SOUTH COAST AIR QUALITY MANAGEMENT DISTRICT

RULE 1469 - HEXAVALENT CHROMIUM EMISSIONS FROM CHROME PLATING AND CHROMIC ACID ANODIZING OPERATIONS
(Adopted October 9, 1998)

(a) Applicability
This rule shall apply to each chromium electroplating or chromic acid anodizing tank at facilities performing hard chromium electroplating, decorative chromium electroplating, or chromic acid anodizing.

(b) Definitions
For the purposes of this rule, the following definitions shall apply:

  1. ADD-ON AIR POLLUTION CONTROL EQUIPMENT means equipment installed in the ventilation system of chromium electroplating and anodizing tanks for the purposes of collecting and containing chromium emissions from the tank(s).
  2. AIR POLLUTION CONTROL TECHNIQUE means any method, such as an add-on air pollution control equipment or a chemical fume suppressant, that is used to reduce chromium emissions from chromium electroplating and chromic acid anodizing tanks.
  3. AMPERE-HOURS means the integral of electrical current applied to a plating tank (amperes) over a period of time (hours).
  4. AREA SOURCE means any stationary source of hazardous air pollutants that is not a major source as defined in this rule.
  5. BASE METAL means the metal or metal alloy that comprises the workpiece.
  6. BATH COMPONENT means the trade or brand name of each component(s) in trivalent chromium plating baths, including the chemical name of the wetting agent contained in that component.
  7. BREAKDOWN means an unforeseeable impairment of an air pollution control equipment or related operating equipment which causes a violation of any emission limitation or restriction prescribed by this rule or by State law and which: is not the result of neglect or disregard of any air pollution control law, rule, or regulation; is not intentional or the result of negligence, or improper maintenance; is not a recurrent breakdown of the same equipment; and, does not constitute a nuisance as defined in the State of California Health and Safety Code, section 41700, with the burden of proving the criteria of this section placed upon the person seeking to come under the provisions of this law.
  8. CHEMICAL FUME SUPPRESSANT means any chemical agent that reduces or suppresses fumes or mists at the surface of an electroplating or anodizing bath; another term for fume suppressant is mist suppressant.
  9. CHROMIC ACID means the common name for chromium anhydride (CrO3).
  10. CHROMIC ACID ANODIZING means the electrolytic process by which an oxide layer is produced on the surface of a base metal for functional purposes (e.g., corrosion resistance or electrical insulation) using a chromic acid solution. In chromic acid anodizing, the part to be anodized acts as the anode in the electrical circuit, and the chromic acid solution, with a concentration typically ranging from 50 to 100 grams per liter (g/L), serves as the electrolyte.
  11. CHROMIUM ELECTROPLATING OR CHROMIC ACID ANODIZING TANK means the receptacle or container in which hard or decorative chromium electroplating or chromic acid anodizing occurs.
  12. COMPOSITE MESH-PAD SYSTEM means an add-on air pollution control equipment typically consisting of several mesh-pad stages. The purpose of the first stage is to remove large particles. Smaller particles are removed in the second stage, which consists of the composite mesh pad. A final stage may remove any reentrained particles not collected by the composite mesh pad.
  13. DECORATIVE CHROMIUM ELECTROPLATING means the process by which a thin layer of chromium (typically 0.003 to 2.5 microns) is electrodeposited on a base metal, plastic, or undercoating to provide a bright surface with wear and tarnish resistance. In this process, the part(s) serves as the cathode in the electrolytic cell and the solution serves as the electrolyte. Typical current density applied during this process ranges from 540 to 2,400 Amperes per square meter (A/m2) for total plating times ranging between 0.5 to 5 minutes.
  14. ELECTROPLATING OR ANODIZING BATH means the electrolytic solution used as the conducting medium in which the flow of current is accompanied by movement of metal ions for the purpose of electroplating metal out of the solution onto a workpiece or for oxidizing the base material.
  15. EMISSION LIMITATION means, for the purposes of this rule, the concentration of total chromium allowed to be emitted expressed in milligrams per dry standard cubic meter (mg/dscm), or the allowable surface tension expressed in dynes per centimeter (dynes/cm) for decorative chromium electroplating and chromic acid anodizing tanks; and the milligrams of hexavalent chromium per ampere-hour (mg/amp-hr) of electrical charge applied to the electroplating tank for hard chromium electroplating tanks.
  16. FACILITY means the major or area source at which chromium electroplating or chromic acid anodizing is performed and/or any source or group of sources or other air contaminant-emitting activities which are located on one or more contiguous properties within the District, in actual physical contact or separated solely by a public roadway or other public right-of-way, and are owned or operated by the same person (or by persons under common control), or an outer continental shelf (OCS) source as determined in 40 CFR Section 55.2. Such above-described groups, if noncontiguous, but connected only by land carrying a pipeline, shall not be considered one facility. Sources or installations involved in crude oil and gas production in Southern California Coastal or OCS Waters and transport of such crude oil and gas in Southern California Coastal or OCS Waters shall be included in the same facility which is under the same ownership or use entitlement as the crude oil and gas production facility on-shore.
  17. FIBER-BED MIST ELIMINATOR means an add-on air pollution control equipment that removes contaminants from a gas stream through the mechanisms of inertial impaction and Brownian diffusion. This equipment is typically installed downstream of another control device, which serves to prevent plugging, and consist of one or more fiber beds. Each bed consists of a hollow cylinder formed from two concentric screens; the fiber between the screens may be fabricated from glass, ceramic, plastic, or metal.
  18. FOAM BLANKET means the type of chemical fume suppressant that generates a layer of foam across the surface of a solution when current is applied to that solution.
  19. FRESH WATER means water, such as tap water, that has not been previously used in a process operation or, if the water has been recycled from a process operation, it has been treated and meets the effluent guidelines for chromium wastewater.
  20. HARD CHROMIUM ELECTROPLATING or INDUSTRIAL CHROMIUM ELECTROPLATING means a process by which a thick layer of chromium (typically greater than 1.0 microns) is electrodeposited on a base material to provide a surface with functional properties such as wear resistance, a low coefficient of friction, hardness, and corrosion resistance. In this process, the part serves as the cathode in the electrolytic cell and the solution serves as the electrolyte. Hard chromium electroplating process is performed at current densities typically ranging from 1,600 to 6,500 A/m2 for total plating times ranging from 20 minutes to 36 hours depending upon the desired plate thickness.
  21. HEXAVALENT CHROMIUM means the form of chromium in a valence state of +6.
  22. HIGH EFFICIENCY PARTICULATE ARRESTORS (HEPA) means filter(s) rated at 99.97 percent or more efficient in collection particle sizes 0.3 microns or larger.
  23. LARGE, HARD CHROMIUM ELECTROPLATING FACILITY means a facility that performs hard chromium electroplating and emits greater than or equal to 10 pounds per year (lbs/yr) controlled emissions of hexavalent chromium.
  24. LEAK means the release of chromium emissions from any opening in the emission collection system prior to exiting the emission control device.
  25. MAJOR SOURCE means any stationary source or group of stationary sources located within a contiguous area and under common control that emits or has the potential to emit considering controls, in the aggregate, 10 tons per year or more of any hazardous air pollutant or 25 tons per year or more of any combination of hazardous air pollutants.
  26. MAXIMUM CUMULATIVE POTENTIAL RECTIFIER CAPACITY means the summation of the total installed rectifier capacity associated with the hard chromium electroplating tanks at a facility, expressed in amperes, multiplied by the maximum potential operating schedule of 8,400 hours per year and 0.7, which assumes that electrodes are energized 70 percent of the total operating time. The maximum potential operating schedule is based on operating 24 hours per day, 7 days per week, 50 weeks per year.
  27. MECHANICAL FUME SUPPRESSANT means any device that reduces fumes or mist at the surfaces of an electroplating or anodizing bath by direct contact with the surface of the bath. Polyballs are the most commonly used mechanical fume suppressant.
  28. MEDIUM, HARD CHROMIUM ELECTROPLATING FACILITY means a facility that performs hard chromium electroplating and emits greater than 2 pounds per year (lbs/yr) but less than 10 pounds per year (lbs/yr) controlled emissions of hexavalent chromium.
  29. MODIFICATION means either:
    1. any physical change in, change in method of operation of, or addition to an existing permit unit that requires an application for a permit to construct and/or operate. Routine maintenance and/or repair shall not be considered a physical change. A change in the method of operation of equipment, unless previously limited by an enforceable permit condition, shall not include:
      1. an increase in the production rate, unless such increases will cause the maximum design capacity of the equipment to be exceeded; or
      2. an increase in the hours of operation; or
      3. a change in ownership of a source; or
    2. the addition of any new permit unit at an existing source; or
    3. the fixed capital cost of the replacement of components exceeding 50 percent of the fixed capital cost that would be required to construct a comparable new source.
  30. OPERATING PARAMETER VALUE means a minimum or maximum value established for a control device or process parameter which, if achieved by itself or in combination with one or more other operating parameter values, determines that an owner or operator is in continual compliance with the applicable emission limitation or standard.
  31. PACKED-BED SCRUBBER means an add-on air pollution control equipment consisting of a single or double packed-bed that contains packing media on which the chromic acid droplets impinge. The packed-bed section of the scrubber is followed by a mist eliminator to remove any water entrained from the packed-bed section.
  32. RESPONSIBLE OFFICIAL means one of the following:
    1. For a corporation: A president, secretary, treasurer, or vice president of the corporation in charge of a principal business function, or any other person who performs similar policy or decision-making functions for the corporation, or a duly authorized representative of such person if the representative is responsible for the overall operation of one or more manufacturing, production, or operating facilities and either:
      1. The facilities employ more than 250 persons or have gross annual sales or expenditures exceeding $25 million (in second quarter 1980 dollars); or
      2. The delegation of authority to such representative is approved in advance by the Administrator.
    2. For a partnership or sole proprietorship: a general partner or the proprietor, respectively.
    3. For a municipality, state, Federal, or other public agency: either a principal executive officer or ranking elected official. For the purposes of this part, a principal executive officer of a Federal agency includes the chief executive officer having responsibility for the overall operations of a principal geographic unit of the agency (e.g., a Regional Administrator of the U.S. Environmental Protection Agency [U.S. EPA]).
    4. For sources (as defined in this rule) applying for or subject to a Title V permit: "responsible official" shall have the same meaning as defined in District’s Regulation XXX.
  33. SMALL, HARD CHROMIUM ELECTROPLATING FACILITY means a facility that performs hard chromium electroplating and emits less than or equal to 2 pounds per year (lbs/yr) controlled emissions.
  34. SOURCE means any chromium electroplating or chromic acid anodizing operation and any equipment or materials associated with the selected associated air pollution control technique.
  35. STALAGMOMETER means a device used to measure the surface tension of a solution.
  36. SURFACE TENSION means the property, due to molecular forces, that exists in the surface film of all liquids and tends to prevent liquid from spreading.
  37. TANK OPERATION means the time in which current and/or voltage is being applied to a chromium electroplating tank or a chromic acid anodizing tank.
  38. TENSIOMETER means a device used to measure the surface tension of a solution.
  39. TRIVALENT CHROMIUM means the form of chromium in a valence state of +3.
  40. TRIVALENT CHROMIUM PROCESS means the process used for electrodeposition of a thin layer of chromium onto a base material using a trivalent chromium solution instead of a chromic acid solution.
  41. WEEKLY means at least once every seven calendar days.
  42. WETTING AGENT means the type of chemical fume suppressant that reduces the surface tension of a liquid.

(c) Requirements

    1. Hard Chrome Electroplating Operations
    During tank operation, each owner or operator of an existing, modified or new source shall control hexavalent chromium emissions discharged to the atmosphere from that source by reducing the hexavalent chromium emissions from the add-on air pollution control equipment serving the electroplating tank as identified below.

    Facility Size

    Controlled1

    Emissions (lb/yr)

    Requirement

        < 60 million amp-hrs 2

    > 60 million amp-hrs2

         

    Option 1

    Option 23

    Large > 10 lbs/yr < 0.006 mg/amp-hr < 0.006 mg/amp-hr < 0.006 mg/amp-hr

    Medium

    <10 lbs/yr but >2 lbs/yr < 0.03 mg/amp-hr < 0.006 mg/amp-hr < 0.03 mg/amp-hr

    and 0.015 mg/dscm

    Small

    < 2 lbs/yr < 0.15 mg/amp-hr < 0.03 mg/amp-hr < 0.15 mg/amp-hr

    and 0.015 mg/dscm

    Facility Size

    Controlled1

    Emissions (lb/yr)

    Requirement

        < 60 million amp-hrs2

    > 60 million amp-hrs2

    Large > 10 lbs/yr < 0.006 mg/amp-hr < 0.006 mg/amp-hr
    Medium/Small < 10 lbs/yr < 0.03 mg/amp-hr < 0.006 mg/amp-hr

    1 combined hexavalent or total chrome emissions from hard chrome plating operations

    2 maximum cumulative potential rectifier capacity or usage limit

    3 "Option 2" is an alternative emission limitation for small and medium facilities that elect to demonstrate compliance with both a mg/amp-hr and mg/dscm requirement.

    2. Decorative Chrome Electroplating and Chromic Acid Anodizing Facilities
    During tank operation, each owner or operator of an existing, modified, or new source shall control hexavalent chromium emissions discharged to the atmosphere by meeting either of the requirements identified below.

Method of compliance

Requirement

Add-on air pollution control equipment, or chemical fume suppressants forming a foam blanket, or mechanical fume suppressants (i.e. polyballs) < 0.01 milligrams per dry standard cubic meter of air (mg/dscm) (4.4x10-6 gr/dscf)
Chemical fume suppressants containing a wetting agent < 45 dynes per centimeter (dynes/cm) (3.1x10-3 pound-force per foot [lbF/ft])

    3. Decorative Chromium Electroplating Tanks Using a Trivalent Chromium Bath
    During tank operation, each owner or operator of an existing, modified, or new source shall control chromium emissions discharged to the atmosphere by meeting either of the requirements identified below.

Method of compliance

Requirement

Add-on air pollution control equipment, or chemical fume suppressants forming a foam blanket, or mechanical fume suppressants (i.e. polyballs) < 0.01 mg/dscm (4.4x10-6 gr/dscf)
Chemical fume suppressants containing a wetting agent Use wetting agent as bath ingredient and comply with recordkeeping and reporting provisions of paragraphs (h)(9) and (i)(5).

(d) Performance Test Requirements and Test Methods

  1. Performance Test Requirement
    Any source subject to the emission standards in subparagraph (c)(1)(A) or (c)(1)(B), or any source electing to comply with the mg/dscm emission standard in paragraphs (c)(2) or (c)(3) shall conduct a performance test to demonstrate compliance with the applicable emission standards within 180 days after initial startup.
  2. Use of Existing Performance Test
    A performance test conducted prior to July 24, 1997 may be used to demonstrate compliance provided the existing source test is approved by the Executive Officer and the U.S. EPA.
  3. Approved Test Methods
    1. Emissions testing shall be conducted in accordance with one of the following test methods:
      1. CARB Test Method 425, last amended July 28, 1997, (section 94135, Title 17, California Code of Regulations (CCR)); or
      2. U.S. EPA Method 306, (40 CFR 63 Appendix A) with a minimum of three test runs; or
      3. SCAQMD Method 205.1, for results reported as total chromium.
    2. Emissions testing from the cover of electroplating and anodizing tanks shall be conducted in accordance with Smoke Test to Verify the Seal Integrity of Covers Designed to Reduce Chromium Emissions from Electroplating and Anodizing Tanks procedures (See Appendix 5).
    3. Surface tension shall be measured in accordance with U.S. EPA Method 306B (40 CFR 63 Appendix A).
  4. Pre-Test Protocol
    Sources subject to the provisions of paragraph (d)(1), above, shall submit a pre-test protocol at least 60 days prior to conducting a performance test. The pre-test protocol shall include the performance test criteria of the end user and all assumptions, required data, and calculated targets for testing the source target chromium concentration, the preliminary chromium analytical data, and the planned sampling parameters. In addition, the pre-test protocol shall include information on equipment, logistics, personnel, and other resources necessary for an efficient and coordinated test.
  5. Emission Points Test Requirements
    Each emission point subject to the requirements of this rule shall be tested unless a waiver is granted by U.S. EPA and approved by the Executive Officer.

(e) Parameter Monitoring

  1. Ampere-hou
  2. Each tank or group of tanks shall have a continuous recording, non resettable, ampere-hour meter installed that operates on the electrical power lines connected to the tank or group of tanks. A separate meter shall be hard-wired for each rectifier.
  3. Pressure Drop
    The owner or operator shall continuously monitor the pressure drop across an add-on control device such as a composite mesh-pad (CMP), packed-bed scrubber (PBS), a CMP/PBS, fiber-bed mist eliminator, and a High Efficiency Particulate Arrestors (HEPA) filter with a mechanical gauge. The gauge shall be located so that it can be easily visible and in clear sight of the operation or maintenance personnel. The pressure drop shall be maintained within + 1 inch of water of the value established during the performance test to demonstrate compliance with the emission limitation for CMP, PBS, a CMP/PBS, and a fiber-bed mist eliminator. The pressure drop shall be maintained within –1/2 times to +2 times the inches of water of the value established during the performance test to demonstrate compliance with the emission limitation for HEPA filters.
  4. Inlet Velocity Pressure
    The owner or operator shall continuously monitor the inlet velocity pressure of a packed-bed scrubber with a mechanical gauge. The gauge shall be located so that it can be easily visible and in clear sight of the operation or maintenance personnel. The inlet velocity pressure shall be maintained within + 10 percent of the value established during the performance test to demonstrate compliance with the emission limitation.
  5. Surface Tension
    The owner or operator shall monitor the surface tension of the chrome plating or chromic acid anodizing tank that contains a wetting agent with either a stalagmometer or tensiometer using U.S. EPA Method 306B. The surface tension shall be maintained at or below the value required by paragraph (c)(2). Surface tension shall be measured daily for 20 operating days, and weekly thereafter as long as there is no violation of the surface tension requirement. If a violation occurs, the measurement frequency shall return to daily for 20 operating days, and weekly thereafter.
  6. Foam Blanket Thickness
    The owner or operator shall monitor the foam blanket thickness across the surface of the chrome plating or chromic acid anodizing tank. The foam blanket thickness shall be maintained consistent with the requirements established during the performance test to demonstrate compliance with the emission limitation. Foam thickness shall be measured hourly for 15 operating days, and daily thereafter as long as there is no violation of the foam thickness requirement. If a violation occurs, the measurement frequency shall return to hourly for 15 operating days, and daily thereafter.
  7. Polyballs or Similar Mechanical Fume Suppressants
    he owner or operator shall visually inspect the chrome plating or chromic acid anodizing tank for coverage comparable to the coverage during the performance test daily.

(f) Inspection and Maintenance Requirements

  1. Hard and decorative chrome electroplating, and chromic acid anodizing operations using add-on air pollution control equipment shall comply with the applicable inspection and maintenance requirements listed in Table 1.

    Table 1
    Summary of Inspection and Maintenance Requirements for Sources Using
    Add-on Air Pollution Control Devices

    Control Technique/Equipment

    Inspection and Maintenance Requirements

    Frequency

    Composite mesh-pad (CMP) system. 1. Visually inspect device to ensure that there is proper drainage, no unusual chromic acid buildup on the pads, and no evidence of chemical attack that affects the structural integrity of the device. 1. Once per quarter.
      2. Visually inspect back portion of the mesh pad closest to the fan to ensure there is no breakthrough of chromic acid mist. 2. Once per quarter.
      3. Visually inspect ductwork from tank to the control device to ensure there are no leaks. 3. Once per quarter.
      4. Perform washdown of the composite mesh-pads in accordance with manufacturer’s recommendations. 4. Per manufacturer.
    Packed-bed scrubber (PBS) 1. Visually inspect device to ensure there is proper drainage, no unusual chromic acid buildup on the packed-beds, and no evidence of chemical attack that affects the structural integrity of the device. 1. Once per quarter.
      2. Visually inspect back portion of the chevron blade mist eliminator to ensure that it is dry and there is no breakthrough of chromic acid mist. 2. Once per quarter.
      3. Same as number 3 above for CMP
    system.
    3. Once per quarter.
      4. Add fresh makeup water to the packed-bed A. 4. Whenever makeup is added.
    PBS/CMP system 1. Same as for CMP system 1. Once per quarter.
      2. Same as for CMP system 2. Once per quarter.
      3. Same as for CMP system 3. Once per quarter.
      4. Same as for CMP system 4. Per manufacturer.
    Fiber-bed mist eliminatorB 1. Visually inspect fiber-bed unit and prefiltering device to ensure there is proper drainage, no unusual chromic acid buildup in the units, and no evidence of chemical attack that affects the structural integrity of the devices. 1. Once per quarter.
      2. Visually inspect ductwork from tank or tanks to the control device to ensure there are no leaks. 2. Once per quarter.
      3. Perform washdown of fiber elements in accordance with manufacturer’s recommendations. 3. Per manufacturer.
    High Efficiency Particulate Arrestors filter (HEPA) 1. Look for changes in the pressure drop. 1. Once per week
      2. Replace HEPA filter. 2. Per manufacturers specifications or Districts requirement.
    Chrome Tank Covers 1. Drain the air-inlet (purge air) valves at the end of each day that the tank is in operation. 1. Once per day.
      2. Visually inspect access door seals and membranes for integrity. 2. Once per week.
      3. Drain the evacuation unit directly into the plating tank or into the rinse tanks (for recycle into the plating tank). 3. Once per week.
      4. Visually inspect membranes for perforations using a light source that adequately illuminates the membrane (e.g., Grainger model No. 6X971 Fluorescent Hand Lamp). 4. Once per month.
      5. Visually inspect all clamps for proper operation; replace as needed. 5. Once per month.
      6. Clean or replace filters on evacuation unit. 6. Once per month.
      7. Visually inspect piping to, piping from, and body of evacuation unit to ensure there are no leaks and no evidence of chemical attack. 7. Once per quarter.
      8. Replace access door seals, membrane evacuation unit filter, and purge air inlet check valves in accordance with the manufacturer’s recommendations. 8. Per manufacturer.
    Pitot tube Backflush with water, or remove from the duct and rinse with fresh water. Replace in the duct and rotate 180 degrees to ensure that the same zero reading is obtained. Check Pitot tube ends for damage. Replace Pitot tube if cracked or fatigued. Once per quarter.
    Ampere-hour meter Install and maintain per manufacturer’s specifications Per manufacturer.

    A Horizontal packed-bed scrubbers without continuous recirculation must add make-up water to the top of the packed-bed.

    B Inspection and maintenance requirements for the control device installed upstream of the fiber-bed mist eliminator to prevent plugging do not apply as long as the inspection and maintenance requirements for the fiber-bed unit are followed.

  2. Hard and decorative chrome electroplating, and chromic acid anodizing operations using chemical fume suppressants (i.e. wetting agent, foam) or mechanical fume suppressants (i.e., polyballs) shall comply with the applicable inspection and maintenance requirements in Table 2.

Table 2 - Summary of Inspection and Maintenance Requirements for Sources Using
Chemical or Mechanical Fume Suppressants

Equipment

Inspection and Maintenance Requirement for Monitoring Equipment

Frequency

Ampere-hour meter Install and maintain per manufacturer’s specifications Per manufacturer.
Stalagmometer/
Tensiometer
Calibrate and maintain per manufacturer’s specifications Per manufacturer.

(g) Operation and Maintenance Plan Requirements

  1. Operation and Maintenance Plan
    The owner or operator subject to the inspection and maintenance requirements of paragraph (f)(1) shall prepare an operation and maintenance plan. For major sources, the plan shall be incorporated by reference into the source's Title V permit. The plan shall incorporate the inspection and maintenance requirements for that device or monitoring equipment, as identified in Table 1 shall include the following elements:
    1. A standardized checklist to document the operation and maintenance of the source, the add-on air pollution control device, and the process and control system monitoring equipment; and
    2. Procedures to be followed to ensure that equipment is properly maintained.
  2. The owner or operator may use applicable standard operating procedure (SOP) manuals, Occupational Safety and Health Administration (OSHA) plans, or other existing plans, provided the alternative plans meet the requirements of this subdivision.
  3. Operation and Maintenance Plan Availability
    The owner or operator shall keep the written operation and maintenance plan on record after it is developed, to be made available for inspection, upon request.
  4. Operation and Maintenance Plan Modifications
    Any changes made by the owner or operator should be documented in an addendum to the plan. In addition, the owner or operator shall keep previous (i.e., superseded) versions of the operation and maintenance plan on record to be made available for inspection, upon request, for a period of 5 years after each revision to the plan.
  5. Breakdown Provisions In Operation and Maintenance Plan
    The operation and maintenance plan shall be revised as necessary to minimize breakdowns.

(h) Recordkeeping

  1. Inspection records for sources using add-on control air pollution control devices:
    The owner or operator shall maintain inspection records to document that the inspection and maintenance requirements of subdivision (f) and Table 1, and that the provisions of the operation and maintenance plan required by subdivision (g) have been met. The record can take the form of a checklist and should identify:
    1. the device inspected,
    2. the date and time of inspection,
    3. a brief description of the working condition of the device during the inspection,
    4. maintenance activities performed on the components of the air pollution control system (i.e. duct work replacement, filter pad replacement, fan replacement, etc.), and
    5. any actions taken to correct deficiencies found during the inspection.
  2. Inspection Records for Sources Using Chemical Fume Suppressants (i.e. wetting agent, foam) or Mechanical Fume Suppressants (i.e., polyballs).
    The owner or operator shall maintain inspection records to document that the inspection and maintenance requirement of paragraph (f)(2) and Table 2 have been met. The record can take the form of a checklist.
  3. Performance Test Records
    The owner or operator shall maintain test reports documenting the conditions and results of all performance tests.
  4. Monitoring Data Records
    The owner or operator shall maintain records of monitoring data required by subdivision (e) that are used to demonstrate compliance with the requirements of subsection (c) including the date and time the data are collected.
    1. Cumulative Rectifier Usage Records
      Record the actual cumulative rectifier usage expended during each month of the reporting period, and the total usage expended to date.
    2. Pressure Drop
      The owner or operator shall record the pressure drop once a week.
    3. Inlet Velocity Pressure
      The owner or operator shall record the inlet velocity pressure weekly.
    4. Surface Tension
      The owner or operator shall record the surface tension daily for 20 operating days, and weekly thereafter as long as there is no violation of the surface tension requirement. If the surface tension exceeds 45 dynes/cm, the owner or operator shall again record the surface tension daily for 20 operating days, and weekly thereafter.
    5. Foam Thickness
      The owner or operator shall record the foam thickness hourly for 15 operating days, and daily thereafter as long as there is no violation of the foam thickness requirement. If a violation occurs, the measurement frequency shall return to hourly for 15 operating days, and daily thereafter.
  5. Breakdown Records
    The owner or operator shall maintain records of the occurrence, duration, and cause (if known) and action taken on each breakdown.
  6. Records of Excesses
    The owner or operator shall maintain records of exceedances of: the emission limitations in subdivision (c), the monitoring parameter values established under subdivision (e), or any site-specific operating parameters established for alternative equipment. The records shall include the date of the occurrence, the duration, cause (if known), and, where possible, the magnitude of any excess emissions.
  7. Records Demonstrating Facility Size
    An owner or operator may demonstrate the size of a hard chromium electroplating facility through the definitions in subdivision (b). Alternatively, an owner or operator of a facility with a maximum cumulative potential rectifier capacity of 60 million amp-hr/yr or more may be considered small or medium if the actual cumulative rectifier usage is less than 60 million amp-hr/yr as demonstrated using either of the following procedures:
    1. Annual Actual Cumulative Rectifier Capacity
      Show by records that the facility's previous annual actual cumulative rectifier capacity was less than 60 million amp-hr/yr, by using nonresettable ampere-hour meters and keeping monthly records of actual ampere-hour capacity for each 12-month rolling period following the compliance date. The actual cumulative rectifier capacity for the previous 12-month rolling period shall be tabulated monthly by adding the capacity for the current month to the capacities for the previous 11 months; or
    2. Maximum Cumulative Potential Rectifier Usage Limit
      By accepting a limit on the maximum cumulative potential rectifier usage of a hard chromium electroplating facility through a Title V permit condition or a District operating permit condition and by maintaining monthly records in accordance with subparagraph (h)(4)(A) to demonstrate that the limit has not been exceeded.
  8. Records of Fume Suppressant Additions
    For sources using fume suppressants to comply with the standards, the owner or operator shall maintain records of the date, time, approximate volume, and product identification of the fume suppressants that are added to the electroplating or anodizing bath.
  9. Records of Trivalent Bath Components
    For sources complying with paragraph (c)(3) using trivalent chrome baths, the owner or operator shall maintain records of the bath components purchased, with the wetting agent clearly identified as a bath constituent contained in one of the components.
  10. New/Modified Source Review Information
    The owner or operator shall maintain records supporting the notifications and reports required by the District’s new source review provisions and/or subdivision (j).
  11. Records Retention
    All records shall be maintained for five years, at least two years on site.

(i) Reporting

  1. Performance Test Documentation
    1. Notification of Performance Test
      1. The owner or operator of a source shall notify the Executive Officer of his or her intention to conduct a performance test at least 60 calendar days before the performance test is scheduled.
      2. The provisions in clause (i)(1)(A)(i), above, do not apply if the performance test was conducted prior to July 24, 1997 and was approved by the Executive Officer and the U.S. EPA.
    2. Reports of Performance Test Results
      The owner or operator shall report performance test results to the Executive Officer. Reports of performance test results shall be submitted no later than 90 calendar days following the completion of the required performance test, and shall be submitted as part of the notification of compliance status required by paragraph (2) of this subsection.
    3. The content of performance test reports is identified in Appendix 1
  2. Initial Compliance Status Report
    An initial compliance status report is required each time that a source becomes subject to the requirements of this section. The owner or operator shall submit to the Executive Officer an initial compliance status report, signed by the responsible official who shall certify its accuracy, attesting to whether the source has complied with this rule.
    1. Initial Compliance Status Report Due Date
      1. For sources required to conduct a performance test, the initial compliance status report shall be submitted to the Executive Officer no later than 90 calendar days following completion of the compliance demonstration.
      2. For sources that are not required to complete a performance test, the initial compliance status report shall be submitted to the Executive Officer no later than 30 calendar days after the effective date of this rule for existing sources, or at start-up for new sources.
    2. The content of the initial compliance status report is identified in Appendix 2.
  3. Ongoing Compliance Status Reports
    The owner or operator shall submit a summary report to the Executive Officer to document the ongoing compliance status.
    1. Frequency of Ongoing Compliance Status Reports
      1. The report shall be submitted annually for major sources.
      2. The report shall be prepared annually and made available to the Executive Officer upon request for area sources.
    2. The content of ongoing compliance status reports is identified in Appendix 3.
  4. Reports of Breakdowns
    The owner or operator shall report breakdowns as required by District Rule 430.
  5. Reports Associated with Trivalent Chromium Baths Using a Wetting Agent
    Owners or operators with trivalent chromium baths using a wetting agent are not subject to paragraphs (1) through (3) of this subdivision, but shall instead submit the following reports:
    1. Sources Currently Using Trivalent Chrome
      No later than 30 calendar days after the effective date of this rule, the owner or operator shall submit a notification of compliance status that contains:
      1. The name and address of each source subject to this paragraph;
      2. A statement that a trivalent chromium process that incorporates a wetting agent will be used to comply; and
      3. The list of bath components that comprise the trivalent chromium bath, with the wetting agent clearly identified.
    2. Sources Changing to Trivalent Chrome
      Within 30 days of a change to the trivalent chromium electroplating process, a report that includes:
      1. A description of the manner in which the process has been changed and the emission limitation, if any, now applicable to the source; and
      2. The notification and reporting requirements of paragraphs (1), (2), and (3) of this subdivision, if the source complies with the emission limitation option, or paragraph (5) of this subdivision, if the source uses a wetting agent to comply. The report shall be submitted in accordance with the schedules identified in those paragraphs.
  6. Adjustments to the Timeline for Submittal and Format of Reports
    The Executive Officer may adjust the timeline for submittal of periodic reports, allow consolidation of multiple reports into a single report, establish a common schedule for submittal or reports, or accept reports prepared to comply with other state or local requirements. Adjustments shall provide the same information and shall not alter the overall frequency of reporting.

(j) New and Modified Sources

  1. Notification of Construction
    After the effective date of this rule no person may construct or modify a source, such that it becomes a source subject to this section, without submitting a notification of construction or modification to the Executive Officer and receiving approval in advance to construct or modify the source. The contents of the Notification of Construction shall include information as listed in Appendix 4.
  2. New Source Review Rules
    In lieu of complying with the requirements in paragraph (j)(1) of this subdivision, a facility may fulfill these requirements by complying with the District's new source review rule or policy, provided similar information is obtained.

(k) Procedure for Establishing Alternative Requirements

  1. Request Approval of an Alternative Requirement
    Any person may request approval of an alternative requirement. The person seeking such approval shall submit the proposed alternative requirement to the Executive Officer for approval. The request shall include the proposed alternative requirement, the reason for requesting the alternative requirement, and information demonstrating that the criteria for approval identified in Table 3 is met.
  2. Approval of an Alternative Requirement
    The Executive Officer may approve an alternative requirement if it determines that application of the alternative requirement meets the criteria for approval identified in Table 3 and the Executive Officer has submitted the proposed alternative requirements and has received concurrence from the applicable concurring agencies identified in Table 3.
  3. Approval Criteria
    Nothing in this subdivision prohibits the Executive Officer from establishing approval criteria more stringent that required in Table 3.
  4. Alternatives Already Approved by U.S. EPA
    Waivers for alternatives already approved by the U.S. EPA prior to the effective date of this rule shall remain in effect unless rescinded by U.S. EPA.

Table 3 - Requirements for Approval of Alternatives

Subdivision

Requirement

Criteria for Approval

Approving

Agency

Concurring

Agency1

(a)

applicability equivalent type and size of source regulated

District

U.S. EPA

(c)

standards equivalent emission reductions

District

U.S. EPA

(d)(1)

performance test requirement equivalent means of determining compliance

District

U.S. EPA

(d)(2)

use of existing performance tests overall existing tests provide a similar level of compliance assurance

District

U.S. EPA

(d)(3)

alternative test method provides a similar level of accuracy and precision

District

U.S. EPA/ARB

(d)(4)

amendments to the pre-test protocol equivalent means of determining compliance

District

U.S. EPA

(d)(5)

test all emission points equivalent means of determining compliance

District

U.S. EPA

(e)

parameter monitoring equivalent means of determining and assuring compliance

District

U.S. EPA

(f)

inspection maintenance requirements equivalent means of assuring compliance

District

U.S. EPA

(g)

operation and maintenance plans equivalent means of assuring compliance

District

U.S. EPA

(h)(1)-

(10)

recordkeeping equivalent means of assuring compliance

District

U.S. EPA

(h)(11)

retention of records assure historical records avail-able for up to 5 years

District

U.S. EPA

(i)

reporting equivalent means of assuring compliance

District

U.S. EPA

1 - U.S. EPA or the implementing agency in accordance with any delegation of authority to approve alternatives from the U.S. EPA,

(l) Exemptions

  1. This rule shall not apply to process tanks associated with a chromium electroplating or chromic acid anodizing process, but in which neither chromium electroplating nor chromic acid anodizing is taking place. Examples of such tanks include, but are not limited to, rinse tanks, etching tanks, cleaning tanks. Tanks that contain a chromium solution, but in which no electrolytic process occurs, are not subject to this rule. An example of such a tank is a chrome conversion coating tank where no electrical current is applied.
  2. The requirements of subdivisions (e), (f), and (g) do not apply to decorative chrome electroplating tanks using a trivalent chromium bath with a wetting agent.
  3. The requirements of subdivisions (c) and (g) do not apply during periods of equipment breakdown, provided the provisions of the District’s Rule 430 are met, notwithstanding subparagraph 430(b)(3)(B).

(m) Title V Permit Requirements

The owner or operator of a major source facilities subject to the requirements of this section is required to obtain a Title V permit from the District in accordance with the procedures set forth in District Regulation XXX.


Appendix 1 - Content of Performance Test Reports.

Performance test reports shall contain, at a minimum, the following information:

  1. A brief process description;
  2. Sampling location description(s);
  3. A description of sampling and analytical procedures and any modifications to standard procedures;
  4. Test results;
  5. Quality assurance procedures and results;
  6. Records of operating conditions during the test, preparation of standards, and calibration procedures;
  7. Original data for field sampling and field and laboratory analyses;
  8. Documentation of calculations; and
  9. Any other information required by the test method.

Note: Test reports consistent with the provisions of ARB Method 425 will fulfill the above performance test report content requirement.


Appendix 2 - Content of Initial Compliance Status Reports.

Initial compliance status reports shall contain, at a minimum, the following information:

  1. The applicable emission limitation and the methods that were used to determine compliance with this limitation;
  2. If a performance test is required, the test report documenting the results of the performance test, which contains the elements listed in Appendix 1;
  3. The type and quantity of hazardous air pollutants emitted by the source reported in mg/dscm or mg/hr for decorative and anodizing operations. (If the owner or operator is subject to the construction and modification provisions of subdivision (j) and had previously submitted emission estimates, the owner or operator shall state that this report corrects or verifies the previous estimate.) For sources not required to conduct a performance test, the surface tension measurement may fulfill this requirement;
  4. For each monitored parameter for which a compliant value is to be established under subdivision (e), the specific operating parameter value, or range of values, that corresponds to compliance with the applicable emission limit;
  5. The methods that will be used to determine continuous compliance, including a description of monitoring and reporting requirements, if methods differ from those identified in this section;
  6. A description of the air pollution control technique for each emission point;
  7. A statement that the owner or operator has completed and has on file the operation and maintenance plan as required by subdivision (g);
  8. If the owner or operator is determining facility size based on actual cumulative rectifier usage, records to support that the facility is small or medium. For existing sources, records from any 12-month period preceding the compliance date shall be used or a description of how operations will change to meet a small or medium designation shall be provided. For new sources, records of projected rectifier usage for the first 12-month period of tank operation shall be used;
  9. A statement by the owner or operator as to whether the source has complied with the provisions of this section.


Appendix 3 - Content of Ongoing Compliance Status Reports.

Ongoing compliance status reports shall, at a minimum, contain the following information:

  1. The company name and address of the source;
  2. An identification of the operating parameter that is monitored for compliance determination, as required by subdivision (e);
  3. The relevant emission limitation for the source, and the operating parameter value, or range of values, that correspond to compliance with this emission limitation as specified in the notification of initial compliance status required by Appendix 2;
  4. The beginning and ending dates of the reporting period;
  5. A description of the type of process performed in the source;
  6. The actual cumulative rectifier usage expended during the reporting period, on a month-by-month basis, if the source is a hard chromium electroplating tank;
  7. A summary of any excess emissions or exceeded monitoring parameters as identified in the records required by paragraph (h)(6);
  8. A certification by a responsible official that the inspection and maintenance requirements in subdivision (f) were followed in accordance with the operation and maintenance plan for the source;
  9. If the operation and maintenance plan required by subdivision (g) was not followed, an explanation of the reasons for not following the provisions, an assessment of whether any excess emissions and/or monitoring parameter excesses are believed to have occurred, and a copy of the record(s) required by paragraph (h)(1) documenting that the operation and maintenance plan was not followed;
  10. A description of any changes in monitoring, processes, or controls since the last reporting period;
  11. The name, title, and signature of the responsible official who is certifying the accuracy of the report; and
  12. The date of the report.


Appendix 4 - Notification of Construction Reports.

Notification of Construction reports shall contain the following information:

  1. The owner or operator's name, title, and address;
  2. The address (i.e., physical location) or proposed address of the source if different from the owner's or operator's;
  3. A notification of intention to construct a new source or make any physical or operational changes to a source that may meet or has been determined to meet the criteria for a modification;
  4. The expected commencement and completion dates of the construction or modification;
  5. The anticipated date of (initial) startup of the source;
  6. The type of process operation to be performed (hard or decorative chromium electroplating, or chromic acid anodizing);
  7. A description of the air pollution control technique to be used to control emissions, such as preliminary design drawings and design capacity if an add-on air pollution control device is used; and
  8. An estimate of emissions from the source based on engineering calculations and vendor information on control device efficiency, expressed in units consistent with the emission limits of this subpart. Calculations of emission estimates should be in sufficient detail to permit assessment of the validity of the calculations.

Note: A facility can fulfill these report content requirements by complying with the District's new source review rule or policy, provided similar information is obtained.


Appendix 5 - Smoke Test for Chrome Tank Covers.

SMOKE TEST TO VERIFY THE SEAL INTEGRITY OF COVERS DESIGNED

TO REDUCE CHROMIUM EMISSIONS FROM ELECTROPLATING AND ANODIZING TANKS

  1. Applicability and Principle
      1.1 Applicability. This alternative method is applicable to all hard chromium electroplating and anodizing operations where a chrome tank cover is used on the tank for reducing chromium emissions.
      1.2 Principle. During chromium electroplating or anodizing operations, bubbles of hydrogen and oxygen gas generated during the process rise to the surface of the tank liquid and burst. Upon bursting, tiny droplets of chromic acid (chromium mist) become entrained in the air above the tank. Because the chrome tank cover completely encloses the air above the tank, the chromium mist either falls back into the solution because of gravity or collects on the inside walls of the chrome tank cover and runs back into the solution. A semi-permeable membrane allows passage of the hydrogen and oxygen out of the chrome tank cover. A lit smoke device is placed inside the chrome tank cover to detect leaks at the membrane, joints, or seals.
  2. Apparatus
      2.1 Smoke device. Adequate to generate 500 to 1000 ft3 of smoke/20 ft2 of tank surface area (e.g., Model #1A=15 SECONDS from Superior Signal, New York).
      2.2 Small container. To hold the smoke device.
  3. Procedure
    Place the small container on a stable and flat area at center of the chrome tank cover (you can use a board and place it on the buss bars). Place the smoke device inside the container. After lighting the smoke device, quickly close the access door to avoid smoke from escaping. Let smoke device completely burn; entire space under the chrome tank cover will now be filled with the smoke. Observe for leaks of smoke from each seal, joint, and membrane of the chrome tank cover. Record these observations including the locations and a qualitative assessment of any leaks of smoke.

    When all seals, joints, and membranes have been observed, evacuate the unit to remove the smoke from the chrome tank cover.