DEPARTMENT OF 

ECOLOGY 

State of Washington 

PREVENTION OF SIGNIFICANT DETERIORATION (PSD) PERMIT 

Issued To: 

Facility Location: 

Permit Number: 

Date of Original Permit Issuance: 

Effective Date ofPermit: 

The Boeing Company 

Boeing Commercial Airplanes 

Everett Facility 

3003 West Casino Road 

Everett, Washington 98203 

PSD-14-01 

September 10, 2014 

September 10,2014 

1bis PSD permit is issued under the authority of the Washington State Clean Air Act, Chapter 

70.94 Revised Code of Washington; the Washington State Department of Ecology regulations 

for the Prevention of Significant Deterioration of Air Quality as set forth in Washington 

.Administrative Code 173-400-700 through 750; and the agreement for the delegation of the 

federal Prevention of Significant · by the United States Environmental 

Protection Agency to the Washington dated December 10, 2013. 

REVIEWED BY: 

Marc E. Crooks, P .E. 

Science and Engineering Section 

Air Quality Program 

APPROVED BY: 

Stuart A. Clark 

_ ..... _____ , . 

Air Quality Program Manager 

Washington State Department ofEcology 

Date 
ii

TABLE OF CONTENTS

PROJECT SUMMARY.................................................................................................................iii

APPROVAL CONDITIONS.......................................................................................................... 1

I. EFFECTIVE DATE OF PERMIT ................................................................................... 1

II. PERMIT EXPIRATION .................................................................................................. 1

III. PERMIT NOTIFICATION REQUIREMENTS .............................................................. 2

IV. EQUIPMENT RESTRICTIONS...................................................................................... 2

V. EMISSION LIMITS......................................................................................................... 4

VI. BACT EMISSION LIMITS............................................................................................. 5

VII. SPECIFIC OPERATING REQUIREMENTS ................................................................. 7

VIII. COMPLIANCE MONITORING REQUIREMENTS ................................................... 10

IX. RECORDKEEPING AND REPORTING REQUIREMENTS ..................................... 12

X. GENERAL RESTRICTIONS ON FACILITY OPERATIONS .................................... 13

XI. MALFUNCTION AND EXCESS EMISSIONS REPORTING.................................... 13

XII. RIGHT OF ENTRY ....................................................................................................... 14

XIII. TRANSFER OF OWNERSHIP..................................................................................... 15

XIV. ADHERENCE TO APPLICATION AND COMPLIANCE WITH OTHER 

ENVIRONMENTAL LAWS......................................................................................... 15

XV. APPEAL PROCEDURES.............................................................................................. 16

ACRONYMS AND ABBREVIATIONS..................................................................................... 17
iii

PROJECT SUMMARY

Boeing Commercial Airplane’s Everett facility (Boeing Everett) builds wide-body airplanes. 

Boeing Everett manufactures the model 747, 767, 777, and 787 airplanes. This manufacturing 

effort includes making the airplane cabin interior components for the Boeing 737, as well as for 

the 747, 767, 777, and 787. 

Boeing proposes to produce new models of the Boeing 777, hereafter referred to as the “777X”

models in this document. Production of the 777X is scheduled to begin in 2017. Delivery of the 

first 777X is targeted for 2020. As production of the 777X ramps up, production of the current 

777 models, hereafter referred to as “legacy 777s” in this document, will decrease. By the early 

to mid 2020s, production of the legacy 777 models is expected to be phased out. 

Certain components for the 777X wing will be made in Everett in a new building located on the 

Boeing Everett site. Final assembly of the 777X will occur in the same building where the 

legacy 777 models are currently assembled. 

The proposed project includes two phases. The first phase will transition production of legacy

777 models to 777X models. The second phase will increase the maximum production capacity 

and thereafter the production rate from the current rate of about 8.3 legacy 777s per month (or 

about 100 per year) to as many as 10.4 777X models per month (about 125 777X per year). 

Boeing requested Phase 1 to consist of two components:

1. The first component of Phase 1 will be to make the changes to the facility necessary to 

begin production of the 777X model while maintaining production of legacy 777 models 

at levels up to approximately 8.3 airplanes per month per existing approval under PSD 

Permit No. 11-01. The changes include constructing a new building to manufacture the 

components for the new composite wing and creating additional wing and airplane 

assembly capacity for the 777X within the existing buildings.

2. The second component of Phase 1 is an increase in 777X production capacity and rate to 

approximately 8.3 airplanes per month that corresponds with a decrease production of 

legacy 777 models to the point where eventually the facility will no longer produce 

legacy 777 models. During Phase 1, Boeing Everett does not plan to exceed a combined 

777 production rate (i.e., rate for legacy 777s plus 777Xs) of approximately 8.3 airplanes 

per month.

Phase 1 will include the following modifications at Boeing Everett to achieve a production 

capacity of 8.3 777Xs per month: 

1. Constructing a new building (Building 40-58) to fabricate 777X wing components.

2. Installing a new 777X wing spar build-up line in an existing building. 

3. Installing a new 777X wing assembly line in an existing building.

4. Installing a new 777X final assembly line in an existing building.
iv

5. Reconfiguring the existing legacy 777 final assembly line to accommodate final assembly 

of the 777X.

6. Constructing new 777X vertical fin spray booths and prep booths in an existing building. 

7. Changing existing tooling and equipment throughout the 777 factory to accommodate the 

larger 777X body sections and/or wings. 

Boeing requested Phase 2 be included in this permit. The second phase of this project will be to 

make further changes to the Boeing Everett facility with the intent of increasing the overall 777X 

production capacity. Phase 2 will make further changes to Boeing Everett to increase overall 

777X production capacity to up to about 10.4 airplanes per month. Phase 2 is tentatively 

scheduled to begin in 2021, and will involve additional tooling and equipment to increase the 

777X production capacity. For example, additional tape layup machines for fabricating wing 

panels might be installed in the wing component fabrication building, and include additional 

spray booths. 

A Prevention of Significant Deterioration (PSD) analysis was performed for the project for all 

pollutants to determine if any increase was above the “significance” level. The project will result

in a significant net emissions increase of volatile organic compounds (VOC). 

A full technical review of the project for VOC, including a Best Available Control Technology 

(BACT) analysis, and the project’s effect on national ambient air quality standards (NAAQS), 

PSD increments, visibility, soils, and vegetation, is required and included in a Technical Support 

Document (TSD) prepared by the Washington State Department of Ecology (Ecology) on July 

30, 2014. 

The emissions of other air pollutants not subjected to PSD review will be covered in the Puget 

Sound Clean Air Agency (PSCAA) Notice of Construction (NOC) approval for this project. 
Boeing Everett 777X Project Page 1 of 18

Permit No.: PSD-14-01 

Issued: September 10, 2014

APPROVAL CONDITIONS

Based on the PSD permit application submitted by Boeing on February 20, 2014, the additional 

information submitted on May 23, 2014, and the technical review performed by Ecology, 

Ecology finds that all requirements for issuance of this PSD permit have been satisfied. Ecology 

determined the application complete on June 23, 2014. Approval of the project is granted 

subject to the following conditions:

I. EFFECTIVE DATE OF PERMIT

In accordance with 40 CFR § 124.15 and § 124.19, and the Washington Administrative 

Code (WAC) 173-400-730(2)(c), the effective date of this PSD permit is one of the 

following dates: 

A. If no comments requesting a change in the preliminary determination were 

received: the date of issuance; or

B. If comments requesting a change in the preliminary determination were received: 

thirty (30) days after the applicant and the commenters receive the final 

determination; or

C. If a review of the final determination is requested pursuant to 40 CFR § 124.13 

and 40 CFR § 124.19 (see WAC 173-400-730(4)), the effective date of this permit

is suspended until such time as the review and any subsequent appeal against this

permit are resolved.

II. PERMIT EXPIRATION

Pursuant to 40 CFR § 52.21(r)(2) and WAC 173-400-730(5), and unless an extension is 

granted by Ecology prior to expiration, Boeing’s authorization to construct under this 

PSD permit expires as follows:

A. This permit expires, and re-permitting will be required before any further 

construction activity may occur, if:

1. Construction of Phase 1 has not commenced (as defined in 40 CFR § 52.2l

(b)(9)) within eighteen (18) months of the effective date of this permit; or

2. Construction of Phase 1 is discontinued for a period of eighteen (18) months 

or more; or 

3. Construction of Phase 1 is not completed within a reasonable time.

B. Phase 2 of this permit expires, and re-permitting will be required before any 

further construction activity occurs on the Phase 2 changes, if:
Boeing Everett 777X Project Page 2 of 18

Permit No.: PSD-14-01 

Issued: September 10, 2014

1. Construction of Phase 2 has not commenced (as defined in 40 CFR § 

52.21(b)(9)) within eighteen (18) months of December 1, 2021; or

2. Construction of Phase 2 is discontinued for a period of eighteen (18) months 

or more; or

3. Construction of Phase 2 is not completed within a reasonable time.

C. The expiration of Boeing’s authorization to continue construction of the Phase 2 

changes pursuant to Section II.B. does not affect Boeing’s authorization to 

continue construction the Phase 1 changes subject to all applicable requirements 

of this permit.

III. PERMIT NOTIFICATION REQUIREMENTS

A. Boeing’s requirements in this PSD permit to notify, report to, or acquire approval 

or agreement from “Ecology and/or the PSCAA” may be satisfied by providing 

such notification, reporting, or approval request to PSCAA if the conditions of 

this PSD permit have been incorporated into Boeing Everett’s Title V Air 

Operating Permit issued pursuant to 40 CFR Part 70 and Chapter 173-401 WAC.

B. Boeing must notify Ecology and PSCAA in writing or electronic mail of the date 

construction on the 777X project is commenced, postmarked or received no later 

than thirty (30) days after such date. 

C. By June 15 of each year, Boeing must submit to Ecology, in writing or electronic 

mail, an annual report containing a brief summary of the construction activities 

related to the 777X project that occurred during the previous calendar year. This 

reporting obligation shall end when Boeing submits a notification to Ecology, in 

writing or electronic mail, that all construction activities related to the 777X

project have been completed. This notification of completion shall contain a brief 

summary of any construction activities related to the 777X project that have not 

been included in a prior annual report. 

IV. EQUIPMENT RESTRICTIONS

This PSD permit authorizes the construction of the new and modified equipment 

associated with the 777X project, as listed in Table IV-1. However, Boeing may choose 

not to construct all the listed equipment.
Boeing Everett 777X Project Page 3 of 18

Permit No.: PSD-14-01 

Issued: September 10, 2014

Table IV-1. New and Modified Equipment Associated with the 777X Project

Unit ID Equipment Description

New or

Modified

WCF-2 Gas-fired heater for liquid nitrogen vaporization unit New

WCF-3a Gas-fired process heater for autoclave #1 New

WCF-3b Gas-fired process heater for autoclave #2 New

WCF-3c Gas-fired process heater for autoclave #3 New

WCF-4 Vacuum pump(s) servicing autoclaves New

WCF-6a Wing panel wash stall #1 New

WCF-6b Wing panel wash stall #2 New

WCF-6c Wing spar and stringer wash stall #1 New

WCF-6d Wing spar and stringer wash stall #2 New

WCF-7 Gas-fired plasma unit for treatment of wing panel stringers New

WCF-8a Up to two (2) Wing panel prep booth(s) (abrasive blast/sanding, solvent 

hand-wipe, edge seal) New

WCF-8b Wing spar prep booth (abrasive blast/sanding, solvent hand-wipe, edge 

seal) New

WCF-9a Wing panel spray booth #1 New

WCF-9b Wing panel spray booth #2 New

WCF-9d Wing panel spray booth #3 New

WCF-9c Wing spar spray booth New

WCF-10a Wing panel primer curing booth #1 New

WCF-10b Wing panel primer curing booth #2 New

WCF-10c Wing spar primer curing booth New

WCF-11 Small quantity paint mix booth New

WCF-12a Coating equipment cleaning booth #1 New

WCF-12b Coating equipment cleaning booth #2 New

WCF-14 Up to four (4) Wing spar seal booth(s) New

WBSP-1a Robotic wing spray booth for left hand wing Modified

WBSP-1b Robotic wing spray booth for right hand wing Modified

WBSP-2 Forward body section spray booth Modified

WBSP-3 Mid body section spray booth Modified

WBSP-4 Aft body section spray booth Modified

WBSP-6 Forward body section corrosion-inhibiting compound spray booth Modified

WBSP-7 Mid body section corrosion-inhibiting compound spray booth Modified

WBSP-8 Aft body section corrosion-inhibiting compound spray booth Modified

WBSP-10 Vertical fin hybrid laminar flow control prep booth New

WBSP-11a Vertical fin hybrid laminar flow control spray booth #1 New

WBSP-11b Vertical fin hybrid laminar flow control spray booth #2 New

WBSP-11c Vertical fin hybrid laminar flow control spray booth #3 New

AA-2a Wing stub spray coating enclosure #1 New

AA-2b Wing stub spray coating enclosure #2 Modified
Boeing Everett 777X Project Page 4 of 18

Permit No.: PSD-14-01 

Issued: September 10, 2014

Table IV-1. New and Modified Equipment Associated with the 777X Project

Unit ID Equipment Description

New or

Modified

F-1

Combustion equipment for comfort or process heating not otherwise 

identified elsewhere in this table; multiple units, most of which will be less 

than 5 MMBtu/hr, and all of which will be less than 10 MMBtu/hr

New

F-2a Up to nine (9) 2,750-kW diesel generators New

F-2b 750-kW diesel generator New

IRC-1a Adhesive spray booth #1 New

IRC-1b Adhesive spray booth #2 New

IRC-1c Adhesive spray booth #3 New

IRC-2 Paint spray booth New

IRC-3 Crushed core press New

V. EMISSION LIMITS

1. Consistent with requirements of 40 CFR § 52.21(j)(3), the following limitations apply 

to VOC emissions from the Boeing 777X project:

a. This permit hereby amends the VOC emission limit from wing cleaning and 

coating operations in the two 777 robotic wing laydown spray booths and the 

nonrobotic southwest wing laydown spray booth in Building 40-37 in Approval 

Condition IV.A3. of PSD-11-01 from 34 tons per year (tpy) to 59 tpy in any 

twelve (12) consecutive months and in Approval Condition IV.A.2. of PSD-11-01 

from 0.17 tons per wing to 0.24 ton per wing. 

b. This permit hereby amends the VOC emission limit from wing cleaning and 

coating operations in the two 777 robotic wing laydown spray booths and the 

nonrobotic southwest and southeast wing laydown spray booths in Building 40-37 

in Approval Condition IV.B of PSD-11-01 from 36.3 tpy to 61.3 tpy in any twelve 

(12) consecutive months. 

c. This permit hereby amends the 777 assembly operations VOC emission limit in 

Approval Condition 3.1 of PSD-91-06 from 238.8 tpy to 513 tpy in any twelve 

(12) consecutive months. For purposes of demonstrating compliance with 

Approval Condition 3.1 of PSD PSD-91-06, all 777X related production 

operations in Building 40-58 are considered part of 777 assembly operations. 

d. This permit hereby amends the Interiors Manufacturing VOC emission limit in 

Approval Condition 4 of PSD-05-02 from 205 tpy to 239 tpy in any (12) 

consecutive months. 
Boeing Everett 777X Project Page 5 of 18

Permit No.: PSD-14-01 

Issued: September 10, 2014

e. VOC emission from 777X wing component fabrication operations in Building 40-

58 must not exceed 1.73 tons per completed shipset of 777X wing components, on 

a 12-month rolling average. 

f. As used in this PSD permit, VOC means any compound defined as VOC in 40

CFR § 51.100(s).

2. Boeing Shall limit the increase in non-VOC criteria pollutant emissions resulting 

from the 777X project as follows:

NOx: 39 tpy

CO: 99 tpy

CO2e: 74,000 tpy

PM2.5: 9 tpy

3. Boeing Everett shall limit natural gas usage from the new 777X project combustion 

emission units listed in Table VI-1 below to 1,000,000 MMBtu per calendar year. 

The annual natural gas usage must be reported to PSCAA in writing or electronic 

mail, postmarked or received by June 15 of the following year.

VI. BACT EMISSION LIMITS

A. BACT for VOC Coatings Operations: 

For cleaning and coating operations in the new and modified 777X spray booths, 

prep booths, and seal booths, the Boeing Everett facility must comply with all 

applicable VOC emission standards of the Aerospace NESHAP in 40 CFR 63 

Subpart GG, as in effect on July 1, 2014. These requirements are described in 

more detail in Condition VII.A below. 

B. BACT for Natural Gas Operations: 

Boeing is required to use good combustion practices as BACT for VOC emissions 

from the proposed new natural gas combustion units listed in Table VI-1. 

Table VI-1. Proposed Natural Gas Combustion Units

10–50 MMBtu/hr

Unit ID (from Table IV-1) Description

WCF-3a Gas-fired process heater for autoclave #1

WCF-3b Gas-fired process heater for autoclave #2

WCF-3c Gas-fired process heater for autoclave #3

WCF-9a Space heating - wing panel spray booth #1
Boeing Everett 777X Project Page 6 of 18

Permit No.: PSD-14-01 

Issued: September 10, 2014

Unit ID (from Table IV-1) Description

WCF-9b Space heating - wing panel spray booth #2

WCF-9d Space heating – wing panel spray booth #3

WBSP-11a Space heating - vertical fin HLFC spray booth #1

WBSP-11b Space heating - vertical fin HLFC spray booth #2

WBSP-11c Space heating - vertical fin HLFC spray booth #3

5–10 MMBtu/hr

Unit ID (from Table IV-1) Description

F-1

Combustion equipment for comfort or process heating not otherwise 

identified elsewhere in this table; multiple units, most of which will 

be less than 5 MMBtu/hr, and all of which will be less than 10 

MMBtu/hr

WCF-2 Gas-fired heater for liquid nitrogen vaporization unit (if this option is 

chosen to supply autoclaves with nitrogen

WCF-10a Space heating - wing panel primer curing booth #1

WCF-10b Space heating - wing panel primer curing booth #2

2–5 MMBtu/hr

Unit ID (from Table IV-1) Description

WBSP-10 Space heating - vertical fin HLFC prep booth

WCF-9c Space heating - wing spar spray booth

WCF-8a Space heating - wing panel prep booth

WCF-14 Space heating - wing spar seal booth

<2 MMBtu/hr

Unit ID (from Table IV-1) Description

WCF-7 Gas-fired plasma unit for treatment of wing panel stringer

WCF-10c Space heating - wing spar primer curing booth

WCF-6a Space heating - wing panel wash stall #1

WCF-6b Space heating - wing panel wash stall #2

WCF-8b Space heating - wing spar prep booth

WCF-6c Space heating - wing spar and stringer wash stall #1

WCF-6d Space heating - wing spar and stringer wash stall #2
Boeing Everett 777X Project Page 7 of 18

Permit No.: PSD-14-01 

Issued: September 10, 2014

C. BACT for Emergency Generators:

This permit for the 777X project authorizes up to nine 2,750-kW diesel 

emergency generators for the autoclaves in Building 40-58, and one 750-kW 

diesel emergency generator for other emergency backup power needs in Building 

40-58. 

Boeing is required to meet the emergency generator requirements for VOC 

emissions contained in 40 CFR 60 Subpart IIII, Standards of Performance for 

Stationary Compression Ignition Internal Combustion Engines. These standards 

require emergency diesel engines of the size for the 777X project to comply with 

the Tier 2 emission standards for VOC emissions in 40 CFR 89.112, which are 

6.4 g/kWh for VOC and NOX combined. Compliance with the VOC emission 

standards will be determined by maintaining the engine according to 

manufacturer’s recommendation, and an EPA issued emissions certificate which 

certifies that the engine complies with EPA Tier 2 emission rates. The operating 

requirements for emergency stationary internal combustion engines are provided 

in 40 CFR 60, Subpart IIII, which limit non-emergency use of each engine to 100 

hours per year per engine. 

VII. SPECIFIC OPERATING REQUIREMENTS

A. For cleaning and coating operations in the new and modified 777X spray booths, 

prep booths, and seal booths, Boeing Everett must comply with all applicable 

VOC emission standards of the Aerospace NESHAP, 40 CFR Part 63, Subpart 

GG (as in effect on July 1, 2014), including but not limited to the following 

requirements, as applicable:

1. Cleaning solvent laden cloth, paper, or any other absorbent applicators used 

for cleaning will be deposited in bags or other closed containers upon 

completing their use to the extent required by 40 CFR § 63.744(a)(1). 

2. Fresh and spent cleaning solvents, except semi-aqueous solvent cleaners as 

defined in 40 CFR § 63.742 must be stored in closed containers to the extent 

required by 40 CFR § 63.744(a)(2). 

3. Conduct the handling and transfer of cleaning solvents to or from enclosed 

systems and other cleaning operation equipment that hold or store fresh or 

spent cleaning solvents in a manner that minimizes spills to the extent 

required by 40 CFR § 63.744(a)(3). 

4. Hand wipe cleaning solvents must comply with 40 CFR § 63.744(b): 

a. A VOC composite vapor pressure not greater than 45 mm Hg at 20°C; or 
Boeing Everett 777X Project Page 8 of 18

Permit No.: PSD-14-01 

Issued: September 10, 2014

b. The composition requirements in Table 1 of 40 CFR § 63.744.

5. To the extent required by 40 CFR § 63,744(d), when conducting flush 

cleaning operations subject to 40 CFR Part 63, Subpart GG (excluding those 

in which the cleaning solvents used either meet the composition requirements 

in Table 1 of 40 CFR § 63.744 or are semi-aqueous as defined in 40 CFR § 

63.742), Boeing shall empty the used cleaning solvent each time aerospace 

parts or assemblies, or components of a coating unit (with the exception of 

spray guns) are flush cleaned into an enclosed container or collection system 

that is kept closed when not in use or into a system with equivalent emission 

control. 

6. The VOC content level in primers and topcoats must meet the following 

requirements:

a. Exterior primers: Not greater than 5.4 lb VOC per gallon, as applied, less 

water and exempt solvents to the extent required by 40 CFR § 

63.745(c)(2).

b. All other primers: Not greater than 2.9 lb VOC per gallon as applied, less 

water and exempt solvents to the extent required by 40 CFR § 

63.745(c)(4).

c. Topcoats: Not greater than 3.5 lb VOC per gallon, as applied, less water 

and exempt solvents to the extent required by 40 CFR § 63.745(c)(4). 

7. To the extent required by 40 CFR § 63.745(f)(1), spray applied primers and 

topcoats for wings must be applied using High Volume Low Pressure 

(HVLP), electrostatic, or other spray coating application methods, as approved 

by Ecology and/or PSCAA as specified in Condition III.A., with a transfer 

efficiency equivalent to or greater than HVLP or electrostatic spray 

application methods.

8. To the extent required by 40 CFR § 63.744(c), spray guns and hoses will be 

cleaned by one or more of the methods specified below, or equivalent 

methods that are approved by Ecology and/or PSCAA as specified in 

Condition III.A:

a. Enclosed system to the extent required by 40 CFR § 63.744(c)(1):

i. Clean the spray gun in an enclosed system that is closed at all 

times except when inserting or removing the spray gun.

ii. Cleaning must consist of forcing solvent through the gun.
Boeing Everett 777X Project Page 9 of 18

Permit No.: PSD-14-01 

Issued: September 10, 2014

b. Non-atomized cleaning to the extent required by 40 CFR § 63.744(c)(2):

i. Clean the spray gun by placing cleaning solvent in the pressure 

pot and forcing it through the gun with the atomizing cap in 

place.

ii. No atomizing air is to be used.

iii. Direct the cleaning solvent from the spray gun into a vat, drum, 

or other waste container that is closed when not in use.

c. Disassembled spray gun cleaning to the extent required by 40 CFR § 

63.744(c)(3):

i. Disassemble the spray gun and clean the components by hand in 

a vat, which must remain closed at all times except when in use; 

or

ii. Soak the components in a vat, which must remain closed during 

the soaking period and when not inserting or removing 

components.

d. Atomized cleaning to the extent required by 40 CFR § 63.744(c)(4):

i. Clean the spray gun by forcing the cleaning solvent through the 

gun.

ii. Direct the resulting atomized spray into a waste container that is 

fitted with a device designed to capture the atomized cleaning 

solvent emissions.

B. In addition to complying with the VOC emission standards of the Aerospace 

NESHAP, 40 CFR Part 63, Subpart GG (as in effect on July 1, 2014), cleaning 

solvent for all cleaning and coating operations in the new and modified 777X 

spray booths, prep booths, and seal booths must comply with the following 

requirements:

1. All wing panel and wing spar cleaning solvents must be applied either 

manually or by low pressure applicators, except in the following situations:

a. Cleaning intricate surfaces;

b. Where access is limited to the extent that using a low pressure applicator 

is infeasible;
Boeing Everett 777X Project Page 10 of 18

Permit No.: PSD-14-01 

Issued: September 10, 2014

c. Use of a cleaning solvent that either meets the composition requirements 

in Table 1 of 40 CFR § 63.744 or meets the definition of a semi-aqueous 

cleaning solvent as defined in 40 CFR § 63.742 (as in effect on July 1, 

2014).

2. Solvent used for hand wiping inside of fuel cells, fuel tanks, and confined 

spaces must have a VOC composite vapor pressure not greater than 72 mm 

Hg at 20°C.

VIII. COMPLIANCE MONITORING REQUIREMENTS

A. Boeing must monitor compliance with Condition V.1.a. and V.1.b. by complying 

with the compliance monitoring requirements in Condition V.1.a. of PSD 11-01.

B. Boeing must monitor compliance with Condition V.1.c. by complying with the 

compliance monitoring requirements in Condition 15 of PSD 91-06.

C. Boeing must monitor compliance with Condition V.1.d. by complying with the 

compliance monitoring requirements in Condition 6 of PSD 05-02.

D. Beginning the first calendar month that production operations begin in Building 

40-58, Boeing must monitor compliance with Condition V.1.e. as follows: 

1. Quantify the amount of each VOC-containing material used in each calendar 

month in the 777X wing component fabrication operations in Building 40-58

and calculate the corresponding total consumption over the previous twelve 

(12) consecutive months. For this calculation, the amount of each VOCcontaining material used in the 777X wing component fabrication operations 

in Building 40-58 during the eleven (11) months prior to the first month in 

which production operations begin in building 40-58 will be considered zero.

2. Determine VOC content of each VOC-containing material from the 

corresponding Material Safety Data Sheets (MSDS) or other data supplied by 

the material’s manufacturer, or other method approved by Ecology and/or 

PSCAA.

3. Calculate the monthly VOC emissions from each VOC-containing material 

used in the 777X wing component fabrication operations in Building 40-58 

by multiplying the VOC content of each material as obtained in Condition 

VIII.D.2. by the amount of that material used during the month as obtained in 

Condition VIII.D.1, then sum the monthly total VOC-emissions from all VOC 

containing materials used over the previous twelve (12) consecutive months.

4. Quantify the total number of 777X wing component shipsets completed in 

Building 40-58 over the previous twelve (12) consecutive months. Verify 
Boeing Everett 777X Project Page 11 of 18

Permit No.: PSD-14-01 

Issued: September 10, 2014

compliance with Condition V.1.e. by dividing the twelve (12) consecutive 

month total VOC emissions as obtained in Condition VIII.D.3. by the total 

number of 777X wing component shipsets completed in Building 40-58.

5. Boeing may deduct from the total VOC emissions calculated:

a. Any VOCs that are included in the coating formulation as reactive 

components to the extent that they are incorporated into the final wing 

coating as verified by the coating’s manufacturer documentation.

b. Any VOCs recovered for reuse, recycling or disposal, or discharged from 

Boeing Everett to wastewater or solid waste, from materials used in the 

777X wing component fabrication operations in Building 40-58.

E. Beginning the first calendar month that any of the new and modified 777X spray 

booths, prep booths, or seal booths are first used, Boeing must monitor 

compliance with conditions VII.A.1. through VII.A.5., VII.A.7., VII.A.8., and 

VII.B by:

1. Conducting inspections of the work practice activities in the new and modified 

777X spray booths, prep booths, or seal booths at least once per calendar year.

2. Work practices will be randomly sampled during each inspection, and 

observed for consistency with permit requirements.

3. To monitor compliance with Condition VII.A.4.a. and VII.B.2., Boeing must 

determine, as applicable, each cleaning solvent’s VOC composite vapor 

pressure in accordance with:

a. 40 CFR § 63.750(b)(1) for single component solvents (as in effect on July 1, 

2014); or

b. The equation in 40 CFR § 63.750(b) (2) for blended solvents (as in effect on 

July 1, 2014).

4. To monitor compliance with Condition VII.A.4.b., Boeing must determine, as 

applicable, each cleaning solvent’s composition in accordance with 40 CFR § 

63.750(a) (as in effect on July 1, 2014) or by another method approved by 

Ecology and/or PSCAA.
Boeing Everett 777X Project Page 12 of 18

Permit No.: PSD-14-01 

Issued: September 10, 2014

F. Beginning the first calendar month that any of the new or modified 777X spray 

booths, prep booths, or seal booths are first used for cleaning and coating, Boeing 

must monitor compliance with Condition VII.A.6. by determining the VOC 

content (less water and exempt solvents) for each affected coating from the 

MSDS or other data supplied by the manufacturer, or by another method 

approved by Ecology and/or PSCAA as specified in Condition III.A.

G. Boeing must monitor compliance with Condition V.2 by complying with the 

requirements in WAC 173-400-720(4)(b)(iii)(D).

IX. RECORDKEEPING AND REPORTING REQUIREMENTS

A. Beginning the first calendar month that any of the 777X production begins, 

Boeing must keep the following records at the site (or electronically accessible at 

the site):

1. Number of 777X wing component shipsets completed in Building 40-58 in 

the previous twelve (12) consecutive month period.

2. The calculations and results pursuant to Condition VIII.D. 

3. An annually updated list of all VOC containing materials used in the 777X 

wing component fabrication operations in Building 40-58 within the 

immediate past twelve (12) months. For the purpose of this record, the 

immediate past twelve (12) moths shall not include any month prior to the 

month that production operation began in Building 40-58.

4. For material containing VOCs that were deducted as reactive VOCs, the 

manufacturer documentation verifying the quantity of reactive VOC 

incorporated into the final wing coating.

5. For VOCs that were deducted as waste, inventory records verifying the 

quantity of VOCs recovered for reuse, recycling or disposal, or discharged 

from Boeing Everett to wastewater or solid waste, from materials used in the 

777X wing component fabrication operations in Building 40-58.

B. Records must be retained for not less than five (5) years after their origination.

1. At a minimum, the most recent two (2) years of data must be retained onsite 

(or be electronically accessible at the site). The remaining three (3) years of 

data may be retained offsite.

2. Records must be available for inspection by Ecology and PSCAA within ten 

(10) days of request.
Boeing Everett 777X Project Page 13 of 18

Permit No.: PSD-14-01 

Issued: September 10, 2014

C. Beginning the first calendar year after 777X production operations begin in 

Building 40-58, Boeing must report in writing or electronic mail, postmarked or 

received by June 15 of each year, the following information to Ecology and/or 

PSCAA.

1. The types and corresponding monthly and rolling 12-month total quantities of 

VOC containing materials used in the 777X wing component fabrication 

operations in Building 40-58 for the previous calendar year.

2. The quantity of VOCs in the VOC containing materials reported.

3. For VOCs that were deducted, the monthly and rolling 12-month total 

quantity of reactive VOCs incorporated into the final coating for the previous 

calendar year.

4. For VOCs that were deducted, the monthly and rolling 12-month total 

quantity of VOCs recovered for reuse, recycling or disposal, or discharged 

from Boeing Everett to wastewater or solid waste, from materials used in the 

777X wing component fabrication operations in Building 40-58 for the

previous calendar year.

D. Boeing must keep records and submit reports with regard to Condition V.2 as 

specified in WAC 173-400-720(4)(b)(iii)(D).

X. GENERAL RESTRICTIONS ON FACILITY OPERATIONS

A. At all times, Boeing must, to the extent practicable, maintain and operate the 

777X spray and sealing booths, including any associated air pollution control 

equipment, in a manner consistent with good air pollution control practices for 

minimizing emissions.

B. Determination of whether acceptable operating and maintenance procedures are 

being used for the 777X spray and sealing booths will be based on information 

available to Ecology, PSCAA, EPA and/or their authorized representatives, which 

may include, but is not limited to, monitoring results, opacity observations, 

review of operating and maintenance procedures, and inspection of the source.

XI. MALFUNCTION AND EXCESS EMISSIONS REPORTING

A. Prior to incorporation of the conditions of this PSD permit into Boeing’s Title V 

Air Operating Permit issued pursuant to 40 CFR Part 70 and WAC 173-401, 

Boeing must report to Ecology and PSCAA, in writing or electronic mail, 

following the discovery of any malfunction of air pollution control equipment, 

process equipment, or of a process, which results in an increase in VOC emissions 
Boeing Everett 777X Project Page 14 of 18

Permit No.: PSD-14-01 

Issued: September 10, 2014

above the allowable emission limits of this permit, in accordance with WAC 173-

400-107 and the following conditions:

1. Boeing must notify Ecology and PSCAA, in writing or electronic mail, 

postmarked or received no later than thirty (30) days after the end of the 

month in which a malfunction is discovered, for any malfunction of air 

pollution control equipment, process equipment, or of a process, which results 

in an increase in emissions above the allowable emission limits of this permit. 

This notification must include a description of the malfunctioning equipment, 

process equipment or process, the date and time of the initial malfunction (if 

known), the period of time over which emissions were increased due to the 

malfunction, the cause of the malfunction (if known), the estimated resultant 

excess emissions, and the methods utilized to mitigate emissions and restore 

normal operations.

2. For purposes of this permit, “malfunction” means any failure of air pollution 

control equipment, process equipment, or of a process to operate in a normal 

manner.

B. After the conditions of this PSD permit have been incorporated into Boeing’s

Title V Air Operating Permit issued pursuant to 40 CFR Part 70 and WAC 173-

401, Boeing shall report to PSCAA the discovery of any malfunction of air 

pollution control equipment, process equipment, or of a process, which results in 

an increase in emissions above the allowable emission limits specified in this 

permit, pursuant to the deviation reporting requirements and, if applicable, 

pursuant to the unavoidable excess emissions reporting requirements of that Title 

V Air Operating Permit.

C. Compliance with the malfunction notification requirements, as applicable, will 

not excuse or otherwise constitute a defense to any violation of this PSD permit or 

any law or regulation such malfunction may cause.

XII. RIGHT OF ENTRY

Section 114 of the federal Clean Air Act, 42 U.S.C. § 7414, and the Revised Code of 

Washington (RCW) 70.94.200, and WAC 173-400-105(3) provide authorized 

representatives of EPA, Ecology, and PSCAA certain rights to enter and inspect the 

source. Refusal by Boeing to allow such entry and inspection may be a violation of the 

federal Clean Air Act and/or the RCW subject to penalty as provided in those statutes. 

Pursuant to these statutes, authorized representatives of EPA, Ecology, and PSCAA, 

upon the presentation of credentials:

A. Have a right of entry to, upon, or through any premises of Boeing or any premises 

in which any records this permit requires Boeing to maintain are located.
Boeing Everett 777X Project Page 15 of 18

Permit No.: PSD-14-01 

Issued: September 10, 2014

B. Have the right, at reasonable times, to access and copy any records this permit

requires Boeing to maintain.

C. Have the right, at reasonable times, to inspect any monitoring equipment or 

method required by this permit.

D. Have the right, at reasonable times, to sample any emissions that Boeing is 

required to sample under this permit.

XIII. TRANSFER OF OWNERSHIP

A. In the event of any changes in control or ownership of facilities to be constructed, 

this PSD permit will be binding on all subsequent owners and operators. The 

applicant must notify the succeeding owner and operator of the existence of this 

PSD permit and its conditions by letter, a copy of which must be forwarded to 

Ecology and/or PSCAA as specified in Condition III.A.

B. If the conditions of this PSD permit have been incorporated into Boeing Everett’s 

Title V Air Operating Permit issued pursuant to 40 CFR Part 70 and WAC 173-

401, then the provisions for amending that Title V Air Operating Permit to allow

for a change in ownership or operational control shall apply in place of the 

notification provisions in Condition XIII.A.

XIV. ADHERENCE TO APPLICATION AND COMPLIANCE WITH OTHER 

ENVIRONMENTAL LAWS

A. Pursuant to 40 CFR § 52.21(r) (1), Boeing must construct and operate the 

proposed emissions units in accordance with this PSD permit and the application 

on which this permit is based.

B. Pursuant to 40 CFR § 52.21(r)(3), this PSD permit shall not relieve Boeing of the 

responsibility to comply fully with applicable provisions of the State 

Implementation Plan and any other requirements under local, state, or federal law.

C. Any applicant who fails to submit any relevant facts or who has submitted 

materially incorrect relevant information in a permit application must, upon 

becoming aware of such failure, or incorrect submittal, promptly submit such 

supplementary facts or corrected information.

D. To the extent provided by 40 CFR § 52.12(c), for the purpose of establishing 

whether or not Boeing has violated or is in violation of any requirement of this 

permit, nothing in this permit shall preclude the use, including the exclusive use, 

of any credible evidence or information relevant to whether Boeing would have 

been in compliance with applicable requirements if the appropriate performance 

or reference test or procedure had been performed.
Boeing Everett 777X Project Page 16 of 18

Permit No.: PSD-14-01 

Issued: September 10, 2014

XV. APPEAL PROCEDURES 

This PSD permit, or any conditions contained in it, may be appealed to:

A. The Pollution Control Hearings Board (PCHB) as provided in Chapter 43.21B

RCW and Chapter 371-08 WAC; and/or

B. EPA's Environmental Appeals Board (EAB) as provided in 40 CFR § 124.13 and 

40 CFR § 124.19.
Boeing Everett 777X Project Page 17 of 18

Permit No.: PSD-14-01 

Issued: September 10, 2014

ACRONYMS AND ABBREVIATIONS

°C degrees Celsius

°F degrees Fahrenheit

ASTM American Society for Testing and Materials

BACT Best Available Control Technology

Boeing Everett The Boeing Company, Boeing Commercial Airplanes–Everett Facility

CFR Code of Federal Regulations

CEMS Continuous Emissions Monitoring System

CO carbon monoxide

CO2e carbon dioxide equivalents

EAB Environmental Appeals Board

Ecology Washington State Department of Ecology

EPA United States Environmental Protection Agency

gal gallon(s)

GHG greenhouse gases

H2SO4 sulfuric acid mist

HVLP High Volume Low Pressure

kW kilowatt

lb pound(s)

lb/hr pound(s) per hour

mm Hg millimeters of mercury column

MMBtu/hr million British thermal units per hour

MSDS Material Safety Data Sheet

NESHAP National Emission Standards for Hazardous Air Pollutants

NOX nitrogen oxides

NWCAA Northwest Clean Air Agency

O2 oxygen

PCHB Pollution Control Hearings Board

PM particulate matter

PM10 particulate matter less than 10 micrometers in diameter

PM2.5 particulate matter less than 2.5 micrometers in diameter 
Boeing Everett 777X Project Page 18 of 18

Permit No.: PSD-14-01 

Issued: September 10, 2014

ppm parts per million

ppmv parts per million by volume

ppmvd parts per million by volume on a dry basis

PSCAA Puget Sound Clean Air Agency

PSD Prevention of Significant Deterioration of Air Quality

RCW Revised Code of Washington

scf standard cubic feet

SCR selective catalytic reduction

tpy tons per year

ULSD ultra-low sulfur diesel

U.S.C. United States Code

VOC volatile organic compounds

WAC Washington Administrative Code