Tenn. Comp. R. & Regs. 1200-03-18-.11 - AUTOMOBILE AND LIGHT-DUTY TRUCK COATING OPERATIONS

(1) Applicability of this rule is as follows:

(a) This rule applies to operations in Davidson, Hamilton, Knox, Rutherford, Shelby, Sumner, Williamson, and Wilson Counties.

(b) This rule applies to the following coating operations in an automobile or light-duty truck assembly plant: each prime coat operation, each electrodeposition (EDP) prime coat operation, each primer surfacer operation, each topcoat operation, and each final repair operation.

(c) Antichip coatings, as applied to automobile and light-duty truck components such as, but not limited to, rocker panels, the bottom edge of doors and fenders, and the leading edge of the hood or roof, are considered primer surfacers.

(d) Application to metal parts of underbody antichip coatings (e.g., underbody plastisol) and coatings other than prime, primer surfacer, topcoat, and final repair shall be subject to the requirements of Rule .20 of this chapter (Coating of Miscellaneous Metal Parts).

(e) The requirements in Paragraph (3) of this rule do not apply to automobile and light-duty truck assembly plants whose plant-wide, actual emissions without control devices are less than 6.8 kilograms (kg) (15 pounds [lb]) of volatile organic compounds (VOC's) per day.

(2) For the purpose of this rule, the following definitions apply:

(a) "Application area" means the area where a coating is applied by dipping or spraying.

(b) "Automobile and light-duty truck body" means the exterior and interior surfaces of an automobile or light-duty truck including, but not limited to, hoods, fenders, cargo boxes, doors, grill opening panels, engine compartment, all or portions of the passenger compartment, and trunk interior.

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

(d) "Final repair operation" means the application area(s), flashoff area(s), and oven(s) used to apply and dry or cure coatings that are used to repair topcoat on fully assembled automobile or light-duty truck bodies from a single assembly line.

(e) "Prime coat operation" means the application area(s), flashoff area(s), and oven(s) that are used to apply and dry or cure the prime coat on components of automobile and light-duty truck bodies on a single assembly line.

(f) "Primer surfacer operation" means the application area(s), flashoff area(s), and oven(s) that are used to apply and dry or cure primer surfacer between the prime coat and the topcoat operations on components of automobile and light-duty truck bodies on a single assembly line. The primer surfacer coat is also referred to as the "guidecoat".

(g) "Solids turnover ratio (R_T)" means the ratio of total volume of coating solids that is added to the EDP system in a calendar month divided by the total volume design capacity of the EDP system.

(h) "Topcoat operation" means the application area(s), flashoff area(s), and oven(s) used to apply and dry or cure topcoat on components of automobile and light-duty truck bodies on a single assembly line.

(i) "Topcoat protocol" means the EPA document "Protocol for Determining the Daily VOC Emission Rate of Automobile and Light-Duty Truck Topcoat Operations," EPA 450/3-88-018, December 1988, and as revised to include procedures for testing VOC emissions from primer surfacer operations and a procedure for calculating credit for spray booth control.

(j) "Volume design capacity" means for the EDP system the total liquid volume that is contained in the EDP system (tanks, pumps, recirculating lines, filters, etc.) at the system's designed liquid operating level. The EDP system volume design capacity is designated L . E

(3) Standards as follow apply:

(a) No owner or operator of an automobile or light-duty truck prime coat, EDP prime coat, or final repair operation subject to this rule shall cause or allow the application of any coating on that operation with VOC content, as applied, that exceeds the emission limits as follow:

1. 0.14 kilograms per liter (kg/L) (1.2 pounds per gallon [lb/gal]) of coating, excluding water and/or exempt compounds, as applied, from any prime coat operation.

2. 0.58 kg/L (4.8 lb/gal) of coating, excluding water and/or exempt compounds, as applied, from any final repair operation.

3. 0.17 kg/L (1.4 lb/gal) of coating solids from any EDP prime coat operation when the solids turnover ratio (R_T) is 0.16 or greater. R_T shall be calculated as

follows:

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where:

T_V = total volume of coating solids that is added to the EDP system in a calendar month (liters); and

L_E = volume design capacity of the EDP system (liters).

4. 0.17 x 350^{(0.160 - R T)} kg/L (1.4 x 350^{(0.160 - R} _T) lb/gal) of coating solids from any EDP prime coat operation when R_T is greater than or equal to 0.040 and less than 0.160.

5. When R_T is less than 0.040 for any EDP prime coat operation, there is no emission limit. When R is less than 0.040, the owner or operator shall comply T with the certification, recordkeeping, and reporting requirements in Subparagraph(8)(e) of this rule.

(b) For topcoat and primer surfacer operations:

1. No owner or operator of an automobile or light-duty truck topcoat operation or primer surfacer operation subject to this rule may cause or allow on any day emissions which exceed 1.8 kg/L (15.1 lb/gal) of solids deposited, or

2. In the alternative, no owner or operator of an automobile or light-duty truck topcoat or primer surfacer operation shall cause or allow the application of any topcoat or primer surfacer on that operation with VOC content in excess of 0.34 kilograms per liter (kg/L) (2.8 pounds per gallon [lb/gal]) of coating, excluding water and/or exempt compounds, as applied.

(c) As an alternative to compliance with the emission limits in Parts (3)(a)1 and 2 of this rule for prime coat and final repair operations, respectively, and Subparagraph (3)(b) of this rule for primer surfacer operations, an owner or operator may meet the requirements of Paragraph (4) or (5) of this rule.

(4) No owner or operator subject to this rule shall apply coatings in any nonelectrodeposition prime coat, final repair or primer surfacer operation, during any day, whose weighted average VOC content exceeds the applicable emission limits in Parts (3)(a)1 and 2 and Subparagraph (3)(b) of this rule.

(5) Control device requirements as follow apply:

(a) An owner or operator subject to this rule shall comply with the applicable emission limits for any prime coat, final repair, or primer surfacer operation by:

1. Installing and operating a capture system and a control device on that operation;

2. Determining for each day the overall emission reduction efficiency needed to demonstrate compliance. The overall emission reduction needed is the lesser of the value calculated according to the procedure in this chapter or 95 percent; and

3. Demonstrating each day that the overall emission reduction efficiency achieved is greater than or equal to the overall emission reduction efficiency required.

(b) An owner or operator subject to this rule shall ensure that:

1. A capture system and control device are operated at all times the coating operation is in use, and the owner or operator demonstrates compliance with this rule through the applicable coating analysis and capture system and control device efficiency test methods specified in this chapter; and

2. The control device is equipped with the applicable monitoring equipment specified in this chapter, and the monitoring equipment is installed, calibrated, operated, and maintained according to the vendor's specifications at all times the control device is in use.

(6) The following compliance procedures for EDP prime coat operations apply:

(a) For any EDP prime coat operation that does not comply with the emission limit in Part (3)(a)3 or 4 of this rule by using a capture system and control device to reduce emissions, the owner or operator shall use the procedures in 40 C.F.R. 60.393(c)(1) as of July 1, 1991, to determine compliance.

(b) The owner or operator shall use the procedures in 40 C.F.R. 60.393(c)(2) as of July 1, 1991, to determine compliance if a capture system and a control device that destroys VOC are used to comply with the emission limit in Part (3)(a)3 or 4 of this rule.

(c) The owner or operator shall use the procedures in 40 C.F.R. 60.393(c)(3) as of July 1, 1991, to determine compliance if a capture system and a control device that recovers the VOC are used to comply with the emission limit in Part (3)(a)3 or 4 of this rule.

(7)

(Reserved)

(8) The following recordkeeping and reporting requirements for prime coat and final repair operations apply:

(a) through (d) (Reserved)(e) An owner or operator of an automobile or light-duty truck EDP prime coat operation subject to this rule and complying with the requirements in Part (3)(a)3 or 4 of this rule shall:

1. By April 22, 1994, or upon startup of a new EDP prime coat operation, certify to the Technical Secretary that the coating line or operation is in compliance with the requirements in Parts (3)(a)3 or 4 of this rule. Such certification shall include:

(i) The name and location of the facility;

(ii) The address and telephone number of the person responsible for the facility;

(iii) Identification of subject sources; and

(iv) A copy of the calculations performed to determine R_T and the calculations performed pursuant to Paragraph (6) of this rule to demonstrate compliance for the EDP prime coat operation for the month prior to submittal of the certification.

2. On and after April 22, 1994, or on and after the initial startup date of a new EDP prime coat operation, collect and record the following information for each EDP prime coat operation. These records shall be maintained at the facility for at least 3 years and shall be made available to the Technical Secretary upon request:

(i) For each month, the total volume of coating solids that is added to the EDP system;

(ii) For each month, calculation of R_T using the equation in Part (3)(a)3 of this rule; and

(iii) For each month, the calculations used in the compliance determinations specified in Paragraph (6) of this rule.

3. On and after April 22, 1994, notify the Technical Secretary in the following instances:

(i) Any record showing noncompliance with the appropriate emission limit for the EDP prime coat operation; and

(ii) At least 30 calendar days before changing the method of compliance from one of the procedures in Paragraph (6) of this rule to another of the procedures in Paragraph (6), the owner or operator shall comply with the certification requirements in Part (8)(e)1 of this rule.

(9) The following recordkeeping and reporting requirements for topcoat and primer surfacer operations apply:

(a) An owner or operator of an automobile or light-duty truck coating operation subject to this rule and complying with Subparagraph (3)(b) of this rule shall comply with the following requirements:

1. At least 180 days prior to the initial compliance date, the owner or operator of a coating operation subject to the topcoat and primer surfacer limit shall have submitted to the Technical Secretary a detailed proposal specifying the method of demonstrating how the compliance test will be conducted according to the topcoat protocol.

2. The proposal shall include a comprehensive plan (including a rationale) for determining the transfer efficiency at each booth through the use of in-plant or pilot testing; the selection of coatings to be tested (for the purpose of determining transfer efficiency) including the rationale for coating groupings; and a method for tracking coating usage during the transfer efficiency test.

3. Upon approval by the Technical Secretary, the owner or operator may proceed with the compliance demonstration.

(b) The owner or operator shall maintain at the source for a period of 3 years or until a new test is performed all test results, data, and calculations used to determine VOC emissions from each topcoat and each primer surfacer operation according to the topcoat protocol.

(c) If control devices are used to control emissions from an automobile or light-duty truck topcoat or primer surfacer operation, the owner or operator shall maintain records according to Parts .03(5)(b)6 through 11 of this chapter.

(d) Any instance of noncompliance with the emission limit in Subparagraph (3)(b) shall be reported to the Technical Secretary within 30 calendar days.

Notes

Tenn. Comp. R. & Regs. 1200-03-18-.11

Original rule filed May 15, 1979; effective July 10, 1979. Amendment filed April 23, 1992; effective June 7, 1992. Repeal and new rule filed March 8, 1993; effective April 22, 1993.

Authority: T.C.A. §§ 4-5-202 and 68-201-105.