Name: Guy C. Packard

Title: Site Business Manager - JH Campbell

Company: Consumers Energy

Sign Date: 9/1/2010

Name: Randal J. Tysar

Title: Senior Environmental Engineer

Company: BT Environmental Consulting, Inc.

Sign Date: 9/1/2010

Permitted Facility Representative / Date Testing Company Representative / Date

Consumers Energy Boilers 1&2 Test Plan

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.

Thursday, February 24, 2011 Page 1 of 12
Consumers Energy Boilers 1&2 Test Plan

9/1/2010

Facility Information:

Consumers Energy J.H. Campbell Power St

17000 Croswell Street

West Olive MI 49460

Contact: Ms. Katie Cunningham

Phone: (517) 768-3462

Fax: 517-788-2329

Email: kmcunningham@cmsenergy.com

Testing Company:

BT Environmental Consulting, Inc.

2615 Wolcott Street

Ferndale MI 48220

Contact:Todd Wessel

Phone: (616) 885-4013

Fax: (248) 548-8073

Email: twessel@btecinc.com

Air Permit Number:

MI-ROP-B2835-2005b

Permitted Source ID/Name:

B2835 EUBOILER1 and EUBOILER2

Permitted Maximum Process Rate:

N/A

Max. Normal Operation Process Rate:

N/A

Target Process Test Rate

Approximately 600 MW for 

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

 process flow diagram:

The source to be tested is the common exhaust from Boiler No. 1 and 2 located at the J.H. Campbell Power Station. 

Both boilers are equipped with electrostatic precipitator emissions control

Industry/SCC/NAIS 221112

Sampling Location Information:

Test Parameter Information:

AFS #: 2613900060 FRS #: 110000411108

SCC / Description 10100211 External Combustion Boilers - Electric Generation - Bituminous/Subbituminous 

Coal - Wet Bottom (Tangential) (Bituminous 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

Boilers 1&2 228 0 0 0 2016 2004 4 48

Target

Parameter 

Test

Method

Number of

Test Runs

Test Run

Duration

Sample 

Location Points Comments

Boilers 1&2 Flowrate Method 1 - 4 6 240 0

Boilers 1&2 % H2O Method 1 - 4 6 240 0

Regulation Description Compound Limit Unit

EUBOILER1 Total Particulate 0.16 lb/1000 lb exhaust 

gas corrected to 

50% excess air

EUBOILER2 Total Particulate 0.15 lb/1000 lb exhaust 

gas corrected to 

50% excess air

Thursday, February 24, 2011 Page 2 of 12
Consumers Energy Boilers 1&2 Test Plan

9/1/2010

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.

Method 29 for Mercury instead of Method 30B. 

Use hexane in place of MeCl2 for solvent in OTM 28.

Organic Condensible 

Particulate

OTM - 27/28 3 240 0 Approx 240 min. 

Vary due to constant 

sampling rate.

Boilers 1&2

Inorganic (Aqueous) 

Condensible Part.

OTM - 27/28 3 240 0 Approx 240 min. 

Vary due to constant 

sampling rate.

Boilers 1&2

Filterable PM2.5 OTM - 27/28 3 240 0 Approx 240 min. 

Vary due to constant 

sampling rate.

Boilers 1&2

Total PM2.5 OTM - 27/28 3 240 0 Approx 240 min. 

Vary due to constant 

sampling rate.

Boilers 1&2

Boilers 1&2 Nickel Method 29 3 240 0

Boilers 1&2 Antimony Method 29 3 240 0

Boilers 1&2 Arsenic Method 29 3 240 0

Boilers 1&2 Beryllium Method 29 3 240 0

Boilers 1&2 Cobalt Method 29 3 240 0

Boilers 1&2 Chromium Method 29 3 240 0

Boilers 1&2 Lead Method 29 3 240 0

Boilers 1&2 Selenium Method 29 3 240 0

Boilers 1&2 Mercury Method 29 3 240 0

Boilers 1&2 Filterable Particulate Method 29 3 240 0

Boilers 1&2 Manganese Method 29 3 240 0

Boilers 1&2 Cadmium Method 29 3 240 0

Boilers 1&2 O2 Method 3A O2 3 240 0

Boilers 1&2 Co2 Method 3A CO2 3 240 0

Thursday, February 24, 2011 Page 3 of 12
Consumers Energy Boilers 1&2 Test Plan

9/1/2010

Sampling / Stack Data Results Summary

Location Boilers 1&2 - Method 29

Average

Run Number M29-R1 M29-R2 M29-R3

Test Date 6/2/2010 6/3/2010 6/3/2010

Run Start Time 10:12:00 AM 7:57:00 

AM

2:07:00 PM

Run Finish Time 3:56:00 PM 1:10:00 PM 7:06:00 PM

Net Run Time, minutes 240 240 240

Dry Gas Meter Volume Sampled, dscf 197.985 202.109 199.162 199.752

Moisture Content of Stack Gas, % 10.15 9.73 9.53 9.803

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

Carbon Dioxide, % 12.26 12.65 13.02 12.643

Oxygen, % 7.22 6.97 6.63 6.940

Average Stack Gas Temperature, °F 295.71 293.52 294.63 294.620

Dry Volumetric Flow Rate, dry scfm 1,313,164.1 1,341,341.7 1,322,211.2 1,325,572.33

3

Actual Wet Volumetric Flue Gas Flow Rate, acfm 2,126,637.6 2,155,897.8 2,123,575.5 2,135,370.30

0

Percent Isokinetic of Sampling Rate, % 100.8 100.7 100.7 100.733

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

Thursday, February 24, 2011 Page 4 of 12
Consumers Energy Boilers 1&2 Test Plan

9/1/2010

Location Boilers 1&2 - 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

Thursday, February 24, 2011 Page 5 of 12
Consumers Energy Boilers 1&2 Test Plan

9/1/2010

Emissions Summary

Location: Boilers 1&2 - Method 29

Compound: Antimony

Average

RunNumber M29-R1 M29-R2 M29-R3

Mass_mg 0.0048 0.0048 0.0048 0.005

Elb/hr 4.21E-03 4.21E-03 4.22E-03 0.004

lb/mmBtuO2 7.99E-07 7.68E-07 7.61E-07 0.000

Compound: Arsenic

Average

RunNumber M29-R1 M29-R2 M29-R3

Mass_mg 0.009 0.00939 0.00954 0.009

Elb/hr 7.90E-03 8.24E-03 8.38E-03 0.008

lb/mmBtuO2 1.50E-06 1.50E-06 1.51E-06 0.000

Compound: Beryllium

Average

RunNumber M29-R1 M29-R2 M29-R3

Mass_mg 0.00134 0.00139 0.00141 0.001

Elb/hr 1.18E-03 1.22E-03 1.24E-03 0.001

lb/mmBtuO2 2.23E-07 2.22E-07 2.24E-07 0.000

Compound: Cadmium

Average

RunNumber M29-R1 M29-R2 M29-R3

Mass_mg 0.00181 0.00149 0.00157 0.002

Elb/hr 1.59E-03 1.31E-03 1.38E-03 0.001

lb/mmBtuO2 3.01E-07 2.38E-07 2.49E-07 0.000

Compound: Chromium

Average

RunNumber M29-R1 M29-R2 M29-R3

Mass_mg 0.01148 0.01149 0.01053 0.011

Elb/hr 1.01E-02 1.01E-02 9.25E-03 0.010

lb/mmBtuO2 1.91E-06 1.84E-06 1.67E-06 0.000

Compound: Cobalt

Average

RunNumber M29-R1 M29-R2 M29-R3

Mass_mg 0.00363 0.00397 0.00429 0.004

Elb/hr 3.18E-03 3.49E-03 3.77E-03 0.003

lb/mmBtuO2 6.04E-07 6.35E-07 6.80E-07 0.000

Compound: Filterable Particulate

Average

RunNumber M29-R1 M29-R2 M29-R3

Mass_mg 67.3 65.9 72.5 68.567

Elb/hr 5.90E+01 5.79E+01 6.37E+01 60.200

lb/mmBtuO2 1.12E-02 1.05E-02 1.15E-02 0.011

Thursday, February 24, 2011 Page 6 of 12
Consumers Energy Boilers 1&2 Test Plan

9/1/2010

Compound: Lead

Average

RunNumber M29-R1 M29-R2 M29-R3

Mass_mg 0.0107 0.01228 0.01056 0.011

Elb/hr 9.39E-03 1.08E-02 9.27E-03 0.010

lb/mmBtuO2 1.78E-06 1.97E-06 1.67E-06 0.000

Compound: Manganese

Average

RunNumber M29-R1 M29-R2 M29-R3

Mass_mg 0.02565 0.02965 0.06685 0.041

Elb/hr 2.25E-02 2.60E-02 5.87E-02 0.036

lb/mmBtuO2 4.27E-06 4.75E-06 1.06E-05 0.000

Compound: Mercury

Average

RunNumber M29-R1 M29-R2 M29-R3

Mass_mg 0.004387 0.004251 0.0041219 0.004

Elb/hr 3.85E-03 3.73E-03 3.62E-03 0.004

lb/mmBtuO2 7.30E-07 6.80E-07 6.54E-07 0.000

Compound: Nickel

Average

RunNumber M29-R1 M29-R2 M29-R3

Mass_mg 0.02069 0.01639 0.01449 0.017

Elb/hr 1.82E-02 1.44E-02 1.27E-02 0.015

lb/mmBtuO2 3.44E-06 2.62E-06 2.30E-06 0.000

Compound: Selenium

Average

RunNumber M29-R1 M29-R2 M29-R3

Mass_mg 0.1348 0.1606 0.146 0.147

Elb/hr 1.18E-01 1.41E-01 1.28E-01 0.129

lb/mmBtuO2 2.24E-05 2.57E-05 2.31E-05 0.000

Location: Boilers 1&2 - OTM - 27/28

Compound: Filterable PM2.5

Average

RunNumber PM2.5 R1 PM2.5 R2 PM2.5 R3

Mass_mg 19.4 19.6 24.7 21.233

Elb/hr 3.98E+01 4.16E+01 5.13E+01 44.233

gr/dscf 3.49E-03 3.54E-03 4.45E-03 0.004

lb/mmBtuO2 7.45E-03 7.42E-03 9.10E-03 0.008

Compound: Inorganic (Aqueous) Condensible Pa

Average

RunNumber PM2.5 R1 PM2.5 R2 PM2.5 R3

Mass_mg 10.5 5 1.1 5.533

Elb/hr 2.15E+01 1.06E+01 2.29E+00 11.463

gr/dscf 1.89E-03 9.03E-04 1.98E-04 0.001

lb/mmBtuO2 4.03E-03 1.89E-03 4.05E-04 0.002

Thursday, February 24, 2011 Page 7 of 12
Consumers Energy Boilers 1&2 Test Plan

9/1/2010

Process Run Data

Compound: Organic Condensible Particulate

Average

RunNumber PM2.5 R1 PM2.5 R2 PM2.5 R3

Mass_mg 2.6 2.4 2.2 2.400

Elb/hr 5.33E+00 5.09E+00 4.57E+00 4.997

gr/dscf 4.68E-04 4.34E-04 3.96E-04 0.000

lb/mmBtuO2 9.99E-04 9.09E-04 8.10E-04 0.001

Compound: Total PM2.5

Average

RunNumber PM2.5 R1 PM2.5 R2 PM2.5 R3

Mass_mg 32.5 27 28 29.167

Elb/hr 6.66E+01 5.73E+01 5.82E+01 60.700

gr/dscf 5.85E-03 4.88E-03 5.04E-03 0.005

lb/mmBtuO2 1.25E-02 1.02E-02 1.03E-02 0.011

Thursday, February 24, 2011 Page 8 of 12
Consumers Energy Boilers 1&2 Test Plan

9/1/2010

Process Run Data

APCD Run Data

Process Lab Run Data

Run Name Value UOM Comments

Target

Value

1 Combined Boilers 1 and 2 Heat Input Rate 5466.5 mmbtu/hr 0

1 Boiler 1 Average Coal Feed Rate 149.9 tph 0

1 Boiler 2 Average Coal Feed Rate 143.6 tph 0

1 Boiler 1 Average Steam Output 1847.6 kpph 0

1 Boiler 2 Average Steam Output 2353.5 kpph 0

2 Combined Boilers 1 and 2 Heat Input Rate 5502.1 mmbtu/hr 0

2 Boiler 1 Average Coal Feed Rate 152 tph 0

2 Boiler 2 Average Coal Feed Rate 145.8 tph 0

2 Boiler 1 Average Steam Output 1834 kpph 0

2 Boiler 2 Average Steam Output 2373.8 kpph 0

3 Combined Boilers 1 and 2 Heat Input Rate 5512 mmbtu/hr 0

3 Boiler 1 Average Coal Feed Rate 149.6 tph 0

3 Boiler 2 Average Coal Feed Rate 146.9 tph 0

3 Boiler 1 Average Steam Output 1832 kpph 0

3 Boiler 2 Average Steam Output 2395 kpph 0

Run Name Value UOM Comments

1 Boiler 1 Coal Higher Heating Value 12063 Btu/lb

1 Boiler 1 Coal Moisture Content 28.16 %

1 Boiler 1 Coal Mercury Content 0.1 ppm

1 Boiler 1 Coal Arsenic Content 1 ppm

1 Boiler 1 Coal Beryllium Content 0.3 ppm

1 Boiler 1 Coal Cadmium Content 0.2 ppm

1 Boiler 1 Coal Chromium Content 4 ppm

1 Boiler 1 Coal Lead Content 2 ppm

1 Boiler 1 Coal Manganese Content 16 ppm

1 Boiler 1 Coal Nickel Content 5 ppm

1 Boiler 1 Coal Selenium Content 1 ppm

2 Boiler 1 Coal Higher Heating Value 12040 Btu/lb

2 Boiler 1 Coal Moisture Content 29.06 %

2 Boiler 1 Coal Mercury Content 0.12 ppm

2 Boiler 1 Coal Arsenic Content 1 ppm

Thursday, February 24, 2011 Page 9 of 12
Consumers Energy Boilers 1&2 Test Plan

9/1/2010

2 Boiler 1 Coal Beryllium Content 0.3 ppm

2 Boiler 1 Coal Cadmium Content 0.2 ppm

2 Boiler 1 Coal Chromium Content 5 ppm

2 Boiler 1 Coal Lead Content 2 ppm

2 Boiler 1 Coal Manganese Content 16 ppm

2 Boiler 1 Coal Nickel Content 6 ppm

2 Boiler 1 Coal Selenium Content 1 ppm

2 Boiler 2 Coal Higher Heating Value 12848 Btu/lb

2 Boiler 2 Coal Moisture Content 16.03 %

2 Boiler 2 Coal Mercury Content 0.08 ppm

2 Boiler 2 Coal Arsenic Content 4 ppm

2 Boiler 2 Coal Beryllium Content 1.6 ppm

2 Boiler 2 Coal Cadmium Content 0.2 ppm

2 Boiler 2 Coal Chromium Content 14 ppm

2 Boiler 2 Coal Lead Content 6 ppm

2 Boiler 2 Coal Manganese Content 13 ppm

2 Boiler 2 Coal Nickel Content 6 ppm

2 Boiler 2 Coal Selenium Content 4 ppm

3 Boiler 1 Coal Higher Heating Value 11998 Btu/lb

3 Boiler 1 Coal Moisture Content 28.29 %

3 Boiler 1 Coal Mercury Content 0.1 ppm

3 Boiler 1 Coal Arsenic Content 1 ppm

3 Boiler 1 Coal Beryllium Content 0.3 ppm

3 Boiler 1 Coal Cadmium Content 0.2 ppm

3 Boiler 1 Coal Chromium Content 5 ppm

3 Boiler 1 Coal Lead Content 2 ppm

3 Boiler 1 Coal Manganese Content 16 ppm

3 Boiler 1 Coal Nickel Content 6 ppm

3 Boiler 1 Coal Selenium Content 1 ppm

3 Boiler 2 Coal Higher Heating Value 12811 Btu/lb

3 Boiler 2 Coal Moisture Content 17.34 %

3 Boiler 2 Coal Mercury Content 0.08 ppm

3 Boiler 2 Coal Arsenic Content 3 ppm

3 Boiler 2 Coal Beryllium Content 1.5 ppm

3 Boiler 2 Coal Cadmium Content 0.2 ppm

3 Boiler 2 Coal Chromium Content 13 ppm

3 Boiler 2 Coal Lead Content 5 ppm

3 Boiler 2 Coal Manganese Content 16 ppm

3 Boiler 2 Coal Nickel Content 12 ppm

3 Boiler 2 Coal Selenium Content 4 ppm

Thursday, February 24, 2011 Page 10 of 12
Consumers Energy Boilers 1&2 Test Plan

9/1/2010

Sampling / Stack Data Results Detail

Location Boilers 1&2 - Method 29

Average

Run Number M29-R1 M29-R2 M29-R3

Test Date 6/2/2010 6/3/2010 6/3/2010

Run Start Time 10:12:00 AM 7:57:00 AM 2:07:00 PM

Run Finish Time 3:56:00 PM 1:10:00 PM 7:06:00 PM

Net Traversing Points 24 24 24

Net Run Time, minutes 240 240 240

Nozzle Diameter, inches 0.18 0.18 0.18 0.180

Pitot Tube Coefficient 0.84 0.84 0.84 0.840

Dry Gas Meter Calibration Factor 1.012 1.012 1.012 1.012

Barometric Pressure, inches of Mercury 29.73 29.73 29.73 29.730

Average Orifice Meter Differential, inches H2O 2.07 2.11 2.05 2.077

Dry Gas Meter Volume Sampled, cubic feet 201.487 203.497 200.657 201.880

Average Dry Gas Meter Temperature, °F 83.10 77.38 77.64 79.373

Dry Gas Meter Volume Sampled, dscf 197.985 202.109 199.162 199.752

Total Moisture Liquid collected, g 475 463 446 461.333

Volume of Water Vapor, standard cubic feet 22.36 21.79 20.99 21.713

Moisture Content of Stack Gas, % 10.15 9.73 9.53 9.803

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

Dry Mole Fraction 0.8985 0.9027 0.9047 0.902

Carbon Dioxide, % 12.26 12.65 13.02 12.643

Oxygen, % 7.22 6.97 6.63 6.940

Carbon Monoxide & Nitrogen, % 80.52 80.38 80.35 80.417

Fuel Factor 1.12 1.10 1.10

Dry Molecular Weight, lb/lb-Mole 30.25 30.30 30.35 30.300

Wet Molecular weight, lb/lb-Mole 29.01 29.10 29.17 29.093

Flue Gas Static Pressure, inches of H2O -4.1 -4.1 -4.1 -4.100

Absolute Flue Gas Pressure, inches of Mercury 29.43 29.43 29.43 29.430

Average Stack Gas Temperature, °F 295.71 293.52 294.63 294.620

Average Velocity Head, inches of H2O 3.4236752801

1419

3.539471157

23648

3.437722660

41924

3.467

Average Stack Gas Velocity, feet/second 125.01 126.73 124.83 125.523

Stack Cross-Sectional Area, square feet 283.529 283.529 283.529 283.529

Dry Volumetric Flow Rate, dry scfm 1,313,164.1 1,341,341.7 1,322,211.2 1,325,572.3

33

Actual Wet Volumetric Flue Gas Flow Rate, acfm 2,126,637.6 2,155,897.8 2,123,575.5 2,135,370.3

00

Percent Isokinetic of Sampling Rate, % 100.8 100.7 100.7 100.733

Percent Excess Air, % 51.4 48.9 45.5 48.600

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

Round Duct Diameter, inches 228 228 228

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

Thursday, February 24, 2011 Page 11 of 12
Consumers Energy Boilers 1&2 Test Plan

9/1/2010

Location Boilers 1&2 - 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

Thursday, February 24, 2011 Page 12 of 12