INTHUU MEASUREMENTS CC VAT REG NO.: 4960254359 REG NO.: 2009/190265/23 P.O. Box 14769 Bredell, 1623 Plot 2/410 Seventh Road Bredell A/H, Kempton Park, 1619 Tel: +27 (0)82 572-2380 Fax: +27 (0)86 659-2231 Eskom Holdings SOC Ltd Medupi Power Station Lephalale 0555 Date Your Reference Our Reference Enquiries CC Scheepers 22 August 2015 Order No.: To be advised RCCS236 Cell: 082 572 2380 e-mail: coen@inthuu.co.za REPORT 2015/08/21/RCCS236 PARTICULATE EMISSION MONITOR CORRELATION SPOT CHECK ON UNIT 6 AT MEDUPI POWER STATION Herewith the report for the particulate emission monitor correlation spot check measurements carried out on the 19 th of August 2015. Tests were carried out in Stack 2 on the flue of Unit 6. We thank you for the opportunity to be of service and trust that your requirements have been interpreted correctly. If you have any queries, please contact us at the above numbers, we will gladly assist. Yours faithfully Inthuu Measurements cc CC Scheepers Page 1 of 29
INTHUU MEASUREMENTS CC Submitted by: Checked by: Approved by: Not available at the time of signing this document Signature:... KW Mohapi (Stack Tester) Signature:... CC Scheepers Signature:... CC Scheepers REPORT CUSTOMER : ESKOM MEDUPI POWER STATION OPERATING COMPANY : MEDUPI POWER STATION LOCATION : LEPHALALE IN LIMPOPO TYPE OF MEASUREMENT : PARTICULATE EMISSION MONITOR CORRELATION SPOT CHECK TITLE : PARTICULATE EMISSION MONITOR CORRELATION SPOT CHECK ON UNIT 6 AT MEDUPI POWER STATION ORDER No s. : TO BE ADVISED REPORT No. : 2015/08/21/RCCS236 REPORT DATE : 22 AUGUST 2015 COPYRIGHT ON THIS DOCUMENT IS RESERVED. PUBLICATION OR DISSEMINATION OF ITS CONTENTS WITHOUT WRITTEN PERMISSION IS NOT ALLOWED. Page 2 of 29
Index Page Index Summary Glossary 4 1. Measurement Objective 5 2. Plant Description and Materials Handled 5 3. Description of the Measurement Site 5 4. Measurement and Analytical Methods and Apparatus 5 5. Plant Operating Conditions during the Measurements 6 6. Presentation of Measurement Results and Discussion 6 Appendices A. Calibration Function B. Plant Parameters C. Monitor Calibration Certificates D. Schematic of Leaking bags found in the FFP E. Reference Gas and Equipment Calibration Certificates 9 12 14 15 16 7. Distribution list 30 Summary: Plant : Medupi Power Station Operating times : 24 hours Emission source : Power generation - fossil fuel boilers Measured components : Particulate Matter Date of measurement : 19 August 2015 Emission source No. : Unit 6 flue Measurement results : 1. At 700 MW, three measurements showed emission concentrations below 50 mg/nm 3 (d) at 10% O 2 2. It was reported that leaking bags were detected in various areas throughout the Fabric Filter Plant of Unit 6. Test Measured Unit of measure Mean value Limit value No. component 1 7.9 2 PM [mg/nm 3 (d)] at 10% O 2 21.0 50 3 11.2 The DCS may be programmed to display the emissions on a continuous basis, using the formula, y = m*x + c Where: y = Particulate emissions [mg/nm 3 (d)] at 10% O 2] [A constant giving the slope of m = 36.711 the linear regression] x = Monitor output, AO2 [ma] c = -146.89 [A constant giving the intercept of the linear regression on the Y-axis] Page 3 of 29
GLOSSARY Some of the following abbreviations were used in the text, figures and Tables: AMS Automated Measurement System SRM Standard Reference Method CEM Continuous Emission Monitor ESP Electrostatic Precipitator FFP Fabric Filter Plant MCR Maximum Continuous Rating C Degrees Celsius Pa (g) Gauge pressure in Pascal kpa (abs) Absolute pressure in kilo Pascal % v/v Percentage on a Volume-by-Volume basis Am 3 Actual Cubic Metres Nm 3 Normal Cubic Metres Am 3 (w) Actual Cubic Metres on a wet basis Nm 3 (w) Normal Cubic Metres on a wet basis Am 3 (d) Actual Cubic Metres on a dry basis Nm 3 (d) Normal Cubic Metres on a dry basis ATPD Actual Temperature and Pressure Dry NTPD Normalised Temperature and Pressure - Dry g/s Grams per second mg/s Milligrams per second dp Differential pressure AO Analogue Output Actual refers to the measured temperature and pressure conditions of the gases in the duct. Normal or Standard refers to the actual conditions being normalised to 0 C and 101,325 kpa. Page 4 of 29
1 MEASUREMENT OBJECTIVE Medupi Power Station has installed an Automated Measuring System (AMS) for the monitoring of particulate emissions in compliance with the National Environmental Management: Air Quality Act, 2004 (Act No. 39 of 2004). The Installation was completed before August 2015. Inthuu Measurements CC was contracted by Eskom Holdings SOC Ltd, to perform the correlation spot check measurements. From the linear regression determined from the gravimetric measurements by SRM and the corresponding AMS signal, constants are used in the DCS, allowing continuous emissions measurement from which monthly reports are generated. Tests were carried out on the 19 th of August 2015. 2 PLANT DESCRIPTION AND MATERIALS HANDLED The power station currently operates one power generation unit, but will finally consists of six units, each consisting of a steam driven turbine and a boiler supplying the steam. The boilers are specially designed to burn low grade coal, which contains high percentages of ash and sulphur. Each unit is equipped with particulate matter abatement technology. Medupi uses Fabric filters (FFPs) to clean the boiler waste gases. Currently, no further emission abatement technology is implemented at Medupi Power Station. 3 DESCRIPTION OF THE MEASUREMENT SITE The measuring site is located on the inside of the multi-flue stack. The stack consists of a concrete outer windshield with one flue inside the windshield. The measurement platform is situated at 180m above ground level. The particulate AMS is positioned on the 150m level below the measurement ports for the SRM. 4 MEASUREMENT AND ANALYTICAL METHODS AND APPARATUS Compound Method Comment Particulate Matter ISO 9096:2003 With deviations (A) Low mass concentrations BS EN 13284-1:2002 With deviations (B) Eskom s Emissions Monitoring and Reporting Standard 240-56242363 With deviations (C) Page 5 of 29
5 PLANT OPERATING CONDITION DURING THE MEASUREMENTS 5.1 PRODUCTION PLANT Normal operating conditions were maintained on unit 6 for the duration of the emission survey. It was requested that soot blowing be carried out and completed at a time before the start of the tests. To ensure further stability of the combustion process and to ensure steady flow of gas through the stack, it was requested that the Automatic Group Control (AGC) and the Frequency Bias be switched off for the duration of the stratification tests. The tests were carried out at a condition which represents the normal state of power production. The coal which was burnt during the test period was the normal supply. The economiser outlet oxygen levels were representative of normal running excess air levels. Air ingress may be expected at the air heaters and the FFPs, but no abnormal ingress air was noticed from the O 2 readings in the stack. Additional operating data is tabulated in the Appendices. The tests were carried out at a constant load of 700MW for the full duration of three consecutive tests 5.2 WASTE GAS CLEANING UNITS Medupi Power Station employs Fabric Filter Plants (FFPs) for gas cleaning in terms of particulate matter. No gaseous emission abatement is available. The FFPs were in service during the tests. It was reported on the 17 th of August that broken bags were detected in a large percentage of the FFP cells. These were receiving attention at the time. No formal documentation was supplied Boiler ashing and FFP de-dusting are manual processes. The stratification tests and cleaning operations were scheduled so that they would not coincide. 6 PRESENTATION OF MEASUREMENT RESULTS AND DISCUSSION 6.1 EVALUATION OF THE OPERATING CONDITIONS DURING THE MEASUREMENTS It is an Eskom standard that the correlation tests are carried out at a load most commonly experienced. Tests are carried out without soot blowing and oil support in each case. The recommended loads are: Test No. Nominal Boiler Load MW Control room MW Standard deviation of Boiler Load % of Boiler Load Measured Gas flow [Nm 3 /s (d)] at 10% O2 Dust Concentratio n mg/nm 3 (d) at 10% O2 Average face velocity % Isok Nozzle diamete r cm/s % mm Comment 1 700 700.00 0.2 848.1 7.9 4.95 91.0 5.0 2 700 699.99 0.2 823.4 21.0 4.45 100.9 5.0 Significant spike noticeable, experimental error is possible. 3 700 699.98 0.2 830.1 11.2 4.49 101.1 5.0 Page 6 of 29
No unusual operating occurrences were reported during the tests. Test No. 1 2 3 Date dd-mm-yy 2015/08/19 2015/08/19 2015/08/19 Start Time HH:mm 00H38 03H16 05H37 End Time HH:mm 02H32 05H02 07H33 Boiler load MW 700 700 700 Gross Active Power Generator Output 60MKA10CE901_YQ65 MW 700.00 699.99 699.98 Gas A/H 1 Inlet Flue Gas O2 2V3 60HNA11CQ901A_YQ60 % 3.67 2.42 2.67 Gas A/H 2 Outlet Flue Gas O2 2V3 60HNA22CQ901_YQ60 % 5.87 4.92 5.20 BOILER COAL CONSUMPTION 60HFB00FF910_YQ60 kg/s 82.53 82.06 80.91 Gas A/H 1 Outlet Flue Gas Temperature 2V3 60HNA12CT901A_YQ60 C 141.53 138.96 135.10 Gas A/H 2 Outlet Flue Gas Temperature 2V3 60HNA22CT901A_YQ60 C 139.96 139.22 133.39 ID Fan 1 Suction Flue Gas Temperature 60HNC10CT001A_XQ50 C 122.02 121.82 122.14 ID Fan 2 Suction Flue Gas Temperature 60HNC20CT001A_XQ50 C 123.02 123.32 124.90 Boiler Furnace Purge SETP MEAS 60HLA21DP901A_YE60 kg/s 712.81 663.40 653.09 Feed Water Corrected Flow 2V3 60LAB75FF911A_YJ60 kg/s 493.89 495.81 498.35 Belt Conveyor 10 DE Gear Box Speed 60HFB10CS001A_XQ50 RPM 5.70 5.94 5.77 Belt Conveyor 20 DE Gear Box Speed 60HFB20CS001A_XQ50 RPM 5.27 5.23 5.18 Belt Conveyor 30 DE Gear Box Speed 60HFB30CS001A_XQ50 RPM 5.34 5.09 5.16 Belt Conveyor 40 DE Gear Box Speed 60HFB40CS001A_XQ50 RPM 5.16 5.00 5.21 Belt Conveyor 50 DE Gear Box Speed 60HFB50CS001A_XQ50 RPM 0.00 0.00 0.00 Boiler Oil Capacity % 60HJF00FF910_YJ60 RPM 0.35 0.09 0.09 6.2 MEASUREMENT RESULTS Correlation spot check measurement information: The correlation function was determined from three parallel measurements. The second test was omitted from the calculations. The function yields the emission in mg/nm 3 (d) at 10% O 2 corrected for temperature, pressure, moisture and oxygen. This is a deviation from ISO 15259, but at this short notice, it would be difficult for the Power Station to make all the changes for converting from AMS conditions to Standard conditions. This may be addressed in a revised report. The table below gives the correlation function constants, m and c to be used in the formula: y = mx + c. Where: y = Particulate emissions [mg/nm 3 (d)] at 10% O 2 ] m = 36.711 [A constant giving the slope of the linear regression] x = Monitor output, AO2 [ma] c = -146.89 [A constant giving the intercept of the linear regression on the Y - axis] Page 7 of 29
Detailed results from the sampling process: Test No. 1 2 3 Stack tester: KWM KWM KWM Date dd-mm-yy 2015/08/19 2015/08/19 2015/08/19 Start Time HH:mm 00H38 03H16 05H37 End Time HH:mm 02H32 05H02 07H33 Boiler load MW 700 700 700 Outlet Conditions. Gas Temperature C 124.9 124.4 125.4 Barometric pressure kpa (g) 89.7 89.7 89.7 Duct pressure Pa -211.5-186.0-189.5 Duct pressure kpa (abs) 89.5 89.5 89.5 Moisture Mass mg 42.5 56.0 59.5 Moisture %v/v 4.8 6.4 6.7 Oxygen % 8.6 7.3 7.3 Velocity m/s 21.04 18.89 19.09 Duct area m2 61.81 61.81 61.81 Gas Volume Flow (Qact) Am3/s 1300.39 1167.72 1179.77 Gas Volume Flow (Qnw) Nm3/s 788.05 708.79 714.58 Gas Volume Flow (Qnd) Nm3/s 749.84 663.41 666.51 Gas Volume Flow (Qnd 6 %O2) Nm3/s 621.93 603.81 608.72 Gas Volume Flow (Qnd 10 %O2) Nm3/s 848.09 823.37 830.08 Gas flow rate kg/s 1013.56 917.31 924.82 Thimbles used Gas density in duct kg/m3 0.779 0.786 0.784 Sampling time Minutes 160 160 160 Nozzle diameter mm Field Blank used PL 04 PL 04 PL 04 Mass gain by F/B mg 0.55 0.55 0.55 Sampled dust mass mg 9.89 27.13 14.84 Dust mass mg 9.3 26.6 14.3 Gas Volume Sampled (Vact) Am3 (w) 1.8036 1.7954 1.8186 Gas Volume Sampled (Vnw) Nm3 (w) 1.0930 1.0897 1.1015 Gas Volume Sampled (Vad) Am3 (d) 1.7163 1.6805 1.6963 Gas Volume Sampled (Vnd) Nm3 (d) 1.0401 1.0200 1.0274 Dust Concentration mg/am3 (w) 5.2 14.8 7.9 Dust Concentration mg/nm3 (w) 8.5 24.4 13.0 Dust Concentration mg/am3 (d) 5.4 15.8 8.4 Dust Concentration mg/nm3 (d) 9.0 26.1 13.9 Measured O2 % 8.6 7.3 7.3 O2 @ 6 % 6.0 6.0 6.0 O2 @ 10 % 10.0 10.0 10.0 Correction factor 1.2 1.1 1.1 Correction factor 0.9 0.8 0.8 Dust Concentration Normalised to 6% O2 mg/nm3 (d) @ 6% O2 10.8 28.6 15.2 Dust Concentration Normalised to 10% O2 mg/nm3 (d) @ 10% O2 7.9 21.0 11.2 Outlet Dust Flowrate mg/s 6730.6 17287.8 9272.1 Moisture Concentration g/nm3 (d) 81.7 109.8 115.9 Average Face velocity cm/s 5.0 4.4 4.5 Isokineticity % 91.0 100.9 101.1 Average O/M Signal % of output 4.25 4.21 4.28 Detailed information is given in the Appendices: Appendix A Calibration function Figure 1 and Figure 1a Appendix B Plant parameters Appendix C Monitor calibration certificates Appendix D Schematic of leaking bags found in the FFP Appendix E Reference gas and equipment calibration certificates Page 8 of 29
APPENDIX A Calibration Function Figure 1 Showing the full range Figure 1a Showing the curve at higher resolution Page 9 of 29
MEDUPI POWER STATION Emission Monitor Correlation Certificate Plant: Unit 6 Location of monitor: Stack 2 Monitor information: Make of Monitor: Dr. Födisch Model: PFM 97 ED Serial Numbers: Limits of validity: Lower limit 7.94 mg/nm3 (d) [as an hourly average] Optical head: Upper limit 11.16 mg/nm3 (d) [as an hourly average] Reflector: 0 Hourly cycle checks are not included in linear regression Operational data: Path length: N/A Monitor range: mm [Stack flange to Stack flange] 4-20 ma Analogue Output AO 1: - (mg/m 3 ) Measuring Range: N/A Analogue Output AO 2: 0-100 (mg/m 3 ) Measuring Range: 0-587.3 mg/nm 3 at 10 %O 2 Dates: Calibration date: Not available Correlation dates: 19 August 2015 AEL Limit 50 mg/nm3 @ 10% O 2 Linear function: E AO1 = Not measured Correlation coefficient(r) = 0.99 E AO2 = 36.711x - 146.89 where: E = Emission [mg/nm 3 (d)@ 10% O 2 ] x = Monitor output [ma] Emission [mg/nm 3 (d)] at 10 %O 2 600 500 400 300 200 100 0 4.0 8.0 12.0 16.0 20.0 Monitor output [ma] Prepared by: FIGURE 1 Inthuu Measurements Page 10 of 29
MEDUPI POWER STATION Emission Monitor Correlation Certificate Plant: Unit 6 Location of monitor: Stack 2 Monitor information: Make of Monitor: Dr. Födisch Model: PFM 97 ED Serial Numbers: Limits of validity: Lower limit 7.94 mg/nm3 (d) [as an hourly average] Optical head: Upper limit 11.16 mg/nm3 (d) [as an hourly average] Reflector: 0 Hourly cycle checks are not included in linear regression Operational data: Path length: N/A mm [Stack flange to Stack flange] Monitor range: 4-20 ma Analogue Output AO 1: - (mg/m 3 ) Measuring Range: N/A Analogue Output AO 2: 0-100 (mg/m 3 ) Measuring Range: 0-587.3 mg/nm 3 at 10 %O 2 Dates: Calibration date: Not available Correlation dates: 19 August 2015 AEL Limit 50 mg/nm3 @ 10% O 2 Linear function: E AO1 = Not measured Correlation coefficient(r) = 0.99 E AO2 = 36.711x - 146.89 where: E = Emission [mg/nm 3 (d)@ 10% O 2 ] x = Monitor output [ma] Emission [mg/nm 3 (d)] at 10 %O 2 50 40 30 20 10 0 4.0 4.2 4.4 4.6 4.8 5.0 5.2 5.4 5.6 5.8 6.0 Monitor output [ma] Prepared by: FIGURE 1a Inthuu Measurements Note: The omitted co-ordinate is shown in a green coloured marker. Page 11 of 29
APPENDIX B Plant Parameters Page 12 of 29
Plant parameters for the duration of the tests: Test No. 1 2 3 Date dd-mm-yy 2015/08/19 2015/08/19 2015/08/19 Start Time HH:mm 00H38 03H16 05H37 End Time HH:mm 02H32 05H02 07H33 Boiler load MW 700 700 700 Gross Active Power Generator Output 60MKA10CE901_YQ65 MW 700.00 699.99 699.98 Gas A/H 1 Inlet Flue Gas O2 2V3 60HNA11CQ901A_YQ60 % 3.67 2.42 2.67 Gas A/H 2 Outlet Flue Gas O2 2V3 60HNA22CQ901_YQ60 % 5.87 4.92 5.20 BOILER COAL CONSUMPTION 60HFB00FF910_YQ60 kg/s 82.53 82.06 80.91 Gas A/H 1 Outlet Flue Gas Temperature 2V3 60HNA12CT901A_YQ60 C 141.53 138.96 135.10 Gas A/H 2 Outlet Flue Gas Temperature 2V3 60HNA22CT901A_YQ60 C 139.96 139.22 133.39 ID Fan 1 Suction Flue Gas Temperature 60HNC10CT001A_XQ50 C 122.02 121.82 122.14 ID Fan 2 Suction Flue Gas Temperature 60HNC20CT001A_XQ50 C 123.02 123.32 124.90 Boiler Furnace Purge SETP MEAS 60HLA21DP901A_YE60 kg/s 712.81 663.40 653.09 Feed Water Corrected Flow 2V3 60LAB75FF911A_YJ60 kg/s 493.89 495.81 498.35 Belt Conveyor 10 DE Gear Box Speed 60HFB10CS001A_XQ50 RPM 5.70 5.94 5.77 Belt Conveyor 20 DE Gear Box Speed 60HFB20CS001A_XQ50 RPM 5.27 5.23 5.18 Belt Conveyor 30 DE Gear Box Speed 60HFB30CS001A_XQ50 RPM 5.34 5.09 5.16 Belt Conveyor 40 DE Gear Box Speed 60HFB40CS001A_XQ50 RPM 5.16 5.00 5.21 Belt Conveyor 50 DE Gear Box Speed 60HFB50CS001A_XQ50 RPM 0.00 0.00 0.00 Boiler Oil Capacity % 60HJF00FF910_YJ60 RPM 0.35 0.09 0.09 Page 13 of 29
APPENDIX C Monitor Calibration certificates (These were not available at the time of compiling the report) Page 14 of 29
APPENDIX D Schematic of leaking bags found in the FFP (This was not available at the time of compiling the report) Page 15 of 29
APPENDIX E Reference Gas and Equipment Calibration Certificates Reference gases Reference equipment Page 16 of 29
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7 DISTRIBUTION LIST W Wilson CC Scheepers Boiler Contract Manager - Medupi Inthuu Measurements CC Page 30 of 29