Name: John M. McManus

Title: Vice President- Environmental Service

Company: American Electric Power

Sign Date: 6/30/2010

Name: Scott W. Banach

Title: Director, Project Engineering

Company: Platt Environmental

Sign Date: 6/25/2010

Permitted Facility Representative / Date Testing Company Representative / Date

Cardinal Unit 1

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.

Tuesday, January 18, 2011 Page 1 of 21
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Facility Information:

Cardinal Unit 1

306 County Road 7 East

Brilliant OH 43913

Contact: Paul Jackson

Phone: 614-716-3278

Fax: 614-716-1252

Email: pmjackson@aep.com

Testing Company:

Platt Environmental Services, Inc.

1520 Kensington Road

Suite 204

Oak Brook IL 60523

Contact: Scott Banach

Phone: 630-521-9400

Fax: 630-521-9494

Email: sbanach@plattenv.com

Air Permit Number:

06-41-05-0002

Permitted Source ID/Name:

Unit 1 Unit 1

Permitted Maximum Process Rate:

N/A

Max. Normal Operation Process Rate:

N/A

Target Process Test Rate

N/A

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

 process flow diagram:

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.

Industry/SCC/NAIS 221112

Sampling Location Information:

Test Parameter Information:

AFS #: FRS #:

SCC / Description 10100202 External Combustion Boilers - Electric Generation - Bituminous/Subbituminous 

Coal - Pulverized Coal: Dry Bottom (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

Stack 357.6 0 0 0 715.2 2861 4 12

Target

Parameter 

Test

Method

Number of

Test Runs

Test Run

Duration

Sample 

Location Points Comments

Stack Hydrogen Fluoride Method 26A 3 0

Stack Hydrogen Chloride Method 26A 3 0

Stack O2 Method 3A O2 3 0

Stack Co2 Method 3A CO2 3 0

Tuesday, January 18, 2011 Page 2 of 21
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Tuesday, January 18, 2011 Page 3 of 21
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Sampling / Stack Data Results Summary

Location Stack - Method 26A

Average

Run Number M26A-1 M26A-2 M26A-3

Test Date 5/18/2010 5/18/2010 5/19/2010

Run Start Time 8:00:00 AM 11:40:00 

AM

7:07:00 AM

Run Finish Time 11:15:00 AM 2:50:00 PM 10:17:00 AM

Net Run Time, minutes 180 180 180

Dry Gas Meter Volume Sampled, dscf 108.039 108.170 106.367 107.525

Moisture Content of Stack Gas, % 13.97 13.63 14.04 13.880

Moisture Saturation at Stack Gas Temperature, % 12.75 12.79 13.11 12.883

Carbon Dioxide, % 11.8 11.88 12.12 11.933

Oxygen, % 7.06 6.94 7.28 7.093

Average Stack Gas Temperature, °F 122.08 122.21 122.83 122.373

Dry Volumetric Flow Rate, dry scfm 1,556,664.4 1,560,981.7 1,520,714.3 1,546,120.13

3

Actual Wet Volumetric Flue Gas Flow Rate, acfm 2,057,661.2 2,064,775.4 2,036,737.3 2,053,057.96

7

Percent Isokinetic of Sampling Rate, % 105.7 105.5 106.5 105.900

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

Location Stack - 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

Tuesday, January 18, 2011 Page 4 of 21
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Location Stack - 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

Tuesday, January 18, 2011 Page 5 of 21
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Emissions Summary

Process Run Data

Location: Stack - Method 26A

Compound: Hydrogen Chloride

Average

RunNumber M26A-1 M26A-2 M26A-3

Mass_mg 0.48 0.4 0.53 0.470

lb/mmBtuO2 1.45E-04 1.19E-04 1.65E-04 0.000

Compound: Hydrogen Fluoride

Average

RunNumber M26A-1 M26A-2 M26A-3

Mass_mg 0.28 0.25 0.32 0.283

lb/mmBtuO2 8.44E-05 7.46E-05 9.95E-05 0.000

Tuesday, January 18, 2011 Page 6 of 21
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Process Run Data

Run Name Value UOM Comments

Target

Value

1 Bituminous Coal Burned 452 klb/h The ERT requires 

that the process 

data collected 

during the stack 

test period be 

accompanied by a 

target value. For 

the AEP tests, we 

want to clarify that 

the target value 

provided does not 

represent any limit 

or maximum 

design set point for 

operation of the 

steam generators 

and associated 

control 

equipment. In 

some cases, the 

value is a permit or 

regulatory limit, 

such as the case of 

opacity. Operation 

outside of the 

target value does 

not represent 

abnormal 

operation.

450

Tuesday, January 18, 2011 Page 7 of 21
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1 Load 586 MW The ERT requires 

that the process 

data collected 

during the stack 

test period be 

accompanied by a 

target value. For 

the AEP tests, we 

want to clarify that 

the target value 

provided does not 

represent any limit 

or maximum 

design set point for 

operation of the 

steam generators 

and associated 

control 

equipment. In 

some cases, the 

value is a permit or 

regulatory limit, 

such as the case of 

opacity. Operation 

outside of the 

target value does 

not represent 

abnormal 

operation.

550

Tuesday, January 18, 2011 Page 8 of 21
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1 Steam Pressure 3580 psig The ERT requires 

that the process 

data collected 

during the stack 

test period be 

accompanied by a 

target value. For 

the AEP tests, we 

want to clarify that 

the target value 

provided does not 

represent any limit 

or maximum 

design set point for 

operation of the 

steam generators 

and associated 

control 

equipment. In 

some cases, the 

value is a permit or 

regulatory limit, 

such as the case of 

opacity. Operation 

outside of the 

target value does 

not represent 

abnormal 

operation.

3600

Tuesday, January 18, 2011 Page 9 of 21
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1 Excess Air 23.7 % The ERT requires 

that the process 

data collected 

during the stack 

test period be 

accompanied by a 

target value. For 

the AEP tests, we 

want to clarify that 

the target value 

provided does not 

represent any limit 

or maximum 

design set point for 

operation of the 

steam generators 

and associated 

control 

equipment. In 

some cases, the 

value is a permit or 

regulatory limit, 

such as the case of 

opacity. Operation 

outside of the 

target value does 

not represent 

abnormal 

operation.

25

Tuesday, January 18, 2011 Page 10 of 21
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2 Bituminous Coal Burned 452 klb/h The ERT requires 

that the process 

data collected 

during the stack 

test period be 

accompanied by a 

target value. For 

the AEP tests, we 

want to clarify that 

the target value 

provided does not 

represent any limit 

or maximum 

design set point for 

operation of the 

steam generators 

and associated 

control 

equipment. In 

some cases, the 

value is a permit or 

regulatory limit, 

such as the case of 

opacity. Operation 

outside of the 

target value does 

not represent 

abnormal 

operation.

450

Tuesday, January 18, 2011 Page 11 of 21
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2 Load 586 MW The ERT requires 

that the process 

data collected 

during the stack 

test period be 

accompanied by a 

target value. For 

the AEP tests, we 

want to clarify that 

the target value 

provided does not 

represent any limit 

or maximum 

design set point for 

operation of the 

steam generators 

and associated 

control 

equipment. In 

some cases, the 

value is a permit or 

regulatory limit, 

such as the case of 

opacity. Operation 

outside of the 

target value does 

not represent 

abnormal 

operation.

550

Tuesday, January 18, 2011 Page 12 of 21
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2 Steam Pressure 3580 psig The ERT requires 

that the process 

data collected 

during the stack 

test period be 

accompanied by a 

target value. For 

the AEP tests, we 

want to clarify that 

the target value 

provided does not 

represent any limit 

or maximum 

design set point for 

operation of the 

steam generators 

and associated 

control 

equipment. In 

some cases, the 

value is a permit or 

regulatory limit, 

such as the case of 

opacity. Operation 

outside of the 

target value does 

not represent 

abnormal 

operation.

3600

Tuesday, January 18, 2011 Page 13 of 21
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2 Excess Air 23.7 % The ERT requires 

that the process 

data collected 

during the stack 

test period be 

accompanied by a 

target value. For 

the AEP tests, we 

want to clarify that 

the target value 

provided does not 

represent any limit 

or maximum 

design set point for 

operation of the 

steam generators 

and associated 

control 

equipment. In 

some cases, the 

value is a permit or 

regulatory limit, 

such as the case of 

opacity. Operation 

outside of the 

target value does 

not represent 

abnormal 

operation.

25

Tuesday, January 18, 2011 Page 14 of 21
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3 Bituminous Coal Burned 452 klb/h The ERT requires 

that the process 

data collected 

during the stack 

test period be 

accompanied by a 

target value. For 

the AEP tests, we 

want to clarify that 

the target value 

provided does not 

represent any limit 

or maximum 

design set point for 

operation of the 

steam generators 

and associated 

control 

equipment. In 

some cases, the 

value is a permit or 

regulatory limit, 

such as the case of 

opacity. Operation 

outside of the 

target value does 

not represent 

abnormal 

operation.

450

Tuesday, January 18, 2011 Page 15 of 21
Cardinal Unit 1

6/30/2010

3 Load 586 MW The ERT requires 

that the process 

data collected 

during the stack 

test period be 

accompanied by a 

target value. For 

the AEP tests, we 

want to clarify that 

the target value 

provided does not 

represent any limit 

or maximum 

design set point for 

operation of the 

steam generators 

and associated 

control 

equipment. In 

some cases, the 

value is a permit or 

regulatory limit, 

such as the case of 

opacity. Operation 

outside of the 

target value does 

not represent 

abnormal 

operation.

550

Tuesday, January 18, 2011 Page 16 of 21
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3 Steam Pressure 3580 psig The ERT requires 

that the process 

data collected 

during the stack 

test period be 

accompanied by a 

target value. For 

the AEP tests, we 

want to clarify that 

the target value 

provided does not 

represent any limit 

or maximum 

design set point for 

operation of the 

steam generators 

and associated 

control 

equipment. In 

some cases, the 

value is a permit or 

regulatory limit, 

such as the case of 

opacity. Operation 

outside of the 

target value does 

not represent 

abnormal 

operation.

3600

Tuesday, January 18, 2011 Page 17 of 21
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APCD Run Data

Process Lab Run Data

3 Excess Air 23.7 % The ERT requires 

that the process 

data collected 

during the stack 

test period be 

accompanied by a 

target value. For 

the AEP tests, we 

want to clarify that 

the target value 

provided does not 

represent any limit 

or maximum 

design set point for 

operation of the 

steam generators 

and associated 

control 

equipment. In 

some cases, the 

value is a permit or 

regulatory limit, 

such as the case of 

opacity. Operation 

outside of the 

target value does 

not represent 

abnormal 

operation.

25

Run Name Value UOM Comments

Target

Value

1 ELECTROSTATIC PRECIPITATOR - HIGH 

EFFICIENCY

10 % 20

2 ELECTROSTATIC PRECIPITATOR - HIGH 

EFFICIENCY

10 % 20

3 ELECTROSTATIC PRECIPITATOR - HIGH 

EFFICIENCY

10 % 20

1 SCR (SELECTIVE CATALYTIC REDUCTION) 0.054 lb/mmbtu 0.08

2 SCR (SELECTIVE CATALYTIC REDUCTION) 0.054 lb/mmbtu 0.08

3 SCR (SELECTIVE CATALYTIC REDUCTION) 0.054 lb/mmbtu 0.08

1 SCRUBBER 0.15 lb/mmbtu 0.2

2 SCRUBBER 0.15 lb/mmbtu 0.2

3 SCRUBBER 0.15 lb/mmbtu 0.2

Tuesday, January 18, 2011 Page 18 of 21
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Tuesday, January 18, 2011 Page 19 of 21
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Sampling / Stack Data Results Detail

Location Stack - Method 26A

Average

Run Number M26A-1 M26A-2 M26A-3

Test Date 5/18/2010 5/18/2010 5/19/2010

Run Start Time 8:00:00 AM 11:40:00 AM 7:07:00 AM

Run Finish Time 11:15:00 AM 2:50:00 PM 10:17:00 AM

Net Traversing Points 28 28 28

Net Run Time, minutes 180 180 180

Nozzle Diameter, inches 0.216 0.216 0.216 0.216

Pitot Tube Coefficient 0.84 0.84 0.84 0.840

Dry Gas Meter Calibration Factor 0.995 0.995 0.995 0.995

Barometric Pressure, inches of Mercury 28.75 28.75 28.53 28.677

Average Orifice Meter Differential, inches H2O 1.07 1.08 1.04 1.063

Dry Gas Meter Volume Sampled, cubic feet 117.405 117.901 116.403 117.236

Average Dry Gas Meter Temperature, °F 90.08 91.75 89.69 90.507

Dry Gas Meter Volume Sampled, dscf 108.039 108.170 106.367 107.525

Total Moisture Liquid collected, g 372.8 362.6 369.2 368.200

Volume of Water Vapor, standard cubic feet 17.55 17.07 17.38 17.333

Moisture Content of Stack Gas, % 13.97 13.63 14.04 13.880

Moisture Saturation at Stack Gas Temperature, % 12.75 12.79 13.11 12.883

Dry Mole Fraction 0.8725 0.8721 0.8689 0.871

Carbon Dioxide, % 11.8 11.88 12.12 11.933

Oxygen, % 7.06 6.94 7.28 7.093

Carbon Monoxide & Nitrogen, % 81.14 81.18 80.6 80.973

Fuel Factor 1.17 1.18 1.12

Dry Molecular Weight, lb/lb-Mole 30.17 30.18 30.23 30.193

Wet Molecular weight, lb/lb-Mole 28.84 28.77 28.79 28.800

Flue Gas Static Pressure, inches of H2O -2 -2 -2 -2.000

Absolute Flue Gas Pressure, inches of Mercury 28.60 28.60 28.38 28.527

Average Stack Gas Temperature, °F 122.08 122.21 122.83 122.373

Average Velocity Head, inches of H2O 0.6643636813

2686

0.667148751

724792

0.643841365

859838

0.658

Average Stack Gas Velocity, feet/second 49.17 49.34 48.67 49.060

Stack Cross-Sectional Area, square feet 697.465 697.465 697.465 697.465

Dry Volumetric Flow Rate, dry scfm 1,556,664.4 1,560,981.7 1,520,714.3 1,546,120.1

33

Actual Wet Volumetric Flue Gas Flow Rate, acfm 2,057,661.2 2,064,775.4 2,036,737.3 2,053,057.9

67

Percent Isokinetic of Sampling Rate, % 105.7 105.5 106.5 105.900

Percent Excess Air, % 49.2 47.9 52.0 49.700

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

Round Duct Diameter, inches 357.6 357.6 357.6

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

Tuesday, January 18, 2011 Page 20 of 21
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Location Stack - 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

Tuesday, January 18, 2011 Page 21 of 21
Cardinal Unit 1

6/30/2010

Location Stack - 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

Tuesday, January 18, 2011 Page 22 of 21