Sec. 214.7. Oven doors

(a) Door leakage.

No more than 10 percent of all coke oven doors on a single battery including pusher side, coke side and chuck doors may emit visible emissions as measured in accordance with the procedure set forth in subdivision (b) of this section.

(b) For the purpose of determining compliance with subdivision (a) of this section, visible emissions are those emissions of any degree of opacity greater than zero, observed to be emanating from the oven doors of a battery. An inspection of the coke oven doors will consist of an observer or observers walking the length of a coke battery at a steady pace from a ground level position (25 to 100 feet from the battery). Each door (coke side, push side and chuck doors) is to be observed during the inspection for only that period of time necessary to determine whether or not there is a visible emission coming from the door. The observer will then shift his attention to the adjacent door, if possible, and check for emissions in the same manner. If a temporary machine obstruction occurs, blocking the view of one or more ovens, those oven(s) will be bypassed and the remaining doors on that side of the battery will be inspected. After the traverse on that side of the battery, the bypassed ovens and only those ovens will be reinspected. Compliance will not be determined if it is not possible to reinspect the blocked ovens. Where the inspector has reason to believe that emissions emanate from a leaking chuck door within a leaking oven door, the emissions will be counted as two leaks. The percentage of leaking doors will be calculated by the following equation:

Percentage of Leaking Doors =^A/_{B × C}

A = 100 × (number of leaking doors)

B = number of doors/oven

C = number of inservice ovens/battery

The number of doors/oven is normally three—pusher side, coke side and chuck. Compliance is determined for all doors in aggregate, not for each separate door type.

(c) Oven door maintenance.

Any person operating a by-product coke oven battery must implement the following work practices:

(1) Self-sealing coke oven doors.

(i) Each oven door will be inspected for visible emissions within one hour after the charge. A record will be made of any door leaking one hour after the charge.

(ii) Doors leaking one hour after the charge will be adjusted prior to the end of the second hour after the charge.

(iii) Each oven door leaking one hour after the charge will be reinspected for visible emissions two hours after the charge. A record will be made of any door leaking two hours after the charge.

(iv) Any door leaking two hours after each of two successive charges must be replaced with a repaired or rebuilt door prior to the next charge to that oven.

(v) An adequate supply of repaired and rebuilt doors will be maintained on site to allow the frequency of replacement necessary to comply with this section.

(vi) If a newly installed, rebuilt or repaired door leaks more than two hours after the charge, the door and jamb must be inspected when the door is next removed from the oven. If the door is found to be defective, it must be replaced with a repaired or rebuilt door to that oven as soon as it is reasonably possible, normally within two charges to that oven. If the door is not found to be defective, the jamb must be replaced as soon as it is reasonably possible.

(2) Luted doors.

(i) Luted doors leaking 15 minutes after the charge must be immediately reluted.

(ii) Doors that fail to seal after the first reluting must be recorded.

(iii) Leaks appearing after the first reluting must be reluted immediately.

(3) Chuck doors.

(i) Chuck doors must be inspected within one hour after the charge. A record must be made of any chuck door leaking one hour after the charge.

(ii) Chuck doors leaking one hour after the charge must be gasketed or luted, prior to the next charge to that oven.

(iii) If a freshly gasketed door is leaking one hour after the charge, the gasket or the oven door shall be replaced prior to the next charge to that oven.

(iv) If a luted chuck door is leaking one hour after the charge, it must be reluted.

(4) All doors and jambs will be cleaned completely prior to each charge.

(5) Records of inspections required by this section, including the names of inspectors, the date and time of each door inspection and ovens observed leaking must be maintained.

(6) Work practices other than the above may be substituted after approval by the commissioner.

(d) Work practice and maintenance plan.

Any person who owns a by-product coke oven battery must submit a proposed work practice and maintenance plan to the office which issued the certificate to operate for that source. The work practice and maintenance plan must be approved before the by-product coke battery may be operated. The plan must include:

(1) the name and title of the person responsible for oven door maintenance;

(2) the procedures to be followed to assure compliance with subdivision (c) of this section;

(3) the number of replacement doors and jambs kept on site for each battery; and

(4) the coal charging procedures.