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 Services, Inc.

Sign Date: 6/25/2010

Permitted Facility Representative / Date Testing Company Representative / Date

Cardinal Unit 2

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 2

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 2 Unit 2

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 4/13/2010 4/13/2010 4/14/2010

Run Start Time 8:07:00 AM 12:10:00 

PM

6:45:00 AM

Run Finish Time 11:37:00 AM 3:31:00 PM 10:00:00 AM

Net Run Time, minutes 180 180 180

Dry Gas Meter Volume Sampled, dscf 115.897 115.938 115.400 115.745

Moisture Content of Stack Gas, % 12.89 13.12 12.93 12.980

Moisture Saturation at Stack Gas Temperature, % 12.04 11.91 11.90 11.950

Carbon Dioxide, % 12.2 12.2 12.3 12.233

Oxygen, % 6.9 6.9 6.9 6.900

Average Stack Gas Temperature, °F 120.67 120.25 119.79 120.237

Dry Volumetric Flow Rate, dry scfm 1,527,925.0 1,524,110.8 1,529,533.5 1,527,189.76

7

Actual Wet Volumetric Flue Gas Flow Rate, acfm 1,963,503.5 1,954,296.9 1,984,008.9 1,967,269.76

7

Percent Isokinetic of Sampling Rate, % 100.1 100.4 99.6 100.033

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 1 2 3

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

Run Start Time 7:53:00 AM 9:37:00 

AM

11:33:00 AM

Run Finish Time 9:31:00 AM 11:14:00 

AM

1:27:00 PM

Carbon Dioxide, % 12.2 12.2 12.3 12.233

Oxygen, % 6.9 6.9 6.9 6.900

Dry Volumetric Flow Rate, dry scfm 1458181 1456909 1461356 1,458,815.33

3

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

Moisture, % 12.1 11.9 11.9 11.967

Fuel Type Coal - 

Bituminous

Coal - 

Bituminous

Coal - 

Bituminous

Fw 10640 10640 10640 10,640.000

Fc 1800 1800 1800 1,800.000

Tuesday, January 18, 2011 Page 4 of 21
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Location Stack - Method 3A O2

Average

Run Number 1 2 3

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

Run Start Time 7:53:00 AM 9:37:00 

AM

11:33:00 AM

Run Finish Time 9:31:00 AM 11:14:00 

AM

1:27:00 PM

Carbon Dioxide, % 12.2 12.2 12.3 12.233

Oxygen, % 6.9 6.9 6.9 6.900

Dry Volumetric Flow Rate, dry scfm 1458181 1456909 1461356 1,458,815.33

3

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

Moisture, % 12.1 11.9 11.9 11.967

Fuel Type Coal - 

Bituminous

Coal - 

Bituminous

Coal - 

Bituminous

Fw 10640 10640 10640 10,640.000

Fc 1800 1800 1800 1,800.000

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 0.52 0.89 0.59 0.667

lb/mmBtuO2 1.44E-04 2.47E-04 1.65E-04 0.000

Compound: Hydrogen Fluoride

Average

RunNumber M26A-1 M26A-2 M26A-3

Mass_mg 0.28 0.31 0.29 0.293

lb/mmBtuO2 7.78E-05 8.61E-05 8.09E-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 440 klb/hr 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 632 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.

635

Tuesday, January 18, 2011 Page 8 of 21
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1 Steam Pressure 3581 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 26 % 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.

28

Tuesday, January 18, 2011 Page 10 of 21
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2 Bituminous Coal Burned 440 klb/hr 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 632 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.

635

Tuesday, January 18, 2011 Page 12 of 21
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2 Steam Pressure 3581 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 26 % 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.

28

Tuesday, January 18, 2011 Page 14 of 21
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3 Bituminous Coal Burned 440 klb/hr 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
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3 Load 632 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.

635

Tuesday, January 18, 2011 Page 16 of 21
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3 Steam Pressure 3582 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 26 % 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.

28

Run Name Value UOM Comments

Target

Value

1 ELECTROSTATIC PRECIPITATOR - HIGH 

EFFICIENCY

8.8 % 20

2 ELECTROSTATIC PRECIPITATOR - HIGH 

EFFICIENCY

8.8 % 20

3 ELECTROSTATIC PRECIPITATOR - HIGH 

EFFICIENCY

8.8 % 20

1 SCRUBBER 0.15 lb/mmBTU 0.2

2 SCRUBBER 0.15 lb/mmBTU 0.2

3 SCRUBBER 0.15 lb/mmBTU 0.2

1 SCR (SELECTIVE CATALYTIC REDUCTION) 0.041 lb/mmBTU 0.08

2 SCR (SELECTIVE CATALYTIC REDUCTION) 0.041 lb/mmBTU 0.08

3 SCR (SELECTIVE CATALYTIC REDUCTION) 0.041 lb/mmBTU 0.08

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 4/13/2010 4/13/2010 4/14/2010

Run Start Time 8:07:00 AM 12:10:00 PM 6:45:00 AM

Run Finish Time 11:37:00 AM 3:31:00 PM 10:00:00 AM

Net Traversing Points 28 28 28

Net Run Time, minutes 180 180 180

Nozzle Diameter, inches 0.232 0.232 0.232 0.232

Pitot Tube Coefficient 0.84 0.84 0.84 0.840

Dry Gas Meter Calibration Factor 0.989 0.989 0.989 0.989

Barometric Pressure, inches of Mercury 29.26 29.26 28.9 29.140

Average Orifice Meter Differential, inches H2O 1.18 1.17 1.19 1.180

Dry Gas Meter Volume Sampled, cubic feet 121.955 121.807 121.714 121.825

Average Dry Gas Meter Temperature, °F 78.96 78.10 73.60 76.887

Dry Gas Meter Volume Sampled, dscf 115.897 115.938 115.400 115.745

Total Moisture Liquid collected, g 364.3 372.1 364.2 366.867

Volume of Water Vapor, standard cubic feet 17.15 17.51 17.14 17.267

Moisture Content of Stack Gas, % 12.89 13.12 12.93 12.980

Moisture Saturation at Stack Gas Temperature, % 12.04 11.91 11.90 11.950

Dry Mole Fraction 0.8796 0.8809 0.881 0.881

Carbon Dioxide, % 12.2 12.2 12.3 12.233

Oxygen, % 6.9 6.9 6.9 6.900

Carbon Monoxide & Nitrogen, % 80.9 80.9 80.8 80.867

Fuel Factor 1.15 1.15 1.14

Dry Molecular Weight, lb/lb-Mole 30.23 30.23 30.24 30.233

Wet Molecular weight, lb/lb-Mole 28.91 28.99 28.97 28.957

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

Absolute Flue Gas Pressure, inches of Mercury 29.11 29.11 28.75 28.990

Average Stack Gas Temperature, °F 120.67 120.25 119.79 120.237

Average Velocity Head, inches of H2O 0.6187408035

50323

0.614942421

689983

0.626260205

941808

0.620

Average Stack Gas Velocity, feet/second 46.92 46.70 47.41 47.010

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

Dry Volumetric Flow Rate, dry scfm 1,527,925.0 1,524,110.8 1,529,533.5 1,527,189.7

67

Actual Wet Volumetric Flue Gas Flow Rate, acfm 1,963,503.5 1,954,296.9 1,984,008.9 1,967,269.7

67

Percent Isokinetic of Sampling Rate, % 100.1 100.4 99.6 100.033

Percent Excess Air, % 47.7 47.7 47.8 47.733

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 1 2 3

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

Run Start Time 7:53:00 AM 9:37:00 AM 11:33:00 AM

Run Finish Time 9:31:00 AM 11:14:00 AM 1:27:00 PM

Carbon Dioxide, % 12.2 12.2 12.3 12.233

Oxygen, % 6.9 6.9 6.9 6.900

Fuel Factor 1.15 1.15 1.14

Dry Volumetric Flow Rate, dry scfm 1458181 1456909 1461356 1,458,815.3

33

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

Moisture, % 12.1 11.9 11.9 11.967

Analyzer Make Servomex ServoMex ServoMex

Analyzer Model 01440D1 01440D1 01440D1 14,400.000

Analyzer Serial Number 3790 3790 3790 3,790.000

Operating Range 20 20 20 20.000

Operating Units % % %

No. Readings/Avg. 98 97 126 107.000

Calibration Set 0 0 0 0.000

Calibration Pre Zero Cylinder ID CC59368-CO2 CC59368-

CO2

CC59368-

CO2

Calibration Pre Zero Cylinder Instrument Response 0.02 0.06 0.04 0.040

Calibration Pre Zero Cylinder Bias 0 0.2 0.1 0.100

Calibration Pre Zero Cylinder Drift 0 0 0 0.000

Calibration Pre High Cylinder ID SG9150811B

AL-CO2

SG9150811B

AL-CO2

SG9150811B

AL-CO2

Calibration Pre High Cylinder Instrument Response 10.03 10.1 10.08 10.070

Calibration Pre High Cylinder Bias 0 0.35 0.25 0.200

Calibration Pre High Cylinder Drift 0 0 0 0.000

Calibration Post Zero Cylinder ID CC59368-CO2 CC59368-

CO2

CC59368-

CO2

Calibration Post Zero Cylinder Instrument Response 0.06 0.04 0.04 0.047

Calibration Post Zero Cylinder Bias 0.2 0.1 0.1 0.133

Calibration Post Zero Cylinder Drift 0.2 0.1 0 0.100

Calibration Post High Cylinder ID SG9150811B

AL-CO2

SG9150811B

AL-CO2

SG9150811B

AL-CO2

Calibration Post High Cylinder Instrument Response 10.1 10.08 10.07 10.083

Calibration Post High Cylinder Bias 0.35 0.25 0.2 0.267

Calibration Post High Cylinder Drift 0.35 0.1 0.05 0.167

Cavg 12 12 12.2 12.067

Cavg Units %vd %vd %vd

Cgas 11.8825 11.8548 12.0691 11.935

Cgas Units %vd %vd %vd

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

Tuesday, January 18, 2011 Page 21 of 21
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6/30/2010

Location Stack - Method 3A O2

Average

Run Number 1 2 3

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

Run Start Time 7:53:00 AM 9:37:00 AM 11:33:00 AM

Run Finish Time 9:31:00 AM 11:14:00 AM 1:27:00 PM

Carbon Dioxide, % 12.2 12.2 12.3 12.233

Oxygen, % 6.9 6.9 6.9 6.900

Fuel Factor 1.15 1.15 1.14

Dry Volumetric Flow Rate, dry scfm 1458181 1456909 1461356 1,458,815.3

33

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

Moisture, % 12.1 11.9 11.9 11.967

Analyzer Make ServoMex ServoMex ServoMex

Analyzer Model 01440D1 01440D1 01440D1 14,400.000

Analyzer Serial Number 3790 3790 3790 3,790.000

Operating Range 25 25 25 25.000

Operating Units % % %

No. Readings/Avg. 98 97 126 107.000

Calibration Set 1 1 1 1.000

Calibration Pre Zero Cylinder ID SG9150811B

AL-O2

SG9150811B

AL-O2

SG9150811B

AL-O2

Calibration Pre Zero Cylinder Instrument Response -0.01 -0.04 -0.06 -0.037

Calibration Pre Zero Cylinder Bias 0 -0.12 -0.2 -0.107

Calibration Pre Zero Cylinder Drift 0 0 0 0.000

Calibration Pre High Cylinder ID CC59368-O2 CC59368-O2 CC59368-O2

Calibration Pre High Cylinder Instrument Response 11.98 11.96 11.98 11.973

Calibration Pre High Cylinder Bias 0 -0.08 0 -0.027

Calibration Pre High Cylinder Drift 0 0 0 0.000

Calibration Post Zero Cylinder ID SG9150811B

AL-O2

SG9150811B

AL-O2

SG9150811B

AL-O2

Calibration Post Zero Cylinder Instrument Response -0.04 -0.06 -0.05 -0.050

Calibration Post Zero Cylinder Bias -0.12 -0.2 -0.16 -0.160

Calibration Post Zero Cylinder Drift 0.12 0.08 0.04 0.080

Calibration Post High Cylinder ID CC59368-O2 CC59368-O2 CC59368-O2

Calibration Post High Cylinder Instrument Response 11.96 11.98 11.98 11.973

Calibration Post High Cylinder Bias -0.08 0 0 -0.027

Calibration Post High Cylinder Drift 0.08 0.08 0 0.053

Cavg 7.1 7 6.8 6.967

Cavg Units %vd %vd %vd

Cgas 7.1577 7.0676 6.8635 7.030

Cgas Units %vd %vd %vd

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

Tuesday, January 18, 2011 Page 22 of 21