### 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.

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### 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: Bailly 7 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) 396 990 3366 4 0 12 0 0

Target Parameter Test Method Number of

Test Runs Test Run

Duration Sample

Points Comments Location Hydrogen Fluoride Method 26A 3 180 0 Common Stack (CS1) Hydrogen Chloride Method 26A 3 180 0 Common 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.

O2 Method 3A O2 3 180 0 Common Stack (CS1) Co2 Method 3A CO2 3 180 0 Common Stack (CS1) Sulfur Dioxide Method 6C 3 180 0 Common Stack (CS1) Nitrogen oxides (NOx) Method 7E 3 180 0 Common 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 1603 Million Btus/million BTU using CO2 1600


### 2 Heat Input 1654 Million Btus/million BTU using CO2 1600
3 Heat Input 1591 Million Btus/million BTU using CO2 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