Name:

Title:

Company:

Sign Date:

Name:

Title:

Company:

Sign Date:

Permitted Facility Representative / Date Testing Company Representative / Date

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.

Friday, February 25, 2011 Page 1 of 13
Facility Information:

AES Beaver Valley

394 Frankfort Road

Monaca PA 15061

Contact: Person to contact for more detail

Phone: Of above personsadf

Fax: Of above personasdf

Email: Of above personsdf

Testing Company:

URS Corporation

1600 Permeter Park Dr.

Morrisville NC 27560

Contact:Brad Justus

Phone: 919-461-1326

Fax: 919-461-1415

Email: Brad_Justus@urscorp.com

Air Permit Number:

10676

Permitted Source ID/Name:

Boiler 4 Boiler 4

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:

40 MW, low NOX burners, overfire air, selective non-catalytic reduction, electrostatic precipitator, wet flue gas 

desulfurization

Industry/SCC/NAIS 221112

Sampling Location Information:

Test Parameter Information:

AFS #: 4200700002 FRS #: 110000329083

SCC / Description 10100212 External Combustion Boilers - Electric Generation - Bituminous/Subbituminous 

Coal - Pulverized Coal: Dry 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

Stack Exit 91 0 0 0 960 960 4 6

Target

Parameter 

Test

Method

Number of

Test Runs

Test Run

Duration

Sample 

Location Points Comments

Stack Exit % H2O Method 1 - 4 3 180 0

Stack Exit Carbon Monoxide Method 10 3 120 0

Stack Exit Formaldehyde Method 0011 3 120 0

Stack Exit 2,3,7,8-TCDD Method 23 3 480 0

Stack Exit 1,2,3,7,8-PeCDD Method 23 3 480 0

Stack Exit 1,2,3,4,7,8-HxCDD Method 23 3 480 0

Stack Exit 1,2,3,6,7,8-HxCDD Method 23 3 480 0

Friday, February 25, 2011 Page 2 of 13
Stack Exit 1,2,3,7,8,9-HxCDD Method 23 3 480 0

Stack Exit 1,2,3,4,6,7,8-HpCDD Method 23 3 480 0

Stack Exit OCDD Method 23 3 480 0

Stack Exit 2,3,7,8-TCDF Method 23 3 480 0

Stack Exit 1,2,3,7,8-PeCDF Method 23 3 480 0

Stack Exit 2,3,4,7,8-PeCDF Method 23 3 480 0

Stack Exit 1,2,3,4,7,8-HxCDF Method 23 3 480 0

Stack Exit 1,2,3,6,7,8-HxCDF Method 23 3 480 0

Stack Exit 2,3,4,6,7,8-HxCDF Method 23 3 480 0

Stack Exit 1,2,3,7,8,9-HxCDF Method 23 3 480 0

Stack Exit 1,2,3,4,6,7,8-HpCDF Method 23 3 480 0

Stack Exit 1,2,3,4,7,8,9-HpCDF Method 23 3 480 0

Stack Exit OCDF Method 23 3 480 0

Stack Exit Other TCDD Method 23 0

Stack Exit Other PeCDD Method 23 0

Stack Exit Other HxCDD Method 23 0

Stack Exit Other HpCDD Method 23 0

Stack Exit Other TCDF Method 23 0

Stack Exit Other PeCDF Method 23 0

Stack Exit Other HxCDF Method 23 0

Stack Exit Other HpCDF Method 23 0

Stack Exit Total Dioxins Method 23 3 480 0

Stack Exit Total Furans Method 23 3 480 0

Stack Exit 3,3',4,4'-TCB (PCB77) Method 23 3 480 0

Stack Exit 3,4,4',5-TCB (PCB81) Method 23 3 480 0

Stack Exit 2,3,3',4,4'-PeCB (PCB105) Method 23 3 480 0

Stack Exit 2,3,4,4',5-PeCB (PCB114) Method 23 3 480 0

Stack Exit 2,3',4,4',5-PeCB (PCB118) Method 23 3 480 0

Stack Exit 2',3,4,4',5-PeCB (PCB123) Method 23 3 480 0

Stack Exit 3,3',4,4',5-PeCB (PCB126) Method 23 3 480 0

2,3,3',4,4',5/2,3,3',4,4',5'-

HxCB (PCBs156/157)

Stack Exit Method 23 3 480 0

Stack Exit 2,3',4,4',5,5'-HxCB (PCB167) Method 23 3 480 0

Stack Exit 3,3',4,4',5,5'-HxCB (PCB169) Method 23 3 480 0

2,3,3',4,4',5,5'-HpCB 

(PCB189)

Stack Exit Method 23 3 480 0

Stack Exit Total PCBs Method 23 3 480 0

Stack Exit Total TEQ Method 23 3 480 0

Total organic compounds 

(TOC) as Propane

Stack Exit Method 25A 3 120 0

Stack Exit Hydrogen Chloride Method 26 3 180 0

Stack Exit Hydrogen Fluoride Method 26 3 180 0

Stack Exit Hydrogen Fluoride Method 26A 3 180 0

Stack Exit Hydrogen Chloride Method 26A 3 180 0

Filterable PM2.5 OTM - 27/28 3 240 0 Use only for dry 

stacks. Delete Method 

5/OTM28 tests.

Stack Exit

Filterable Particulate OTM - 27/28 3 240 0 Use only for dry 

stacks. Delete Method 

5/OTM28 tests.

Stack Exit

Inorganic (Aqueous) 

Condensible Part.

OTM - 27/28 3 240 0 Use only for dry 

stacks. Delete Method 

5/OTM28 tests.

Stack Exit

Friday, February 25, 2011 Page 3 of 13
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.

Organic Condensible 

Particulate

OTM - 27/28 3 240 0 Use only for dry 

stacks. Delete Method 

5/OTM28 tests.

Stack Exit

Total PM2.5 OTM - 27/28 3 240 0 Use only for dry 

stacks. Delete Method 

5/OTM28 tests.

Stack Exit

Total Particulate OTM - 27/28 3 240 0 Use only for dry 

stacks. Delete Method 

5/OTM28 tests.

Stack Exit

Stack Exit Filterable Particulate Method 29 3 240 0

Stack Exit Antimony Method 29 3 240 0

Stack Exit Arsenic Method 29 3 240 0

Stack Exit Beryllium Method 29 3 240 0

Stack Exit Cadmium Method 29 3 240 0

Stack Exit Chromium Method 29 3 240 0

Stack Exit Lead Method 29 3 240 0

Stack Exit Magnesium Method 29 3 240 0

Stack Exit Manganese Method 29 3 240 0

Stack Exit Mercury Method 29 3 240 0

Stack Exit Selenium Method 29 3 240 0

Stack Exit Nickel Method 29 3 240 0

Stack Exit O2 Method 3A O2 3 480 0

Stack Exit Co2 Method 3A CO2 3 120 0

Stack Exit O2 Method 3A O2 3 240 0

Stack Exit O2 Method 3A O2 3 120 0

Total Particulate Method 5/OTM-28 3 240 0 Use only for wet 

stacks. Delete 

OTM27/OTM28 test.

Stack Exit

Filterable Particulate Method 5/OTM-28 3 240 0 Use only for wet 

stacks. Delete 

OTM27/OTM28 test.

Stack Exit

Inorganic (Aqueous) 

Condensible Part.

Method 5/OTM-28 3 240 0 Use only for wet 

stacks. Delete 

OTM27/OTM28 test.

Stack Exit

Organic Condensible 

Particulate

Method 5/OTM-28 3 240 0 Use only for wet 

stacks. Delete 

OTM27/OTM28 test.

Stack Exit

Stack Exit Filterable Particulate Method 5 3 240 0

Stack Exit Sulfur Dioxide Method 6C 3 180 0

Stack Exit Nitrogen oxides (NOx) Method 7E 3 180 0

Friday, February 25, 2011 Page 4 of 13
Sampling / Stack Data Results Summary

Location Stack Exit - Method 10

Average

Run Number 1 2 3

Test Date 4/14/2010 4/13/2010 4/14/2010

Run Start Time 10:20:00 AM 12:40:00 

PM

5:05:00 PM

Run Finish Time 12:20:00 PM 2:58:00 PM 7:11:00 PM

Carbon Dioxide, % 7.25 7.61 7.37 7.410

Oxygen, % 12.04 11.5 11.5 11.680

Dry Volumetric Flow Rate, dry scfm 0 0 0 0.000

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

Moisture, % 0 0 0 0.000

Fuel Type Coal - 

Bituminous

Coal - 

Bituminous

Coal - 

Bituminous

Fw 10640 10640 10640 10,640.000

Fc 1800 1800 1800 1,800.000

Location Stack Exit - Method 25A

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

Friday, February 25, 2011 Page 5 of 13
Location Stack Exit - 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

Location Stack Exit - 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

Friday, February 25, 2011 Page 6 of 13
Emissions Summary

Process Run Data

Location: Stack Exit - Method 10

Compound: Carbon Monoxide

Average

Run 1 2 3

mg/dscm 1.06E+01 2.44E+01 1.72E+01 17.400

ppm 9.10E+00 2.09E+01 1.48E+01 14.933

ppm@7%O2 1.43E+01 3.09E+01 2.19E+01 22.367

Location: Stack Exit - Method 25A

Compound: Total organic compounds (TOC) as 

Average

Run 1 2 3

Elb/hr 0.00E+00 0.00E+00 0.00E+00 0.000

gr/dscf 3.71E-03 2.86E-03 2.33E-02 0.010

lb/mmBtuO2 1.22E-02 8.89E-03 7.22E-02 0.031

mg/dscm 8.49E+00 6.55E+00 5.32E+01 22.747

ppm 4.63E+00 3.57E+00 2.90E+01 12.400

ppm@7%O2 7.26E+00 5.28E+00 4.29E+01 18.480

Friday, February 25, 2011 Page 7 of 13
Process Run Data

Run Name Value UOM Comments

Target

Value

1 Heat Input 0 Million Btus 0

2 Heat Input 0 Million Btus 0

3 Heat Input 0 Million Btus 0

1 Average Heat Input 0 MMBtu/hr 0

2 Average Heat Input 0 MMBtu/hr 0

3 Average Heat Input 0 MMBtu/hr 0

1 Steam Output 0 1000 lb steam/hr 0

2 Steam Output 0 1000 lb steam/hr 0

3 Steam Output 0 1000 lb steam/hr 0

1 Synfuel Firing Rate 0 0

2 Synfuel Firing Rate 0 0

3 Synfuel Firing Rate 0 0

1 Petroleum Coke Firing Rate 0 0

2 Petroleum Coke Firing Rate 0 0

3 Petroleum Coke Firing Rate 0 0

1 Coal Gas Firing Rate 0 0

2 Coal Gas Firing Rate 0 0

3 Coal Gas Firing Rate 0 0

1 Fuel Oil Firing Rate 0 0

2 Fuel Oil Firing Rate 0 0

3 Fuel Oil Firing Rate 0 0

1 Flue Gas Flow Rate 0 dscfm 0

1 Pressure Drop Across FGD (if applicable) 0 in H20 0

1 FGD Scrubber Liquor pH 0 pH 0

1 FGD Scrubber Liquor Flow Rate 0 gal/min 0

1 Sorbent Type and Sorbent Injection Rate (if 

applicable)

0 lb/hr 0

1 Flue Gas Oxygen Content 0 % 0

1 Flue Gas Carbon Dioxide Content 0 % 0

1 Flue Gas Moisture Content 0 % 0

1 Flue Gas Sampling Point Temperature 0 Deg F 0

1 Flue Gas Pressure 0 atm 0

1 Standard Pressure 0 atm 0

1 Standard Temperature 0 Deg F 0

Friday, February 25, 2011 Page 8 of 13
APCD Run Data

Process Lab Run Data

1 Unit Gross Electrical Output 0 MW 0

1 Unit Net Electric Generation 0 MWh 0

Run Name Value UOM Comments

Target

Value

1 LOW NOX BURNERS 0 0

1 OVERFIRE AIR 0 0

1 SELECTIVE NONCATALYTIC REDUCTION 

FOR NOX

0 0

1 ELECTROSTATIC PRECIPITATOR 0 0

1 CAUSTIC SCRUBBER 0 0

Run Name Value UOM Comments

1 Fuel Higher Heating Value 0 Btu/lb

1 Fuel Moisture 0 %

1 Fuel Mercury Content 0 ppm

1 Fuel Cadmium Content 0 ppm

1 Ultimate/Proximate Analysis 0

1 Fuel Nickel Content 0 ppm

1 Fuel Arsenic Content 0 ppm

1 Fuel Chromium Content 0 ppm

1 Fuel Beryllium Content 0 ppm

1 Fuel Lead Content 0 ppm

1 Fuel Manganese Content 0 ppm

1 Fuel Chlorine Content 0 ppm

1 Fuel Fluorine Content 0 ppm

Friday, February 25, 2011 Page 9 of 13
Sampling / Stack Data Results Detail

Location Stack Exit - Method 10

Average

Run Number 1 2 3

Test Date 4/14/2010 4/13/2010 4/14/2010

Run Start Time 10:20:00 AM 12:40:00 PM 5:05:00 PM

Run Finish Time 12:20:00 PM 2:58:00 PM 7:11:00 PM

Carbon Dioxide, % 7.25 7.61 7.37 7.410

Oxygen, % 12.04 11.5 11.5 11.680

Fuel Factor 1.22 1.24 1.28

Dry Volumetric Flow Rate, dry scfm 0 0 0 0.000

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

Moisture, % 0 0 0 0.000

Analyzer Make

Analyzer Model

Analyzer Serial Number

Operating Range 0 0 0 0.000

Operating Units

No. Readings/Avg. 0 0 0 0.000

Calibration Set 3 3 3 3.000

Calibration Pre Zero Cylinder ID zero zero zero

Calibration Pre Zero Cylinder Instrument Response 2.68 2.77 0.22 1.890

Calibration Pre Zero Cylinder Bias 0.55 0.56 0.04 0.383

Calibration Pre Zero Cylinder Drift 0 0 0 0.000

Calibration Pre High Cylinder ID CC121718 CC121718 CC121718

Calibration Pre High Cylinder Instrument Response 224.85 224.91 227.7 225.820

Calibration Pre High Cylinder Bias -1.17 -1.15 -0.58 -0.967

Calibration Pre High Cylinder Drift 0 0 0 0.000

Calibration Post Zero Cylinder ID zero zero zero

Calibration Post Zero Cylinder Instrument Response 2.77 0.22 -0.42 0.857

Calibration Post Zero Cylinder Bias 0.56 0.04 -0.09 0.170

Calibration Post Zero Cylinder Drift 0.01 0.51 0.64 0.387

Calibration Post High Cylinder ID CC121718 CC121718 CC121718

Calibration Post High Cylinder Instrument Response 224.91 227.7 223.39 225.333

Calibration Post High Cylinder Bias -1.15 -0.58 -1.46 -1.063

Calibration Post High Cylinder Drift 0.02 0.59 0.29 0.300

Cavg 11.4 21.7 14.2 15.767

Cavg Units ppmvd ppmvd ppmvd

Cgas 9.0985 20.9411 14.7661 14.935

Cgas Units ppmvd ppmvd ppmvd

Fuel Type Coal - 

Bituminous

Coal - 

Bituminous

Coal - 

Bituminous

Fw 10640 10640 10640 10,640.000

Fc 1800 1800 1800 1,800.000

Cgasw 0 0 0 0.000

Cgasw Units

Friday, February 25, 2011 Page 10 of 13
Location Stack Exit - Method 25A

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

Friday, February 25, 2011 Page 11 of 13
Location Stack Exit - 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

Friday, February 25, 2011 Page 12 of 13
Location Stack Exit - 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

Friday, February 25, 2011 Page 13 of 13