REPORT NUMBER: 102523311MID-001b REPORT DATE: November 10, 2016
EVALUATION CENTER Intertek Testing Services NA Inc.
8431 Murphy Drive Middleton, WI 53562
RENDERED TO HY-C Company, LLC 10950 Linpage Place St. Louis, MO 63132
PRODUCT EVALUATED: MODEL FC1700 WOOD FORCED-AIR FURNACE
Report of Testing Model FC1700 Wood Forced-Air Furnace for compliance as an “Affected Wood Heater” with the applicable requirements of the following criteria: CAN/CSA B415.1-2010 Performance Testing of Solid- Fuel-Burning Heating Appliances, ASTM E2515-11 Determination of Particulate Matter Emissions Collected by a Dilution Tunnel, and EPA 40 CFR Part 60 “Standards of Performance for New Residential Wood Heaters, New Residential Hydronic Heaters and Forced-Air Furnaces”, March 16, 2015.
This report is for the exclusive use of Intertek's Client and is provided pursuant to the agreement between Intertek and its Client. Intertek's responsibility and liability are limited to the terms and conditions of the agreement. Intertek assumes no liability to any party, other than to the Client in accordance with the agreement, for any loss, expense or damage occasioned by the use of this report. Only the Client is authorized to copy or distribute this report and then only in its entirety. Any use of the Intertek name or one of its marks for the sale or advertisement of the tested material, product or service must first be approved in writing by Intertek. The observations and test results in this report are relevant only to the sample tested. This report by itself does not imply that the material, product, or service is or has ever been under an Intertek certification program.
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HY-C Company, LLC
Date: November 10, 2016
Project No. G102523311
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Contents I.
INTRODUCTION................................................................................................................ 4 I.A PURPOSE OF TEST ............................................................................................................................ 4 I.B LABORATORY .................................................................................................................................... 4 I.C DESCRIPTION OF UNIT ..................................................................................................................... 4 I.D REPORT ORGANIZATION .................................................................................................................. 5 II. SUMMARY......................................................................................................................... 5 II.A PRETEST INFORMATION ................................................................................................................ 5 II.B INFORMATION LOG ....................................................................................................................... 6
II.B(1) TEST STANDARD........................................................................................................................ 6
II.B(2)
Deviation from Standard Method......................................................................................... 6
II.C SUMMARY OF TEST RESULTS ........................................................................................................ 6 II.D DESCRIPTION OF TEST RUNS ......................................................................................................... 6 II.D SUMMARY OF OTHER DATA .......................................................................................................... 8
TABLE 1. – DATA SUMMARY PART A.................................................................................................... 8
TABLE 3. – WEIGHTED AVERAGE.......................................................................................................... 8
TABLE 5. - GENERAL SUMMARY OF RESULTS ....................................................................................... 9 III. PROCESS DESCRIPTION ................................................................................................ 9 III.A TEST SET-UP DESCRIPTON ............................................................................................................. 9 III.B AIR SUPPLY SYSTEM ...................................................................................................................... 9 III.C TEST FUEL PROPERTIES ................................................................................................................. 9 IV. SAMPLING SYSTEMS......................................................................................................10 IV.A. SAMPLING LOCATIONS ................................................................................................................ 10 IV.A.(1) DILUTION TUNNEL ................................................................................................................ 11 IV.B. OPERATIONAL DRAWINGS .......................................................................................................... 12
HY-C Company, LLC
Date: November 10, 2016
Project No. G102523311 Page 3 of 16 IV.B.(1) STACK GAS SAMPLE TRAIN .................................................................................................... 12 IV.B.(2). DILUTION TUNNEL SAMPLE SYSTEMS ............................................................................... 13 V. SAMPLING METHODS ........................................................................................................13 V.A. PARTICULATE SAMPLING ............................................................................................................... 14 VI. QUALITY ASSURANCE ......................................................................................................14 VI.A. INSTRUMENT CALIBRATION ........................................................................................................... 14 VI.A. (1). DRY GAS METERS ............................................................................................................ 14 VI.A.(2). STACK SAMPLE ROTAMETER ........................................................................................... 15 VI.A.(3). GAS ANALYZERS .............................................................................................................. 15 VI.B. TEST METHOD PROCEDURES ...................................................................................................... 15 VI.B.(1). LEAK CHECK PROCEDURES .............................................................................................. 15 VI.B.(2). TUNNEL VELOCITY/FLOW MEASUREMENT ..................................................................... 16 VI.B.(3). PM SAMPLING PROPORTIONALITY....................................................................................... 16 VII. CONCLUSION ..................................................................................................................16
REVISION SUMMARY DATE
SUMMARY
HY-C Company, LLC
Date: November 10, 2016
Project No. G102523311
Page 4 of 16
I.
INTRODUCTION
Intertek Testing Services NA (Intertek) has conducted testing for HY-C Company, LLC, on model FC1700 Wood Air Furnace to evaluate all applicable performance requirements included in “Determination of particulate matter emissions from wood forced-air furnaces.” I.A PURPOSE OF TEST The test was conducted to determine if the unit is in accordance with U.S EPA requirements under EPA 40 CFR Part 60 “Standards of Performance for New Residential Wood Heaters, New Residential Hydronic Heaters and Forced-Air Furnaces”. This evaluation was started on May 9, 2016 and completed on June 23, 2016. The following test methods were applicable: ASTM E2515-11- Standard Test Method for Determination of Particulate Matter Emissions Collected by a Dilution Tunnel CSA B415.1-10 - Performance Testing of Solid-Fuel-Burning Heating Appliances I.B LABORATORY The tests on the model FC1700 Wood Forced-Air Furnace were conducted at the Intertek testing Services Laboratory located at 8431 Murphy Drive, Middleton, WI, 53562. The laboratory is accredited by the U.S. EPA, Certificate Number 3. The test was conducted by Brian Ziegler and observed by Dan Haynes of HY-C Company, LLC. I.C DESCRIPTION OF UNIT The model FC1700 Wood Forced-Air Furnace is constructed of sheet steel. The outer dimensions are 50-inches deep, 52-inches high, and 26-inches wide. The unit has a fueling door located on the front. (See product drawings.)
Proprietary drawings and manufacturing methods are on file at Intertek in (Intertek location)
HY-C Company, LLC
Date: November 10, 2016
Project No. G102523311
Page 5 of 16
I.D
REPORT ORGANIZATION
This report includes summaries of all data necessary to determine compliance with the regulations. Raw data, calibration records, intermediate calculations, drawings, specifications and other supporting information are contained in appendices to this report.
II. SUMMARY II.A PRETEST INFORMATION
A sample was submitted to Intertek directly from the client. The sample was not independently selected for testing. The test unit was received at Intertek in Middleton, WI on May 9, 2016 and was shipped via the client. The unit was inspected upon receipt and found to be in good condition. The unit was set up following the manufacturer's instructions without difficulty. Following assembly, the unit was placed on the test stand. Prior to beginning the emissions tests, the unit was operated for a minimum of 10 hours at high-to-medium burn rates to condition the heater. This conditioning burn was performed by HY-C and the documents are included in the final report. The unit was found to be operating satisfactory during this break-in. The 10 plus hours of pre-burning were conducted from April 29, 2016 to May 2, 2016. The fuel used for the break-in process was cordwood. Following the pre-burn break-in process the unit was allowed to cool and ash and residue was removed from the firebox. The unit's chimney system and laboratory dilution tunnels were cleaned using standard wire brush chimney cleaning equipment. On May 9, 2016 the unit was set-up for testing.
HY-C Company, LLC
Date: November 10, 2016
Project No. G102523311
Page 6 of 16
II.B INFORMATION LOG II.B(1) TEST STANDARD
From May 9, 2016 through June 23, 2016, the unit was tested for EPA emissions. For Wood Forced-Air Furnaces, the test was conducted in accordance with CSA B415.1- 2010. The fuel used for the test run was Oak cordwood. The applicable EPA regulatory limits are: Step 1 – 2016 – 0.93 lbs/MMBtu Output (0.4 g/MJ) – For furnaces rated less than 65,000 Btu/hr Step 1 – 2017 – 0.93 0.93 lbs/MMBtu Output (0.4 g/MJ) – For furnaces rated more than 65,000 Btu/hr Step 2 – 2020 – 0.15 lbs/MMBtu Output (0.026 g/MJ) II.B(2) DEVIATION FROM STANDARD METHOD No deviations from the standards were performed, however, only the applicable sections from each standard were used during all testing. II.C SUMMARY OF TEST RESULTS
The appliance tests resulted in the following performance:
Particulate Emissions: 0.261 lbs/MMBtu Output (0.225 g/MJ) Carbon Monoxide Emissions: 139.44 g/hr Heating Efficiency: 64.1% (Higher Heating Value Basis)
II.D DESCRIPTION OF TEST RUNS
RUN #1 (May 9, 2016). The furnace was set to a category 3 draw rate. The combustion blower was turned on to maintain the desired heat rate. The Test Load weighed 37.51 lbs. and utilized a 7.5 lb. coal bed. The average Btu/hr output was 51,504. Burn time was 3.57 hours. The kg/hr burn rate was 3.89.
HY-C Company, LLC
Date: November 10, 2016
Project No. G102523311
Page 7 of 16 RUN #2 (May 10, 2016). The furnace was set to a category 2 draw rate. The combustion blower was turned on to maintain the desired heat rate. The Test Load weighed 44.09 lbs. and utilized a 4.6 lb. coal bed. The average Btu/hr output was 29,008. Burn time was 6.75 hours. The kg/hr burn rate was 2.41. RUN #3 (May 11, 2016). The furnace was set to draw a category 4 draw rate. The combustion blower was turned on to maintain the desired heat rate. The Test Load weighed 38.15 lbs. and utilized a 7.6 lb. coal bed. The average Btu/hr output was 64,070. Burn time was 2.50 hours. The kg/hr burn rate was 5.63. RUN #4 (May 11, 2016). Test run #3 resulted in a slightly lower output than expected, so the client wanted to perform a second category 4 test. The furnace was set to draw a category 4 draw rate. The combustion blower was turned on to maintain the desired heat rate. The Test Load weighed 41.18 lbs. and utilized an 8.2 lb. coal bed. The average Btu/hr output was 70,603. Burn time was 2.57 hours. The kg/hr burn rate was 5.91. Test runs #3 and #4 will be averaged together. RUN #5 (May 12, 2016). The furnace was set to draw a category 1 draw rate. The combustion blower was turned on to maintain the desired heat rate. The Test Load weighed 44.03 lbs. and utilized a 4.5 lb. coal bed. The average Btu/hr output was 25,777. Burn time was 6.92 hours. The kg/hr burn rate was 2.33. This run has been determined to be invalid as the deviation between the two sample trains is greater than 7.5% and more than 0.50 g/kg. RUN #6 (June 22, 2016). The furnace was set to draw a category 1 draw rate. The combustion blower was turned on to maintain the desired heat rate. The Test Load weighed 44.17 lbs. and utilized a 5.9 lb. coal bed. The average Btu/hr output was 28,632. Burn time was 6.10 hours. The kg/hr burn rate was 2.59. This run has been determined to be invalid as the fan wheel on the combustion blower was found to be loose, which reduced the amount of combustion air to the firebox. RUN #7 (June 23, 2016). The furnace was set to draw a category 1 draw rate. The combustion blower was turned on to maintain the desired heat rate. The Test Load weighed 43.24 lbs. and utilized a 4.9 lb. coal bed. The average Btu/hr output was 25,586. Burn time was 6.90 hours. The kg/hr burn rate was 2.30.
HY-C Company, LLC
Date: November 10, 2016
Project No. G102523311
Page 8 of 16
II.D SUMMARY OF OTHER DATA TABLE 1. – DATA SUMMARY PART A
W fuel
MC ave
Q in
Q out
Θ
Wood Weight as-fired
Run No.
Load % Capacity
Target Load Btu/hr 26,250
Actual Load Btu/hr 25,586
Test Duration
Wood Moisture
Heat Input
Heat Output
Category
Actual Load
% of Max
hrs
lb
% DB 23.51
Btu
Btu
<35% of Max 36-53% of Max 54-76% of max Max capacity
I
7
34.1
6.90
43.24
297,589
176,540
II
2
33,000
29,088
38.8
6.75
44.09
22.84
305,086
196,343
III
1
48,750
51,504
68.7
3.57
37.51
22.50
260,270
183,699
IV
3 & 4
75,000
67,337
89.8
2.53
39.67
23.07
273,941
170,695
TABLE 2. – DATA SUMMARY PART B
η del
η SLM
E T
E
E
E g/hr
PM Output Based
Stack Loss Efficiency
Run No.
Load % Capacity
Total PM Emissions
PM Output Based lb/mmBtu Out
PM Rate g/hr 2.94
Delivered Efficiency
Category
g
g/MJ 0.11
%
%
<35% of Max 36-53% of Max 54-76% of max Max capacity
I
7
20.26
0.25
59.3%
68.8%
II
2
26.23
0.29
0.13
3.89
64.4%
67.8%
III
1
19.29
0.23
0.10
5.41
70.6%
67.0%
IV
3 & 4
20.50
0.26
0.11
8.09
62.3%
54.8%
TABLE 3. – WEIGHTED AVERAGE
Run No.
Weighting Factor
η del,i x F i - HHV
Category
E g/MJ,i x F i
E lb/mmbtu,i x F i
E g/hr,i x F i
CO g/hr,i x F i
7 2 1
0.250 0.250 0.250 0.250 1.000
0.148 0.161 0.176 0.156 0.641
0.027 0.032 0.025 0.028 0.112
0.063 0.074 0.058 0.066 0.261
0.734 0.972 1.352 2.021 5.079
38.365 30.845 39.383 30.845 139.438
I
II
III IV
3 & 4
Totals
HY-C Company, LLC
Date: November 10, 2016
Project No. G102523311
Page 9 of 16
TABLE 5. - GENERAL SUMMARY OF RESULTS
1 st Hour Emissions (g/hr)
Burn Rate (kg/hr)(Dry)
Run Time (min)
Run No.
7 2 1 3 4
2.30 2.41 3.89 5.63 5.91
15.29 11.91 10.51 8.89 4.09
414 405 214 150 154
TABLE 6. – CSA B415.1 RESULTS Run No.
CO Emissions (g/hr)
Heating Efficiency (% HHV)
Heat Output (Btu/hr)
7 2 1 3 4
153.46 123.38 157.53 312.05 289.21
68.8 67.8 67.0 48.4 61.1
29,718 30,678 48,188 50,944 67,064
III. PROCESS DESCRIPTION
III.A TEST SET-UP DESCRIPTON
A standard 6” diameter vertical single wall pipe and insulated chimney system was installed to 15’ above floor level. The singe wall pipe extended to 8 feet above the floor and insulated chimney extended the remaining height. III.B AIR SUPPLY SYSTEM Combustion air enters a combustion blower located on the back of the heater, which is directed to the firebox. All gases exit through the 6” flue also located at the top back of the heater. The exhaust gases are assisted by a combustion blower. III.C TEST FUEL PROPERTIES
Wood used for the testing is split and seasoned oak cordwood. Oak has a default heating value of 8500 Btu/hr (19752 kJ/kg) and a moisture content between 18% and 28% on a dry basis.
HY-C Company, LLC
Date: November 10, 2016
Project No. G102523311
Page 10 of 16
IV.
SAMPLING SYSTEMS
IV.A. SAMPLING LOCATIONS
Particulate samples are collected from the dilution tunnel at a point 20 feet from the tunnel entrance. The tunnel has two elbows and two mixing baffles in the system ahead of the sampling section. (See Figure 3.) The sampling section is a continuous 13 foot section of 6 inch diameter pipe straight over its entire length. Tunnel velocity pressure is determined by a standard Pitot tube located 60 inches from the beginning of the sampling section. The dry bulb thermocouple is located six inches downstream from the Pitot tube. Tunnel samplers are located 60 inches downstream of the Pitot tube and 36 inches upstream from the end of this section. (See Figure 1.) Stack gas samples are collected from the steel chimney section 8 feet ± 6 inches above the scale platform. (See Figure 2.)
HY-C Company, LLC
Date: November 10, 2016
Project No. G102523311
Page 11 of 16
IV.A.(1)
DILUTION TUNNEL
HY-C Company, LLC
Date: November 10, 2016
Project No. G102523311
Page 12 of 16
IV.B. OPERATIONAL DRAWINGS
IV.B.(1) STACK GAS SAMPLE TRAIN
IV.B.
OPERATIONAL DRAWINGS
IV.B.(1). STACK GAS SAMPLE TRAI
HY-C Company, LLC
Date: November 10, 2016
Project No. G102523311
Page 13 of 16
IV.B.(2). DILUTION TUNNEL SAMPLE SYSTEMS
Figure 3
HY-C Company, LLC
Date: November 10, 2016
Project No. G102523311
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V. SAMPLING METHODS
V.A. PARTICULATE SAMPLING
Particulates were sampled in strict accordance with ASTM E2515-2011. This method uses two identical sampling systems with Gelman A/E 61631 binder free, 47-mm diameter filters. The dryers used in the sample systems are filled with “Drierite” before each test run. In order to measure first-hour emissions rates the a third filter set is prepared at one hour into the test run, the filter sets are changed in one of the two sample trains. The two filter sets used for this train are analyzed individually to determine the first hour and total emissions rate.
VI. QUALITY ASSURANCE
VI.A. INSTRUMENT CALIBRATION
VI.A. (1).
DRY GAS METERS
At the conclusion of each test program the dry gas meters are checked against our standard dry gas meter. Three runs are made on each dry gas meter used during the test program. The average calibration factors obtained are then compared with the six-month calibration factor and, if within 5%, the six-month factor is used to calculate standard volumes. Results of this calibration are contained in Appendix D.
An integral part of the post test calibration procedure is a leak check of the pressure side by plugging the system exhaust and pressurizing the system to 10” W.C. The system is judged to be leak free if it retains the pressure for at least 10 minutes.
The standard dry gas meter is calibrated every 6 months using a Spirometer designed by the EPA Emissions Measurement Branch. The process involves sampling the train operation for 1 cubic foot of volume. With readings made to .001 ft 3 , the resolution is .1%, giving an accuracy higher than the ±2% required by the standard.
HY-C Company, LLC
Date: November 10, 2016
Project No. G102523311
Page 15 of 16
VI.A.(2).
STACK SAMPLE ROTAMETER
The stack sample rotometer is checked by running three tests at each flow rate used during the test program. The flow rate is checked by running the rotometer in series with one of the dry gas meters for 10 minutes with the rotometer at a constant setting. The dry gas meter volume measured is then corrected to standard temperature and pressure conditions. The flow rate determined is then used to calculate actual sampled volumes.
VI.A.(3).
GAS ANALYZERS
The continuous analyzers are zeroed and spanned before each test with appropriate gases. A mid-scale multi-component calibration gas is then analyzed (values are recorded). At the conclusion of a test, the instruments are checked again with zero, span and calibration gases (values are recorded only). The drift in each meter is then calculated and must not exceed 5% of the scale used for the test. At the conclusion of each unit test program, a three-point calibration check is made. This calibration check must meet accuracy requirements of the applicable standards. Consistent deviations between analyzer readings and calibration gas concentrations are used to correct data before computer processing. Data is also corrected for inter- ferences as prescribed by the instrument manufacturer’s instructions.
VI.B. TEST METHOD PROCEDURES
VI.B.(1).
LEAK CHECK PROCEDURES
Before and after each test, each sample train is tested for leaks. Leakage rates are measured and must not exceed 0.02 CFM or 4% of the sampling rate. Leak checks are performed checking the entire sampling train, not just the dry gas meters. Pre- test and post-test leak checks are conducted with a vacuum of 10 inches of mercury. Vacuum is monitored during each test and the highest vacuum reached is then used for the post test vacuum value. If leakage limits are not met, the test run is rejected. During, these tests the vacuum was typically less than 2 inches of mercury. Thus, leakage rates reported are expected to be much higher than actual leakage during the tests.
HY-C Company, LLC
Date: November 10, 2016
Project No. G102523311
Page 16 of 16
VI.B.(2).
TUNNEL VELOCITY/FLOW MEASUREMENT
The tunnel velocity is calculated from a center point Pitot tube signal multiplied by an adjustment factor. This factor is determined by a traverse of the tunnel as prescribed in EPA Method 1. Final tunnel velocities and flow rates are calculated from EPA Method 2, Equation 6.9 and 6.10. (Tunnel cross sectional area is the average from both lines of traverse.) Pitot tubes are cleaned before each test and leak checks are conducted after each test.
VI.B.(3). PM SAMPLING PROPORTIONALITY
Proportionality was calculated in accordance with ASTM E2515-11. The data and results are included in Appendix C.
VII. CONCLUSION
This test demonstrates that this unit is an affected facility under the definition given in the regulation. The emission rate of 0.261 g/hr meets the EPA requirements for the Step 1 limits. Model FC1700 was tested as a representative sample of similar models FC1900, SF3100, and SF4200. SF3100 is identical to the FC1700, with the only difference being the color. Models FC1900 and SF4200 have the same internal construction as models FC1700 and SF3100, with the difference being that the FC1900 and SF4200 models have weather tight enclosures for outdoor installation. SF Series is sold under the Shelter Furnace name and the FC Series is sold under the Fire Chief Industries name. INTERTEK TESTING SERVICES NA
Evaluated by:
Brian Ziegler Technical Team Lead - Hearth
Reviewed by:
Ken Slater Associate Engineer - Hearth
Certificate of Conformity
Emissions – Wood Burning Forced Air Furnace EPA 40 CFR Part 60, Subpart QQQQ, CSA B415.1-2010 Certificate number: WHI15 – 10583802
Organization: Company Name: HY-C Company, LLC Address: 10950 Linpage Place City, State: St. Louis, MO Zip Code: 63132 Country: USA
This is a certificate of conformity to certify that the bearer has successfully completed the requirements of the above scheme which include the testing of products, the initial assessment, and are subject to continuing annual assessments of their compliance and testing of samples of products taken from production (as applicable to the scheme) and has been registered within the scheme for the products detailed.
Product: Model FC1700, FC 1900, SF3100, and SF4200 Manufacturer’s Rated Output: 75,000 Btu/hour Weighted Average Emissions: 0.26 lb/million Btu/hour Weighted Average Annual Delivered Efficiency: 64% Test Fuel Type: Cordwood Compliance: Certified to comply with 2017 particulate emissions standard. Report Number: 102523311MID-001b
Certification body: Intertek Testing Services NA, Inc. Initial registration: November 11, 2016 Date of expiry: May 16, 2020 Issue status: 1
Dustin Behling Certification Coordination Manager
11/11/2016
Name
Signature
Date
www.intertek.com The certificate and schedule are held in force by regular annual surveillance visits by Intertek Testing Services NA, Inc. and the reader or user should contact Intertek to validate its status. This certificate remains the property of Intertek Testing Services NA, Inc. and must be returned to them on demand. This Certificate is for the exclusive use of Intertek's Client and is provided pursuant to the Certification agreement between Intertek and its Client. Intertek's responsibility and liability are limited to the terms and conditions of the agreement. Intertek assumes no liability to any party, other than to the Client in accordance with the agreement, for any loss, expense or damage occasioned by the use of this certificate. Only the Client is authorized to permit copying or distribution of this certificate and then only in its entirety. Use of Intertek’s Certification mark is restricted to the conditions laid out in the agreement. Any further use of the Intertek name for the sale or advertisement of the tested material, product or service must first be approved in writing by Intertek. Initial Factory Assessments and Follow up Services are for the purpose of assuring appropriate usage of the Certification mark in accordance with the agreement, they are not for the purposes of production quality control and do not relieve the Client of their obligations in this respect. Registered address: Intertek Testing Services NA, Inc. 545 E. Algonquin Rd. Arlington Heights, IL 60005 USA
INTERTEK/WARNOCK HERSEY AIR FURANCE EMISSIONS AND EFFICIENCY TESTING LABORATORY OPERATING PROCEDURES pg. 1 INTRODUCTION This document provides a systematic guide for the technician conducting tests to CAN/CSA B415.1-2010 Performance Testing of Solid-Fuel-Burning Heating Appliances. This guide cannot cover every possible contingency that may develop during a particular test program. Many questions that may arise can be answered by a complete understanding of the test protocol and its intent. When in doubt on any detail check with the laboratory manager and be sure you understand the procedures involved. The primary measurements to be obtained are particulate emission data and efficiency data. The technician's duties include the following steps. It is critical that all spaces on the data forms be properly filled in. Each test must be represented by
a complete record of what was done and when. I. APPLIANCE INSPECTION AND SET-UP A. Incoming Inspection B. Unit Set-Up II. SAMPLING SYSTEMS - SET-UP A. Gas Analysis B. Dilution Tunnel III. TEST CONDUCT A. Pre-Test Fuel Load
B. Test Fuel Load C. Unit Start - up D. Test Run
IV.
POST TEST PROCEDURE A. Leak Checks B. Particulate Sample Recovery
V.
TEST EQUIPMENT AND FIGURES
VI.
FUEL HANDLING AND STORAGE The technician running this test must be familiar with the following documents that are to be kept in the laboratory at all times. 1. ASTM E2515 2. CSA B415.1
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INTERTEK/WARNOCK HERSEY AIR FURANCE EMISSIONS AND EFFICIENCY TESTING LABORATORY OPERATING PROCEDURES pg. 2
I. APPLIANCE INSPECTION AND SET-UP A. Incoming Inspection
1. Check for completeness of unit including parts, accessories, installation and operating instructions, drawings and specifications, etc. Note any discrepancies or missing parts. 2. Check for shipping damage. If damage has occurred, notify the laboratory manager. In some cases repairs may be made, provided the manufacturer and laboratory manager concur that repairs will not affect the unit’s performance. If damage is irreparable, a new unit will need to be obtained. 3. Note whether unit is catalytic or non-catalytic. 4. Mark unit with manufacturer's name, model number, work order number, and date received. 5. If unit is safety listed, note label data including listing agency and serial number. B. Unit Set-Up 1. Prior to placing unit on scale, the scale must be turned on and allowed to warm up for 1-hour minimum. 2. Place unit on scale and align so chimney will be centered in hood. Record the weight of the unit and all accessories. (Do not weigh with chimney attached.) 3. Chimney and connector should be cleaned with a wire brush prior to mounting. Attach chimney and connector then seal all joints. Be sure the single wall stove pipe terminates and insulated pipe starts at proper level above scale platform. Chimney must be supported from scale so that it does not touch test enclosure or hood walls. 5. Measure firebox dimensions and record on appropriate data form. Make a three dimensional sketch of the firebox including firebrick, baffles, and obstructions. Calculate load area volume in cubic feet. See Section 8.2 of the CAN/CSA B415.1-2010 Performance Testing of Solid-Fuel-Burning Heating Appliances for details. 7. Plug thermocouples into data acquisition system jacks and verify that all instrumentation is working properly. 8. Dilution tunnel must be cleaned prior to each certification test series, and at anytime a higher burn rate follows a lower burn rate. 9. Install outlet air duct in accordance with the manufacturer’s requirements and section 5.3.2 of CAN/CSA B415.1-2010 Performance Testing of Solid-Fuel-Burning Heating Appliances. 10. Set duct static pressure to 0.2 in/wc or to the manufacturer’s specifications by reducing the duct outlet size uniformly.
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INTERTEK/WARNOCK HERSEY AIR FURANCE EMISSIONS AND EFFICIENCY TESTING LABORATORY OPERATING PROCEDURES pg. 3
II.
SAMPLING SYSTEMS SET-UP A. Gas Analysis 1. All instruments should be turned on and allowed to warm up for 1-hour minimum. 2. Prior to calibrating, make sure that the outlet pressure on each calibration gas bottle reads 10 PSI. Adjust flow meters at each gas analyzer to required flow. All gas analyzers (CO 2 , CO, O 2 ) are zeroed on nitrogen. The O 2 analyzer is spanned on air and set for 20.93%. CO 2 and CO analyzers are spanned with their respective gases. Calibrate analyzers as follows: a. With calibration switch at "SPAN", adjust all span controls to values specified on span gas label. b. Switch to "ZERO" and adjust zero controls to provide 0.00 readout on all analyzers. c. Repeat a. and b. until no further adjustment is required. d. Record these values on the appropriate data sheet. e. Switch to "CAL." and record all analyzer values. 3. Response time synchronization check. a. With switch at "SAMPLE" and no fire in unit, allow readings to stabilize (O 2 analyzer should read 20.93, CO and CO 2 should read 0.00). b. Switch to "CAL" setting and start the stopwatch. Note the time required for each unit to reach the calibration gas bottle value. If all three analyzers reach this value within 5 seconds of each other, synchronization is adequate. If not, contact the laboratory manager. Synchronization is adjusted by either internal instrument setting or adjustment of sample line length. c. Use section 8 of ASTM E2515 for procedures to check calibration of instruments. 4. Sample clean-up train. a. Load a new filter in 4-inch glass filter holder. b. Load four Impingers as follows:
#1: 100 ml. distilled or de-ionized water #2: 100 ml. distilled or de-ionized water #3: Empty #4: 200-300 grams Drierite.
G:\Hearth\EE - Emissions and Efficiencey\Furnace solid fuel\Lab Procedures for EPA Air Furnaces 11.11.16.doc
INTERTEK/WARNOCK HERSEY AIR FURANCE EMISSIONS AND EFFICIENCY TESTING LABORATORY OPERATING PROCEDURES pg. 4
c. Place Impingers in container and connect with greased "U TUBES". (Grease carefully on bottom half of ball joint so that grease will not get into tubes.) d. Connect filter to impinger #1 and sample line to impinger #4.
e. Connect stack probe to filter. f. Leak check system as follows: 1) Plug probe. 2)
Turn on sample system and increase flow rate slowly. Set vacuum-adjust valve to obtain a vacuum of 10 inches mercury.
3)
4) If sapphire float in rotometer does not stabilize below 10 on scale, system must be resealed. 5) Repeat leak-check procedure until satisfactory results are obtained. 6) Unplug probe slowly, then decrease flow rate slowly before shutting off system. g. Just prior to starting test, fill impinger container with ice. B. Dilution Tunnel Sample Train Set-Up: 1. Filters and holders. a. Clean probes and filter holder front housings carefully and desiccate to a constant weight prior to use. b. Filters and filter probe combinations should be numbered and labeled prior to use. c. Weigh desiccated filters and probe filter units on analytical balance. Record the weights on the appropriate form. Note that the probe and front half of the front filter holder is to be weighed as a unit. d. Carefully assemble the filter holder units and connect to sampling systems. 2. Leak checking. a. Each sample system is to be checked for leakage prior to inserting probes in tunnel. b. Plug probes and start the samplers. Adjust pump bypass valve to produce a vacuum reading of 10 inches mercury. NOTE: During test, highest vacuum recorded is required for posttest leak check. c. Allow vacuum indication to stabilize at 10" mercury, record dry gas meter readings, (DGM 1 , DGM 2 ). At a convenient DGM value start stopwatch. Time for 1 minute then stop vacuum pumps. Record dry gas meter readings again, (DGM 3 , DGM 4 ). NOTE: If rotometer ball is floating above the 5-mm mark, system is leaking too much and all seals should be checked.
G:\Hearth\EE - Emissions and Efficiencey\Furnace solid fuel\Lab Procedures for EPA Air Furnaces 11.11.16.doc
INTERTEK/WARNOCK HERSEY AIR FURANCE EMISSIONS AND EFFICIENCY TESTING LABORATORY OPERATING PROCEDURES pg. 5
d. Calculate leakage rate as follows. System 1: DGM3-DGM 1 = CFM 1 System 2: DGM4-DGM 2 = CFM 2
If CFM 1 or CFM 2 is greater than 0.02 cfm, or 1 S greater than 0.04 x Sample Rate, leakage is unacceptable and system must be resealed. For most tests the sample rate will be 0.25 cfm, thus leakage rates in excess of 0.04 x 0.25 = 0.010 cfm are not acceptable. e. To prevent contamination, do not insert probes in tunnel until the start of the test run. TEST CONDUCT A. Pre-Test Fuel Load 1. Using oak wood, operate normally until the unit is heated and has cycled at least 2 times. Then remove all contents and zero scale 2. Reload with oak wood (pieces approximately 2” thick) and allow to burn down to specified coal bed weight. B. Test Fuel Load 1. Determine optimum load weight by multiplying loading area volume (ft 3 ) by 10lbs/ft 3 . This is the ideal load weight. 2. Test load fuel shall be red or white oak cordwood with a dimension of 20- inches (± 4”). Moisture content of each piece needs to be within 18-28%, with the overall average to be between 18-28%. 3. Weigh out test load and adjust weight by shortening or lengthening all pieces equally if necessary. 4. Measure and record moisture content of each fuel piece (using five total measurements). Determine if fuel load moisture content is within required range (18-28%). If not, construct new fuel pieces using wood with required moisture content. Contact laboratory manager if you cannot find suitable pieces. C. Unit Start-Up 1. With all doors and air controls closed, zero draft magnehelic using screw located at bottom of meter. 2. Before lighting a fire turn on dilution tunnel and set flow rate to 60 scfm. 3. Check draft imposed on cold stove. All inlets must be closed and a draft gauge in the chimney. If draft is greater than 0.005 inches water column, adjust tunnel to stack gap until draft is less than 0.005 inches water column.
III.
G:\Hearth\EE - Emissions and Efficiencey\Furnace solid fuel\Lab Procedures for EPA Air Furnaces 11.11.16.doc
INTERTEK/WARNOCK HERSEY AIR FURANCE EMISSIONS AND EFFICIENCY TESTING LABORATORY OPERATING PROCEDURES pg. 6
4. With hot wire anemometer check for ambient airflow around unit (must be less than 50 ft/min). 5. Zero scale and start fire with newspaper and kindling. (Make sure stack sample probe is on the unit.) 6. Once kindling is burning well, add preload fuel. Operate at high fire for sufficient time to get fuel load burning well. Then adjust settings to intended test run levels. 7. Perform the dilution tunnel traverse as prescribed in ASTM #2515, Section 9.3. (Pitot tube should be carefully cleaned prior to each test.) 8. Pretest load must burn until the unit has cycled at least 2 times. 9. Stir fire often during preburn (after a reading) to get a good coal bed. Fire can only be raked once (door open 1 minute or less) during the 15 minutes prior to the start of the test. 10.Traverse the outlet duct velocity with a vane anemometer and enter into the spreadsheet. D. Test Run 1. Stack gas analyzers should be on and in the sample mode. 2. When the fuel bed is between 10-20% of the test load weight the test is to be started. a. Insert the sample probes into the tunnel being careful not to hit sides of tunnel with probe tip. b. Check tunnel Pitot tube for proper position. c. Record initial readings. d. Turn on probe sample systems and start timing test. e. Tare platform scale. f. Open stove doors and load stove. Close door or follow manufacturer's start-up procedures. Five minutes is the maximum time before all doors and controls must be set to final positions for duration of test. g. Record length of time door and bypass are open, include any air control setting adjustments. h. Every 10 minutes or less record the following: 1) Dry gas meter readings. 2) Weight remaining. 4) Tunnel Pitot tube reading. 5) Draft reading. 6) Rotometer readings. i. Every 1 minute record the following: 1) All temperature points 2) Water meter 3) Delta T thermopile
G:\Hearth\EE - Emissions and Efficiencey\Furnace solid fuel\Lab Procedures for EPA Air Furnaces 11.11.16.doc
INTERTEK/WARNOCK HERSEY AIR FURANCE EMISSIONS AND EFFICIENCY TESTING LABORATORY OPERATING PROCEDURES pg. 7
j. Filter temperatures shall not exceed 90ºF anytime during the test. If the filters are approaching 90ºF turn on cooling pump. Filters must be kept above the dilution tunnel wet bulb temperature in order to prevent condensation. k. Regularly check impinger train for ice level during test. l. After 30 seconds of 0.00 lbs. weight, and on the minute, shut off
sample trains and record last reading. m. Record final dry gas meter values.
IV. POST TEST PROCEDURES A. Leak Checks 1. Dilution Tunnel
a. Remove both sample probes from tunnel and plug with rubber stopper. b. Turn on sample system and set vacuum to 10" mercury or to the highest value reached during the test. c. At a convenient value start stopwatch and record the DGM starting value. d. After 1 minute stop sample system and record ending DGM value. e. Calculate leakage rate per pre-test description (see II.B.2.c.). 2. Gas Analyzers a. Set stack sample flow to about 75 mm on the rotometer. b. Plug with rubber stopper. c. Adjust vacuum to 10" mercury. d. Let system stabilize then record rotometer readings. e. If the rotometer readings do not equal zero, check with the laboratory manager. f. SLOWLY unplug probe and decrease flow rate to zero. g. Turn off stack sampling system. h. Zero, span and calibrate the analyzers (see Gas Analysis). RECORD ONLY these meter values. B. Particulate Sample Recovery 1. Disassemble filter holder and scrape gasket with scalpel. Collect all loose material on filters. 2. Weigh and record probes and filters for each train. NOTE: 24 hours of desiccation must pass before final "no change" weight values can be recorded. 3. Weigh and record probes and fillers at 6-hour intervals until weight change between weighing is less than 0.2 mg.
G:\Hearth\EE - Emissions and Efficiencey\Furnace solid fuel\Lab Procedures for EPA Air Furnaces 11.11.16.doc
INTERTEK/WARNOCK HERSEY AIR FURANCE EMISSIONS AND EFFICIENCY TESTING LABORATORY OPERATING PROCEDURES pg. 8
V.
TEST EQUIPMENT AND FIGURES Figure 1 – Dilution Tunnel
∆ T
Figure 2 – Flue Gas Sample Train
G:\Hearth\EE - Emissions and Efficiencey\Furnace solid fuel\Lab Procedures for EPA Air Furnaces 11.11.16.doc
INTERTEK/WARNOCK HERSEY AIR FURANCE EMISSIONS AND EFFICIENCY TESTING LABORATORY OPERATING PROCEDURES pg. 9
Figure 4 – Dilution Tunnel Sample System
VI. FUEL HANDLING AND STORAGE Test fuel is purchased at various sources and once received; the moisture is checked by the Intertek staff. The fuel is then placed in a sealed room with the humidity and temperature maintained at a desired level to equilibrate and maintain the moisture content of the fuel. The room is only opened as necessary to retrieve the fuel for preparation prior to the test.
G:\Hearth\EE - Emissions and Efficiencey\Furnace solid fuel\Lab Procedures for EPA Air Furnaces 11.11.16.doc
VERSION: 2.2
12/14/2009
Manufacturer: HY-C
Appliance Type: Non-Cat (Cat, Non-Cat, Pellet)
Model: FC1700 Date: 5/9/2016
Temp. Units Weight Units
Default Fuel Values
F (F or C) lb (kg or lb)
Run: 1
D. Fir
Oak
Control #: G102523311
HHV (kJ/kg)
19,810 19,887
Test Duration: 214
%C %H %O
48.73
50
Output Category: 3
Fuel Data
6.87 43.9
6.6
D. Fir
42.9
Wood Moisture (% wet): Load Weight (lb wet): Burn Rate (dry kg/h): Total Particulate Emissions:
HHV 19,887 kJ/kg
%Ash
0.5
0.5
18.37 36.74
%C %H %O
50
3.81
6.6
Note 1: For other fuels, use the heating value and fuel composition determined by analysis of fuel sample in accordance with Clause 9.2.
19.57 g
42.9
%Ash
0.5
10.88 502.57 74.81
Averages
0.42
9.10
Temp. (ºF)
Note 2: In cases where the "Fuel Weight Remaining" is the same for three or more readings in a row, a "divide by zero error" will occur in the calculation sheet. In such cases, adjust the weight values by interpolation between the first occurence and the next reading showing a decrease in weight.
Elapsed
Fuel Weight Remaining (lb)
Flue Gas Composition (%)
Flue Room Gas Temp
O 2
Time (min)
CO CO 2
0 1 2 3 4 5 6 7 8 9
36.74 36.24 35.54 34.84 34.35 33.84 33.43 32.95 32.54 32.05 31.64 31.24 30.83 30.53 30.15 29.74 29.33 28.94 28.63
0.12 0.09 0.25 0.90 1.62 2.43 1.80 1.29 0.99 0.80 0.65 0.59 0.56 0.49 0.39 0.30 0.22 0.20 0.18
11.03
8.91 761.2 75.5
6.27 14.02 961.4 75.8
10.79 15.29 16.47 17.29 17.19 16.82 16.40 16.15 15.95 15.69 15.49 15.14 14.81 14.56 14.56 14.50 14.31
8.59 1065.9 75.4 3.45 833.0 76.7 2.20 794.5 76.1 2.14 784.7 75.3 2.61 773.5 75.3 3.10 763.4 76.1 3.65 754.4 75.6 4.04 746.9 75.9 4.35 743.2 75.5 4.64 737.0 75.9 4.86 727.7 75.0 5.25 720.6 75.7 5.60 716.3 76.1 5.89 713.6 75.6 5.93 709.6 75.7 5.99 707.1 75.5 6.19 701.1 75.3
10 11 12 13 14 15 16 17 18
Reading Interval
1 Minutes
1 2
3
4
5
13
14
15
Degrees F
Elapsed
Flue
Room Tunnel
DGM 1 DGM 1 Filter 1
Time temp 1 temp 2 dry bulb 3 Outlet air Inlet Air
In
Out
0 623.1 1 637.7 2 660.4 3 668.2 4 672.1 5 671.6 6 691.4 7 721.8 8 732.9 9 732.8 10 734.4 11 732.3 12 734.4 13 732.6 14 736.0 15 733.1 16 731.8 17 735.1 18 733.6 19 787.7 20 748.2 21 746.6 22 744.7 23 742.1 24 739.2 25 736.6 26 735.9 27 734.1 28 731.9 29 733.0 30 737.6 31 740.1 32 739.1 33 739.2 34 741.9 35 743.4 36 742.4 37 742.1 38 739.6 39 739.5 40 735.5 41 734.1 42 729.7 43 729.9 44 728.6 45 725.6 46 720.5
66.2 66.7 67.0 67.2 67.2 67.5 67.8 68.2 68.9 68.7 68.7 69.1 69.4 69.4 69.4 69.8 70.0 70.0 70.0 70.5 71.1 71.0 71.2 70.9 71.4 71.5 71.9 71.5 72.3 71.3 71.5 71.8 72.2 72.0 72.1 72.5 72.4 72.7 72.3 72.5 72.2 72.6 72.4 72.5 72.6 73.7 73.3
86.0 88.1 88.9 89.7 91.2 90.5 98.9 96.0 97.4 97.8 98.6 99.2 99.0
118.8 148.5 165.9 168.3 164.3 174.5 183.6 194.7 197.0 180.0 187.6 213.4 184.3
66.5 70.06504 68.96067 -37.4924 66.7 69.8755 68.75105 -139.141 66.7 70.0238 68.90603 17.07746 67.0 70.11029 69.10632 -78.9851 66.8 70.07596 68.92473 3.239831 67.0 69.94517 68.94118 -162.058 67.2 69.83311 68.88937 -20.1421 67.6 70.21513 68.95681 22.46635 67.8 70.13552 69.13824 -36.5015
67.6
69.9178 68.99413 -140.269
67.8 70.37749 68.89829 -37.1854
68.0
70.2048 69.13388 67.43372
68.0 70.07421 69.13716 68.8426 68.3 70.02898 69.20571 69.84821 68.3 70.59124 69.6408 69.91518 68.4 70.16705 69.37725 69.59138 68.6 70.27865 69.41522 69.70297 68.7 70.39243 69.41523 69.77661 68.5 70.18286 69.1655 69.57372 69.2 70.53767 69.33959 69.5671 69.2 70.4564 69.29847 69.56614 69.6 70.64248 69.344 69.47111 69.0 70.43224 69.1003 69.29433 69.1 70.34228 69.19774 69.29807 69.3 70.45075 69.15227 69.16558 69.5 70.60452 69.41312 69.41975 69.7 70.61633 69.47179 69.3847 69.5 70.79067 69.80677 69.37833 69.7 70.85823 69.5062 69.38565 69.7 70.74441 69.71365 69.41908 69.5 70.92981 69.78527 69.52416 70.0 70.86813 69.73028 69.46248 69.5 70.78151 69.63697 69.32901 69.9 70.76893 69.72478 69.3365 70.3 70.93433 69.5823 69.4015 69.8 70.93883 69.72066 69.31899 70.1 71.07391 69.92937 69.49423 69.5 70.98648 69.88879 69.65445 69.6 71.02038 69.98293 69.50094 70.1 71.06577 70.0417 69.5664 69.5 70.4439 69.50685 69.15204 69.4 71.045 69.95401 69.41178 69.6 71.18015 70.26318 69.74772 70.0 71.28503 70.29443 69.77898 70.5 71.45457 70.16278 69.50676 70.7 71.13371 70.1431 69.53394 69.9 71.1116 69.98045 69.47168
100.1 212.8 100.1 185.7 101.4 181.8 100.5 209.4 101.1 186.8 103.2 183.7 109.6 183.9 103.4 183.1 103.0 183.0 102.5 182.8 100.0 182.8 101.9 184.6 101.7 185.4 102.0 186.0 102.7 187.7 99.6 183.4 103.6 188.3 104.1 189.3 104.4 190.5 104.2 191.7 103.8 192.3 102.9 194.2 103.1 195.1 103.8 196.0 103.3 197.4 103.9 197.3 104.4 198.6 103.8 199.4 102.7 199.8 102.6 199.7 103.0 200.6 101.1 200.7
99.6 99.2
201.3 202.1
47 716.7 48 715.8 49 711.2 50 753.0 51 890.5 52 736.6 53 727.9 54 730.5 55 719.3 56 726.1 57 693.4 58 693.5 59 705.1 60 707.8 61 704.7 62 694.3 63 683.0 64 674.5 65 665.6 66 657.0 67 650.7 68 641.8 69 630.4 70 620.5 71 610.5 72 601.2 73 595.6 74 587.8 75 694.3 76 704.1 77 699.4 78 698.6 79 696.2 80 696.2 81 690.4 82 681.7 83 674.9 84 671.0 85 665.7 86 662.3 87 652.0
72.5 72.9 72.7 73.2 73.1 74.3 73.8 73.3 73.6 73.5 73.9 72.7 72.6 72.4 73.1 72.3 72.4 72.5 73.0 72.8 72.7 74.0 73.7 73.3 72.4 73.1 72.8 73.2 73.0 72.9 73.5 72.8 73.6 73.5 74.3 73.5 72.9 72.9 73.6 73.4 74.0
99.9 99.7
202.0 201.8
70.0 71.24447 70.0397 69.43722 70.5 71.45018 70.17847 69.61615 70.2 71.19058 70.0862 69.56404 70.4 71.23444 70.13005 69.64805 69.7 71.38429 70.21298 69.87154 72.0 71.23628 70.19214 69.48926 71.2 71.33674 70.31937 69.74366
101.2 201.9 112.2 202.2 136.3 206.2 109.6 208.9 106.0 210.5 103.1 210.3 102.0 209.9 116.2 208.4 102.8 208.4 102.9 209.5 103.0 210.4 103.0 210.9 103.3 210.4 101.7 209.2 100.8 207.7 101.6 206.1
71.3 70.9 71.1
71.4297 70.41902 69.80985 71.4267 70.46288 70.0612 71.618 70.71441 70.09855
71.3 71.55373 70.25525 69.90041 70.8 71.25699 70.2597 70.0722 70.2 71.64848 70.68466 69.8613
70.3
71.3836 70.29259 69.83067
70.1 71.49168 70.2869 69.89191
70.0
71.7374 70.56609 69.93014
70.2 71.42802 70.55121 70.02904 70.2 71.49188 70.24694 70.05273 70.7 71.64615 70.39452 70.05975
99.9 98.2 97.6 95.7 96.0 95.4 94.9 95.3 94.5 93.9
204.1 202.2 200.3 198.2 195.9 193.3 191.4 189.5 187.1 184.8
70.2 70.3
71.6253 70.38705 69.89165 71.6984 70.54047 69.97144
70.6 71.74943 70.30369 69.81497 70.5 71.95248 70.74101 70.17199 70.0 71.57672 70.31839 70.31829 70.2 71.53907 70.42799 69.85896 70.3 71.78348 70.47829 70.1703 70.2 71.51974 70.42204 69.94672 70.9 71.66698 70.48228 70.27468 70.1 71.83015 70.49819 70.45793 70.6 71.87347 70.52145 70.41425 70.4 71.52312 70.35181 70.27807 70.5 71.78415 70.39865 70.41862 71.1 71.75416 70.30842 70.26814 70.8 71.68879 70.51747 70.30317 70.8 71.87212 70.56024 70.43295 71.0 71.99344 70.70164 70.46057 70.1 71.91059 70.67235 70.3978 70.4 71.92619 70.48045 70.40671 70.8 71.83926 70.50062 70.50719 70.5 72.02415 70.5918 70.66531
124.8 182.9 105.3 186.7 102.1 190.1 101.1 193.1 100.0 195.0
99.6 99.7 98.7 99.3 98.0 97.0 96.2 96.7
196.8 198.1 198.3 197.2 196.4 196.2 195.4 195.0
70.5
72.0017 70.65636 70.46214
0 0 0 0 0 0 0 0 0 0 0
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