Name: Gregory Costakis

Title: Manager Environmental Health and Sa

Company: Northern Indiana Public Service Comp

Sign Date: 9/7/2010

Name: Carl Vineyard

Title: Utility MACT Program Manager

Company: Grace Consulting, Inc.

Sign Date: 9/1/2010

Permitted Facility Representative / Date Testing Company Representative / Date

NIPSCO, BAILLY 7

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, BAILLY 7

9/7/2010

Facility Information:

Bailly

Northern Indiana Public Service Company

246 Bailly Station Road

Chesterton IN 46304

Contact: Gregory Costakis

Phone: 219-956-5125

Fax: 219-956-5228

Email: gcostakis@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@gcitest.com

Air Permit Number:

995

Permitted Source ID/Name:

7 Bailly

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:

Unit 7 - 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, with a selective catalytic 

reduction system for post-combustion NOx control and desulfurization system for control of sulfur dioxide. This 

facility also has a reagent injection system for SO3.

Industry/SCC/NAIS 221112

Sampling Location Information:

Test Parameter Information:

AFS #: 1812700002 FRS #: 110000397730

SCC / Description 10100203 External Combustion Boilers - Electric Generation - Bituminous/Subbituminous 

Coal - Cyclone Furnace (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

Common 

Stack (CS1)

396 0 0 0 990 3366 4 12

Target

Parameter 

Test

Method

Number of

Test Runs

Test Run

Duration

Sample 

Location Points Comments

Common Hydrogen Fluoride Method 26A 3 180 0

Stack (CS1)

Common Hydrogen Chloride Method 26A 3 180 0

Stack (CS1)

Regulation Description Compound Limit Unit

0

Monday, February 07, 2011 Page 2 of 13
NIPSCO, BAILLY 7

9/7/2010

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.

The HCN was sampled using CTM 033 with 2 Normal NaOH and an additional impinger for one hour per the 

clarification given by the USEPA in FAQ TEST-010. The preferred method is EPA CTM 033. The analysis is then 

with ion chromatography. Complete documentation is in the comment section of the ERT.

Common O2 Method 3A O2 3 180 0

Stack (CS1)

Common Co2 Method 3A CO2 3 180 0

Stack (CS1)

Common Sulfur Dioxide Method 6C 3 180 0

Stack (CS1)

Common Nitrogen oxides (NOx) Method 7E 3 180 0

Stack (CS1)

Monday, February 07, 2011 Page 3 of 13
NIPSCO, BAILLY 7

9/7/2010

Sampling / Stack Data Results Summary

Location Common Stack (CS1) - Method 26A

Average

Run Number 1 2 3

Test Date 7/8/2010 7/9/2010 7/9/2010

Run Start Time 6:50:00 PM 7:07:00 

AM

10:35:00 AM

Run Finish Time 10:04:30 PM 10:15:30 

AM

1:43:30 PM

Net Run Time, minutes 180 180 180

Dry Gas Meter Volume Sampled, dscf 109.531 112.235 112.019 111.262

Moisture Content of Stack Gas, % 15.96 16.25 16.17 16.127

Moisture Saturation at Stack Gas Temperature, % 14.69 14.86 15.04 14.863

Carbon Dioxide, % 12.7 12.6 12.7 12.667

Oxygen, % 6.7 6.8 6.8 6.767

Average Stack Gas Temperature, °F 128.08 128.46 128.92 128.487

Dry Volumetric Flow Rate, dry scfm 1,352,682.1 1,349,258.6 1,345,354.4 1,349,098.36

7

Actual Wet Volumetric Flue Gas Flow Rate, acfm 1,808,957.4 1,811,010.1 1,811,010.1 1,810,325.86

7

Percent Isokinetic of Sampling Rate, % 99.0 101.7 101.8 100.833

F-Factor, dscfm/MMBtu @ %O2 9676 9669 9647 9,664.000

Fw 0 0 0 0.000

Fc 0 0 0 0.000

Location Common Stack (CS1) - 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, BAILLY 7

9/7/2010

Location Common Stack (CS1) - 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 Common Stack (CS1) - Method 6C

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 5 of 13
NIPSCO, BAILLY 7

9/7/2010

Location Common Stack (CS1) - Method 7E

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 6 of 13
NIPSCO, BAILLY 7

9/7/2010

Emissions Summary

Process Run Data

Location: Common Stack (CS1) - Method 26A

Compound: Hydrogen Chloride

Average

RunNumber 1 2 3

Mass_mg 2.094 2.134 1.864 2.031

lb/mmBtuO2 6.00E-04 6.01E-04 5.25E-04 0.001

Compound: Hydrogen Fluoride

Average

RunNumber 1 2 3

Mass_mg 0.41 0.42 0.42 0.417

lb/mmBtuO2 1.18E-04 1.18E-04 1.18E-04 0.000

Location: Common Stack (CS1) - Method 6C

Compound: Sulfur Dioxide

Average

Run 1 2 3

lb/mmBtuO2 6.86E-02 1.21E-01 1.54E-01 0.115

ppm 2.90E+01 5.07E+01 6.46E+01 48.100

ppm@7%O2 2.84E+01 5.00E+01 6.37E+01 47.367

Location: Common Stack (CS1) - Method 7E

Compound: Nitrogen oxides (NOx)

Average

Run 1 2 3

lb/mmBtuO2 1.11E-01 1.26E-01 1.19E-01 0.119

ppm 6.50E+01 7.37E+01 7.00E+01 69.567

ppm@7%O2 6.36E+01 7.27E+01 6.90E+01 68.433

Monday, February 07, 2011 Page 7 of 13
NIPSCO, BAILLY 7

9/7/2010

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 1603 1600

2 Heat Input Million Btus/million BTU using CO2 1654 1600

3 Heat Input Million Btus/million BTU using CO2 1591 1600

1 Coal Flow 114 Klb/hr 115

2 Coal Flow 114 Klb/hr 115

3 Coal Flow 115 Klb/hr 115

1 MW 150 MWg 150

2 MW 149 MWg 150

3 MW 149 MWg 150

Run Name Value UOM Comments

Target

Value

1 OVERFIRE AIR 0.766 lb/mmBtu 0.75

2 OVERFIRE AIR 0.74 lb/mmBtu 0.75

3 OVERFIRE AIR 0.75 lb/mmBtu 0.75

1 SCR (SELECTIVE CATALYTIC REDUCTION) 0.114 lb/mmBtu 0.12

2 SCR (SELECTIVE CATALYTIC REDUCTION) 0.123 lb/mmBtu 0.12

3 SCR (SELECTIVE CATALYTIC REDUCTION) 0.12 lb/mmBtu 0.12

1 MISCELLANEOUS CONTROL DEVICES 

(Reagent Injection System for SO3)

NONE

2 MISCELLANEOUS CONTROL DEVICES 

(Reagent Injection System for SO3)

NONE

3 MISCELLANEOUS CONTROL DEVICES 

(Reagent Injection System for SO3)

NONE

1 ELECTROSTATIC PRECIPITATOR 9.09 Opacity 40

2 ELECTROSTATIC PRECIPITATOR 10.03 Opacity 40

3 ELECTROSTATIC PRECIPITATOR 2.8 Opacity 40

1 WET SCRUBBER 97.3 Percent 95

2 WET SCRUBBER 96.4 Percent 95

3 WET SCRUBBER 95.7 Percent 95

Run Name Value UOM Comments

1 N/A 0

Monday, February 07, 2011 Page 8 of 13
NIPSCO, BAILLY 7

9/7/2010

Sampling / Stack Data Results Detail

Location Common Stack (CS1) - Method 26A

Average

Run Number 1 2 3

Test Date 7/8/2010 7/9/2010 7/9/2010

Run Start Time 6:50:00 PM 7:07:00 AM 10:35:00 AM

Run Finish Time 10:04:30 PM 10:15:30 AM 1:43:30 PM

Net Traversing Points 24 24 24

Net Run Time, minutes 180 180 180

Nozzle Diameter, inches 0.267 0.267 0.267 0.267

Pitot Tube Coefficient 0.84 0.84 0.84 0.840

Dry Gas Meter Calibration Factor 0.967 0.967 0.967 0.967

Barometric Pressure, inches of Mercury 29.12 29.09 29.09 29.100

Average Orifice Meter Differential, inches H2O 1.37 1.36 1.37 1.367

Dry Gas Meter Volume Sampled, cubic feet 118.404 120.809 121.171 120.128

Average Dry Gas Meter Temperature, °F 79.04 76.17 78.83 78.013

Dry Gas Meter Volume Sampled, dscf 109.531 112.235 112.019 111.262

Total Moisture Liquid collected, g 442 462.5 459 454.500

Volume of Water Vapor, standard cubic feet 20.80 21.77 21.61 21.393

Moisture Content of Stack Gas, % 15.96 16.25 16.17 16.127

Moisture Saturation at Stack Gas Temperature, % 14.69 14.86 15.04 14.863

Dry Mole Fraction 0.8531 0.8514 0.8496 0.851

Carbon Dioxide, % 12.7 12.6 12.7 12.667

Oxygen, % 6.7 6.8 6.8 6.767

Carbon Monoxide & Nitrogen, % 80.6 80.6 80.5 80.567

Fuel Factor 1.12 1.12 1.11

Dry Molecular Weight, lb/lb-Mole 30.30 30.29 30.30 30.297

Wet Molecular weight, lb/lb-Mole 28.72 28.71 28.65 28.693

Flue Gas Static Pressure, inches of H2O 1.2 1.2 1.2 1.200

Absolute Flue Gas Pressure, inches of Mercury 29.21 29.18 29.18 29.190

Average Stack Gas Temperature, °F 128.08 128.46 128.92 128.487

Average Velocity Head, inches of H2O 0.3436966085

56804

0.343815073

833822

0.342849303

620784

0.343

Average Stack Gas Velocity, feet/second 35.25 35.29 35.29 35.277

Stack Cross-Sectional Area, square feet 855.299 855.299 855.299 855.299

Dry Volumetric Flow Rate, dry scfm 1,352,682.1 1,349,258.6 1,345,354.4 1,349,098.3

67

Actual Wet Volumetric Flue Gas Flow Rate, acfm 1,808,957.4 1,811,010.1 1,811,010.1 1,810,325.8

67

Percent Isokinetic of Sampling Rate, % 99.0 101.7 101.8 100.833

Percent Excess Air, % 46.0 47.0 47.1 46.700

F-Factor, dscfm/MMBtu @ %O2 9676 9669 9647 9,664.000

Round Duct Diameter, inches 396 396 396

Rectangular Duct Width, inches 0 0 0

Rectangular Duct Length, inches 0 0 0

Fw 0 0 0 0.000

Fc 0 0 0 0.000

Monday, February 07, 2011 Page 9 of 13
NIPSCO, BAILLY 7

9/7/2010

Location Common Stack (CS1) - 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 10 of 13
NIPSCO, BAILLY 7

9/7/2010

Location Common Stack (CS1) - 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 11 of 13
NIPSCO, BAILLY 7

9/7/2010

Location Common Stack (CS1) - Method 6C

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, BAILLY 7

9/7/2010

Location Common Stack (CS1) - Method 7E

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 13 of 13