Project No. 73-SPP-3
o
AIR POLLUTIO
EMISSION TEST
Kansas Power and Light Company
Lawrence, Kansas
"W".
UNITED STATES ENVIRONMENTAL PROTECTION AGENCY
Office of Air and Waste Management
Office of Air Quality Planning and Standards
Emission Measurement Brand)
Research Triangle Park, North Carolina
-------
MANUAL SOURCE TESTING AND CONTINUOUS MONITORING
CALIBRATIONS AT THE LAWRENCE ENERGY CENTER OF
KANSAS POWER AND LIGHT COMPANY,
LAWRENCE, KANSAS
by
Emile Baladi
Midwest Research Institute
EPA Project Report No. 73-SPP-3
INTERIM REPORT TASK NO. 33
May 7, 1976
EPA Contract No. 68-02-0228
MRI Project No. 3585-C(34)
For
Office of Air Quality Planning and Standards
Environmental Protection Agency
Research Triangle Park, North Carolina 27711
Attn: Mr. Lance Granger
-------
PREFACE
The work reported herein was conducted by Midwest Research
Institute under Environmental Protection Agency Contract No. 68-02-0228,
Task No. 33.
The project was under the technical supervision of Mr. Paul C.
Constant, Jr., Head, Environmental Measurements Section of the Physical
Sciences Division. Mr. Emile Baladi served as project leader and was as-
sisted by Messrs. Robert Stultz, George Cobb, Bruce DaRos, Thomas Merrifield,
William Maxwell, George Scheil, Peter Orloff, Dewayne Hiddlestone, and William
Stanton. Ms. Christine Guenther was responsible for the data reduction and
computer analysis of the manual testing data. Analysis of the samples was
done under the supervision of Dr. James Spigarelli, Head, Analytical Chemistry
Section.
Approved:
MIDWEST RESEARCH INSTITUTE
Paul C. Constant, Jr.
Head, Environmental Measurements Section
May 7, 1976
111
-------
I. TABLE OF CONTENTS
Page
List of Figures vii
List of Tables vii
II. Introduction 1
III. Installation and Operation of Continuous Monitoring System. . 5
A. Monitoring System 5
B. System Acquisition 6
C. Site Preparation and Installation 6
D. Operation 10
IV. Summary and Discussion of Results 12
A. Summary of Results 12
B. Discussion of Results 18
V. Process Description and Operation 18
VI. Sampling and Analytical Procedures 21
A. Manual Samplings 21
B. Monitor System Performance 22
C. Location of Sampling Points 22
Appendix A - Opacity and Transmissometer Field Data 23
Appendix B - Sample Calculations of the Performance Tests 31
Appendix C - Field and Calculated Results of Performance
Specification Tests 37
Appendix D - S02~Field, Analysis and Computer Printout Data .... 84
Appendix E - NO -Field, Analysis and Computer Printout Data .... 159
X
Appendix F - Moisture Determination Field Data 217
Appendix G - S02 and NOX Sample Calculations 233
Appendix H - Field Test Log 237
C
V
-------
TABLE OF CONTENTS (concluded)
Appendix I - Daily Field Log 291
Appendix J - Fuel Burning Combination 572
Appendix K - Calibration Gas Analysis 574
Appendix L% - Instruments and Major Components 592
Appendix M - Manufacturers Calibration Certificates 595
Appendix N - Correspondence with Power Plant Personnel 598
vi
-------
LIST OF FIGURES
No. Title Page
1 Schematic Block Diagram of the Source 4
2 Schematic Illustration of the Test Site 7
3 MRI Modification of Du Pont Probe 11
4 Schematic Top View of the Stack at the Sampling Loca-
tion 13
5 Schematic of S02 Removal System 19
6 Flow Diagram of Air Pollution Control System for Unit 5
at KP&L 20
LIST OF TABLES
No. Title Page
1 Man-Hour Breakdown of the Subcontractor 9
2 Proposed Performance Specifications Results 14
3 Performance Specifications Results 15
4 Summary of Results - SC^j NOX, and Moisture 16
5 Visual and Continuous Monitoring: Opacity 17
vii
-------
II. INTRODUCTION
The Emission Measurement Branch, Emission Standards and Engineer-
ing Division, Office of Air Quality Planning and Standards, of the Environ-
mental Protection Agency (EPA), is seeking information on performance and
attendant methodology needed to determine the acceptability of monitoring
systems installed at electrical generating power plants to monitor pollu-
tant emissions. As part of this mission, EPA contracted with Midwest
Research Institute (MRI) under Task No. 33 of EPA Contract No. 68-02-0228
to search, acquire, check, install, and operate a continuous monitoring
system of air pollutant emissions at the Lawrence Energy Center, 9th and
Tennessee, Lawrence, Kansas. This center is owned and operated by the
Kansas Power and Light Company, 818 Kansas Avenue, Topeka, Kansas. (Appen-
dix N comprises MRl's communiques with this power plant.)
The scope and objectives of the project include:
1. To discover the reliability of the continuous monitor's
operation and to develop guideline specifications for monitors during per-
formance testing.
2. To determine the costs of buying, installing, and operating
a continuous monitor over an extended period of time.
3. To obtain and evaluate continuous emission data along with
the effect of process operational variations on emissions over an extended
period of time.
4. To determine the feasibility of using a continuous monitor
for compliance testing.
As part of MRI's task, Proposed Performance Specification Tests
(Federal Register. Vol. 39, No. 177, Part II, 11 September 1974) were to be
performed on the monitors. These tests, as well as information on the search,
acquisition, check, and installation of the equipment needed to monitor pol-
lutants, are subjects of this report. Also, included in this .interim
report is the calculation of the modified Performance Specification Tests
(Federal Register, Vol. 40, No. 194, Part V, 6 October 1975).
The purpose of the manual and calibration tests was to determine
the ability of the monitors to meet the Proposed Performance Specification
requirements. These requirements were published by EPA in the Federal
Register (Vol. 39, No. 177, Part II, 11 September 1974).
-------
Boiler No. 5 of the Kansas Power and Light Company plant at
Lawrence, Kansas, was selected as the site at which to monitor the pollu-
tants of interest—sulfur dioxide (802), nitrogen oxides (NOX), and opacity.
Oxygen is also monitored to calculate the emissions and emissions factors.
This boiler is equipped to burn coal, oil, and/or natural gas. Its predicted
performance data, when 1007o coal is burned, are as follows:
Maximum rated capacity - M.W. 385
Steam flow - Ib/hr 3,000,000
Operating pressure - psig 2,400
Steam temperature - °F 1,000
Boiler efficiency - % 88.5
The control device associated with this boiler is a lime-injection wet
scrubber that was acquired from Combustion Engineering Corporation.
An extensive search was conducted in selecting the monitoring
system, since different manufacturers offer instruments with different oper-
ational principles. The instruments selected and acquired that comprise the
monitoring system are identified below:
1. The Du Pont S02/NOX Monitor* operates on the principal of
measuring the ultraviolet light attenuated by the measured pollutants.
2. The Lear Siegler Opacity Monitor* operates on the principle
of measuring the visible light attenuated by the particulates present in
the measured gas.
3. The Beckman Oxygen Monitor* operates on the principle of
measuring the current flowing, as a result of oxygen reduction, in a
polarographic sensor.
4. The Westinghouse Data Recorder* operates on the principle of
recording the data in the form of pulses on magnetic tape cartridges.
5. The Analog Data Recorders operate on the principle of con-
tinuous data recording on a chart. (The recorder point is driven by a
servo motor.)
The use of brand or trade names does not constitute endorsement by the
U.S. Environmental Protection Agency.
-------
The Performance Specification Tests, which comprised both cali-
bration tests of monitoring instruments and manual sampling, were conducted
by MRI personnel during the period 4-21 December 1974. Due to the failure
of some of the monitors to pass all the required Performance Tests, a sec-
ond series of these tests was performed during the period 22-25 April 1975.
Field data and calculated results of these tests are included in this report.
The location of the test points for these tests is on the first
platform of the stack of No. 5 boiler downstream from the scrubber (Figure
1). Hence, the measured data represent the boiler emission. There were
no tests conducted by MRI upstream from the scrubber.
The measurements of pollutants monitored instrumentslly, sulfur
dioxide, nitrogen oxides, opacity, and oxygen, were recorded on analog and
magnetic tape recorders.
The manual source tests conducted for this project were:
4-21 December 1974 Tests 22-25 April 1975 Tests
Eighteen sulfur dioxides Ten sulfur dioxides
Twenty-seven nitrogen oxides Twenty-seven nitrogen oxides
Nine moisture determinations Three moisture determinations
Opacity readings
The opacity-reading test was conducted 21 November 1974. The SOo, NO , and
£» X
moisture content tests were conducted concurrently with the monitor calibra-
tion tests.
Mr. Lance Granger of EPA and Mr. Larry Bonam of Du Pont were pres-
ent during part of the first manual sampling and calibration period.
The S02/NOX and oxygen monitors were calibrated with zero and
calibration gases. The calibration gases were ordered to represent approx-
imately 30%, 60%, and 90% of the monitors spans. The concentration of the
respective pollutant in these gases was determined by means of the appli-
cable EPA method of the Federal Register, Vol. 36, No. 247, Part II, 23
December 1971.
During the test periods, the boiler fuel was a combination of
coal, gas, and oil as is shown in Appendix J.
-------
1st. Platform
(Sampling Points)
Figure 1. Schematic block diagram of the source.
-------
The remaining sections of this report are:
Section III. Installation and Operation of Continuous Monitoring
System
Section IV. Summary and Discussion of Results
Section V. Process Description and Operation
Section VI. Sampling and Analytical Procedures
III. INSTALLATION AND OPERATION OF CONTINUOUS MONITORING SYSTEM
The monitoring system, which is composed of several subsystems,
was acquired, installed and operated by MRI personnel. This system is de-
fined. Acquisition, installation, and operation difficulties and problems,
as well as detail installation cost, are discussed.
A. Monitoring System
The continuous monitoring system consists of the following:*
1. Du Pont 460/1** source monitoring system and its related com-
ponents for S02 and NOX.
2. Lear Siegler, Inc. (LSI) RM4** opitcal transmissometer for op-
tical density and opacity measurements.
3. Beckman Model 742** process oxygen analyzer for oxygen measure-
ment in the stack.
4. Westinghouse WR-4C** magnetic tape recorder, Enviro. Package
ElB for continuous data recording.
5. Analog recorder for each monitor.
6. DeKoron**-heated sampling lines and related components for
Du Pont and Beckman sampling interfaces.
* See Appendix L for a listing of the instruments and their major components
that comprised the monitoring system.
** The use of brand or trade names does not constitute endorsement by the
U.S. Environmental Protection Agency.
5
-------
7. Controlled environment shed for the housing of the monitors
control components.
8. Other related components and materials such as calibration
gases, oxygen, regulators, etc.
B. System Acquisition
Acquisition of the monitors and their components started in
October 1973. However, gaps of several months were encountered between
purchasing and delivering dates. Upon receiving a monitor, a complete
test of its components was done at MRl's home base in Kansas City. Broken,
missing, defective, and unshipped parts were discovered during these tests.
For example, a complete circuit board was missing from LSI control station
which took MRI several days to discover due to an incomplete circuit dia-
gram. Another example: 12 defective capacitors were found in the Westing-.
house magnetic tape recorder. Representative problems encountered during
these tests are listed in Appendix H.
C. Site Preparation and Installation
The manufacturers' specification and instructions were followed
in preparing the site (Figure 2). Some permanent modifications of the site
and some temporary structurally attached installations were required.
These modifications and installations had to be accomplished by profes-
sional union personnel (union-registered), according to Mr. Brunton, the
plant superintendent, and the local labor unions. Therefore, extensive
discussions between MRI, Mr. Brunton, and the Union resulted in a plant-
union subcontract. The cost of this subcontract was to be billed to MRI
by the power plant. The professional union specialist accomplished the
following permanent modifications (1 through 4) and temporary installa-
tions (5 and 6):
1. Cutting two 4-1/2 in. circular holes in the stack wall at
the first platform and welding two 4-1/2 in. LSI flanges on the holes to
carry the optical transmissometer.
2. Cutting one 3-1/2 in. circular hole in the stack wall at the
same first platform and welding one 3-1/2 in. Du Pont flange to support the
Du Pont and Beckman probes.
-------
Manual Sampling
Ports
Boiler! No.5 Stack
DuPont & Beckman Probes
LSI Transmissometer
1st Platform
*• Boiler
DuPont Analyzer
8th Floor
Figure 2. Schematic illustration of the test site.
-------
3. Welding 2x2 in. nipples on the stack wall below LSI
flanges to support the transraissometer service components. '
4. Tapping the plant 480-volt by 480/110 volt transformer,
provided by MRI, to power the monitors and their components.
5. Installing a 110-volt service line between the controlled
environment shed and the Du Pont field unit, and from this field unit to
the stack's first platform. This service line is used to power the transmis-
someter unit on the stack, the Du Pont field unit on the plant's eighth floor
and the temperature controllers of the DeKoron sampling line.
6. Installing the temperature controllers and the splice connec-
tions of the DeKoron sampling line.
These six modifications were completed between 5 and 27 February
1974.
The man-hour breakdown of the above work (1 through 6) is shown
in Table 1. The cost of the electrical service installations was $1,200.00.
The approximate breakdown in man-days for MRI field personnel is
as follows:
1. Site preparation 17
2. Monitoring system setup 22
Several difficulties were encountered during the course of site
preparation and installation. Listed below are some of these difficulties
(see also Appendix H):
1. Finding the needed professional union specialists to do a
relatively small job on a power plant stack 300 ft above the ground.
2. Reticence of these professionals to cut holes in the stack
wall, which consisted of a 5/16-in. steel plate and 2-in. gunnite layer.
3. Transporting some of the instruments and service components
to the site from MRl's home base (45 miles) due to their weight and bulki-
ness (Du Pont weighing 1 ton, DeKoron reels measuring 4.25 ft in diameter).
4. Difficulties in placing the heavy and bulky instruments in
their corresponding places on the site (Du Pont on the eighth floor, LSI on
the stack, and DeKoron between stack, Du Pont, and shed).
-------
Table 1. MAN-HOUR BREAKDOWN OF THE SUBCONTRACTOR
No. of
Date man-hours Title of personnel involved Job descriptions
2-5-74 5 Boiler maker's general foreman Ports opening, flange and
6 Boiler maker foreman nipples welding.
29 Boiler maker
6 Pipe fitter
6 Pipe fitter welder
2-7'-74 2 Pipe fitter general foreman
1 14.5 Pipe fitter welder
14.5 Pipe fitter
40 Boiler maker
2.5 Boiler maker (overtime)
2-26-74 2 Pipe fitter general foreman DeKoron installation
2 Pipe fitter
2 Pipe fitter welder
1 Pipe fitter welder (overtime)
^j-27-74 1 Pipe fitter general foreman
6 Pipe fitter welder
3-28-74 5 Pipe fitter A/C installation
-------
D. Operation
The startup of each monitoring system began with the completion
of its installation. However, repeated startup failure of Du Pont and LSI
caused considerable delay of the start of the system operation. The delay
caused several interruptions of the operation schedule. These interruptions
delayed the 168-hr initial operation period (EPA Proposed Performance Spe-
cification Tests, Federal Register. Vol. 39, No. 177, Part II, 11 September
1974) several months (see Appendix H). Also, during the summer months the
boiler fuel was 100% natural gas. This caused some delay for the Du Pont
tests, since natural gas burning does not produce measurable amounts of S02
on the instrument span.
During regular checks on 26 June 1974, MR! discovered that the
Du Pont probe in the stack was broken at the flange. The probe and its
screen were missing. The logical explanation for the breakage was the
high vibration at the sampling ports. Therefore, a new probe and screen
were ordered from Du Pont. Figure 3 shows MRl's modification on the new
probe to strengthen it against vibration or sudden surge of the stack flue
gas velocity.
Particulate buildup on the instack filter of the Beckman probe
resulted in saturating the filter and stopping the sample flow through the
probe in a few hours after the instrument was started. The buildup was
due to the relatively high concentration of limestone particulate and
moisture in the stack flue gas. Therefore, a periodic blow-back system was
incorporated with the Beckman sampling interface. The system consists of
a solenoid-operated, pneumatic valve and a 1-hr timer. Filtered plant com-
pressed air was used to operate the system. (Appendix H lists the instal-
lation sequence in chronological order.)
Although the LSI monitor and the field unit of Du Pont instrument
were built for field (uncontrolled environment) installations, extreme am-
bient temperatures affect the operation of these instruments. This is
especially so for the zeros and calibration readings.
Several attempts to sample, calibrate and operate the monitoring
systems were performed unsuccessfully. The reasons for failure ranged from
boiler troubles to monitor problems. These failures, along with their
reasons, are listed in Appendices H and I.
The monitors, recorders, and service components are checked daily
by an MRI employee for malfunctions. A daily-field log for the instrument
was designed by MRI for the daily checks and is used by this employee. Ap-
pendix I contains these formats through the end of the operation period.
10
-------
(a) Before Modification
Stainless Steel Jacket
/
Screen Probe
Port Flange
~(b) Sectional View of the Modified Probe
Weld
Flange
(c) Three-Dimensional View of the Supporting Collar
Figure 3. MRI modification of Du Pont probe.
11
-------
IV. SUMMARY AND DISCUSSION OF RESULTS
A. Summary of Results
Two Performance Specification Tests (Federal Register. Vol. 39,
No. 177, Part II, 11 September 1974) were conducted on the monitors. These
tests included the attainment of the parameters: (a) calibration error,
(b) zero drift (2 and 24 hr), (c) calibration drift (2 and 24 hr), (d)
response time, and (e) accuracy. To obtain parameters (a), (b), (c), and
(d), two different concentrations of calibration gases were used in each
monitor. Parameter (e) was obtained by sampling the stack manually and
recording the monitor readings of this stack instrumentally. The manual
sampling and recording were accomplished concurrently. The sampling points
for both manual and monitor sampling were within 2 ft inside the stack
(Figures 2 and 4) .
Field data and results of the two Performance Specification Tests
are summarized in Tables 2 through 5, and presented in Appendices A through
G and Appendix K. Table 2 presents the results of these tests according to
the EPA* Proposed Performance Specification Tests for S02/NOX and oxygen.
Results that were calculated according to the EPA** Performance Specifica-
tion Tests are presented in Table 3. Table 4 presents a summary of the
manual-sampling results used to calculate the accuracy of S02/NOX monitors.
Appendix C contains the field data and calculated results; Appendix B con-
tains sample calculation of these results. Appendices D, E, and F contain
field and computer printouts of the manual sampling data and reductions of
SC>2/NOX and moisture, respectively. Run No. 1 of Test No. 1 of NOX manual
sampling was scrapped due to flask breakage. Appendix G contains sample
calculations of S02 and NOx results. Appendix K contains computer printout
of the manual analysis and the manufacturer analysis report of SC^ and NOX
calibration gas concentrations along with sample calculations. Table 4
presents a summary of the opacity readings according to EPA Method 9 of the
Federal Register (Vol. 39, No. 247, Part II, 23 December 1971), as compared
to LSI transmissometer monitor recording. Appendix A contains the field
data of the opacity.
* EPA Proposed Performance Specification Tests, Federal Register, Vol. 39,
No. 177, Part II, September 1974.
** EPA Performance Specification Tests, Federal Register. Vol. 40, No. 194,
Part V, 6 October 1975.
12
-------
•Platform
Stack
LSI Trarismissometer
Splice Connection
DeKoron Lines
ToJDuPqnt
& Beckman
Stainless
Steel Probes
Beckman
Filter
DuPont
Filter
SO0/NOX Manual
Figure 4. Schematic top view of the stack at the sampling location.
13
-------
Table 2. PROPOSED PERFORMANCE SPECIFICATIONS RESULTS
(EPA-P)£/
Performance specification 1st
Calibration error:
Mid. (%)£/
High (%)£/
NOV
A
Monitor
test^/ 2nd test^7
4.1
1.5
Accuracy (7o) 174.3 22.3
Zero drift (2 hr) (7»)
Calibration drift (2 hr) (7=)
Zero drift (24 hr) (7o)
Calibration drift (24 hr) (7o)
Response time (min)
Note: NO = nitrogen oxides.
X
S02 = sulfur dioxide.
02 = oxygen.
Monitor = monitor results.
a/ EPA-P = EPA Proposed Performance
Part II, September 1974.
b/ 1st test = test performed during
1.2
3.3 13.0
1.8
4.8
Specification Tests,
EPA-P
<: 5
<: 5
£ 20
< 2
< 2
<, 4
< 5
Federal
so2
Monitor
1st test 2nd test
1.1
2.5
274.9 128.7
0.3
3.9
0.6
6.0
0.3
Register, Vol. 39, No
°2
Monitor
EPA-P 1st test
£ 5
<. 5
< 20
£ 2 0.0
£ 2 0.6
£ 4 0.0
<. 5 1.2
< 15 < 1.0
. 177,
EPA-P
< 1
<: 1
£ 2
<; 2
the period 4-21 December 1974.
2nd test = test performed during the period 22-25 April 1975.
Mid. (7o) = percent midspan range.
High (7o) = percent upper span range.
-------
Table 3. PERFORMANCE SPECIFICATIONS RESULTS
NOX
Monitor
S02
Monitor
Performance specification 1st test^/ 2nd testk/ EPA 1st test 2nd test EPA
Calibration error:
Mid. (%)£/ 4.1
High (%)£/ 1.5
Accuracy (?„) 174.3
Zero drift (2 hr) (%) 0.7
Calibration drift (2 hr) (%) 2.2
Zero drift (24 hr) (%) 1.2
Calibration drift (24 hr) (%) 3.3
Response time (min)
Note: NO = nitrogen oxides.
X
SOo = sulfur dioxide.
02 = oxygen.
Monitor = monitor results.
a/ EPA = EPA Performance Specification
6 October 1975.
b/ 1st test = test performed during the
2nd test = test performed during the
£/ Mid. (%) = percent midspan range.
High (%) = percent upper span range.
^ 5 . 1.
* 5 2.
22.3 £ 20 274.
2 0.
1.9 2 1.
2 0.
2.5 1.
0.
Tests, Federal Register, Vol. 40
period 4-21 December 1974.
period 22-25 April 1975.
1 - £5
5 - £ 5
9 128.7 * 20
1 2
4 1.6 2
2 - 2
2 3.9 2.5
3 - 15
, No. 194, Part V,
02
Monitor
1st test EPA
_ _
-
-
0.0 0.3
0.2 0.3
0.0 0.3
0.3 0.3
< 1 10
-------
Table 4. SUMMARY OF RESULTS - S02,
NOX, AND MOISTURE
Test
1
1
1
1
1
1
1
1
1
2
2
2
2
2
2
2
2
2
Run
1
2
3
4
5
6
7
8
9
1
2
3
4
5
6
7
8
9
Date
12-4-74
12-4-74
12-5-74
12-5-74
12-5-74
12-6-74
12-6-74
12-9-74
12-10-74
4-22-75
4-23-75
4-23-75
4-23-75
4-24-75
4-24-75
4-24-75
4-24-75
4-25-75
Average
Ib/dscfS/
(x ID'6)
80.3
99.1
2.1
3.5
0.6
6.3
5.7
35.7
27.4
6.4
14.8
5.3
13.6
13.4
-
-
-
S02
ppm3-/
484.8
299.3
12.8
20.9
3.8
38.1
34.5
215.6
165.4
38.4
89.3
32.3
82.2
81.1
- •
-
-
Average
Ib/dscf
(x KT5)
2.3
2.2
1.9
1.8
1.9
2.6
2.7
2.9
1.1
1.6
1.2
1.6
2.1
1.8
1.9
2.2
1.1
NOX
ppm
197.5
181.5
158.5
155.3
160.9
216.2
230.4
242.4
92.8
134.8
101.5
131.2
180.5
155.0
159.6
181.8
96.5
Moisture
By volume
(%)
8.7
7.1
8.5
5.6
4.8
8.2
8.4
5.3
2.5
11.9
10.0
10.0
10.0
10.1
10.1
10.1
10.1
10.0
£/ lb/dscf = pounds dry standard cubic foot.
ppm = parts per million.
16
-------
Table 5. VISUAL AND CONTINUOUS MONITORING: OPACITY
Time
13:20-13:24
13:25-13:29
13:30-13:34
13:35-13:39
13:40-13:44
13:45-13:49
13:50-13:54
13:55-13:59
14:00-14:04
14:05-14:09
14:10-14:14
14:15-14:19
14:20-14:24
14:25-14:29
14:30-14:34
14:35-14:39
14:40-14:44
14:45-14:49
14:50-14:54
14:55-14:59
15:00-15:04
15:05-15:09
Average
observation data
(7e> opacity)
45
45
45
45
45
42
45
45
45
45
45
45
45
50
66
71
67
62
55
58
60
57
Reading
time
13:20
13:25
13:30
13:35
13:40
13:46
13:50
13:55
14:00
14:05
14:10
14:15
14:20
14:25
14:30
14:35
14:40
14:45
14:50
14:55
15:00
15:05
Opacity
meter reading
(% opacity)
46
47
45
45
46
44
44
45
46
48
56
50
48
47
49
49-55
58
48-52
49
49
44
45
Difference
(%)
1
2 '
0
0
1
2
1
0
1
3
11
5
3
3
17
~ 16
9
~ 10
6
9
16
12
17
-------
B. Discussion of Results •
Referring to Table 3 of this report, the S02/NOX monitor has met
the performance specifications for calibration error, NOX accuracy, zero
drift (2 hr), zero drift (24 hr), calibration drift (2 hr), calibration
drift (24 hr), and the response time. It failed to meet the performance
specifications for S02 accuracy. There are several possible explanations
for this failure. There is some evidence to indicate that limestone may
interfere with Method 6 and it is not known what effect limestone will have
on a UV analyzer. Unfortunately there was no opportunity to investigate
this problem further.
At the time of the S02 accuracy test, the source was firing a
varying mixture of natural gas and coal. Over a 24-hr period approximately
98% of the energy source was natural gas. The scrubber was operating at
all times during the performance test. As a result of the large usage of
natural gas, the S0£ emission rates were not representative of typical coal
firing and limestone scrubber operation. The low variable concentration
in itself may have contributed to the difference between the methods. More
important, it became known at about the same time that future plant operation
would be primarily with gas firing. Therefore, further evaluation of the
instrument was not warranted.
The oxygen monitor has passed all the Performance Specification
Tests of the Federal Register as is shown in Tables 2 and 3.
V. PROCESS DESCRIPTION AND OPERATION
Unit No. 5 at Kansas Power and Light Company's Lawrence station
is a 430 Mw steam electric generating plant. The steam generator, supplied
by Combustion Engineering, is designed to fire coal, oil or gas separately
or in combinations through tangential, corner-located burners. The steam
generator utilizes the conventional subcritical steam cycle of 2,400 psi
with main and reheat temperatures of 1000°F and provides approximately 3
million pounds of steam per hour at peak load. The high pressure steam
is fed to a Westinghouse, tandem, compound, two-flow turbine rated 448 Mw
at 26,000 volts. Combustion gases from the furnace are directed to a
limestone injection wet scrubber also designed by Combustion Engineering.
Figures 5 and 6 illustrate the furnace and scrubber system.
18
-------
I I
I
COAL
"SUPPLY
ADDITIVE
[~ SUPPLY
i_L_
Y
MILL
FURNACE
AIR
HEATER
STACK GAS
REHEATER
STACK GAS
REHEAT-
SYSTEM
TO STACK
DEMISTER
HEAT /
EXCHANGER
SETTLING TANK-
BED
RECYCLE
AND
MAKE UP
WATER
TO DISPOSAL
Figure 5 - Schematic of S02 Removal System
-------
Ni
O
LIUCSTOHE SUPPLY —
COM. SUPPLr-
f Ct DC K - ''
PULVtPIZCR —
Figure 6 - Flow Diagram of Air Pollution Control System for Unit 5 at -KP&L
-------
The scrubbing system is designed to remove 99% of the entrained
particulate matter and 80 to 90% of the sulfur oxides formed during com-
bustion. Sulfur oxides removal actually begins in the furnace itself as
limestone is injected along with the fossil fuel. About 30% of the sulfur
oxides generated chemically combine with the pulverized limestone in the
furnace in a dry reaction forming solid SOg and SO^ compounds. These com-
pounds, the fly ash, and the combustion gases then pass through the boiler
section and on to the bottom plenum of the wet scrubber.
In the scrubber, the remaining sulfur oxides are reacted in a
turbulent marble bed zone. Solid SOg and SO^ compounds and fly ash are
washed from the combustion gases and the resulting slurry is collected
at the scrubber bottom and sent to a settling pond. The clean combustion
gases exit the scrubber top and are sent to the stack.
The process data collected from the plant during the 6 month
monitoring period are too voluminous to include here but are available for
inspection in the Emission Measurement Branch file.
VI. SAMPLING AND ANALYTICAL PROCEDURES
The monitoring system was calibrated on site according to EPA
Proposed Performance Specifications 2 and 3 of the Federal Register.*
These specifications required that a concurrent manual sampling should be
conducted during the calibration period. The manual sampling and calibra-
tion methods and the analytical procedures used are described.
A. Manual Samplings
1. Calibration and zero gases; Seven size A cylinders of cali-
bration and zero gases for the Du Pont SO^/NO analyzer were tested to
" X
determine the concentration of the respective pollutant in each cylinder.
EPA Methods 6 and 7 of the Federal Register (Vol. 36, No. 247, Part II,
23 December 1971) were followed in the sampling and analyzing of these
gases. Appendix K contains field and computer printout of the data.
Federal Register, Vol. 39, No. 177, Part II, 11 September 1974.
21
-------
2. Stack/ gases; EPA Methods 4, 6, 7, and 9 of the Federal Regis-
ter (Vol. 36, No. 247, Part II, 23 December 1971), were followed in the sam-
pling and analysis procedures of moisture, SOo, NO , and opacity, respectively.
™ X
Field and calculated data are listed in the appendices.
B. Monitor System Performance
EPA Performance Specifications 2 and 3 of the Federal Register
(Vol. 39, No. 177, Part II, 11 September 1974, and Vol. 40, No. 149, Part V,
6 October 1975) were followed in the determination of the performance of
the S00/N0 and 09 analyzers. Appendix G lists the applicable field data.
z x ^
The LSI transmissometer was installed before receiving its per-
formance specifications from EPA. Therefore, Performance Specification 1
of the above Federal Registers was not followed in the determination of the
transmissometer performance. However, Mr. Warren Alden of Lear Siegler,
Inc. calibrated the instrument in the field according to Paragraph 8.1 of
the Performance Specification 1 above. The LSI and Du Pont certificates of
calibration are shown in Appendix M.
C. Location of Sampling Points
A schematic top view of the stack at the sampling location is
shown in Figure 4. The inlets to SC>2 and NOX manual sampling probes were
within 2 ft of the inlet to Du Pont probe in the stack. The Du Pont probe
extends about 4 ft into the stack. The sampling ports are located 140 ft
above the plant's sixth floor on the first stack platform. The port used
for moisture determination is located on the same platform. The closest
obstructions of the stack flue gas are the fan breeching 5.3 diameter up-
stream and the stack exit 7 diameter downstream from the sampling ports.
The controlled environment shed, which houses the control station of the
monitors, is located on the sixth floor. The Du Pont field unit is located
on the plant's eighth floor (see Figure 2).
The position of the opacity reader was on the ground. Opacity
reading was conducted according to EPA Method 9 of the Federal Register
(Vol. 36, No. 247, Part II, 23 December 1971).
22
------- |