Name: Bert Valenkamph

Title: Director of Station Chemistry & Envir

Company: Northern Indiana Public Service Comp

Sign Date:

Name: Carl Vineyard

Title: Utility MACT Program Manager

Company: Grace Consulting, Inc.

Sign Date: 7/1/2010

Permitted Facility Representative / Date Testing Company Representative / Date

NIPSCO, Michigan City

Final Test Report 

for

/ /

Based on information and belief formed 

after reasonable inquiry, I certify that the 

statements and information in this test 

report are true, accurate, and complete.

I have reviewed all testing details and 

results in this test report and hereby 

certify that the test report is authentic 

and accurate.

Monday, February 07, 2011 Page 1 of 13
NIPSCO, Michigan City

Facility Information:

Michigan City Generating Station

Northern Indiana Public Service Company

101 Wabash Street

Michigan City IN 46360

Contact: Bert Valenkamph

Phone: 219-477-6265

Fax: 219-477-6269

Email: bcvalenkamph@nisource.com

Testing Company:

Grace Consulting, Inc.

510 Dickson Street

Wellington OH 44090

Contact:Carl Vineyard

Phone: 440-647-6672

Fax: 440-647-6673

Email: carlvineyard@aol.com

Air Permit Number:

997

Permitted Source ID/Name:

12 Michigan City

Permitted Maximum Process Rate: Max. Normal Operation Process Rate: Target Process Test Rate

Description of the source (including control equipment). Please see the attachments for source or

 process flow diagram:

Coal-fired, wet bottom cyclone boiler, with over-fire air Nox combustion control, with a cold side electrostatic 

precipitator, without flue gas conditioning, for control of particulate matter, and a selective catalytic reduction system 

for post-combustion Nox control.

Industry/SCC/NAIS 221112

Sampling Location Information:

Test Parameter Information:

AFS #: 1809100021 FRS #: 110000592154

SCC / Description 10100223 External Combustion Boilers - Electric Generation - Bituminous/Subbituminous 

Coal - Cyclone Furnace (Subbituminous Coal) 

The following state and federal regulations that apply to the proposed testing:

Location

Round

Duct

Diam.

Distance from 

upstream dist.

Distance from

downstream dist.

Number of

Traverse Ports

Equiv. 

Diam

Min.Travers 

Points

Rect. Duct 

Length /Width

Unit 12 Stack 251.04 0 0 0 1688 3528 4 12

Target

Parameter 

Test

Method

Number of

Test Runs

Test Run

Duration

Sample 

Location Points Comments

Filterable Particulate OTM - 27/28 3 120 0 Run 1 360 min, Runs 

2 & 3 were 120 mins. 

See repsonce to 

question 8.

Unit 12 Stack

Filterable PM2.5 OTM - 27/28 3 120 0 Run 1 360 min, Runs 

2 & 3 were 120 mins. 

See repsonce to 

question 8.

Unit 12 Stack

Monday, February 07, 2011 Page 2 of 13
NIPSCO, Michigan City

The following describes any modifications and/or deviations to the applicable test 

methods. If alternative methods were requested, see the attachments for documentation 

of request AND approval, including dates.

OTM 27/28: The cyclone for PM 2.5 was plugged after 3 hours and a second cyclone and filter was used to complete 

the test run. This was discussed with Peter Westlin of USEPA and a shorter sample time that would allow the test to 

be completed with one cyclone and filter set was approved per Westlin. This took place on 3/10/2010. This is 

consistant with the EPA's answer to FAQ Test 022, where it states "the 3.4 m3 of sample is the more critical of the 

two sampling duration factors in establishing conditions that would provide us with the ability to determine detectable 

levels of metals and PM fine emissions". Our test durations are commented in Question 7A of this ERT.

Total Particulate OTM - 27/28 3 120 0 Run 1 360 min, Runs 

2 & 3 were 120 mins. 

See repsonce to 

question 8.

Unit 12 Stack

Total PM2.5 OTM - 27/28 3 120 0 Run 1 360 min, Runs 

2 & 3 were 120 mins. 

See repsonce to 

question 8.

Unit 12 Stack

Inorganic (Aqueous) 

Condensible Part.

OTM - 27/28 3 120 0 Run 1 360 min, Runs 

2 & 3 were 120 mins. 

See repsonce to 

question 8.

Unit 12 Stack

Organic Condensible 

Particulate

OTM - 27/28 3 120 0 Run 1 360 min, Runs 

2 & 3 were 120 mins. 

See repsonce to 

question 8.

Unit 12 Stack

Unit 12 Stack Beryllium Method 29 3 240 0

Unit 12 Stack Arsenic Method 29 3 240 0

Unit 12 Stack Filterable Particulate Method 29 3 240 0

Unit 12 Stack Cadmium Method 29 3 240 0

Unit 12 Stack Chromium Method 29 3 240 0

Unit 12 Stack Cobalt Method 29 3 240 0

Unit 12 Stack Lead Method 29 3 240 0

Unit 12 Stack Manganese Method 29 3 240 0

Unit 12 Stack Nickel Method 29 3 240 0

Unit 12 Stack Phosphorus (yellow or white) Method 29 3 240 0

Unit 12 Stack Selenium Method 29 3 240 0

Unit 12 Stack Antimony Method 29 3 240 0

Unit 12 Stack Co2 Method 3A CO2 3 240 0

Unit 12 Stack O2 Method 3A O2 3 240 0

Monday, February 07, 2011 Page 3 of 13
NIPSCO, Michigan City

Sampling / Stack Data Results Summary

Location Unit 12 Stack - Method 29

Average

Run Number 1 2 3

Test Date 3/10/2010 3/11/2010 3/11/2010

Run Start Time 8:45:00 AM 6:35:00 

AM

11:35:00 AM

Run Finish Time 12:40:00 PM 10:30:00 

AM

3:30:00 PM

Net Run Time, minutes 240 240 240

Dry Gas Meter Volume Sampled, dscf 176.711 179.786 174.890 177.129

Moisture Content of Stack Gas, % 9.86 9.42 9.79 9.690

Moisture Saturation at Stack Gas Temperature, % 100.00 100.00 100.00 100.000

Carbon Dioxide, % 11.9 11.9 11.9 11.900

Oxygen, % 7.7 7.4 7.5 7.533

Average Stack Gas Temperature, °F 314.83 309.13 318.73 314.230

Dry Volumetric Flow Rate, dry scfm 1,223,184.8 1,249,024.3 1,211,453.1 1,227,887.40

0

Actual Wet Volumetric Flue Gas Flow Rate, acfm 2,086,904.1 2,040,707.2 2,012,246.6 2,046,619.30

0

Percent Isokinetic of Sampling Rate, % 104.0 103.6 103.9 103.833

F-Factor, dscfm/MMBtu @ %O2 9780 9780 9780 9,780.000

Fw 10640 10640 10640 10,640.000

Fc 1800 1800 1800 1,800.000

Location Unit 12 Stack - Method 3A CO2

Average

Run Number

Test Date

Run Start Time

Run Finish Time

Carbon Dioxide, %

Oxygen, %

Dry Volumetric Flow Rate, dry scfm

F-Factor, dscfm/MMBtu @ %O2

Moisture, %

Fuel Type

Fw

Fc

Monday, February 07, 2011 Page 4 of 13
NIPSCO, Michigan City

Location Unit 12 Stack - Method 3A O2

Average

Run Number

Test Date

Run Start Time

Run Finish Time

Carbon Dioxide, %

Oxygen, %

Dry Volumetric Flow Rate, dry scfm

F-Factor, dscfm/MMBtu @ %O2

Moisture, %

Fuel Type

Fw

Fc

Location Unit 12 Stack - OTM - 27/28

Average

Run Number

Test Date

Run Start Time

Run Finish Time

Net Run Time, minutes

Dry Gas Meter Volume Sampled, dscf

Moisture Content of Stack Gas, %

Moisture Saturation at Stack Gas Temperature, %

Carbon Dioxide, %

Oxygen, %

Average Stack Gas Temperature, °F

Dry Volumetric Flow Rate, dry scfm

Actual Wet Volumetric Flue Gas Flow Rate, acfm

Percent Isokinetic of Sampling Rate, %

F-Factor, dscfm/MMBtu @ %O2

Fw

Fc

Monday, February 07, 2011 Page 5 of 13
NIPSCO, Michigan City

Emissions Summary

Location: Unit 12 Stack - Method 29

Compound: Antimony

Average

RunNumber 1 2 3

Mass_mg 0.01025 0.01065 0.01305 0.011

lb/mmBtuO2 1.98E-06 1.98E-06 2.51E-06 0.000

Compound: Arsenic

Average

RunNumber 1 2 3

Mass_mg 0.11889 0.11488 0.14089 0.125

lb/mmBtuO2 2.30E-05 2.13E-05 2.71E-05 0.000

Compound: Beryllium

Average

RunNumber 1 2 3

Mass_mg 0.00466 0.00416 0.00516 0.005

lb/mmBtuO2 9.00E-07 7.72E-07 9.92E-07 0.000

Compound: Cadmium

Average

RunNumber 1 2 3

Mass_mg 0.001105 0.001205 0.001055 0.001

lb/mmBtuO2 2.13E-07 2.24E-07 2.03E-07 0.000

Compound: Chromium

Average

RunNumber 1 2 3

Mass_mg 0.1072 0.0981 0.141 0.115

lb/mmBtuO2 2.07E-05 1.82E-05 2.71E-05 0.000

Compound: Cobalt

Average

RunNumber 1 2 3

Mass_mg 0.01738 0.0158 0.0188 0.017

lb/mmBtuO2 3.36E-06 2.93E-06 3.61E-06 0.000

Compound: Filterable Particulate

Average

RunNumber 1 2 3

Mass_mg 543.7 508.9 524.3 525.633

lb/mmBtuO2 1.05E-01 9.45E-02 1.01E-01 0.100

Compound: Lead

Average

RunNumber 1 2 3

Mass_mg 0.0534 0.0463 0.0567 0.052

lb/mmBtuO2 1.03E-05 8.60E-06 1.09E-05 0.000

Compound: Manganese

Average

Monday, February 07, 2011 Page 6 of 13
NIPSCO, Michigan City

RunNumber 1 2 3

Mass_mg 0.115 0.1026 0.1264 0.115

lb/mmBtuO2 2.22E-05 1.90E-05 2.43E-05 0.000

Compound: Nickel

Average

RunNumber 1 2 3

Mass_mg 0.0939 0.1392 0.0946 0.109

lb/mmBtuO2 1.81E-05 2.58E-05 1.82E-05 0.000

Compound: Phosphorus (yellow or white)

Average

RunNumber 1 2 3

Mass_mg 5.6348 5.0986 6.0796 5.604

lb/mmBtuO2 1.09E-03 9.47E-04 1.17E-03 0.001

Compound: Selenium

Average

RunNumber 1 2 3

Mass_mg 0.1611 0.0856 0.1263 0.124

lb/mmBtuO2 3.11E-05 1.59E-05 2.43E-05 0.000

Location: Unit 12 Stack - OTM - 27/28

Compound: Filterable Particulate

Average

RunNumber 1 2 3

Mass_mg 400.1 118.3 147.6 222.000

lb/mmBtuO2 1.02E-01 8.87E-02 1.10E-01 0.100

Compound: Filterable PM2.5

Average

RunNumber 1 2 3

Mass_mg 123.1 47.6 51 73.900

lb/mmBtuO2 3.15E-02 3.57E-02 3.81E-02 0.035

Compound: Inorganic (Aqueous) Condensible Pa

Average

RunNumber 1 2 3

Mass_mg 232.5 88 87.8 136.100

lb/mmBtuO2 5.95E-02 6.60E-02 6.57E-02 0.064

Compound: Organic Condensible Particulate

Average

RunNumber 1 2 3

Mass_mg 33 7 6.5 15.500

lb/mmBtuO2 8.44E-03 5.25E-03 4.86E-03 0.006

Compound: Total Particulate

Average

RunNumber 1 2 3

Mass_mg 665.6 213.3 241.9 373.600

lb/mmBtuO2 1.70E-01 1.60E-01 1.81E-01 0.170

Monday, February 07, 2011 Page 7 of 13
NIPSCO, Michigan City

Process Run Data

Compound: Total PM2.5

Average

RunNumber 1 2 3

Mass_mg 388.6 142.6 145.3 225.500

lb/mmBtuO2 9.94E-02 1.07E-01 1.09E-01 0.105

Monday, February 07, 2011 Page 8 of 13
NIPSCO, Michigan City

Process Run Data

APCD Run Data

Process Lab Run Data

Run Name Value UOM Comments

Target

Value

1 Heat Input Million Btus/million BTU using CO2 4350 4300

2 Heat Input Million Btus/million BTU using CO2 4318 4300

3 Heat Input Million Btus/million BTU using CO2 4325 4300

1 Coal Flow 395 Klbs/hr 395

2 Coal Flow 395 Klbs/hr 395

3 Coal Flow 396 Klbs/hr 395

1 Steam Output 3469 klbssteam/hr 3500

2 Steam Output 3422 klbssteam/hr 3500

3 Steam Output 3514 klbssteam/hr 3500

Run Name Value UOM Comments

Target

Value

1 OVERFIRE AIR 0.604 lb/mmBtu 0.6

2 OVERFIRE AIR 0.62 lb/mmBtu 0.6

3 OVERFIRE AIR 0.599 lb/mmBtu 0.6

1 SCR (SELECTIVE CATALYTIC REDUCTION) 6 GPM 6

2 SCR (SELECTIVE CATALYTIC REDUCTION) 5.6 GPM 6

3 SCR (SELECTIVE CATALYTIC REDUCTION) 6.2 GPM 6

1 ELECTROSTATIC PRECIPITATOR 39.4 KW 40

2 ELECTROSTATIC PRECIPITATOR 43.3 KW 40

3 ELECTROSTATIC PRECIPITATOR 38.7 KW 40

Run Name Value UOM Comments

1 0

Monday, February 07, 2011 Page 9 of 13
NIPSCO, Michigan City

Sampling / Stack Data Results Detail

Location Unit 12 Stack - Method 29

Average

Run Number 1 2 3

Test Date 3/10/2010 3/11/2010 3/11/2010

Run Start Time 8:45:00 AM 6:35:00 AM 11:35:00 AM

Run Finish Time 12:40:00 PM 10:30:00 AM 3:30:00 PM

Net Traversing Points 48 48 48

Net Run Time, minutes 240 240 240

Nozzle Diameter, inches 0.191 0.191 0.191 0.191

Pitot Tube Coefficient 0.84 0.84 0.84 0.840

Dry Gas Meter Calibration Factor 0.994 0.994 0.994 0.994

Barometric Pressure, inches of Mercury 28.7 29.6 29.6 29.300

Average Orifice Meter Differential, inches H2O 2.15 2.10 2.03 2.093

Dry Gas Meter Volume Sampled, cubic feet 191.650 189.191 185.947 188.929

Average Dry Gas Meter Temperature, °F 89.00 89.23 94.83 91.020

Dry Gas Meter Volume Sampled, dscf 176.711 179.786 174.890 177.129

Total Moisture Liquid collected, g 410.7 397.37 403.18 403.750

Volume of Water Vapor, standard cubic feet 19.33 18.70 18.98 19.003

Moisture Content of Stack Gas, % 9.86 9.42 9.79 9.690

Moisture Saturation at Stack Gas Temperature, % 100.00 100.00 100.00 100.000

Dry Mole Fraction 0.9014 0.9058 0.9021 0.903

Carbon Dioxide, % 11.9 11.9 11.9 11.900

Oxygen, % 7.7 7.4 7.5 7.533

Carbon Monoxide & Nitrogen, % 80.4 80.7 80.6 80.567

Fuel Factor 1.11 1.13 1.13

Dry Molecular Weight, lb/lb-Mole 30.21 30.20 30.20 30.203

Wet Molecular weight, lb/lb-Mole 29.01 29.05 29.01 29.023

Flue Gas Static Pressure, inches of H2O -2.1 -2 -2 -2.033

Absolute Flue Gas Pressure, inches of Mercury 28.55 29.45 29.45 29.150

Average Stack Gas Temperature, °F 314.83 309.13 318.73 314.230

Average Velocity Head, inches of H2O 2.1223967973

1092

2.112091847

88487

2.025095983

38454

2.087

Average Stack Gas Velocity, feet/second 101.19 98.95 97.57 99.237

Stack Cross-Sectional Area, square feet 343.727 343.727 343.727 343.727

Dry Volumetric Flow Rate, dry scfm 1,223,184.8 1,249,024.3 1,211,453.1 1,227,887.4

00

Actual Wet Volumetric Flue Gas Flow Rate, acfm 2,086,904.1 2,040,707.2 2,012,246.6 2,046,619.3

00

Percent Isokinetic of Sampling Rate, % 104.0 103.6 103.9 103.833

Percent Excess Air, % 56.9 53.2 54.4 54.833

F-Factor, dscfm/MMBtu @ %O2 9780 9780 9780 9,780.000

Round Duct Diameter, inches 251.04 251.04 251.04

Rectangular Duct Width, inches 0 0 0

Rectangular Duct Length, inches 0 0 0

Fw 10640 10640 10640 10,640.000

Fc 1800 1800 1800 1,800.000

Monday, February 07, 2011 Page 10 of 13
NIPSCO, Michigan City

Location Unit 12 Stack - Method 3A CO2

Average

Run Number

Test Date

Run Start Time

Run Finish Time

Carbon Dioxide, %

Oxygen, %

Fuel Factor

Dry Volumetric Flow Rate, dry scfm

F-Factor, dscfm/MMBtu @ %O2

Moisture, %

Analyzer Make

Analyzer Model

Analyzer Serial Number

Operating Range

Operating Units

No. Readings/Avg.

Calibration Set

Calibration Pre Zero Cylinder ID

Calibration Pre Zero Cylinder Instrument Response

Calibration Pre Zero Cylinder Bias

Calibration Pre Zero Cylinder Drift

Calibration Pre High Cylinder ID

Calibration Pre High Cylinder Instrument Response

Calibration Pre High Cylinder Bias

Calibration Pre High Cylinder Drift

Calibration Post Zero Cylinder ID

Calibration Post Zero Cylinder Instrument Response

Calibration Post Zero Cylinder Bias

Calibration Post Zero Cylinder Drift

Calibration Post High Cylinder ID

Calibration Post High Cylinder Instrument Response

Calibration Post High Cylinder Bias

Calibration Post High Cylinder Drift

Cavg

Cavg Units

Cgas

Cgas Units

Fuel Type

Fw

Fc

Cgasw

Cgasw Units

Monday, February 07, 2011 Page 11 of 13
NIPSCO, Michigan City

Location Unit 12 Stack - Method 3A O2

Average

Run Number

Test Date

Run Start Time

Run Finish Time

Carbon Dioxide, %

Oxygen, %

Fuel Factor

Dry Volumetric Flow Rate, dry scfm

F-Factor, dscfm/MMBtu @ %O2

Moisture, %

Analyzer Make

Analyzer Model

Analyzer Serial Number

Operating Range

Operating Units

No. Readings/Avg.

Calibration Set

Calibration Pre Zero Cylinder ID

Calibration Pre Zero Cylinder Instrument Response

Calibration Pre Zero Cylinder Bias

Calibration Pre Zero Cylinder Drift

Calibration Pre High Cylinder ID

Calibration Pre High Cylinder Instrument Response

Calibration Pre High Cylinder Bias

Calibration Pre High Cylinder Drift

Calibration Post Zero Cylinder ID

Calibration Post Zero Cylinder Instrument Response

Calibration Post Zero Cylinder Bias

Calibration Post Zero Cylinder Drift

Calibration Post High Cylinder ID

Calibration Post High Cylinder Instrument Response

Calibration Post High Cylinder Bias

Calibration Post High Cylinder Drift

Cavg

Cavg Units

Cgas

Cgas Units

Fuel Type

Fw

Fc

Cgasw

Cgasw Units

Monday, February 07, 2011 Page 12 of 13
NIPSCO, Michigan City

Location Unit 12 Stack - OTM - 27/28

Average

Run Number

Test Date

Run Start Time

Run Finish Time

Net Traversing Points

Net Run Time, minutes

Nozzle Diameter, inches

Pitot Tube Coefficient

Dry Gas Meter Calibration Factor

Barometric Pressure, inches of Mercury

Average Orifice Meter Differential, inches H2O

Dry Gas Meter Volume Sampled, cubic feet

Average Dry Gas Meter Temperature, °F

Dry Gas Meter Volume Sampled, dscf

Total Moisture Liquid collected, g

Volume of Water Vapor, standard cubic feet

Moisture Content of Stack Gas, %

Moisture Saturation at Stack Gas Temperature, %

Dry Mole Fraction

Carbon Dioxide, %

Oxygen, %

Carbon Monoxide & Nitrogen, %

Fuel Factor

Dry Molecular Weight, lb/lb-Mole

Wet Molecular weight, lb/lb-Mole

Flue Gas Static Pressure, inches of H2O

Absolute Flue Gas Pressure, inches of Mercury

Average Stack Gas Temperature, °F

Average Velocity Head, inches of H2O

Average Stack Gas Velocity, feet/second

Stack Cross-Sectional Area, square feet

Dry Volumetric Flow Rate, dry scfm

Actual Wet Volumetric Flue Gas Flow Rate, acfm

Percent Isokinetic of Sampling Rate, %

Percent Excess Air, %

F-Factor, dscfm/MMBtu @ %O2

Round Duct Diameter, inches

Rectangular Duct Width, inches

Rectangular Duct Length, inches

Fw

Fc

Monday, February 07, 2011 Page 13 of 13