Spellman High Voltage Electronics Corporation

Posted on August 3, 2015

Client: Spellman High Voltage Electronics Corporation
Location: Hauppauge, NY and Valhalla, NY
Project Type: New York State and Westchester County Air Permitting and Registration

Project Description

New York State Air Permitting and Registration, Happauge, New York

Spellman High Voltage Electronics Corporation (Spellman) is the world’s leading independent high voltage power supply, X-Ray generator and MONOBLOCK ® X-Ray source manufacturer. Spellman’s high voltage supplies are used in a vast array of applications serving the medical, industrial and scientific communities.Spellman building facility

Dvirka and Bartilucci Consulting Engineers (D&B) was retained by Spellman to complete an air emissions inventory of the Spellman facility located in Hauppauge, New York. The air emissions inventory was prepared in order to evaluate the current regulatory status of the facility and determine the appropriate permit/registration category of the facility in accordance with the New York State air quality regulations specified at 6 NYCRR Part 201.

The first step of the project included conducting a site visit to identify air emission sources and the nature of emissions of regulated air pollutants. As part of the site visit, D&B reviewed records and files that were used to calculate emissions from the facility. Based upon D&B’s site inspection, the following sources of regulated air pollutants were identified at the Spellman facility that could potentially require the facility to obtain an air permit/registration from the New York State Department of Environmental Conservation (NYSDEC):

• Primer Application
• Vacuum Chambers and Curing Ovens
• Wave Solder Process
• PC Board Cleaner
• SMT Oven
• Solder Pots
• Curing Ovens
• Exhaust Hoods
• Manual Soldering
• Oil Processing Systems
• Environmental Chamber
• Chemical Storage Cabinets
• Combustion Sources
• Plasma Etchmachine

D&B was able to classify many existing emissions sources at the facility as “exempt” or “trivial” under New York State regulation in order to minimize the number of emission points requiring permitting or registration, and thus minimize the associated operating fees. Based upon D&B’s review of the regulations versus the operations conducted at the facility, D&B was able to reduce the total number of emission points requiring permitting or registration to the following sources:

• Vacuum Chambers and Curing Ovens
• Wave Solder Process
• SMT Oven
• Solder Pots
• Curing Ovens
• Plasma Etch

Next, in order to calculate emissions from the Spellman facility, D&B utilized product usage data and other process related  information provided by Spellman. For combustion sources, D&B utilized the United States Environmental Protection Agency  (USEPA) AP-42 published emission factors and actual facility fuel usage provided by Spellman. However, due to some of the  unique emission sources at the facility such as Spellman’s plasma etch process, D&B was required to develop site-specific emissions estimates for several processes.

Potential and actual emission rates were calculated for particulate matter (PM/PM10), nitrogen oxides (NOx), carbon monoxide (CO), sulfur dioxide (SO2), volatile organic compounds (VOCs), lead, hazardous air pollutants (HAPs) and plasma etch gases.

Based on the results of the detailed emission inventory, D&B determined that the Spellman Hauppauge facility was eligible for an Air Facility Registration, the lowest permit category under New York State regulation. As a result, D&B prepared, submitted and supported the necessary NYSDEC Air Facility Registration application for the six nonexempt/nontrivial sources operated at the Spellman facility.

Westchester County and New York State Air Permitting and Registration, Valhalla, New Yorkmachine

Spellman High Voltage Electronics Corporation (SHVEC) operates a manufacturing facility in Valhalla, New York that, due to the processes operated, required air permitting from both the New York State Department of Environmental Conservation (NYSDEC) and the Westchester County Department of Health (WCDH). Dvirka and Bartilucci Consulting Engineers (D&B) was retained by SHVEC to prepare and support the required permit applications necessary to obtain the air permits and registrations required by these regulatory agencies.

The first step of the project involved the preparation of a detailed, comprehensive emissions inventory for the industrial  processes operated at the facility. These processes included two different epoxy potting and curing process, a dielectric oil potting process, and several support processes such as painting/coating, solvent cleaning and soldering stations. In order to complete the emissions inventory, D&B conducted a detailed site inspection to gather equipment and process data, emission point location information, product usage data, equipment dimensional data and other pertinent information. Since many of the processes operated at the facility were custom, site-specific processes, publicly available United States Environmental Protection Agency (USEPA) AP-42 emission factors were, in most cases, not applicable.

As a result, D&B was required to develop site-specific emission factors based upon process operating data (pressure, temperature, product composition), on-site measurements, engineering calculations and assumptions. In some cases, D&B coordinated with equipment and product manufacturer’s to obtain technical data pertaining to the processes in order to develop these emission rates.devices

Based upon the results of the detailed emissions inventory, it was determined that the facility was eligible to operate under a Minor Facility Registration to comply with NYSDEC air pollution control regulations. However, in order to comply with WCDH air pollution control regulations, a comprehensive application package was required to obtain Permits-to-Construct and Operate several emission points.

Typically, a facility is required to obtain a Permit-to-Construct (PTC) from the WCDH prior to actually installing an emission source. As a result, even though the processes were already installed at the facility, the County required SVHEC to first obtain PTCs for all the emission points. D&B prepared the detailed application package required by the WCDH in order to obtain these PTCs, which included, among other things, the following:

• WCDH Application Forms outlining facility and process specific information for each emission point, signed and certified by a licensed Professional Engineer (P.E.);
• NYSDEC Process, Exhaust or Ventilation System Application Forms (no longer utilized by NYSDEC, but adopted by WCDH) outlining facility and process specific information for each emission point, as well as emission rate information on an actual and potential basis, signed and sealed by a P.E.;
• WCDH Short Environmental Assessment Form
• Construction drawings for the emission sources and emission points prepared by the HVAC design professional;
• Engineer’s Report providing detailed descriptions of the emission sources and points operated at the facility, signed and sealed by a PE.;
• Material Safety Data Sheets (MSDS) for the products utilized in the various facility industrial processes;
• Detailed emission inventory with backup calculations, signed and sealed by a licensed P.E.;
• Air Quality Impact Analysis utilizing NYSDEC’s DAR-1 screening program to demonstrate that NYSDEC Short-Term or Annual Guideline Concentrations (SGCs and AGCs) would not be exceeded as a result of the project; and
• Detailed equipment information, including catalogue cuts and design specifications, for the emission sources and HVAC equipment.

D&B fully supported the permit during the detailed review conducted by the WCDH, providing any additional requested information, attending meetings with County personnel, and revising the application package as necessary to meet local requirements. Subsequent to receiving the PTCs from the County, D&B reviewed the documents for conformance to the permit application package.

Subsequent to receiving the PTCs from the County, D&B re-inspected the facility for conformance with the PTC application package, and submitted a Permit-to-Operate (PTO) application package to the WCDH.

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