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# OAR Box 1778 Prepped by Ollie Stewart



### Document

Number: 

# 18 ) ll-A- 2 Docket Number: 

# A-90-0 6

Printed 10/28/2008 9:50:52 AM Sheet 18 of 276

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UNITE D STATE S ENVIRONMENTA L PROTECTIO N AGENCY REGIO N V DATE : DEC 0 5 19

W SUBJECT : 

### Inspectio nReport - Wisconsi nElectri c Powe r - Por t WashingtonStatio n TA / Por t

Washington , Wisconsi n FROM : 

### Davi dScholz , Powe

r Plan t Expert Ai r Complianc eSectio nI TO : 

### File s Inspectio n Date : Novembe r 23 , 198 8
Personne l Participating : •Davi d Schul z - U.S" . EP A•••-. . Ken t Walde n - WEPC O Mar k Steinber g - WEPC O Nei l Childres s - WEPC O Pau l Schumake r - WEPC O Plan t Description : WEPCO' s - Por t Washingto n Generatin g Statio n contain s fiv e Combustio n Engineerin g pulverize d coal-fire d units , wit hdesig n generatin g capacitie s o f 8 0 Mtf each . Th e unit s wer e constructe d betwee n 1935

- 1950 . Eac huni t i s equippe d wit ha 3-fiel d cold-sid e Researc h- Cottrel l electrostati c precipitato r (ESP) , whic hwer e installe d durin g th e mid-1960's . Unit s 1- 3 ven t throug ha OJUHUI I 505'stack , wit hUnit s 4 & 5 ventin g throug hanothe r 505 ' stack . Stac k testin g port s ar e locate d i n th e outle t breechin g fro meac huni t leadin g t o th e stack . Th e plan t currentl yha s n o opacit yo r SO ? CEM's , bu t ha s starte d constructio n o f a n elevato r an d scaffoldin g a n eac hstac k t o instal l opacit yCEM's . A n automati c coa l sample r wa s installe d a n th e bel t feedin g th e gree n coa l bunker s i n 198 7 i n orde r t o sampl e an d analyz e coa l burne d t o asses s S0 2 compliance . Uni t specifi c dail ycomposit e sample s ar e take n an d analyze d a t WEPGO' s centra l laboratory facilities . Th e statio n receive s coa l b yshi p (5-1 0 shipload s pe r year) , naintainin g a larg e stockpil e t o allo woperatio n throug hth e winte r month s whe n shippin g i s stopped . Th e statio n operate s i n a cyclin g mode , wit hunit s normall yoperate d fo r severa l day s o r a wee k a t a tim e a s syste mloa d requires .

EP A FOR M 1320- t(REV . S-TV)P. 3



### -2 - Followin g i s a summar yo f plan t parameters : 198 7 Boile r Desig n Rate d Yea r Contro l stac k __£ Typ e Capacit yCapacit y§____Equipmen t Q_qejgh t 1 C-E , P- C 80MW45MW193 5 R-C , ES P Non e 505 ' (1- 3 combined ) 2C-E , P- C 80Mt f 651V

W194 3 R-C , ES PNon e505 ' (1- 3 combined ) 3 C-E , P- C 80M<J 75MW194 8 R-C

- ES P Non e 505 ' (1- 3 combined ) 4 C-E , P- C 80I- W55I

W194 9 R-C , ES PNon e505 ' (4- 5 combined ) 5 C-E , P- C 80I- WOt-

W195 0 R-C , ES P Non e 505 ' (4- 5 combined ) Background : WEPC O ha s propose d a n extensiv e rehabilitatio n an d lif e extensio n progra mfo r thes e unit s t o retur n the mt o thei r origina l desig n capacities . Thi s progra mconsist s i n par t of : stea mdrum replace

ments , ai r heate r replacements , economize r replacement , mai n stea m& rehea t pipin g upgrades , modificatio n o f fa n controls , repai r o f turbin e cylinde r cracks , modificatio n o f turbin e spindles , turbin e blad e replacements , replacemen t o f boile r vate r treatmen t systems , chimne yline r repair s an d ES P repairs . U.S . EP Aha s determine d tha t th e modification s a s propose d wil l subjec t thes e unit s t o NSP S an d PSD . WEPC O ha s initiate d a tes t progra mt o demonstrat e curren t uni t capacitie s an d emissio n rate s t o allo wfo r a reevaluatio n o f NSP S applicability .

Durin g th e tim e o f inspectio n onl yuni t 1 wa s i n service . Uni t 1 operatin g condition s durin g th e inspectio n wer e a s follows : Generatin g Loa d Feedwate r flo wstea mflo wExces s Oxyge n Stea mdru mpressur e 591 W 526,00 0 Ib/h r 440,00 0 lb/h r 3.6 % l,320ps i Plan t personne l indicate d tha t the ydi d no t conside r th e stea mflo w reading s a s a n accurat e indicatio n o f boile r capacit ydu e t o stea mof f take s prio r t o th e poin t o f measurement . The yinstea d rel yo n th e feedwate r flo wmeasurement s t o determin e boile r operatin g capacity .P. 4

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Arevie wo f Uni t 1 ES P reading s showe d th e following :

Primar yvoltag e Primar ycurren t Secondar ycurren t Fiel dVolt s l___l (ma ) inle t 37 0 12 0 76 0 cente r 34 0 8 0 54 0 outle t 33 0 11 8 88 0 Observatio no f th e stac k fo r Uni t 1 showe dopacit yvalue s o f 5-10 % durin g th e inspection , althoug hn o forma l observation s wer e recorded . Plan t personne l indicate dtha t Uni t 1 ha d starte doperatio no n Novembe r 17th . I t wa s indicate dtha t th e uni t initiall yexperience d opacit yproblems , a t whic htim e WEPC O reduce dloa dt o th e poin t a t whic hth e uni t jus t me t th e opacit ylimit . WEPC O the nconducte d a particulat e enissio ntes t ru nwhic hindicate da violatio no f th e particulat e standard . Uni t loa dwa s the nreduce d furthe r an danothe r particulat e tes t ru nconducted . Whe nthi s particulat e tes t agai n showe dviolatio nuni t loa d wa s reduce dfurther , an da thir dtes t run conducted . Whe nthi s thir d tes t ru nshowe dcomplianc e WEPCO ' conducte d tw o additiona l tes t run s a t tha t operatin g load . I t wa s indicate d tha t th e uni t ha d bee noperate d fo r a t leas t 1 0 hour s pe r da ya t tha t loa dsinc e then , excep t fo r on e da yo f onl y8 hour s operation . Plan t personne l indicate dtha t Uni t 4 ha d starte doperatio no n Novembe r 17th . Du e t o preliminar yparticulat e tes t result s indicating violations , particulat e testin g wa s no t complete do nUni t 4 . I t wa s indicate dtha t Uni t 4 ha d bee noperate dunti l Novembe r 22ndwhe nth e uni t wa s take noff-lin e du e t o shorte d ES P field s cause db ya broke n wire , resultin g i nhig hopacit yvalues . I t wa s indicate dtha t unit s 3 & 4 woul d b e teste dth e followin g week , startin g Novembe r 27th . Durin g a followup telephon e cal l o nNovembe r 29t hi t wa s indicate dtha t Uni t 4 ha d experience danothe r ES P short , requirin g tha t uni t t o b e brough t down . Uni t 3 & 4 testin g wa s stil l schedule dt o b e complete d durin g th e wee k o f Novembe r 28th . Discussion s wer e hel dwit hWEPC O personne l concernin g th e forma t an d type s o f informatio nt o b e include di nth e tes t reports , usin g th e Uni t 2 preliminar ytestin g an d operationa l dat a a s a nexample . cc : Wal t Stevenson , ES D (MD-13 ) Sall yFarrell , SSC D (EN-341 ) Bo bMartineau , CG C (LE-132A ) Lydi a Wegman , (A-101 ) Ke e Kertche r Spyropoulo s Paisi e Va nMersberge n Skoulikas , CR C