### 31 May2005 JohnCrouch HPBA 

# lntertek ETLSEMKO

Suite 1001, 1601 NorthKent Street Arlington, VA22209 Subject: IntertekReportNo. 3074064 

## INTRODUCTION The WarnockHerseyDivisionoflntertekTesting ServicesNAInc. of Middleton, Wisconsinevaluatedmodel Brian (Codename for unit) in accordancewiththeproposedTestProtocol for OutdoorBoilerEfficiency andEmissionsTests. 

## PROCEDURE The unitwas setup with4x4 oakand oakcordwoodtestloads andwas run at 50% and25% ofratedcapacityas specifiedbythe manufacturer. Unit rating was 100,000BTU. 

## RESULTS Enclosedis a summary oftheresults. Ifyouhave any questions, please feel free to contactus. Thankyou for givingusthe opportunityto serve you. Sincerely,**~~** 

### Bill Keen AssociateEngineer Enclosures

lntertekTesting Services NA, Inc. 8431 Murphy Drive, Middleton, WI 53562 Telephone: 608-836-4400 Fax: 608-831-9279 Web: www.intertek-etlsemko.com

## -)



## )

) 

# lntertek 

# ETLS'EMKO

TEST OF AN OUTDOOR BOILER FOR EMISSIONS AND EFFICIENCY PER INTERTEK'S PROPOSED PROTOCOL FOR OUTDOOR BOILER EFFICIENCYAND EMISSIONS TESTING lntertek Report No. 3074064 FOR HPBA Attention: Mr. Jack Goldman and Mr. John Crouch Suite 1001 1601 North Kent Street Arlington, VA 22209 TESTED BY: INTERTEK TESTING SERVICES NA INC. 8431 MURPHY DRIVE MIDDLETON, WISCONSIN 53562 TEST DATES: May 11-May 31, 2005 REPORT DATE: May 31, 2005

This report isfor the exclusive use ofthe client of lntertekTesting Services NA, Inc. (lntertek) and is provided pursuantto the agreement between lntertek and its client. lntertek's responsibilityand liabilityarelimitedtotheterms and conditionsoftheagreement. lntertekassumes noliabilitytoanyparty,otherthantotheclientinaccordancewiththeagreement,for anyloss,expenseordamageoccasioned bythe useofthis report. Onlytheclientisauthorizedtocopyordistributethis reportandthen onlyin itsentirety. Anyuseofthelnterteknameor oneofits marksforthesaleoradvertisementofthetested material, productorservice mustfirst beapproved inwriting bylntertek. Alltestswereconductedtoproceduresagreedto by Aqua-Therm LLC and lntertekTesting ServicesNA, Inc. Theobservationsandtestresults inthis reportare relevantonlytothesampletested. The reportbyitselfdoesnotimplythatthe material, product orservice isoreverhas been underan lntertekcertification program.Report No. 3074064 Client: HPBA


## A. 'B. 

# c. D. E. Report Date: May 31, 2005 Model: Brian I. INTRODUCTION General

.............................................................4 Test Unit Description
............................................. 4 Results
..............................................................4 Pretest Information
.............................................. 4 Report Organization

..;........................................... 5 II. SUMMARY OF TEST RESULTS A. Emissions and Efficiency
......................................... 5 B. Fuel data
............';
........· .......· ............................... 6 Ill. PROCESS DESCRIPTION A. Discussion ................................•......................... 7 B.. Unit Dimensions
..................;..............................•. 7 

### C. Air Supply System

................................................. 7 D. Operation during Test.
........................................... 8 E. Start-Up Operation

............................................... 8

, ) · IV. SAMPLING SYSTEMS A. Sampling Locations
............................................... 8 1. Dilution Tunnel (Figure 1)
.....**~**.............................. 9 B. Operational Drawings 1 . Stack Gas Sample Train (Figure 2)
......................... 10 2. Dilution Tunnel Sample Systems (Figure 3)
............... 11 3. Heat Exchanger (Figure 4)
.................................. 12 \ 4. Basic Set-Up (Figure 5)
...................................... 13 5. Fuel Loading (figure**~)** ...................................... 14 6. Thermopile (Figure 7).........................•.............. 14 C. Equipment List
...................................................15 V. SAMPLING METHODS A. Particulate
........................................................16 B. Efficiency
.........................................................16 

## ) Page 2 of 18Report No. 3074064 Client: HPBA Report Date: May 31, 2005 Model: Brian 

### ) .VI. QUALITYASSURANCE

' 

# )

. '

; I ) A. Instrument Calibration 1. Dry Gas Meters
................................................16 2. Stack Sample rotameter
..................................... 16 3. Gas Analyzers
.................................................16 K Test Method Procedures 1. Leak Check Procedures
................................**~**...... 17 2. Tunnel Velocity 

### I Flow Measurement
..................... 17 VII.· APPENDICES Data and Calculation Forms
.......................:............. A Laboratory Operating Procedure ...•........................... B Calibration Data
......,........................................... C
·Calculation Procedures and Sample Calculations

............ E Page 3 of 18

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) Report No. 3074064 Client: HPBA 

### I. I.A. GENERAL Report Date: May 31, 2005 Model: Brian 

### INTRODUCTION Page 4 of 18

From May 13-31, 2005 lntertekTesting Services NA Inc. (lntertek) conducted tests on the Brian (code name for unit) outdoor boiler to determine emission and efficiency results for HPBA. The results to be used to help determine testing procedures for the proposed protocol test method. ' Tests were conducted by Bill Keen and Brian Ziegler. The tests were conducted at the lntertekTesting Services NA Inc. laboratory located at 8431 Murphy Drive, Middleton, Wisconsin. The laboratory elevation is 860 feet above sea level. Tests were evaluated to the Proposed Test Protocol for Outdoor Boiler Efficiency and Emissions Research Testing created by Rick Curkeet, Chief Engineer Building Products, lntertek. 

### I.B. TEST UNIT DESCRIPTION The unit code named Brian is an· outdoor boiler. Further description is withheld to not allow identification. I.C. RESULTS The unit as tested produced an adjusted average emissions rate for oak 4x4 pieces of 68.87 grams/hour and an average emissions rate for cordwood of44.27 grams/hour. 

### J.D. PRETEST INFORMATION The test unitwas received at lntertekTesting Services NA Inc. in Middleton, Wisconsin on April 25, 2005. The unitwas inspected upon receipt and found to be in good condition. The unitwas set up following the manufacturer's instructions without difficulty. Following assembly, the unitwas placed on the test stand and instrumented with thermocouples in the specified locations. The chimney system and laboratory dilution tunnel was cleaned using standard wire brush chimney cleaning equipment. On May 12, 2005, the unitwas ready for testing.



### I.E. REPORT ORGANIZATION 1. 1.The data from this report is for R&D purposes only. This protocol is not a recognized standard and lntertekwill not authorize the use oftest results obtained as the basis for advertising. lntertekwill not offer product certification or labeling services based on these test results. Raw data, calibration r:ecords·, intermediate calculations, drawings and specifications and other supporting information are contained in appendices to this report. ·

### Report'r"l6. 3074064 Client: HPBA


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### Report Date: May 31, 2005 Model: Brian
SUMMARY OF TEST RESULTS EMISSIONS and EFFICICENCY t;1

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### Oak 25 20 21.89 864770 31.3 

### Oak 25 20.1 26.83 825707 36.6 Cord 50 13.2 29.9 830520

32 Cord 25 19.2 28.7**814228~** 31.1 

### Oak 25 19.7 27.63 865141 31.1 Cord 25 18 29.9 824966 39.1 

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- 1.32 1.39 10.08 69.29**~.** -· --Report

### ''NO. 307 4064 Client: HPBA Grouped summary



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.31.1

-- . '- Report Date: May 

### 31, 2005 Model: Brian

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### Oak 50 14.5 20.63 862549 

### Oak 50 13.5 21.89 864770 

### Oak 50 14.3 26.08 837926 Cord 50 13.4 28.18 876249 Cord 50 12.6 28.78 828854 Cord 50 13.2 29.9 830520 

### Oak 25 20 21.89 864770 

### Oak 25 20.1 26.83 825707 

### Oak 25 19.7 27.63 865141 Cord 25 13 29.14 Cord 25 20 25.23 837555 Cord 25 19.2 28.7 814228 Cord 25 18 29.9 824966 

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/

- -

## )



## ) Report No. 3074064 Client: HPBA



### Ill.


### Ill.A. Report Date: May 31, 2005 Model: Brian

PROCESS DESCRIPTION
DISCUSSION Page 7 of 18

RUN #1 (May 11, 2005) the cooling water for the heat exchanger was set to draw 50,000 Btu/hr. Minor adjustments were made to maintain the heat exchange rate. Fuel load was oak 4x4. The average Btu/hroutput was 48,495. The fire appeared to go out (02 wp.s at 18.5 and no change in burn weight) and was stirred after 355 minutes. Burn time was 369 minutes. RUN #2 (May 12, 2005) the cooling water for the heat exchanger was set to draw 50,000 Btu/hr. Minor adjustments were made to maintain the heat exchange rate. Fuel load was red oak cordwood. The average Btu/hr outputwas 51 ,494. Burn time was 355 minutes. RUN #3 (May 13, 2005) the cooling water for the heat exchanger was set to draw 50,000 Btu/hr. Minor adjustments were made to maintain the heat exchange rate. Fuel load was oak 4x4. The average Btu/hr output was 48,021. Burn time was 355 minutes. RUN #4 (May 16, 2005) the cooling water for the heat exchanger was set to draw 25,000 Btu/hr. Minor adjustments were made to maintain the heat exchange rate. Fuel load was red oak cordwood. The fire died. Preload ranges for future low burri rates would be 15 to 25% instead of 10-15%. RUN #5 (May 16, 2005) the cooling water for the heat exchanger was set to draw 50,000 Btu/hr. Minor adjustments were made to maintain the heat exchange rate. Fuel load was red oak cordwood. The average Btu/hr outputwas 49,770. Burn time was 350 minutes. RUN #6 (May 17, 2005) the cooling water for the heat exchanger was set to draw 25,000 Btu/hr. Minor adjustments were made to maintain the heat exchange rate. Fuel load was red oak cordwood. The average Btu/hr outputwas 24,861. Burn time was 565 minutes. RUN #7 (May 18, 2005) the cooling water for the heat exchanger was set to draw 25,000 Btu/hr. Minor adjustments were made to maintain the heat exchange rate. Fuel load was oak 4x4. The average Btu/hroutput was 25562. Burn time was 630 minutes. RUN #8 (May 19, 2005) the cooling water for the heat exchanger was set to draw 25,000 Btu/hr. Minor adjustments were made to maintain the heat exchange rate. Fuel load was oak 4x4. The average Btu/hr output was 25,665. Burn time was 605 minutes.

### )



## ) Report No. 3074064 Client: HPBA Report Date: May 31, 2005 Model: Brian Page 8 of 18

RUN #9 (May 20, 2005) the cooling water for the heat exchanger was set to draw 50,000 Btu/hr. Minor adjustments were made to maintain the heat exchange rate. Fuel load was red oak cordwood. The average Btu/hr outputwas 49,603. Burn time was 368 minutes. RUN #10 (May 23, 2005) the cooling water for the heat exchanger was set to draw 25,000 Btu/hr. Minor adjustments were made to maintain the heat exchange rate. Fuel load was red oak cordwood. The average Btu/hr output was 26,227. Burn time was 596 minutes. ·



## .. RUN #11 (May 24, 2005) the cooling water for the heat exchanger was set to draw 25,000Btu/hr. Minor adjustments were made to maintain the heat exchange rate. Fuel load was oak 4x4. The average Btu/hr outputwas 25,536. Burn time was 633 minutes. RUN #12 (May 25, 2005) the cooling water for the heat exchanger was set to draw 25,000 Btu/hr. Minor adjustments were made to maintain the heat exchange rate. Fuel load was red oak cordwood. The average Btu/hr output was 26,506. Burn time was 580 minutes. RUN #13 (May 27, 2005) the cooling water for the heat exchanger was set to draw 50,000 Btu/hr. Minor adjustments**w~re** made to maintain the heat exchange rate. Fuel load was oak4x4. The average Btu/hr output was. Burn time was 395 minutes. III.B. UNIT DIMENSIONS Suppressed for identification security. III.C. AIR SUPPLY SYSTEM Combustion air enters the unit at thelower rear ofthe unit aided by a combustion air blower. Combustion air is controlled by an aquastat, which in turn starts the combustion blower and operates a solenoid that opens an air damper. This air is directed under the coal bed as under fire air. Combustion products then exit the unit through a eight-inch flue collar located at the top of the unit.
III.D. OPERATION DURING TEST The water-to-water heat exchaf!ger was adjusted for each ofthe heat loads by increasing or decreasing the water flow through the cooling side ofthe heat exchanger. The inlet and outlet cooling water temperatures were monitored along with the Delta-T.

### ' 

# )

) Report No. 3074064 Client: HPBA
III.E. START-UP OPERATION Report Date: May 31, 2005 Model: Brian Page 9 of 18

Each test was started with a clean firebox and the scale zeroed. Afire was started using scrap wood. Once the unit had cycled at least twice, the firebox was cleaned out and the scale rezeroed. Coals were then returned to the firebox along with enough wood to have at least 2 cycles before startingthe test. During the pretest loads, the waterflow was adjusted to establish target heat draw. When the unit met the coal bed requirements; the scale.was rezeroed, test load inserted and the sampling system was startedand was operated for the duration of thetest run. IV. SAMPLING SYSTEMS The EPA Method 5-G3 sampling procedure was used. IV.A. SAMPLING LOCATIONS Particulate samples are collected from the dilution tunnel at a point 16 feet from the tunnel entrance. The tunnel has two elbows ahead ofthe sampling section. (See Figure 3.) The sampling section is a continuous 14"foot section of 12-inch diameter pipe straight over its entire length." Tunnel velocity pressure is determined by a standard Pitot tube located 96 inches from the beginning of the sampling section. The dry bulb thermocouple is located six inches downstream from the Pitot tube. Tunnel samplers are located 36 inches downstream ofthe Pitot tube and 36 inches upstream from the end ofthis section. (See Figure**1~)-** Stack. gas samples are collected from the steel chimney section 8feet ± 6 inches above the scale platform. (See Figure 2.)

## )



## )

) Report No. 3074064 Client: 

### HPBA IV.A.(1) Report Date: May 31, 2005 Model: Brian 

### DILUTION TUNNEL**~---5'**

fl
.....**t~""** prDI:r**~tOOl** SDrpiP pra:Je

FJGURE 1 Page 10 of 18

## )

) ReportNo. 3074064 Client: 

### HPBA
IV.B. IV.B.(1)



# I I I I**I~~:;.=,** 

# I I I Report Date: May 31, 2005 Model: Brian


### OPERATIONAL DRAWINGS 

### STACK GAS SAMPLE TRAIN**FII~URE** 

### 2 (nl Cnl Gn:..:; Gus I 2**l~>:l·ln\~St (>~**  Col (ins 3

oir Page 11 of 18

ZERO GASReport No. 3074064 Client: 

### HPBA Report Date: May 31, 2005 Model: Brian 

# j IV.B.(2). DILUTION TUNNEL SAMPLE SYSTEMS



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### of 18

EXHAUSTReport No. 3074064 Client: .HPBA IV.B.(3). Heat Exchanger :::Figure 4.

.Outto drain



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) Report Date: May 31, 2005 Model: Brian Page 13 of 18

InsulatedBox

Returnto Boiler

In from Boiler

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) Report No. 3074064 Client: HPBA IV.B.(4). Basic Set-Up Figure 5. Report Date: May 31, 2005 Model: Brian Page 14 of 18

SupplyReport No. 3074064 Client: HPBA IV.B.(6) Report Date: May 31, 2005 Model: Brian Figure 7. 5 Pair Type-T Thermopile 

# IEpoxy**~hermowell** 

# IConstantan 

### )
/ Millivolt Meter Page 15 of 18

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## ) Report No. 3074064 Client: HPBA Report Date: May 31, 2005 Model: Brian
IV.C. 

### EMISSION AND EFFICIENCY EQUIPMENT LIST ITEM DESCRIPTION MANUFACTURER MODEL SERIAL# 1. C02 Analyzer (WHI#010) HORIBA PIR-2000 607023 2. CO Analyzer (WHI #009) HORIBA PIR-2000 6110019 3. 02 Analyzer (WHI #011) BECKMAN 755 1001926 4. Dry Gas Meter (WHI #012) Rockwell T-110 26866 5. Dry Gas Meter (WHI #013) Rockwell T-llO 26873 6. Rotameter (WHI # 015) Matheson 602 Tube 7. Rotameter (3) (WHI # 016) Matheson 603 Tube 8. Rotameter (2) (WHI # 019) Matheson 604Tube 9. Inclined Manometer (WHI #022) Dwyer 125-AV 10. Pitot Tube (WHI # 044) 11. Manometer0-10" (WHI #024) Dwyer 400-10 12. Mercury Barometer (WHI # 142) Meriam 310EC10WM 184550-X1 13. Draft Indicator (WHI #027) Dwyer 2000-00 R60825 M29 14. Scale, 1000# Cap./Record.(WHI #025) Toledo Masstron ML222 ( 8013 15. Readout for 1000#Scale (WHI #007) NCI 5780 C800174 16. Scale, 75# Capacity (WHI #006) NCI 3824-100 762117 17. Readout for 75# Scale (WHI #008) NCI 5780 ·G800082 18. Analytical Balance (WHI #028) OHAUS G-110 5336 19. AuditWeights 1 mg-100 g/Class-S (WHI # 029) Ainsworth 4254-S 39392 20. Diaphragm Pumps (4) (WHI # 032 • 035) Dayton Z024 (1) 22866 (3) 21. Method 5H Glassware (WHI # 036) Andersen · 4" Filter, 4-250 mllmpingers 22. Gases; Calibration, Zero, Span Air Gas 23. Regulators for Gases (6) (WHI # 037 • 043) Matheson 8-(XXXX) · 24. High Accuracy Needle Valves (9) Matheson 25. Solenoid Valves (12) (WHI # 045) Dayton 26. Switches (Misc.) (WHI # 045) Dayton 27. ORSAT Gas Analyzer (WHI # 048) Fisher D 28. Oxygen Bomb Calorimeter (WHI # 047) Parr 1341 4514 29. Moisture Meter (WHI #049) Delmhorst RC-1C 14356 30. Humidity Chamber (WHI # 050) Lab Built 31. Dilution Tunnel (WHI # 046) Lab Built 32. Spirometer (WHI #51) Lab Built 33. Data Acquisition System (WHI # 052) Lab Built 34. Drying Oven (WHI # 002) Blue-M SW·11TA-1 SW-291 35. Filter Holders, 47-mm (8) (WHI # 053) Nalgene 36. Type·K Meter (WHI #054) Omega 199 21662 37. DigitalVoltmeter (WHI #055) Newport 2004-3 6090022-3 38. Type KThermocouple Wire 24 Ga. Gordon Special Limits of Error 39. Type KT/CPlugs Gordon K-901/900 40. Dry Gas Meter (WHI #014) Rockwell T-110 27002 41. AuditWeights; 5#, 10# (WHI # 160) Rice Lake Weighing System Class-F 42. Sling Psychrometer (WHI # 126) Taylor 43. Infrared Pyrometer (WHI #102) Omega OS-2000A A4048T 44. Class CWeights 1-500 g (WHI # 161) Ohaus 45. Bomb CalorimeterThermometer (WHI # 162) Parr 1603 3K9347 46. MicrotectorGauge (WHI # 103) Dwyer**14~0** 47. Bubble flow meter (WHI # 415) Humonics 650 570192 48. Soxhlet extractor (WHI # 413) Fisher Scientific 49. ESS Unit (WHI #416) Omni 50. Unimantle (WHI # 413) 51. Magnehelic (WHI #027) Prepared January 1988 by Rick Curkeet I Rev. May1997 by Rick Armstrong Page 16 of 18

## )



## ) Report No. 3074064 Client: HPBA 

## v. V.A. Report Date: May 31, 2005 Model: Brian · 

### SAMPLING METHODS PARTICULATE SAMPLING Page 17 of 18

Particulates were sampled in accordance with EPA Method 5G-3. This method uses two identical sampling systems with Millipore 47-mm diameter glass fiber filters. The dryers used in the sample systems are filled'with uDrierite" before each test run. ' 

### V.B. EFFICIENCY Efficiency is reported in %of input energy delivered to the heated space and is denoted as rroelivered Heating Efficiency". 

### VI. QUALITY ASSURANCE 

### VI.A. INSTRUMENT CALIBRATION 

### VI.A.(1). STACK SAMPLE ROTAMETER The stack sample rotameter is checked by running three tests at each flow rate used during the test program. The flow rate is checked by running the rotameter in series with one ofthe dry gas meters for 10 minutes with the rotameter at a constant setting. The dry gas metervolume measured is then corrected to standard temperature and pressure conditions. The flow rate determined is then used to calculate actual sampled volumes. 

### VI.A.(2). GAS ANALYZERS The continuous analyzers are zeroed and spanned before each test with appropriate gases. A mid-scale multi-component calibration gas is then analyzed (values are recorded). At the conclusion of a test, the instruments are checked again with zero, span and calibration gases (values are recorded only). The drift in each meter is then calculated and must not exceed 5% ofthe scale used for the test. At the conclusion of each unit test program, a five-point calibration check is made. This calibration check must meet accuracy requirements of the applicable standards. Consistent deviations between analyzer readings and calibration gas concentrations are used to correct data before computer processing. Data is also corrected for interferences as prescribed by the instrument manufacturers instructions. Calibration gases are checked by ORSAT analysis when received toverify suppliers analysis.

# )

) Report No. 

### 3074064 Client: HPBA 

### VI.B. VI.B.(1). Report Date: May 

### 31, 2005 Model: Brian TEST METHOD PROCEDURES LEAK CHECK PROCEDURES Page 18 of 18

Before and after each test, each sample train is tested for leaks. Leakage rates are measured and must not exceed 

### 0.02 CFM or

### 4% ofthe sampling rate. Leak checks are performed checking the entire sampling train, not just the dry gas meters. Pre-test ·and post-test leak checks are conducted with a vac;uum of 

### 10 inches of mercury. Vacuum is monitored during each test and the highest vacuum reached is then used for the post test vacuum value. If leakage limits are not met, the test run is rejected. During, these tests the vacuum was typically less than 

### 2 inches of mercury. Thus, leakage rates reported are expected to be much higher than actual leakage during the tests. VI.B.(2). TUNNEL VELOCITY/FLOW MEASUREMENT The tunnel velocity is calculated from a center point pitot tube signal multiplied by an adjustment factor. This factor is determined by a traverse ofthe tunnel as prescribed in EPA Method 1. Final tunnel velocities and flow rates are calculated from EPA Method 

### 2, Equation 

### 6.9 and 

### 6.10. (Tunnel cross sectional area is the average from both lines of traverse.) Pitot tubes are cleaned before each test and leak checks are conducted after each test.

Evaluated and reported by:·

Bill Keen Associate Engineer 

# - Rick Armstrong Technical Projects Manager