ENGINEERING EVALUATION REPORT

PLANT NAME DOE-KAO Sandia Labs

APPLICATION NUMBER 19112

PLANT NUMBER 290

DATE 11-13-2008

1. BACKGROUND

On October 24, 2007, a major revision to the Airborne Toxic Control Measure (ATCM) for 

Chromium Plating and Chromic Acid Anodizing became law in California. As a result, the permit 

conditions for the District chrome platers (there are no chromic acid anodizers operating in the 

BAAQMD) need to be revised to address these changes. Following is a listing of the sources 

involved and the current and revised condition numbers. The ATCM can be found at the following 

website: http://www.arb.ca.gov/toxics/atcm/chroatcm.pdf

Source Old Cond New Cond Bath Control Abatement-1 Abatement-2

77 5952 5952 Any Listed 

Surfactant

In Section

93102.8(a)

n/a n/a

District regulations allow the APCO to make changes of permit conditions, based on certain 

criteria, enumerated in Reg 2-1-403:

Permit Conditions: Except as to permit applications reviewed in accordance with

Section 2-1-311, the APCO may impose any permit condition that he deems

reasonably necessary to insure compliance with federal or California law or District

regulations. For any permit application which was reviewed as a ministerial project in

accordance with Section 2-1-311, the APCO shall only impose permit conditions as

set forth in the District's Permit Handbook for the type of source being permitted. The

APCO may require the installation of devices for measurement or analysis of source

emissions or ground-level concentrations of air contaminants.

The proposed condition changes are to ensure compliance with the Chrome Plating ATCM, 

revised 10-24-2007.

2. EMISSION CALCULATIONS

This facility is located more than 330 feet from the nearest sensitive receptor. Also the chrome 

plating tank is permitted to operate up to 46,000 amp-hr/yr. The ATCM allows facilities to operate 

at throughputs up to 50,000 amp-hr/yr using only a surfactant, if the facility is located more than 

330 feet from the nearest sensitive receptor. The permitted throughput level will not be increased 

though, since that would constitute an emission increase in this case. Therefore, we do not 

expect any change in the emission levels.

Basis Throughput, a-hr/yr Factor, mg/a-hr Emissions, lb/yr

Current 46,000 0.01 0.00101

Post-ATCM 46,000 0.01 0.00101
AN 19112/DOE-Sandia (Plant A290)

RE Frazier, P.E.

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Net Difference 0 0 0

3. CEQA

Since the change of conditions will result in a decrease in the permitted emission levels, this 

application is exempt from CEQA review per Reg 2-1-312.1.

4. BEST AVAILABLE CONTROL TECHNOLOGY

There is no change in emission levels, therefore BACT is not applicable.

5. EXEMPTIONS

There are no applicable exemptions.

6. OFFSETS

Offsets are not applicable, since emissions remain the same, therefore no offset triggers are 

exceeded.

7. TOXIC EVALUATION

Permitted emission levels remain static, therefore no toxic evaluation is required. Previous toxic 

risk evaluations have been conducted showing there are no significant risks to any member of the 

public from these operations. A previous risk evaluation showed risks to the MEI were less than 

10 in a million. Since there is no change in emissions, we do not expect risk levels to change.

8. STATEMENT OF COMPLIANCE

The purpose of revising the permit conditions is to ensure that the facility complies with the newly 

revised air toxic control measure.

9. CONDITIONS

The previous version of Condition 5952 is presented in this application, as is the revised Condition 

5952.

10. RECOMMENDATIONS

Issue a Change of Condition letter for the aforementioned sources, subject to the revised 

Condition 5952.

OLD CONDITION 5952

COND# 5952 --------------------------------------

 1) Throughput 
AN 19112/DOE-Sandia (Plant A290)

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 The total annual combined throughput at source S-77 shall

 not exceed 46,000 amp-hrs in any consecutive twelve month

 period. 

 2) Amp-hours of operation 

 To comply with the above condition, DOE-Sandia

 Laboratories shall keep and maintain monthly records of

 current applied to this source integrated over time, in

 units of ampere-hours. Ampere-hour records to be

 monitored using non-resettable amp-hour meter. Ampere-

 hour meter to be installed in a manner so as to prevent

 the operation of the bath rectifier without the

 simultaneous operation of the ampere-hour meter. 

 3) Abatement- Plating Bath Surface Tension 

 Source S-77 shall not be operated unless the plating bath

 is operated with a wetting-agent additive with bath

 surface tension not to exceed 45 dyne/cm. 

 4) Monitoring of Surface Tension - Frequency 

 To demonstrate compliance with condition 3, above,

 surface tension of source S-77 shall be monitored at a

 frequency of at least one time every 4,000 amp-hours of

 bath operation. 

 If after 40,000 amp-hours of rectifier operation, the

 surface tension monitoring results indicate no

 exceedances of the maximum surface tension standard

 identified in Condition 3, above, the monitoring

 frequency can be reduced to "at least one time every

 8,000 amp-hours of bath operation." 

 If further surface tension monitoring results indicate no

 exceedances of the maximum surface tension standard

 identified in Condition 3, above, after an additional

 40,000 amp-hours of operation, the monitoring frequency

 can be further reduced to "at least one time every 40,000

 amp-hours of bath operation". 

 5) Surface Tension Monitoring - Testing Methods 

 Surface tension testing shall be conducted as specified

 in EPA Method 306-B by the use of a stalagmometer or

 preciser tensiometer as directed by manufacturers

 instructions. Alternate test methods may also be used if

 the method has been appropriately validated using EPA

 Method 301, Appendix A, 40 CFR Part 63. 

 6) Initial Performance Testing - Required Records 

 In the process of conducting the initial performance
AN 19112/DOE-Sandia (Plant A290)

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 testing, the following records shall be kept: 

 a) Sampling and analysis procedures.

 b) Raw data sheets.

 c) Documentation of calculations.

 d) Source testing results. 

 7) Recordkeeping 

 DOE-Sandia Laboratories shall keep and maintain the

 following records associated with source S-77: 

 a) Performance test records.

 b) Operating throughput records (monthly, amp-hour

 throughput)

 c) Records of chemical additions to chrome plating bath.

 8) Reporting 

 DOE-Sandia Laboratories shall provide the BAAQMD with the

 following reports at the specified frequencies identified

 as follows: 

 a) Notification of initial compliance status: Within 90

 days of compliance performance test.

 b) Annual total throughput of chrome plating operation in

 ampere-hours: Submit on an annual basis as requested

 through the BAAQMD annual update program. 

 9) Retention of Records 

 DOE-Sandia Laboratories shall retain copies of all of the

 above required records and reports associated with the

 decorative chrome plating operation for a period of at

 least five years.

NEW CONDITION 5952

COND# 5952 --------------------------------------

 The owner/operator shall comply with the following

 Conditions for hexavalent chrome plating source S-77.

 Basis refers to either BAAQMD Regulations/Rules or

 California Code of Regulations, Title 17, Section 93102 -

 93102.16 and associated appendices, unless otherwise noted.

 Web address: http://www.arb.ca.gov/toxics/atcm/chroatcm.pdf

 1. Performance Standards 

 Throughput: The total annual throughput shall not

 exceed 46,000 ampere-hours in any consecutive 12-month

 period. [Basis: 93102.4(b)(1)] 

 2. Abatement 
AN 19112/DOE-Sandia (Plant A290)

RE Frazier, P.E.

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 Surface Tension: The owner or operator shall control

 hexavalent chrome emissions by the use of one of the

 following CARB-approved chemical fume suppressants,

 with the plating bath surface tension not to exceed the

 following values in dynes/centimeter specific to the

 chosen suppressant additive and surface tension test

 method. [Basis: 93102.8(a)&(b)] 

 Suppressant Name Stalagmometer Tensiometer

 (Manufacturer) (dynes/cm) (dynes/cm) 

 Benchbrite CR 1800 <40 <35

 (Benchmark Products) 

 Clepo Chrome <40 <35

 (MacDermid) 

 Fumetrol 140 <40 <35

 (Atotech U.S.A.) 

 HCA-6.2 <32 <28

 HCA-4 <32 <28

 (Hunter Chemical LLC) 

 3. Training 

 No later than October 24, 2009, and within every two

 calendar years thereafter, the owner or operator shall

 ensure that hexavalent chrome based plating operations

 (including environmental compliance/recordkeeping) are

 under the direction of the owner or operator or current

 employee who is onsite and has completed the ARB

 Compliance Assistance Training Course pertaining to

 chrome plating and chrome anodizing.

 [Basis: 93102.5(b)] 

 4. Housekeeping 

 The following housekeeping requirements shall be

 implemented to reduce potential hexavalent chrome

 fugitive emissions: [Basis: 93102.5(c)] 

 a) Chromic acid materials shall be stored in a closed

 container in an enclosed storage area. 

 b) Chromic acid materials shall be transported from

 storage to the bath in a closed container. 

 c) Any liquid or sold hexavalent chrome containing

 material that is spilled shall be contained or

 cleaned up within one hour after being spilled. 

 d) Dragout shall be minimized by: 
AN 19112/DOE-Sandia (Plant A290)

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 i. handling the plated parts so that chromic acid

 is not dripped outside the tank, and

 ii. installing splash guards at the tank to

 minimize overspray and to ensure that chrome

solution is returned to the tank. 

 e) Surfaces within the chrome storage area and the

 walkways and other areas potentially contaminated

 with hexavalent chrome, shall be cleaned at least

 one time every seven days by either HEPA vacuuming,

 damp cloth hand wiping, wet mopping, use of non-

 toxic dust suppressants or any other District-

 approved method. 

 f) Buffing, grinding or polishing areas shall be

 separated from the chrome plating operation by a

 physical barrier, which may include, but is not

 limited to vertical plastic strip curtains. 

 g) Chromium containing wastes generated as a result of

 any of the above housekeeping activities shall be

 stored, disposed of, recovered, or recycled using

 practices that minimize fugitive dust. 

 5. Monitoring 

 a) Each rectifier shall be hard-wired to a single non-

 resettable meter which records ampere-hours

 continuously during rectifier operation. Each

 ampere-hour meter shall be installed and maintained

 per manufacturer's specifications. The

 owner/operator shall record the total ampere-hours

 used during each month.

 [Basis: 93102.9(a), 93102.12(c)(1)] 

 b) Surface Tension monitoring: In order to

 demonstrate compliance with part 2, above, the

 surface tension shall be initially measured and

 recorded daily for 20 operating days. If there are

 no exceedance of the surface tension standard during

 the initial 20 operating day tests, the measurement

 frequency may be automatically extended to one time

 per calendar week of plating tank operation. If an

 exceedance occurs, the measurement frequency shall

 return to daily for 20 operating days, and weekly

 thereafter. [Basis: 93102.9(d), 93102.12(c)(4)] 

 Surface Tension Testing Methods: If using a

 Tensiometer, test method shall be EPA Method 306B.

 If using a Stalagmometer, test method is noted in

 Section 93102 Appendix 8, or as per written

 manufacturer instructions, or in any other District-

 approved procedure. [Basis: 93102.7(c)(3)] 

 6. Operation & Maintenance (O&M) Plan 
AN 19112/DOE-Sandia (Plant A290)

RE Frazier, P.E.

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 The owner/operator shall prepare an operation and

 maintenance plan for the chrome plating operation,

 which shall be retained onsite and made available for

 inspection upon request. Any revisions to the O & M

 Plan shall be documented in an addendum and all

 versions shall be maintained for a period of 5 years

 after each revision to the plan. The O&M Plan shall at

 a minimum include: 

 a) The inspection and maintenance requirements for the

 chrome plating bath, amp-hr meter(s)/totalizers,

 stalagmometer or tensiometer. [Basis: 93102.11] 

 b) A checklist to document the inspection, operation

 and maintenance for the chrome plating operation,

 including steps to be taken to correct operating

 deficiencies. [Basis: 93102.11] 

 7. Recordkeeping 

 The owner/operator shall maintain the following records

 for at least five years, with the most recent two years

 maintained onsite. 

 a) Inspection Records to demonstrate that such

 inspections were done in accordance with the

 provisions of Section 93102.10 and the O&M Plan.

 Such records can take the form of a checklist and

 shall identify the devices inspected, the date and

 time of the inspection, a brief description of the

 working condition and any corrective actions. 

 b) The owner/operator shall:

 [Basis: 93102.12] 

 i. Record the plating bath surface tension

 according to the testing frequencies noted

in Part 5.b), and

 ii. Record monthly and cumulative 12-month

 rectifier ampere-hour totals. 

 c) Breakdown Records noting the occurrence,

 duration, cause (if known), and action taken. 

 d) Records of excesses of the ampere-hour

 limitations of Part 1 or the surface tension

 limits of Part 2. 

 e) Housekeeping Records demonstrating compliance

 with Part 4, above, including date and time of

 housekeeping activity. 

 8) Reporting 
AN 19112/DOE-Sandia (Plant A290)

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 The owner or operator shall submit an annual compliance

 status report to the District [Compliance & Enforcement

 Division] on or before February 1, and shall include the

 following information for the preceding calendar year. 

 1. Company Information

 a.Facility Name & Plant Number:

 b.Facility Address:

 c.Facility Phone Number:

 d.Name of Owner or Operator

 e.Distance from chrome source to nearest receptor:

 2. Relevant Requirements:

 a.Maximum Ampere-Hour Limit:

 b.Surface Tension Limit to stay below:

 c.Mist Suppressant Additive Used:

 3. Actual cumulative ampere-hour usage on a month by

 month basis, for the calendar year reporting period.

 4. Actual annual hexavalent chrome emissions (lb/yr):

 Annual emissions = actual ampere-hours multiplied by

 0.02203, then divided by 1,000,000 = hex chrome

 emissions in lb/yr

 5. Summary of any excess emissions/exceeded monitoring

 parameters

 6. Were there any changes in monitoring, processes, or

 controls since the last reporting period? Yes No

 (circle the appropriate choice)

 If yes, provide a description of the changes. 

 Certifications: 

 1) I (name and title) certify that the

 inspection and maintenance requirements identified in the

 Operation and Maintenance Plan were or were not followed

 (circle the appropriate choice). If the requirements were

 not followed, provide an explanation, with a copy of the

 report required by Part 6(a) of this Condition. 

 2) I (name and title) certify that the

 following individuals have within the past 2 calendar years,

 completed a CARB-approved Environmental Compliance Training

 Program. 

 Name: Name: 

 Title: Title: 

 Name: 

 Title: 

 Report Certified by: 

 Title: 

 Date: