startup.  Facilities which are subject to NSPS requirements must be built so
they'are testable, or compliance with the standard cannot be determined.
Section 60.8  explicitly requires provision of safe access to sampling
platforms, for  example.

     Your memorandum states that, since seme VE is being discharged from the
building, entry to th« building must occur to determine which affected
facility is omitting the VE.  That is true, but to determine compliance with
the standard, the owner or operator must provide EPA with a means of gathering
the relevant  data.  The building itself, though providing an indication of a
VE violation, cannot thereby preclude followup to determine the source of
thos« emissions.
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     The owner  or  operator in this case may have to install a vent on each
affected facility  for  this purpose. As discussed in the Background
Information Document for  this Subpart  (EPA-450/3-83-001b, April, 1985),  the
owner or operator  has  several options  for determining compliance from affected
facilities.  Separation of emissions by construction of separate vents for
each affected facility is one of these options and should be considered  as a
means for assessing compliance.

     If entry to the building cannot occur, then opacity violations from
outside the building will suffice for  issuing an NOV.  If the building
encloses more than one effected  facility, our assumption will be that all  such
facilities are  in  violation.   It is up to the source to prove otherwise.

     For specific means of reading the opacity of emissions while  inside the
building, the alternatives discussed by Jack Farmer in an April 27, 1988
memorandum to Winston  Snith on this subject seon sufficient.

     Thank you for the opportunity to  respond to your questions.   I am sorry
for th« lateness of this  response.  Please call Ken Malmberg of my staff if
you have any questions.
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