FG{ID}

FLEXIBLE GROUP CONDITIONS

Major Source – Existing or New Limited-Use

Red text identifies options. Select the option that applies to the source and change the text to black. Delete red text that does not apply and renumber conditions if necessary.

Blue text is guidance or notes on the use of the template. DELETE ALL BLUE TEXT PRIOR TO ISSUING THE FINAL PERMIT OR SUBMITTING IT WITH A PERMIT APPLICATION.

This template applies to both new and existing boilers and process heaters designed to burn solid, liquid, or gaseous fuels, but are limited to annual capacity factor or 10 percent or less. If a source that is an area source for HAPs gets a PTI that makes it a major source for HAPs and if the date of installation of the boiler(s) and process heater(s) is June 4, 2010 or earlier, this source is considered an existing source. If it was installed or reconstructed after June 4, 2010, then it is a new source.

Existing sources have 3 years to comply with the requirements of the Boiler MACT after becoming a major source per 40 CFR 63.7495(c)(2). New sources must comply with the Boiler MACT upon startup per 40 CFR 63.7495(c)(1).

Staff may create separate tables for new and existing units (ex. some units may need to do initial tune-ups while other units have already done it) or combine into one table (ex. all units have done their initial tune-up).

If this template is being used for an ROP Reopening or Renewal, AND the MACT conditions were established in a PTI, the appropriate footnotes which reference enforceability must be added to each applicable condition in the template.

Permit staff, if using in a PTI, change the UARs for R 336.1213(2)(d) and R 336.1213(3) to R 336.1205(1)(a) in SC II.1, SC VI.1, SC VI.2, SC VI.2(b), and SC VI.2(c).

DESCRIPTION

Requirements for (a/an; if only one unit) new/ existing/ new and existing (choose one) boiler(s) and process heater(s) at major sources of HAP emissions per 40 CFR Part 63, Subpart DDDDD (Boiler MACT) which qualify as “limited-use” units. “Limited-use boilers or process heaters” as defined in 40 CFR 63.7575 are designed to burn any amount of solid, liquid, or gaseous fuels and have a federally enforceable annual capacity factor of no more than 10 percent.

Emission Unit(s): {Site Specific List of Emission Units}

POLLUTION CONTROL EQUIPMENT

{Enter site specific pollution control equipment or NA}

I. EMISSION LIMIT(S)

NA

II. MATERIAL LIMIT(S)

Material	Limit	Time Period/ Operating Scenario	Equipment	Monitoring/ Testing Method	Underlying Applicable Requirement
Solid, liquid, or gaseous fuels	Annual capacity factor of 10% or less *	12-month time period as determined at the end of each calendar month	List each applicable emission unit in FG{ID}	SC VI.2	R 336.1213(2)(d), 40 CFR 63.7555(a)(3)

* This limit is to satisfy the federally enforceable capacity factor limit associated with the limited-use designation under 40 CFR 63.7575.

III. PROCESS/OPERATIONAL RESTRICTION(S)

OPTIONAL – Use the following condition only for existing areas sources that are now major or for new sources. Delete if not applicable (i.e. if they have the documentation to show that this has been completed) and renumber conditions appropriately. For existing sources that are now major, the DATE will be three years from the date the source becomes major. For new units, the DATE is five years after startup. If they have only existing units or only new units, you may delete the appropriate section of this condition.

The permittee must complete an initial tune-up as specified in SC III.3 by no later than DATE for (list existing units, if necessary) and no later than DATE for (list new units, if necessary). (40 CFR 63.7510(e))

ALWAYS INCLUDE

Each limited-use boiler and process heater must complete a tune-up every 5 years (no more than 61 months after the previous tune-up). If the limited-use boiler or process heater is not operating on the required date for tune-up, the tune-up must be conducted within 30 calendar days of startup. (40 CFR 63.7500(a)(1) and (c), 40 CFR 63.7515(d) and (g), 40 CFR 63.7540(a)(13))

The permittee shall conduct a tune-up of each limited-use boiler or process heater as specified in the following: (40 CFR 63.7540(a)(12))

As applicable, inspect the burner, and clean or replace any components of the burner as necessary. The permittee may perform the burner inspection any time prior to the tune up or may delay the burner inspection until the next scheduled or unscheduled unit shutdown (the permittee must inspect each burner at least once every 72 months). (40 CFR 63.7540(a)(10)(i) and (12))

Inspect the flame pattern, as applicable, and adjust the burner as necessary to optimize the flame pattern. The adjustment should be consistent with the manufacturer's specifications, if available. (40 CFR 63.7540(a)(10)(ii))

Inspect the system controlling the air-to-fuel ratio, as applicable, and ensure that it is correctly calibrated and functioning properly (the permittee may delay the inspection until the next scheduled unit shutdown). (40 CFR 63.7540(a)(10)(iii))

Optimize total emissions of CO. This optimization should be consistent with the manufacturer’s specifications, if available, and with any NOX requirement to which the unit is subject. (40 CFR 63.7540(a)(10)(iv))

Measure the concentrations in the effluent stream of CO in parts per million, by volume, and oxygen in volume percent, before and after the adjustments are made (measurements may be either on a dry or wet basis, as long as it is the same basis before and after the adjustments are made). Measurements may be taken using a portable CO analyzer. (40 CFR 63.7540(a)(10)(v))

At all times, the permittee must operate and maintain each existing limited-use boiler or process heater, including associated air pollution control equipment and monitoring equipment, in a manner consistent with safety and good air pollution control practices for minimizing emissions. Determination of whether such operation and maintenance procedures are being used will be based on information available to the Administrator that may include, but is not limited to, monitoring results, review of operation and maintenance procedures, review of operation and maintenance records, and inspection of the source. (40 CFR 63.7500(a)(3))

IV. DESIGN/EQUIPMENT PARAMETER(S)

NA

V. TESTING/SAMPLING

Records shall be maintained on file for a period of five years. (R 336.1213(3)(b)(ii))

Permit staff – CHANGE above UAR to R 336.1201(3) if using in a PTI.

NA

VI. MONITORING/RECORDKEEPING

Records shall be maintained on file for a period of five years. (R 336.1213(3)(b)(ii))

Permit staff – CHANGE above UAR to R 336.1201(3) if using in a PTI.

The permittee must keep fuel use records for the days each limited-use boiler or process heater was operating on a calendar month basis. (R 336.1213(3), 40 CFR 63.7525(k), 40 CFR 63.7555(a)(3))

The permittee must keep the following records: (R 336.1213(2)(d), 40 CFR 63.7555(a))

A copy of each notification and report that is submitted to comply with this subpart, including all documentation supporting any Initial Notification or Notification of Compliance Status or 5-year compliance report that the permittee submitted. (40 CFR 63.7555(a)(1))

Records of the actual heat input of fuel burned in each limited-use boiler or process heater on a monthly and 12-month time period as determined at the end of each calendar month. (R 336.1213(3))

For each calendar year, the permittee shall calculate the annual capacity factor at the end of each calendar month for each limited-use boiler or process heater. The annual capacity factor is the ratio between the actual heat input from fuel burned to the potential heat input to the boiler or process heater had it been operated for 8,760 hours during a 12-month time period at the maximum steady state design heat input capacity. (R 336.1213(2)(d), 40 CFR 63.7555(a)(2), 40 CFR 63.7575)

The permittee must keep a copy of the federally enforceable permit that limits the annual capacity factor to less than or equal to 10 percent and fuel use records for the days the boiler or process heater was operating. (40 CFR 63.7555(a)(3))

The permittee shall maintain on-site, and submit if requested by the AQD, the most recent 5-year periodic report containing the following information:

The concentrations of CO in the effluent stream in parts per million by volume, and oxygen in volume percent, measured at high fire or typical operating load, before and after the tune-up of the boiler or process heater. (40 CFR 63.7540(a)(10)(vi)(A))

A description of any corrective actions taken as a part of the tune-up. (40 CFR 63.7540(a)(10)(vi)(B))

The type and amount of fuel used over the 12 months prior to the tune-up, but only if the unit was physically and legally capable of using more than one type of fuel during that period. Units sharing a fuel meter may estimate the fuel used by each unit. (40 CFR 63.7540(a)(10)(vi)(C))

The permittee must keep the records in a form suitable and readily available for expeditious review. (40 CFR 63.7560(a))

The permittee must keep each record for 5 years following the date of each occurrence, measurement, maintenance, corrective action, report, or record. (40 CFR 63.7560(b))

The permittee must keep each record on site, or they must be accessible from on-site (for example, through a computer network), for at least 2 years after the date of each occurrence, measurement, maintenance, corrective action, report, or record. The permittee can keep the records off site for the remaining 3 years. (40 CFR 63.7560(c))

VII. REPORTING

Permit Staff – SC VII.1, 2, and 3, references to Rule 213 are ROP only. Remove before putting into a PTI. Renumber as appropriate.

1.	Prompt reporting of deviations pursuant to General Conditions 21 and 22 of Part A. (R 336.1213(3)(c)(ii))

2.	Semiannual reporting of monitoring and deviations pursuant to General Condition 23 of Part A. The report shall be received by March 15 for reporting period July 1 to December 31 and September 15 for reporting period January 1 to June 30. (R 336.1213(3)(c)(i))

3.	Annual certification of compliance pursuant to General Conditions 19 and 20 of Part A. The report shall be received by March 15 for the previous calendar year. (R 336.1213(4)(c))

If the permittee has switched fuels or made a physical change to the boiler or process heater and the fuel switch or physical change resulted in the applicability of a different subcategory, the permittee must provide notice of the date upon which the permittee switched fuels or made the physical change within 30 days of the switch/change. The notification must identify:

a.	The name of the owner or operator of the affected source, the location of the source, the boiler(s) and process heater(s) that have switched fuels, were physically changed, and the date of the notice. (40 CFR 63.7545(h)(1))

b.	The currently applicable subcategory under 40 CFR Part 63, Subpart DDDDD. (40 CFR 63.7545(h)(2))

c.	The date upon which the fuel switch or physical change occurred. (40 CFR 63.7545(h)(3))

OPTIONAL - use only if the source was recently an area source and has since become a major source or is a new source, otherwise delete and renumber as appropriately.

For the initial compliance demonstration for each boiler or process heater based on the timeframes specified in SC III.1, the permittee must submit the Notification of Compliance Status before the close of business on the 60th day following the completion of the initial boiler tune-up for all boiler or process heaters at the facility. The Notification of Compliance Status report must contain all the information specified below.

A description of the affected unit(s) including identification of which subcategories the unit is in, the design heat input capacity of the unit, a description of the add-on controls used on the unit to comply with 40 CFR Part 63, Subpart DDDDD, description of the fuel(s) burned, including whether the fuel(s) were a secondary material determined by the permittee or the EPA through a petition process to be a non-waste under 40 CFR 241.3, whether the fuel(s) were a secondary material processed from discarded nonhazardous secondary materials within the meaning of 40 CFR 241.3, and justification for the selection of fuel(s) burned during the compliance demonstration. (40 CFR 63.7545(e)(1))

b.	In addition to the information required in 40 CFR 63.9(h)(2), the notification of compliance status must include the following certification(s) of compliance, as applicable, and signed by a responsible official:

i.	“This facility completed the required initial tune-up for all of the boilers and process heaters covered by 40 CFR Part 63, Subpart DDDDD at this site according to the procedures in 40 CFR 63.7540(a)(10)(i) through (vi).” (40 CFR 63.7545(e)(8)(i))

ii.	Except for units that burn only natural gas, refinery gas, or other gas 1 fuel, or units that qualify for a statutory exemption as provided in section 129(g)(1) of the Clean Air Act, include the following: “No secondary materials that are solid waste were combusted in any affected unit.” (40 CFR 63.7545(e)(8)(iii))

OPTIONAL – use only if the source was recently an area source and has since become a major source or is a new source, otherwise delete. DATE should be the same date that is in SC III.1.

The permittee must submit the first 5-year compliance report covering the period beginning on DATE and ending on December 31, YEAR (5-years after DATE). The first 5-year compliance report must be submitted no later than March 15th following the end of the first reporting period. (40 CFR 63.7550(b)(1) and (2), 40 CFR 63.7550(b)(5))

ALWAYS INCLUDE

The permittee must submit boiler or process heater tune-up compliance reports to the AQD and must be submitted by March 15th of the year following the applicable 5-year period starting from January 1 of the year following the previous compliance report to December 31 of the 5th calendar year. Compliance reports must also be submitted to EPA using the Compliance and Emissions Data Reporting Interface (CEDRI) which is accessed through the EPA’s Central Data Exchange (CDX). If the reporting form is not available in CEDRI at the time the compliance report is due, a hardcopy of the compliance report shall be submitted to EPA Region 5. (40 CFR 63.7550(b), 40 CFR 63.7550(h)(3))

A compliance report must contain the following information: (40 CFR 63.7550(c)(1))

a.	Company and Facility name and address; (40 CFR 63.7550(c)(5)(i))

b.	Process unit information, emissions limitations, and operating parameter limitations; (40 CFR 63.7550(c)(5)(ii))

c.	Date of report and beginning and ending dates of the reporting period; (40 CFR 63.7550(c)(5)(iii))

d.	The total operating time during the reporting period; (40 CFR 63.7550(c)(5)(iv))

e.	Include the date of the most recent tune-up for each unit. Include the date of the most recent burner inspection if it was not done on a 5-year period and was delayed until the next scheduled or unscheduled unit shutdown; (40 CFR 63.7550(c)(5)(xiv))

f.	Statement by a responsible official with that official's name, title, and signature, certifying the truth, accuracy, and completeness of the content of the report. (40 CFR 63.7550(c)(5)(xvii))

See Appendix 8 Permit Staff: Remove if PTI since this is ROP only.

VIII. STACK/VENT RESTRICTION(S)

NA

IX. OTHER REQUIREMENT(S)

The permittee shall comply with all applicable provisions of the National Emission Standards for Hazardous Air Pollutants for Major Sources: Industrial, Commercial, and Institutional Boilers and Process Heaters as specified in 40 CFR Part 63, Subparts A and DDDDD. (40 CFR Part 63, Subparts, A and DDDDD)

If the permittee has switched fuels or made a physical change to the boiler or process heater and the fuel switch or physical change resulted in the applicability of a different subcategory, the permittee must demonstrate compliance within 60 days of the effective date of the switch, unless the compliance demonstration for this subcategory has been conducted within the previous 12 months. (40 CFR 63.7510(k))

Footnotes:

1 This condition is state only enforceable and was established pursuant to Rule 201(1)(b).

2 This condition is federally enforceable and was established pursuant to Rule 201(1)(a).