ASME PTC 4 (Steam Generating Units)

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STDOASME PTC 4-ENGL 1998 W 0759b70 Ob14936 321
ASME
PTC 4-1998
[Revision of ASME PTC 4.1 -1964(R1991)]
Fired Steam
Generators
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STD-ASME PTC 4-ENGL 1998 m 0759670 0614937 268
L
Date of Issuance: December 31, 1999
This document will be revised when the Society approves the issuance of a new edition.
There will be no Addenda issued to ASME PTC 4- 1998.
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aspects of this document. The interpretations are not part of the document. ASME PTC
4-1998 is being issued with an automatic subscription service to the interpretations that
will be issued to it up to the publication of the next edition.
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Copyright 8 1999 by
THE AMERICAN SOCIETY OF MECHANICAL ENGINEERS
All Rights Reserved
Printed in U.S.A.
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STD.ASME PTC 4-ENGL 1998 W 0759b70 0634938 IT4 W
FOREWORD
The Test Code for Stationary Steam Generating Units was one of the group of 10 forming
the 1915 Edition of the ASME Power Test codes. A revision of these codes was begun in 1918
and the Test Code for Stationary Steam Generating Units was reissued in revised form in
October 1926. Further revisions were issued in February 1930 and January 1936.
In October 1936 the standing Power Test Code Committee requested Committee No. 4 to
consider a revision of the Code to provide for heat balance tests on large steam generating
units. In rewriting the Code advantage was taken of the experience of the several companies
in the utility field which had developed test methods for large modem units including the
necessary auxiliary equipment directly involved in the operation of the units. At the same time
the needs of the small installations were not overlooked. At the November 3, 1945, meeting of
the standing Power Test Codes Committee, this revision was approved and on May 23, 1946,
the Code was approved and adopted by the Council.
In view of the continuously increasing size and complexity of steam generating units, it was
obvious that changes were required in the 1946 Edition of the Test Code. In May 1958 the
technical committee was reorganized to prepare this revision. The completely revised Code,
the Test Code for Steam Generating Units, was approved by the Power Test Codes Committee
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on March 20, 1964. It was further approved and adopted by the Council as a standard practice
of the Society by action of the Board on Codes and Standards on June 24, 1964.
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The Board on Performance Test Codes (BPTC) in 1980 directed that the Code be reviewed
to determine whether it should be revised to reflect current engineering practices. A committee
was soon formed and it had its first meeting in May 1981. The Committee soon recognized
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that the Code should be totally rewritten to reflect several changes in steam generator technology
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(primarily the increasing usage of fluidized bed combustors and other technologies for emission
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control) and in performance testing technology (primarily the widespread use of electronic
instrumentation and the consideration of test uncertainty analysis as a tool for designing and
measuring the quality of a performance test). The Committee decided that the new code should
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discourage the almost universal use of an abbreviated test procedure (commonly known as “The
Short Form”). The Committee reasoned that the best test is that which requires the parties to
the test to deliberate on the scope of the performance test required to meet the objective(s) of
the test. Measurement uncertainty analysis was selected as the tool whereby the parties could
design a test to meet these objectives. As this Code will be applied to a wide configuration of
steam generators, from small industrial and commercial units to large utility units, the soundness
of this philosophy should be self-evident.
This expanded edition of the Code was retitled Fired Steam Generators to emphasize its
limitation to steam generators fired by combustible fuels. The Code was subjected to a thorough
review by Industry, including members of the BPTC. Many of their comments were incorporated
and the Committee finally approved the Code on June 23, 1998. It was then approved and
adopted by the Council as a Standard practice of the Society by action of the Board on
Performance Test Codes on August 3, 1998. It was also approved as an American National
Standard by the ANSI Board of Standards Review on November 2, 1998.
Calculations associated with the application of this Code can be facilitated by the use of
computer software. Software programs that support calculations for this Code may be available
on the ASME web site (www.asme.org/pdf). Any such software has not been subject to the
ASME consensus process and ASME makes no warranties, express or implied, including,
without limitation, the accuracy or applicability of the program.
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STDOASME PTC 4-ENGL 3998 0759470 Ob34939 030
NOTICE
All Performance Test Codes MUST adhere to the requirements of PTC 1, GENERAL
INSTRUCTIONS. The following information is based on that document and is included here
for emphasis and for the convenience of the user of this Code. It is expected that the Code user
is fully cognizant of Parts I and III of PTC 1 and has read them prior to applying this Code.
ASME Performance Test Codes provide test procedures which yield results of the highest
level of accuracy consistent with the best engineeringknowledge and practice currently available.
They were developed by balanced committees representing all concerned interests. They specify
procedures, instrumentation, equipment operating requirements, calculation methods, and uncer-
tainty analysis.
When tests are run in accordance with a Code, the test results themselves, without adjustment
for uncertainty, yield the best available indication of the actual performance of the tested
equipment. ASME Performance Test Codes do not specify means to compare those results to
contractual guarantees. Therefore, it is recommended that the parties to a commercial test agree
before starting the test and preferably before signing the contract on the method to be used
for comparing the test results to the contractual guarantees. It is beyond the scope of any Code
to determine or interpret how such comparisons shall be made.
Approved by Letter Ballot #95-1 and BPTC AdministartiveMeeting of March 13-14, 1995.
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STD*ASME PTC 4-ENGL 1998 0759b70 Ob34940 8 5 2
PERSONNEL OF PERFORMANCE TEST CODES COMMITTEE NO. 4

ON STEAM GENERATING UNITS
OFFICERS
Philip M. Gerhart, Chair
Patrick G. Davidson, Vice Chair
Jack H. Karian, Secrefaty
COMMITTEE PERSONNEL
Robert R. Carpenter, Duke Power, retired
Richard Carson, Tennessee Valley Authority
Patrick G. Davidson, Black & Veatch
Deirdre L. Hauser, Alternate to Davidson, Black & Veatch
Matthew J. Dooley, ABB CE Services
Richard J. Dube, D B Riley, Inc.
Jack Entwistle, Consultant
Barry L. Fisher, Kvaerner Pulping Inc.
Donald L. Carver, Alternate to Fisher, Kvaerner Pulping Inc
Philip M. Gerhart, University of Evansville
Thomas C. Heil, Babcock & Wilcox
Medhat A. H. Higazy, Detroit Edison
Jack H.Karian, ASME International
Dennis K. Kruse, American Society of Naval Engineers
Arnold M. Manaker, Tennessee Valley Authority
Russell N. Mosher, American Boiler Manufacturers Association
James T. Phillips, Black & Veatch
Ernest Sotelo, Consultant
James J. Youmans, Stone & Webster Engineering Corp.
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BOARD ON PERFORMANCE TEST CODES
OFFICERS
D. R. Keyser, Chair
P. M. Gerhan, Vice Choir
W. O. Hays, Secretary
COMMITTEE PERSONNEL
R. P. Allen S. J. Korellis C. B. Scharp

C. W. Almquist T.H.McCloskey J. Siegmund
R. L. Bannister J. W. Milton J. A. Silvaggio
D. S. Beachler G . H. Mittendorf R. E. Sommerlad
B. Bomstein S. P. Nuspl W. G. Steele
J. M. Bums A. L. Plumley I. C . Westcott
J. G. Yost
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J. R. Friedman R. R. Priestley
G. J. Gerber
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R. S. Heckiinger
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vi
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STD-ASME PTC 4-ENGL 1998 N 0759b70 Ob14742 625 M
CONTENTS
...
Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv
Committee Roster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V
1 Object and Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1.1 Object . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.3 Typical Uncertainty for Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.4 Steam Generator Boundaries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2 Definitions and Description of Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.1 Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.2 Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.3 Units and Conversions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3 Guiding Principles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.2 Performance Test Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3.3 References to Other Codes and Standards . . . . . . . . . . . . . . . . . . . . . 30
3.4 Tolerances and Test Uncertainties . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4 Instruments and Methods of Measurement . . . . . . . . . . . . . . . . . . . . . . . . 33
4.1 Guiding Principles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
4.2 Data Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
4.3 General Measurement Requirements . . . . . . . . . . . . . . . . . . . . . . . . . 37
4.4 Temperature Measuremcnt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
4.5 Pressure Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
4.6 Velocity Traverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
4.7 Flow Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
4.8 Solid Fuel and Sorbent Sampling . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
4.9 Liquid and Gaseous Fuel Sampling . . . . . . . . . . . . . . . . . . . . . . . . . . 69
4.10 Sampling of Flue Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
4.1 1 Residue Sampling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
4.12 Fuel, Sorbent, and Residue Analysis . . . . . . . . . . . . . . . . . . . . . . . . 71
4.13 Flue Gas Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
4.14 Electric Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
4.15 Humidity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
5 Computation of Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
5.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
5.2 Measurement Data Reduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
5.3 Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
5.4 Output (QrO), Btuh (W) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
5.5 Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
5.6 Energy Balance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
5.7 Efficiency. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
5.8 Fuel Properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
5.9 Sorbent and Other Additive Properties ........................ 84
5.10 Residue Properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
5.1 1 Combustion Air Properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
5.12 Flue Gas Products. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
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STD-ASME PTC 4-ENGL 1998 m 0759670 ObL4943 563
5.13 Air and Flue Gas Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

5.14 Losses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
5.15 Credits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
5.16 Uncertainty. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
5.17 Other Operating Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 10
5.18 Corrections to Standard or Guarantee Conditions. . . . . . . . . . . . . . . 11 1
5.19 Enthalpy of Air, Flue Gas, and Other Substances Commonly
Required for Energy Balance Calculations . . . . . . . . . . . . . . . . . 1 19
5.20 Calculation Acronyms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
6 Report of Test Results. . . . . . . . . . . . . . . .................... 143
6.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
6.2 Report Contents . . . . . . . . . . . . . . . . . .................... 143
7 Uncert,ainty Analysis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
7.2 Fundamental Concepts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
7.3 Pretest Uncertainty Analysis and Test Planning . . . . . . . . . . . . . . . . . 151
7.4 Equations and Procedures for Determining Precision Index . . . . . . . . 152
7.5 Equations and Guidance for Determining Bias Limit . . . . . . . . . . . . . 157
7.6 Uncertainty of Test Results. . . . . . . .................. . 162
Figures
1.4-1 Typical Oil and Gas Fired Steam Generator. . . . . . . . . . . . . . . . . . . . . . . 4
1.4-2 Typical Pulverized Coal Fired Steam Generator,
Alternative 1 : Single Air Heater. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Alternative 2: Bisector Air Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Alternative 3: Trisector Air Heater. . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.4-5 Typical Circulating Bed Steam Generator . . . . . . . . . . . . . . . . . . . . . . . . 8
1.4-6 Typical Stoker-Coal Fired Steam Generator . . . . . . . . . . . . . . . . . . . . . . . 9
1.4-7 Typical Bubbling Bed Steam Generator. . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.1-1 Steam Generator Energy Balance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.2-1 Repeatability of Runs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3.2-2 Illustration of Short-Term (Peak to Valley) Fluctuation and Long-Term
Deviation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4.4-1 Sampling Grids-Rectangular Ducts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
4.4-2 Sampling Grid-Circular Ducts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
4.8-1 Full-Cut Solids Sampling Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
4.8-2 Typical “Thief” Probe for Solids Sampling on a Solids Stream. . . . . . . . . 66
5.19-1 Mean Specific Heat of Dry Air Versus Temperature . . . . . . . . . . . . . . . . 126
5.1 9-2 Mean Specific Heat of Water Vapor Versus Temperature. . . . . . . . . . . . . 127
5.19-3 Mean Specific Heat of Dry Flue Gas Versus Temperature . . . . . . . . . . . . 129
5.19-4 Mean Specific Heat of Dry Residue Versus Temperature . . . . . . . . . . . . . 130
7.2-1 Types of Errors in Measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
7.2-2 Time Dependence of Errors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
7.2-3 Constant Value and Continuous Variable Models. . . . . . . . . . . . . . . . . . . 149
7.5-1 Generic Calibration Curve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
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STDaASME PTC 4-ENGL 1998 m 0759b70 Ob14944 4 T 8 =
Tables
1.3-1 Typical Code Test Uncertainties for Efficiency . . . . . . . . . . . . . . . . . . . . 3
2.3-1 Units and Conversions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.1.1 Comparison of Efficiency Determination . . . . . . . . . . . . . . . . . . . . . . . . . 22
3.2- 1 Operating Parameter Deviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.2-2 Minimum Test Run Duration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4.2- 1 Parameters Required for Efficiency Determination by Energy Balance
Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
4.2-2 Parameters Required for Efficiency Determination by Input-Output
Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
4.2-3 Parameters Required for Capacity Determination . . . . . . . . . . . . . . . . . . . 38
4.2-4 Parameters Required for Steam Temperature/Control Range
Determination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
4.2-5 Parameters Required for Exit Flue Gas and Air Entering Temperature
Determinations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
4.2-6 Parameters Required for Excess Air Determination . . . . . . . . . . . . . . . . . 41
4.2-7 Parameters Required for WatedSteam Pressure Drop Determinations . . . . 42
4.2-8 Parameters Required for Air/Flue Gas Pressure Drop Determinations . . . . 43
4.2-9 Parameters Required for Air Infiltration Determination . . . . . . . . . . . . . . . 44
4.2-10 Parameters Required for Sulfur CaptureRetention Determination . . . . . . . 45
4.2-1 1 Parameters Required for Calcium to Sulfur Molar Ratio
Determination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
4.2-12 Parameters Required for Fuel, Air, and Flue Gas Flow Rate
Determinations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
4.3- 1 Potential Instrumentation Bias Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
4.3-2 Potential Bias Limits for Coal Properties . . . . . . . . . . . . . . . . . . . . . . . . . 52
4.3-3 Potential Bias Limits for Limestone Properties . . . . . . . . . . . . . . . . . . . . . 53
4.3-4 Potential Bias Limits for Fuel Oil Properties . . . . . . . . . . . . . . . . . . . . . . 53
4.3-5 Potential Bias Limits for Natural Gas Properties. . . . . . . . . . . . . . . . . . . . 54
4.8-1 F Distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
5.16-1 Two-Tailed Student’s t-Table for the 95 Percent Confidence Level . . . . . . 109
5.20.2-1 Acronyms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
5.20.2-2 Measurement and Uncertainty Acronyms . . . . . . . . . . . . . . . . . . . . . . . . . 141
Nonmandatory Appendices
A Calculation Forms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
B Sample Calculations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
C Derivations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
D Gross Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
E The Probable Effects of Coal Properties on Pulverized Coal and Coal
and Sorbent Properties on Fluidized Bed Steam Generator Design
and Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
F References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
||| | |---
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| |||
|
| ||| | || | ||
--
ix
STD*ASflE PTC 4-ENGL L998 0759b70 0614945 334 W
FIRED STEAM GENERATORS ASME PTC 4-1998
||| | |---
SECTION 1 - OBJECT AND SCOPE
|||| | || ||| | || ||
| |||
1.1 OBJECT 0 comparing performance when firing an alternate fuel
|
0 determining the effects of equipment modifications
| ||| | || | ||
The object of this Code is to establish procedures
for conducting performance tests of fuel fired steam This Code also provides methods for converting
generators. This Code provides standard test procedures certain performance Characteristics at test conditions
--
which can yield results giving the highest level of to those which would exist under specified operating
accuracy consistent with current engineering knowledge conditions.
and practice.
The accuracy of a particular test may be affected
by the fuel fired during the test or other factors within 1.2 SCOPE
the discretion of the operator. A test is considered an
ASME Code test only if the following conditions 1.2.1 General Scope. The rules and instructions pre-
are met: sented in this Code apply to fired steam generators.
These include coal, oil, and gas fired steam generators
test procedures comply with procedures and allowed as well as steam generators fired by other hydrocarbon
variations defined by this Code fuels. The scope also includes steam generators with
O uncertainties of test results, determined in accordance integral fuel-sulfur capture utilizing chemical sorbents.
with Section 7 of this Code, do not exceed target test Steam generators which are not fired by coal, oil,
uncertainties defined by prior written agreement in or gas may be tested using the concepts of this Code,
accordance with Section 3 of this Code but it should be noted that the uncertainty caused by
variability of the fuel may be difficult to determine
This ‘Ode can be used to determine the and is like]” to be greater than the uncertainties in
Y
performance characteristics: sampling and analysis of coal, oil, or gas.
.
0 efficiency
output
0 capacity
Gas turbine heat recovery and other heat recovery
steam generators designed to operate with supplemental
firing should be tested in accordance with Performance
Test Code (PTC) 4.4, Gas Turbine Heat Recovery
o steam temperaturekontroi range
exit flue gas and entering air temperature Steam Generators.
0 excess air
This Code does not apply to nuclear steam supply
waterkteam pressure drop systems, which are specifically addressed in PTC 32.1,
0 aidflue gas pressure drop
Nuclear Steam Supply Systems. This Code does not
air infiltration apply to the performance testing of chemical heat
0 sulfur capturehetention
recovery steam generators, municipal waste fired steam
o calcium to sulfur molar ratio generators, pressurized steam generators with gas side
o fuel, air, and flue gas flow rates pressure greater than 5 atmospheres, or incinerators.
Municipal waste fired steam generators can be tested
These performance characteristics are typically rein accordance with P ï C 34, Waste Combustors with
quired for the following purposes: Energy Recovery.
Testing of auxiliary equipment is not addressed in
o comparing actual performance to guaranteed per- this Code, but shall be governed by the following
formance Performance Test Codes which apply specifically to
o comparing actual performance to a reference the equipment in question:
0 comparing different conditions or methods of oper-
ation 0 PTC 4.2, Coal Pulverizers.
determining the specific performance of individual 0 PTC 4.3, Air Heaters.
parts or components F’TC 11, Fans.
STD.ASME PTC 4-ENGL 1998 0759b70 ObL49Yb 270
ASME PTC 4-1998 FRED STEAM GENERATORS
Steam purity and quality shall be tested in accordance systems as well air quality equipment located within
with PTC 19.11, Water and Steam in the Power Cycle the steam generator envelop. Chemical additives (sor-
(Purity and Quality, Leak Detection and Measurement). bent) may be added for control of emissions. These
||| | |---
Methods used by this Code for determining emission variations in steam generator design influence the energy
|||| | || ||| | || ||
related parameters, e.g., sulfur retention and flue gas balance method uncertainty result.
constituents, are not equivalent to methods required by Table 1.3-1 shows typical values of uncertainty in
EPA, New Stationary Source Performance Standards, steam generator efficiency as a function of fuel type,
4OCFR60 and are not intended to be used for evaluating unit type, and test method selected. The steam generator
| |||
compliance with those standards or any other environ- sizes are shown to allow for defining a test with a
|
mental regulations. cost consistent with the value of the project in accord-
| ||| | || | ||
This Code does not prescribe procedures for testing ance with PTC 1, General Instructions. The utility/
to determine chemical and physical properties of fuels. large industrial category refers in general to steam
Applicable procedures may be found in the PTC 3 series generators that supply steam to turbine/generators.
--
or other pertinent standards such as those published by The lower values shown for the energy balance
ASTM. method for a utility/large industrial unit are based upon
This Code specifically addresses equipment used for Code air temperature, gas temperature, and gas sampling
the generation of steam; however, the basic principles grids with a typical electronic sampling rate. The small
presented are also applicable to other working fluids. industrial unit values are based on a small grid and
Certain types and sizes of equipment used for the obtaining data manually.
recovery of heat released by combustion are not ad- The uncertainty of the input-output method is directly
dressed in any specific Performance Test Code. This proportional to the uncertainty of measurement of feed-
Code can be used as a general guide in developing watedsteam flow, fuel flow, and fuel heating value.
performance tests for such equipment; however, such To achieve the uncertainties shown in Table 1.3-1, the
specially developed performance tests shall not be metering must be selected, manufactured, installed, and
considered ASME Code tests. used in strict accordance with the applicable codes
and standards. Most importantly, the required straight
1.2.2 Design Variations. This Code provides general lengths of differential pressure metering runs and use
procedures for conducting combustible fuel fired steam of flow conditioners must be rigorously adhered to.
generator performance tests; however, it cannot possibly For coal flow, gravimetric feeders must be calibrated
provide detailed procedures applicable to every steam by the direct measurement of coal weight, before and
generator design variation. Design variations considered after the test.
in developing this Code include subcritical and supercrit- With the above guidelines, the input-output uncertain-
¡cal once-through steam generators and oil, gas, stoker, ties are based upon the following flow measurement-
cyclone, pulverized, and fluidized bed firing. For each system uncertainties and fuel sampling criteria:
performance test, a competent engineer must study the
actual steam generator and its relation to the remainder 0 Feedwater, UtilityLarge Industrial - ASME PTC 6
of the steam cycle, and develop test procedures which Flow Nozzle - 0.38% System
are consistent with this Code. 0 Feedwater, Small Industrial - test orificdempirical
formulation - 0.80% System
1.23 Reports. A test report shall be prepared. See Natural Gas - test orificeiempirical formulation -
Section 6. 0.80% system
1.2.4 References. Many references provide useful s u p 0 Oil plow -calibrated positive displacement meter -
plemental information in planning for a performance three viscosities (multiple tests for repeatablility) -
test in accordance with this Code. Those used most 0.63% system
frequently are listed in Section 3.3. 0 Rigorous calibration of coal feeders
Fuel Analysis -multiple samples analyzed inàividu-
ally -ASTM reproduciblity bias plus 0.5% sampling
1.3 TYPICAL UNCERTAINTY FOR bias for oil and gas and 2% sampling bias for coal
EFFICIENCY
Fossil fuel fired steam generators are custom designed 1.4 STEAM GENERATOR BOUNDARIES
for the most severe characteristics of the fuels expected
to be burned. The specific arrangement for any given Boundaries associated with different steam generator
system may contain different low level heat recovery arrangements are shown on Figures 1.4-1 through 1.4-
STD-ASME PTC 4-ENGL 1998 = 0759b70 ObL4947 107 W
TABLE 1.3-1
TYPICAL CODE TEST UNCERTAINTIES FOR EFFICIENCY
Energy Balance Method Input-Output Method
Type of Steam Generator (Percentage Points) (Percentage Points)
Uti Iityllarge Industrial

- Coal fired [Note (1)l 0.4-0.8 3.0-6.O
- Oil fired 0.2-0.4 1.0
- Gas fired 0.2-0.4 1.0
Fluidized Bed [Note i l ) ] O .9-1.3 3.0-6.0
Small Industrial With Heat Trap [Note ( 2 ) l
- Oil 0.3-0.6 1.2
- Gas 0.2-0.5 1.2
Without heat trap
- Oil O.5-0.9 1.2
- Gas O.4-0.8 1.2
NOTES:
(1) It is not recommended t o test coal fired units using the input-output method because of the large
uncertainties measuring coal flow.
(2) Economizer/air heater.
7. The steam generator boundaries shown on these 1.4.3 Flue Gas

figures encompass the equipment to be included in the
||| | |---
0 12 - Leaving Steam Generating Bank (not shown)
steam generator envelope for each case.
0 13 - Entering Economizer (not shown)
The following numbers are used to designate specific
|||| | || ||| | || ||
o 14 - Leaving Economizer
locations.
o 14A - Entering Secondary Air Heater
1.4.1 FueVSorbent 0 14B - Entering Primary Air Heater
14C - Leaving Hot-Side AQC Equipment
| |||
1 - Coal Leaving Feeder or Bunker 15 - Leaving Air Heater(s)
|
1A - Sorbent Leaving Feeder or Bunker
| ||| | || | ||
0 o 15A - Leaving Secondary AH
0 2 - Coal to Burners (leaving pulverizer) 0 15B - Leaving Primary AH
0 3 - Oil to Burners 0 16 - Entering Cold-Side AQC Equipment
3A - Oil to Oil Heaters
--
0 17 - Leaving Cold-Side AQC Equipment
0 4 - Gas to Burners 18 - Entering ID Fan
0 19 - Leaving ID Fan
1.4.2 Air
0 20 -Entering Low Level Heat Exchanger (not shown)
0 5 - Pulverizer Tempering Air 21 -Leaving Low Level Heat Exchanger (not shown)
o 6 - FD Fan Inlet o 22 - Entering Gas Recirculation Fan
0 6A - PA Fan Inlet 0 23 -Leaving Gas Recirculation Fan (entering boiler)
0 7 - FD Fan Discharge 1.4.4 S t e a f l a t e r
0 7A - PA Fan Discharge
7B - Other Air Entering Unit 0 24 - Feedwater Entering
0 8 - Combustion (secondary) Air Entering Boundary 0 25 - Superheater Spray Water
0 8A - Primary Air Entering Boundary o 26 - 1st Reheater Spray Water
0 8B - Combustion Air Leaving APH Coils Within 0 26A - 2nd Reheater Spray Water (not shown)
Boundary 27 - Feedwater Leaving Ecoñomizer

0 8C - Primary Air Leaving APH Coils Within 0 28 - Feedwater Entering Drum
Boundary 0 29 - Steam Generator Water Entering Circulating
0 9 -Combustion (secondary) Air Leaving A'ir Heater Pump
9A - Primary Air Leaving Air Heater 0 30 - Steam Generator Water Leaving Circulating
o 10 - Secondary Air Entering Steam Generator Pump
0 11 - Pulverizer Inlet Air 31 - Saturated Steam Leaving Drum
11A - Pulverizer Outlet Air and Fuel Mixture 31A - Entering Ist Stage SH Desuperheater
~~ ~ ~
STD-ASME PTC '+-ENGL 3998 m 0759670 Ob34948 043 m
ASME FTC 4-1998 FIRED STEAM GENERATORS
||| | |---
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| |||
|
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--
I I
o
æ
~ ~
STDeASME PTC 4-ENGL 1998 0759b70 Ob14949 T8T m
--
| ||| | || | ||
FIRED STEAM GENERATORS
|
| |||
|||| | || ||| | || ||
||| | |---
ASME F'TC 4-1998
W
cl
I
a
w
I-
STD-ASME PTC 4-ENGL A998 0759670 Ob34950 7TL
FRED STEAM GENERATORS
Jä
a
O
||| | |---
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|
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--
||| | |---
|||| | || ||| | || ||
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|
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--
~
STD-ASME PTC 4-ENGL 1998 0759b70 Ob14952 574
--

| ||| | || | ||
|
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|||| | || ||| | || ||
||| | |---
I 5
I
l
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l W
m
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STD-ASME PTC 4-ENGL 1998 0759b70 Ob14953 400 =

FIRED STEAM GENERATORS ASME F'TC 4-1998
--
| ||| | || | ||
|
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||| | |---
~
STD-ASME PTC 4-ENGL 1998 O759670 Ob14954 347
ASME PTC 4-1998

' o 1
I a
10
-- | ||| | || | || | | ||| |||| | || ||| | || || ||| | |---
STD-ASME PTC 4-ENGL 1998 m 0759b70 Ob14955 283 m
FIRED STEAM GENERATORS ASME I'TC 4-1998
31B - Leaving 1st Stage SH Desuperheater 1.4.5 Miscellaneous

31C - Enterhg 2nd Stage SH Desuperheater (not 0 37 - Furnace Refuse
shown) 0 38 - Ash Pit Water In
31D - Leaving 2nd Stage SH Desuperheater (not 39 - Ash Pit Water Out
shown) 0 40 - Cooling Water In
0 32 - Main Steam 41 - Cooling Water Out
33 - Reheat Steam Entering Boundary 42 - Atomizing Steam
33A - Entering 1st Reheat Desuperheater 43 - Steam Entering Fuel Oil Heater
33B - Leaving 1st Reheat Desuperheater 44 - Steam Leaving Fuel Oil Heater
0 33C - Entering 2nd Reheat Desuperheater (not 0 45 - Pulverizer Rejects
shown) 0 46 - Soot Blower Steam
33D - Leaving 2nd Reheat Desuperheater (not 0 46A - Auxiliary Steam
shown) 47 - Boiler Circulating Pump Water Injection
34 - Leaving 1st Reheater 48 - Boiler Circulating Pump Water Leakoff
0 34A - Leaving 2nd Reheater (not shown) 0 49 - Hot Air Recirculation (not shown)
35 - Blowdown 50 - Hot Air Bypass (not shown)
36 - Condensate Leaving APH Coils (internal to 51 - FueYGas Conditioners
boundary) 52 - Economizer Residue
36A - Condensate Leaving Primary APH Coils (in- 0 53 - Hot AQC Equipment Residue
ternal to boundary) 0 54 - Air Heater Residue
0 55 - Cold AQC Equipment Residue
II
-- | ||| | || | || | | ||| |||| | || ||| | || || ||| | |---
~~
STD-ASME PTC 4-ENGL 1998 = 0759b70 ObL495b LLT

HRED STEAM GENERATORS ASME FTC 4-1998
SECTION 2 - DEFINITIONS AND

DESCRIPTION OF TERMS
This Section contains abbreviations, unique terms, air, theoretical: the amount of air required to supply
and variations on typically used engineering definitions the exact amount of oxygen necessary for complete com-
required for the implementation of this Code. bustion of a given quantity of fuel. Theoretical air and
stoichiometric air are synonymous.
air, corrected theoretical: theoretical air adjusted for
2.1 DEFINITIONS unburned carbon and additional oxygen required to com-
plete the sulfation reaction.
addirive: a substance added to a gas, liquid, or solid
stream to cause a chemical or mechanical reaction to air hearer: a heat exchanger that transfers heat from a
enhance collection efficiency. high temperature medium such as hot gas to an incoming
air stream. Regenerative air heaters include bisector and
air, excess: the air supplied to bum a fuel in addition
trisector types, with fixed or rotating heating elements.
to the corrected theoretical air. Excess air is expressed as
Recuperative air heaters include tubular, plate, and heat
a percentage of the corrected theoretical air in this Code.
pipe types.
air, infiltrarion: air that leaks into the steam generator
air prehearer coils: a heat exchanger that typically uses
casing.
steam, condensate, andor glycol to heat air entering the
air, primary: the transport and drying air for the coal steam generator and is often used to control corrosion in
from the pulverizers to the burners in pulverized coal fired regenerative and recuperative air heaters.
applications. The primary air is often at a temperature analysis, proximate: laboratory analysis, in accordance
different from that of the secondary air as it leaves the with the appropriate ASTM standard, of a fuel sample
regenerative air heaters in large steam generators, and providing the mass percentages of fixed carbon, volatile
typically represents less than 25% of the total combustion matter, moisture, and noncombustibles (ash).
air. Oil and gas fired steam generators usually do not
have primary air. Primary air is the air used for fluidizing analysis, ultimate: laboratory analysis, in accordance
the bed material at the base of the combustion chamber with the appropriate ASTM standard, of a fuel sample
in circulating fluidized beds. providing the mass percentages of carbon, hydrogen, oxy-
gen, nitrogen, sulfur, moisture, and ash.
air, secondary: the balance of the combustion air not
provided as primary air in pulverized and fluid bed appli- as-fired fuel: fuel in the condition as it enters the steam
cations. All of the combustion air leaving the air heater generator boundary.
is usually referred to as secondary air in oil and gas fired
ash: the noncombustible mineral matter constituent of
steam generators. Secondary air may be split into overfire
fuel that remains after complete burning of a fuel sample
air or other streams as it enters the furnace; however, it
in accordance with appropriate ASTM standards.
remains secondary air up to and including the wind box.
ash, bottom: all residue removed from the combustion
air, other: a number of other combustion air arrange-
chamber other than that entrained in the flue gas.
ments and splits, e.g., overfire air, tertiary air, encountered
in the combustion processes covered by this Code. ash, fly: particles of residue entrained in the flue gas
leaving the steam generator boundary.
air, standard: air at 77°F (25°C) and 29.53 in. of mer-
cury (100 kPa), l bar absolute pressure, with a specific ash, other: residue extracted from the steam generator
humidity of 0.013 lb moisture/lb dry air (kgkg). Refer at locations such as boiler bank hoppers, air heater hop-
to Subsection 5.1 1.1 for composition of standard dry air. pers, and economizer hoppers.
13
Previous Page
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is Blank
STDOASME PTC 4-ENGL 1998 = 0759b70 Ob14957 O56
ASME PTC 4- 1998 FIRED STEAM GENERATORS
ash fusion remperatures: four temperatures (initial de- coverage: the percentage of observations (measure-
formation, softening, hemispherical, and fluid) deter- ments) of a parameter that can be expected to differ from
mined for a given fuel ash as determined by the appro- the true value of the parameter by no more than the
priate ASTM standard. Frequently used in the singular uncertainty.
to indicate only the softening temperature, the tempera-
credits: energy entering the steam generator envelope
ture at which the test cone has deformed to a shape whose
other than the chemical energy in the as-fired fuel. Credits
height and width are equal.
include sensible heat (a function of specific heat and
ash pit: a pit or hopper located below a furnace where temperature) in the fuel, entering air, and atomizing
residue is collected and removed. steam; energy from power conversion in the pulverizers,
circulating pumps, primary air fans, and gas recirculation
aftemperator: see desuperheater. fans; and chemical reactions such as sulfation. Credits
can be negative, such as when the air temperature is
bias limit: the estimate of error.
below the reference temperature.
calcination: the endothermic chemical reaction which dehydration: the endothermic chemical reaction which
takes place when carbon dioxide is released from calcium takes place when water is released from calcium hydrox-
carbonate to form calcium oxide, or from magnesium ide to form calcium oxide, or from magnesium hydroxide
carbonate to form magnesium oxide. to form magnesium oxide.
calcium to sulfur molar ratio (CdS): the total moles desuperheater: apparatus for reducing and controlling
of calcium in the sorbent feed divided by the total moles the temperature of a superheated vapor (attemperator).
of sulfur in the fuel feed.
dilute phase: the portion of the bed in a circulating
calcium utilization: the percent of calcium in the sor- fluidized bed combustion chamber above the secondary
bent that reacts with sulfur dioxide (SO2)to form calcium air inlet ducts (made up primarily of the circulating partic-
sulfate (Caso4). It is sometimes called sorbent utilization. ulate material).
capacity: the maximum main steam mass flow rate that eficiency, fuel: the ratio of the output to the input as
the steam generator is capable of producing on a continu- chemical energy of fuel.
ous basis with specified steam conditions and cycle con-
figuration (including specified blowdown and auxiliary efficiency, gross: the ratio of the output to the total
steam). This is frequently referred to as maximum contin- energy entering the steam generator envelope.
uous rating. energy balance method: sometimes called the heat bal-
ance method. A method of determining steam generator
capacity, peak: the maximum main steam mass flow
efficiency by a detailed accounting of all energy entering
rate that the steam generator is capable of producing
and leaving the steam generator envelope. Section 3. 1
with specified steam conditions and cycle configuration
provides detailed discussion of this method.
(including specified blowdown and auxiliary steam) for
intermittent operation, i.e., for a specified period of time error, bias: sometimes called bias. The difference be-
without affecting future operation of the unit. tween the average of the total population and the true
value. The true systematic or fixed error which character-
combustion chamber: an enclosed space provided for izes every member of any set of measurements from the
the combustion of fuel. population.
combusrion efficiency: a measure of the completeness error, precision: a statistical quantity that is expected
of oxidation of all fuel compounds. It is usually quantified to be normally distributed. Precision error results from
as the ratio of actual heat released by combustion to the the fact that repeated measurements of the same quantity
maximum heat of combustion available. by the same measuring system operated by the same
combustion split: the portion of energy released in the personnel do not yield identical values. Also called ran-
dense bed region of a fluidized bed expressed as a percent- dom error.
age of the total energy released. error, total: sum of bias error and precision error.
control range: the capacity range over which main exit gus femperature: the average temperature of the
steam temperature and/or reheat steam temperature can flue gas leaving the steam generator boundary. This tem-
be maintained at the rated conditions. perature may or may not be adjusted for air heater leakage.
14
-- | ||| | || | || | | ||| |||| | || ||| | || || ||| | |---
~
STD-ASME PTC 4-ENGL 1996 m 0759b70 Ob34958 T92 m
FIRED STEAM GENERATORS ASME PTC 4- 1998
f i e d carbon: the carbonaceous residue less the ash re- occurring between two temperature levels. Typically used
maining in the test container after the volatile matter has to approximate unburned carbon in residue.
been driven off in making the proximate analysis of a
solid fuel in accordance with the appropriate ASTM stan- losses: the energy which exits the steam generator enve-
dard. Also see volatile matter. lope other than the energy in the output stream(s).
flue gas: the gaseous products of combustion including maximum continuous rating: see capaciry.
excess air.
moisture: water, in the liquid or vapor phase, present
fluidized bed: a bed of suitably sized combustible and in another substance. Moisture in fuel is determined by
noncombustible particles through which a fluid (air in the appropriate ASTM standards.
fluidized bed steam generators) is caused to flow upward
outliers: a data point judged to be spurious.
at a sufficient velocity to suspend the particles and to
impart to them a fluid-like motion. output: energy absorbed by the working fluid that is
fluidized bed, bubbling: a fluidized bed in which the not recovered within the steam generator envelope, such
fluidizing air velocity is less than the terminal velocity as energy to heat the entering air.
of most of the individual particles. Part of the gas passes precision index: the estimate of the precision error.
through the bed as bubbles. This results in a distinct
bed region because an insignificant amount of the bed is purge: to introduce air into the furnace or the boiler
carried away by the fluidizing air. flue passages in such volume and manner as to completely
replace the air or gas-air mixture contained within.
fluidized bed, circulating: a fluidized bed in which the
fluidizing air velocity exceeds the terminal velocity of recycle rate: the mass flow rate of material being rein-
most of the individual particles, so that they are carried jected into a furnace or combustion chamber.
from the combustion chamber and later reinjected.
recycle ratio: the recycle rate divided by the fuel mass
freeboard: the volume from the upper surface of the flow rate.
expanded bed to the exit of the furnace. This definition
applies to a fluidized bed of dense solids (bubbling bed) reinjection: the return or recycle of material back to
in which there is an identifiable bed surface. It does not the furnace.
apply to a circulating fluidized bed.
residue: the solid material remaining after combustion.
furnace: an enclosed space provided for the combustion Residue consists of fuel ash, spent sorbent, inert additives,
of fuel. and unburned matter.
heating value, higher: the total energy liberated per unit run: a complete set of observations made over a period
--
mass of fuel upon complete combustion as determined of time with one or more of the independent variables
| ||| | || | ||
by the appropriate ASTM standards. The higher heating maintained virtually constant.
value includes the latent heat of the water vapor. When
the heating value is measured at constant volume, it must setting infiltration: same as air, infiltration.
|
be converted to a constant pressure value for use in

| |||
sorbent: chemical compound(s) that reacts with and

this Code.
|||| | || ||| | || ||
captures a pollutant or, more generally, a constituent that

heating value, lower: the total heat liberated per unit reacts with and captures another constituent.
mass of fuel minus the latent heat of the water vapor in the
products of combustion as determined by the appropriate spent sorbent: solids remaining after evaporation of the
||| | |---
ASTM standards (not used in this Code). moisture in the sorbent, calcinatioddehydration, and
weight gain due to sulfation.
input: the total chemical energy available from the fuel.
Input is based on the higher heating value. spent bed material: the bed drain residue removed from
a fluidized bed.
input-output method: a method of determining steam
generator efficiency by direct measurement of output and sulfation: the exothermic chemical reaction which takes
input. Referred to as I/O method. place when calcium oxide unites with oxygen and sulfur
dioxide to form calcium sulfate.
loss on ignition: commonly referred to as LOI. The loss
in mass of a dried dust sample, expressed in percent, sulfur capture: see sulfur retention.
15
-~
STDOASME PTC 4-ENGL 1998 m 0759670 Ob14959 929 m
ASME FTC 4-1998 FRED STEAM GENERATORS
sulfur retention: the fraction of the sulfur that enters FC: fixed carbon
with the fuel that does not leave the steam generator as FD: forced draft
sulfur dioxide (SO,). FEGT: furnace exit gas temperature
FG: flue gas
supplemenrulfuel: fuel burned to supply additional en-
FID: flame ionization detector
ergy to the steam generator or to support combustion.
Fw: feedwater
test: a single run or the combination of a series of runs H2 hydrogen
for the purpose of determining performance characteris- H2S: hydrogen sulfide
tics. A test normally consists of two runs. HHV: higher heating value
rolerunce: the acceptable difference between the test HHVF: higher heating value of fuel
result and its nominal or guaranteed value. Tolerances HHVGF: higher heating value gaseous fuels
are contractual adjustments to test results or to guarantees HVT: high velocity thermocouple
and are not part of the Performance Test Codes. YO: input/output
ID: induced draft
unburned combustible: the combustible portion of the K20: potassium oxide
fuel which is not completely oxidized. kWh: kilowatt-hour
uncerruinsl: the estimated error limit of a measurement LOI: loss on ignition
or result for a given coverage. Uncertainty defines a band MB: megabyte
within which the true value is expected to lie with a MAF: moisture and ash free
certain probability. Mg(OH)z magnesium hydroxide
MgC02: magnesium carbonate
volatile matter: the portion of mass, except water vapor,
MgO: magnesium oxide
which is driven off in a gaseous form when solid fuel is
N*: nitrogen
heated in accordance with the applicable ASTM standard.
Also see fixed carbon. N20: nitrous oxide
--
Na20: sodium oxide

| ||| | || | ||
NH3 ammonia
2.2 ABBREVIATIONS NIST: National Institute of Standards and Tech-
nology
|
NO: nitric oxide

| |||
The following abbreviations are used throughout

nitrogen dioxide
|||| | || ||| | || ||
this Code. NOZ:

NO,: nitrogen oxides
AD: analog to digital 02: oxygen
AFBC: atmospheric fluidized bed combustion 03: ozone
||| | |---
AH: air heater PA: primary air

AX: air preheat coils PT: potential transformer
APH: air preheater PTC: Performance Test Code
MI: American Petroleum Institute RAM: random access memory
AQC: air quality control RH: reheater or relative humidity
Ar: argon
RTD: resistance temperature device
C: carbon
S: sulfur
ca/s: calcium to sulfur ratio
SDI: Spatial Distribution Index
Ca(OH)2: calcium hydroxide
Cao: calcium oxide SH: superheater, superheated
Caso4: calcium sulfate SI: International System of Units
CB: gasified carbon SiO2: silicon dioxide, silica
CO: carbon monoxide so5 sulfur dioxide
CO*: carbon dioxide SO3: sulfur trioxide
cos: carbonate so,: sulfur oxides
CT: current transformer TC: thermocouple
DCS : distributed control system TGA: thermogravimetric analysis
EPA: Environmental Protection Agency THC: total hydrocarbons
ESP: electrostatic precipitator VM: volatile matter
16
STD-ASME PTC 4-ENGL 1998 m 0759670 Ob34960 640 D
FIRED STEAM GENERATORS ASME F'ïC 4-1998
TABLE 2.3-1
UNITS AND CONVERSIONS
units Conversion
item US Customary SI [Notes (U,(2)l

Area ft2 9.2903 E-02
Convection and/or radiation heat
transfer coefficient .
Btülft2 . h O F W/mZ . K 5.6779 E+OO
Density Ibmlft' kg/m3 1.6018 E+01
Electrical energy kWh J 3.6000 E+O6
Energy per unit area Btulft2 Jlm2 1.1341 E+04
Energy per unit mass Bt u11 bm Jlkg 2.3237 E+03
Energy, flux Btülft' h Wlm 3.1503 E+OO
Energy, rate Btulh w 2.9307 E-O1
Mass per unit energy IbmIBtu kg/J 4.3036 E-O4
Mass flow rate Ibmh kgls 1.2599 E-O4
Mean specific heat BtuAbm O F Jlkg . K 4.1868 E+03
Moles per unit mass molesllbm Moleslkg 2.2046 E+OO
Pressure in. wg Pa, gauge 2.491 E+02
Pressure, absolute psia Pa 6.8948 E+03
Pressure, gauge Psi9 Pa, gauge 6.8948 E+03
Specific gas constant f t . Ibfllbm . R Jlkg K . 5.3812 E+OO
Temperature "F "C ( O F - 32Y1.8
Temperature, absolute R K ("F + 459.67111.8

Universal molar gas constant f t . Ibflmole . R Jlmole . K 5.3812 E+OO
NOTES:
(1) Care should be taken when converting formulas or equations that contain constant terms or factors. The
value of these terms must be understood and may also require conversion.
(2) Conversion factors between S I Units and US Customary Units are given in ASME SI-1, Orientation and
Guide for Use of S i (Metric) Units ( A N S I 2210.1) C11. Also, refer to Table 2 of ASME SI-9, Guide
for Metrication of Codes and Standards S I (Metric) Units C21, for the number of significant digits to
be retained when rounding Si.
||| | |---
|||| | || ||| | || ||
2.3 UNITS AND CONVERSIONS
The following units and conversions are used through-
| |||
out this volume. To obtain SI Units, multiply US
|
| ||| | || | ||
Customary Units by the conversion factor given in
Table 2.3-1.
--
17
STD*ASME PTC 4-ENGL 1998 0759670 Ob14961 587
SECTION 3 - GUIDING PRINCIPLES
3.1 INTRODUCTION to the fuel input to obtain total input for use in
calculating gross efficiency in accordance with Appen-
In preparing to conduct a steam generator perform-
dix D.
ance test, the parties to the test must make a number
of decisions and establish certain agreements. This 3.1.2 Types of Efficiency. Steam generator efficiency
Section of the Code describes these decisions and is defined by:
agreements and provides guidance for performing a
test in accordance with this Code.
All parties to the test are entitled and encouraged output
to witness the test to ensure that it is conducted in efficiency = -* 100
input
accordance with this Code and any written agreements
made prior to the test.
This single definition yields many different values
3.1.1 Steam Generator Performance. The perform- for efficiency depending upon the choice of items to
ance of a steam generator at a particular operating
be included as output, items to be included as input,
condition is usually quantified by three main character-
and higher or lower heating value of the fuel. Entwistle
istics:
et al. discuss this problem at length and demonstrate
0 capacity - the maximum mass flow rate of steam that at least 14 different values of efficiency can be
produced at specified conditions computed from the same data [2,3].
output - all energy absorbed by the working fluid This Code recognizes two definitions of steam genera-
except that recovered within the steam generator en- tor efficiency:
velope
0 efficiency -the ratio of output energy to input energy 0 Fuel efficiency includes all energy absorbed by the
working fluid as output but counts only chemical en-
Any method for determining steam generator perform- ergy of the fuel as input. Fuel efficiency on a higher
ance must address the following two equally difficult heating value basis is the preferred definition of effi-
questions: ciency for purposes of this Code and is the method
What are the proper definitions of the parameters to supported by the calculations in Section 5.
be measured and the performance characteristics to Gross efficiency also includes all energy absorbed by
be determined (usually by calculation), e.g., exactly the working fluid as output and counts all energy
what should be included in the input and output? inputs entering the steam generator envelope as input.
0 What are the most practicable and accurate methods Thus, gross efficiency is usually less than or equal
for measuring parameters and calculating performance to fuel efficiency. Procedures for calculating gross
characteristics and how accurate must they be to efficiency are contained in Appendix D.
achieve the required test quality? [ 11
Those energies that are considered outputs and inputs
Capacity is easily defined; the main problems associ- (including credits in the case of gross efficiency) are
ated with its determination arise from measurement. shown on Fig. 3.1-1. In all cases, this Code uses the
Output, input, and thus efficiency are subject to several higher heating value of the fuel to determine fuel
possible definitions. This Code uses specific definitions energy input.
for these quantities. Figure 3.1-1 illustrates the defini-
tions used for input and output. This figure shows that 3.1.3 Methods of Measurement and Computation
output includes the energy in all working fluid streams to Determine Efficiency. Two generally accepted meth-
that exit the steam generator envelope, thus accounting ods for determining the efficiency of a steam generator
for ail energy absorbed by the working fluid. The figure are the input/output method and the energy balance
also shows that energy credits (usually minor) are added method.
19
Previous Page
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08/29/2002 18:04:05 MDT Questions or comments about this message: please call is Blank
STD=ASME PTC 4-ENGL 1998 0759b70 Ob149b2 413 W
ASME PTC 4-1998 FIRED STEAM GENERATORS
Energy in fuel (chemical)
QDBDA Enerav in enterina d w air

QpBWA Energy in moisture in entering air
QpBSIF Energy gain due to sulfation Credits

fQpB)
Energy from auxiliary equipment power
- -Envelope
-------
Boundary ,--------k----+ Energy in primarysteam
L -------- c ---- + Energy in auxiliary steam and blowdown
t
I ,-k----- Energy in desuperheater and
'-4:.,=
I
I circulating pump injection water
..--L----- Energy in feedwater
output
(ar01
I
I
I-------- t----+ Energy in reheat steam out
I
'- _,---k-----
Energy in desuperheater water
------++---- Energy in reheat steam in
c--- -I--------
QpLDFg Energy in dry gas
||| | |---
QpL WF Water in fuel
|||| | || ||| | || ||
QpLHZF Water from burning hydrogen
QpL WA Moisture in air
QpLSmUb Unburned carbon and other combustibles
| |||
QpLRs Sensible heat in residue
|
Hot air quality control equipment
| ||| | || | ||
QpLAg
QpLALg Air filtration
Losses
QDLNOX NOx formation
- (QPLI
--
QrLSrc Surface radiation and convection
QrL WAd Energy in additional moisture
QrLClh Calcination and dehydration of sorbent
QrL WSb Water in sorbent
*
QrLAp Radiation to wet ash pit
QrLßy Energy loss from recycled solids and gas
QrLCw Energy in cooling water
QrLAc Air preheater coil
Energy balance:
OUTPUT = INPUT - LOSSES + CREDITS
QrO = QrF - Q ï l + QrB
QpL = 100 x E % QpB= 100 x - QrB %
QrF ' QrF '
Fuel efficiency (percent) = €i(%)
= 100 x
INPUT
= 100 - QpL + QpB
FIG. 3.1-1 STEAM GENERATOR ENERGY BALANCE
20
S T D O A S M E PTC 4-ENGL L978 0759b70 ObL47b3 35”
FIRED STEAM GENERATORS ASME F’TC 4-1998
The inputloutput method uses the equation: than if the values were measured. Losses are sometimes
determined on a “percent input” basis rather than an
output absolute basis.
efficiency = - * 100 Advantages and disadvantages of the inputloutput
input
and energy balance methods are listed in Table 3.1-1.
Efficiency determination by the inputloutput method In many cases, the energy balance method yields lower
requires direct and accurate measurement of all output overall test uncertainty because the quantities used to
as well as all input. The primary measurements required determine efficiency by the energy balance method,
are the following: i.e., losses, are a much smaller portion of the total
energy than is output, which is used to determine
0 feedwater flow rate entering the steam generator efficiency in the inputloutput method. Thus, a given
0 desuperheating water flow rates uncertainty in measured or estimated values has less
o flow rates of all secondary output streams such as effect on the result in the energy balance method [4].
boiler blowdown, auxiliary steam, etc. The energy balance method also provides a means of
0 pressure and temperature of all working fluid streams examining the losses to determine potential improve-
such as entering feedwater, superheater outlet, reheater
--
ments to the unit or its operation. The energy balance

inlet and outlets, auxiliary steam, etc. method allows for corrections of test results to standard
| ||| | || | ||
0 additional measurements in the turbine cycle as re- or guarantee conditions. Accordingly, this Code recom-
quired to determine reheater flows by energy balance mends the energy balance method to determine effi-
|
methods ciency when corrections to such conditions are required.

| |||
0 fuel flow rate In other cases, the choice between the methods should
|||| | || ||| | || ||
0 higher heating value of the fuel be based upon the available instrumentation and ex-
waste energy input pected test uncertainty.
Further measurements may be required to determine
||| | |---
other input credits; however, they usually have a minor

effect on the results. 3.1.4 Unit Design and Construction Considerations
The energy balance method combines the energy to Facilitate Testing. Early planning and frequent
balance equation follow-up during design and construction of a steam
generating unit will help to minimize testing problems
and ensure that tests can be performed in accordance
input + credits = output + losses with this Code after construction is complete. Ideally,
provisions for conducting both acceptance tests and
with the efficiency definition to arrive at
routine performance tests should be included in the
design of a unit. Even if it is decided not to run an
efficiency =
input - losses + credits
input
j* 100 acceptance test, the provisions will be valuable for
gathering information on the unit’s operation and per-
= (I
input
j
- (losses - credits) * 100 formance.
This Code should be used as a guide during prelimi-
nary engineering to determine the required test points
Efficiency determination by the energy balance and sampling provisions. This determination will nor-
method requires the identification and measurement (or mally require interaction between the intended parties
estimation) of all losses. Figure 3.1-1 illustrates these to the test. The required test points and sampling
losses. The primary measurements for efficiency deter- provisions should be included in the specifications.
mination by the energy balance m e t h d are chemical Periodic reviews during design and construction should
analysis of the fuel, sorbent, residue, and flue gas; the ensure that field installation does not jeopardize the
higher heating value of the fuel; and air and flue gas test provisions.
temperatures. One of the problems most commonly encountered
Many other measurements are required to determine in the performance of measurements during testing is
values for all of the losses; however, several of them interference with other structures. Thermowells, pressure
usually have a minor effect on the results. In many taps, and duct ports for air and gas measurements
cases, parties to the test may agree to estimate values should be oriented so that test instruments can be
for certain losses, rather than measuring them; however, installed as required. Bracing and support beam interfer-
the uncertainties of estimated values are usually greater ence with duct sampling must be considered. On large
21
~
STDmASME PTC 4-ENGL 1998 D 0759b70 Ob14964 79b
TABLE 3.1-1
COMPARISON OF EFFICIENCY DETERMINATION
Advantages Disadvantages
InpuVOutput Method
Primary parameters from the efficiency definition Fuel flow and fuel heating value, steam flow
(output, input) are directly measured rates, and steam properties need to be
measured very accurately to minimize
Requires fewer measurements uncertainty
Does not require estimation of unmeasurable Does not aid in locating source of possible
losses inefficiency
Requires the use of energy balance calculation

methodology for correction of test results to
standard or guarantee conditions. Corrections
to standard or guarantee conditions can only be
made using the energy balance methodology.
Energy Balance Method

The primary measurements (flue gas analyses and Requires more measurements
flue gas temperature) can be made very
accurately Does not automatically yield capacity and output
data
Permits corrections of test results to standard or
guarantee conditions Some losses are practically unmeasurable and
value must be estimated
The as-tested efficiency often has lower
uncertainty because the measured quantities
(losses) represent only a small fraction of the
total energy
The effects of fairly substantial errors in

secondary measurements and estimated values
are minimal
Sources of large losses are identified
ducts, overhead clearance for insertion of long sampling 3.2 PERFORMANCE TEST PROCEDURES
probes must also be considered. 3.2.1 Determination of Level of Test. Accurate deter-
Provisions should be made for obtaining the necessary mination of the performance of a steam generator
samples of fly ash, bottom ash, pulverizer rejects, requires a significant expenditure of time and money.
sorbent, and fuel. The equipment and procedures to be Many measurements are required to account for all
used in obtaining the samples should be considered in losses, especially in the determination of efficiency by
the design of sampling provisions. the energy balance method. At the same time, each
Provisions should be made for measurement of auxil- individual loss or an error in its determination may have
iary power used in determining energy credits. only a small effect on the results or their uncertainty.
Consideration should be given to the needs of person- It has long been recognized that no single set of
nel and instrumentation involved in conducting the test. procedures can yield the most cost-effective test for
Examples include safe access to test point locations, all cases. Previous editions of this Code provided for
availability of suitable utilities, and safe work areas for two different levels of test for tests that used the energy
personnel. Potential damage to instrumentation resulting balance method. One level was a complete test in
from extreme ambient conditions such as high tempera- which all losses were determined from measurements.
ture and vibration should be considered. The other was an abbreviated test in which only major
22
-- | ||| | || | || | | ||| |||| | || ||| | || || ||| | |---
__
STDeASME PTC 4-ENGL L99ö 0759b70 Ob14965 L22 m
losses were determined from measurements while sev- ance characteristics. A test normally consists of two
eral minor losses were ignored or aggregated into an or more runs.
unmeasured loss term with an estimated numerical Conducting more than one run will verify the repeat-
value. ability of the test results. Results may not be repeatable
This Code permits the parties to elect various levels due to variations in either the test methodology (test
of testing. While all necessary procedures are specified variations) or the actual performance of the equipment
for the most accurate determination of steam generator being tested (process variations). It is recommended
performance, the parties to the test are permitted to that, at the end of each run that meets the criteria
design a lower level test if appropriate. Typically, a for an acceptable run, the data be consolidated and
lower level test uses less accurate instruments or fewer preliminary results calculated and examined to ensure
instruments or will use assumed or estimated values the results are reasonable. If the parties to the test
for certain parameters rather than measuring them. This agree, the test may be concluded at the end of any run.
Code requires calculation of the uncertainties of the
results to define the quality level of the test: 3.2.2.1 Repeatability. The criterion for repeatability
between runs is that the normalized results of two or
By agreement prior to the test, the parties to the test more runs all lie within the uncertainty intervals of
shall-define acceptable values for the uncertainties of each other. Refer to Fig. 3.2-1 for examples of runs
the results (for example, they may decide that effi- that meet or do not meet this criterion. The results
ciency will be determined with an uncertainty of should be normalized to a base set of conditions.
20.5% and that maximum capacity will be determined For example, efficiency for different runs should be
with an uncertainty of 5 1.O% of the value). These calculated using a single representative fuel analysis
values are called the target uncertainties of the results. and should be normalized for inlet air temperature, etc.
A performance test must be designed to meet the target Refer to Section 5.18. The uncertainty interval calculated
uncertainties. The choices of which parameters to for each run is applied to the normalized result for
measure, which parameters may be estimated, what that run for the purpose of evaluating repeatability
estimated values to use, and the use of fewer or alterna- between runs.
tive instruments will strongly influence the ability to
meet target uncertainties. Parties to the test should 3.2.2.2 Invalidation of Runs. If serious inconsisten-
reach agreement on these choices prior to the test. A cies affecting the results are detected during a run or
pretest uncertainty analysis, described in Section 7.3, during the calculation of the results, the run must be
is strongly recommended to aid in this process. invalidated completely, or it may be invalidated only
The parties to the test shall reach prior agreement on in part if the affected part is at the beginning or at
the uncertainties of values that will not be measured the end of the run. A run that has been invalidated
and on the bias limits of instruments and measurement must be repeated, if necessary, to attain the test objec-
methods. This agreement shall be documented in the tives. The decision to reject a run is the responsibility
written agreement required by Subsection 3.2.3. of the designated representatives of the parties to the test.
After each run has been conducted, the uncertainties
of the results must be calculated in accordance with 3.2.2.3 Multiple Runs. The results of multiple runs
Section 7 and PTC 19.1, as appropriate. If the uncer- that meet the criteria for repeatability and other Code
tainties thus calculated are greater than the previously requirements are averaged to determine the average
test result, The uncertainties shall be reported for each
agreed upon target uncertainty values, the run is in-
valid. individual run but shall not be reported for the average
test result.
It is strongly emphasized that the test uncertainties
thus calculated are not tolerances on steam generator 3.2.3 Prior Agreements. Prior to the test, the parties
performance. The uncertainties are to be used to judge to the test shall prepare a definite written agreement.
only the quality of the performance test and not the This agreement shall state the specific test objectives
acceptability of the steam generator. including the acceptable range of uncertainty for each
result, as well as the method of operation during the
3.2.2 Number of Runs. A run is a complete set of test. For acceptance tests, the agreement shall identify
observations made over a period of time with one or any contract requirements pertinent to the test objectives,
more of the independent variables maintained virtually e.g., guarantee provisions, and it must include estimated
constant. A test is a single run or the combination of values or other clarifications necessary to resolve any
a series of runs for the purpose of determining perform- omissions or ambiguities in the contract.
23
-- | ||| | || | || | | ||| |||| | || ||| | || || ||| | |---
~ ~-
STD-ASME PTC 4-ENGL 1998 = 0759b70 O b L 4 9 b b Ob9

1 1
2
2
3
(a) (b) (Cl
Repeatable Not Repeatable 2 and 3 Repeatable;
1 not Repeatable
--
| ||| | || | ||
Test result plus uncertainty
I
f--
|
| |||
|||| | || ||| | || ||
Legend f-- Test result
f-- Test result minus uncertainty

||| | |---
FIG. 3.2-1 REPEATABILITY OF RUNS
This written agreement shall specifically include the 0 whether to conduct a pretest uncertainty analysis and
following items and should also address other items how to apply results of the analysis to improve the
considered pertinent by the parties to the test. For test (refer to Subsection 3.2.5.1)
routine performance tests, some items may not be 0 number of runs
applicable and may be omitted: 0 pretest checkout procedures
0 establishment of acceptable operating conditions, al-
lowable variance in operating conditions during the
test objectives (e.g., efficiency, steam temperature) run (based on Table 3.2-I), number of load points,
designation of a chief-of-test who will direct the test duration of runs, basis for rejection of runs, and proce-
and exercise authority over all test personnel, prefera- dures to be followed during the test
bly a registered professional engineer with previous 0 means for maintaining constant test conditions
testing and power plant experience, good organiza- maximum permissible deviation of average values of
tional skills, and a thorough understanding of instru- controlled parameters from target values during the
mentation and uncertainty analysis test
designation of representatives from each party to the 0 unit cleanliness prior to the test and how cleanliness
test is to be maintained during the test (including any soot
0 organization, qualifications, and training of test per- blowing to be conducted during the test)
sonnel; arrangementsfor their direction; arrangements 0 readings and observations to be taken; number and
for calculating the test results frequency.
0 interpretation of any relevant contract requirements number, location, type, and calibration of instruments
target test uncertainties (Table 1.3-1 provides typical 0 bias limits of instruments and measurement methods,
values for efficiency tests for various types of steam models for estimating bias, and any precision indexes
generators) that are to be set by agreement (refer to Section 7)
24
STD-ASME PTC 4-ENGL 1998 0759670 Ob14967 TT5
TABLE 3.2-1
OPERATING PARAMETER DEVIATIONS
Short-Term Fluctuation
Parameters (Peak to Valley) Long-Term Deviation
Controlled Parameter
Steam Pressure
> 500 psi set point 4% (25 psi max) 3% (40 psi max)
< 500 psi set point 20 psi 15 psi
Feedwater Flow (Drum Unit) 1o % 3 0x3
Steam Flow (Once-Through Unit) 4 0% 3%
O2 Leaving Boiler/Economizer (by Volume)
Oil and gas units 0.4 (points of 0,) 0.2 (points of 02)
Coal units 1.0 (points of O?) 0.5 (points of Oz)
Steam Temperature (If Controlled) 20°F 10°F
SuperheaüReheat Spray Flow 40% Spray Flow or 2 % Main NfA
Steam Flow
Fuel Flow ( I f Measured) 1o % NIA
Feedwater Temperature 20°F 10°F
Fuel Bed Depth (Stoker) 2 in. 1 in.
SorbenüCoal Ratio (Feeder Speed Ratio) 4% 2%
[Note (1)l
Ash Reinjection Flow 20% 10%
Bed Temperature (Spatial Average/per 50°F 25°F
Compartment) [Note (111
Bed/Unit Operating Solids Inventory [Note
(1)l
Bed pressure 4 in. wg 3 in. wg
Dilute phase pressure drop 4 in. wg 3 in. wg
--
Dependedent Parameters
| ||| | || | ||
Steam Flow 4 Oh 3%
SO, (Units with Sulfur Removal) 150 ppm 75 ppm
CO (If Measured) 150 ppm 50 ppm
|
Freeboard Temperature ( I f Measured) 50°F 25'F

| |||
GENERAL NOTE:
|||| | || ||| | || ||
N/A - Not Applicable.
NOTE:
(1) Applicable to fluid bed units only.
||| | |---
0 parameters to be estimated rather than measured, esti- 0 peak capacity determination:

mated values to be used, and uncertainties of estimated - time limit for operation at peak capacity
values - specific steam pressures (and temperatures for
efficiency determination: superheated steam generators) which define
- energy balance or input-output method peak capacity operation
- parameters to be measured - feedwater pressure and temperature
- estimated values to be used for unmeasured - blowdown rate
parameters 0 fuel to be fired, method and frequency of obtaining
- exiting streams to be included in output fuel samples, laboratory which will make the fuel
- steam or water flow measurement analyses, and fuel test method to be used
- duration equivalence of fuel to standard or contract conditions
capacity determination: or procedures for correcting to those conditions
- exiting streams to be included in capacity 0 procedures to be used for sampling and analysis of
- steam or water flow measurement sorbent and the target sorbent to sulfur ratio (CdS
- duration molar ratio)
25
STD-ASME PTC 4-ENGL 1998 075îb70 ObL49b8 931, =
distribution of residue quantities between various col- may also provide opportunities for economies in con-
lection points and methods of residue sampling and ducting the test by identifying parameters which are
analysis less critical to attainment of target test uncertainties.
procedures to be used for flue gas sampling and These parameters might then be candidates for measure-
analysis ment by lower quality instruments andor the existing
whether to determine the need for and methods of flow plant instrumentation, or they might be considered for
weighting for flue gas temperature and oxygen content estimation of values rather than measurement.
method for determining outliers Section 7 provides guidance for conducting uncer-
corrections to be used for comparison to contract con- tainty analysis including determination of sensitivity
ditions, including any correction curves coefficients.
media, methods, and format to be used for recording
data and providing copies for parties to the test (refer 3.2.5.2 Pretest Checkout. Prior to initiating the
to Subsection 3.2.8) test, the following actions must be taken to ensure the
steam generator is ready for the test and to help avoid
3.2.4 Acceptance Test. An acceptance test should problems which might invalidate the test:
be conducted as soon as practical after initial operation
of the unit or in accordance with the contract require- Parties shall agree that the fuel, sorbent, and additives
ments. to be used during the test are satisfactory for the test
(refer to Appendix E).
Designated representatives of the parties to the test 0 Any departures from standard or previously specified
are encouraged to be present to verify that the test is conditions in the physical state of equipment, cleanli-
conducted in accordance with this Code and the ness of heating surfaces, fuel characteristics, or stabil-
agreements made prior to the test. ity of load must be noted and corrected if possible.
3.2.5 Preparation for the Test A complete record shall be made, fully identifying the
equipment to be tested and the selected testing method.
3.2.5.1 Pretest Uncertainty Analysis. A pretest All instruments must be checked for proper installation
uncertainty analysis should be performed to confirm and for operability.
that the test, as it has been designed and planned, is Parties to the test shall agree that the steam generator
capable of achieving the target test uncertainties. This is ready for testing, Le., that its configuration and
uncertainty analysis will help avoid the possibility of conditions conform to those specified in the pretest
conducting a test that does not achieve the target test agreement.
uncertainties and thus cannot be considered a Code
test. In addition to indicating whether the target test In addition to these mandatory actions, the entire
uncertainties can be achieved, the pretest uncertainty steam generator should be visually inspected for abnor-
analysis provides information which can be used to mal air infiltration. Air heater internal leakage should
design a more cost-effective test which can still achieve also be checked (refer to PTC 4.3). Mechanical discrep-
the test uncertainty targets, or it enables setting achiev- ancies that may contribute to excessive leakage should
able uncertainty targets. be corrected prior to the test.
A sensitivity analysis should be performed as part 3.2.5.3 Preliminary Run. A preliminary run should
of the pretest uncertainty analysis to determine the be made for the following purposes:
relative sensitivity coefficients, i.e., the relationships of
overall test uncertainties to the uncertainty of each determining whether the steam generator and the over-
parameter for which a value will be either measured all plant are in a suitable condition for conducting
||| | |---
or estimated (refer to Sections 5 and 7). All parameters the test

for which the relative sensitivity coefficient is greater making minor adjustments which were not foreseen
|||| | || ||| | || ||
than 5% of the value of the highest sensitivity coefficient during preparation for the test, establishing proper
are considered critical parameters. All critical parameters combustion conditions for the particular fuel and firing
should be measured using accurate instruments. These rate to be employed, and confirming that specified
| |||
instruments should be selected and calibrated in accord- operating conditions and stability (in accordance with
|
ance with the criteria in Section 4. However, proper Subsection 3.2.6.1) are attainable
| ||| | || | ||
installation of the instruments and proper implementa- 0 checking instruments

tion of the chosen sampling schemes are at least as verifying attainability of the target test uncertainty
important as proper calibration in assuring that target acquainting test personnel with the specific facility,
--
test uncertainties are attainable. The sensitivity analysis test instruments, and procedures
26
STD-ASME PTC 4-ENGL L998 m 0759670 0634969 878 m
After a preliminary run has been made, it may be quality of the control system. Table 3.2-1 provides
declared a test run if agreed to by the parties to the criteria for stability of operating parameters which are
test, provided all the requirements of a test run have indicative of units which have reached equilibrium. For
been met. fluidized bed units that use an inert bed material such
as sand, the stoker unit criteria should be used. For
3.2.6 Method of Operation During Test
fluidized bed units which have already been operating
3.2.6.1 Stability of Test Conditions. Prior to any at the specified sorbent/fuel ratio for at least 24 hr, a
test run, the equipment must be operated for a sufficient 4 hr stabilization period is sufficient as long as the
time to establish steady-state conditions. Steady-state stability criteria of Table 3.2-1 are met.
sometimes implies that all input and output characteris- Stability is attained when the agreed upon pretest
tics, as well as all internal characteristics, do not vary stabilization period has been completed and monitoring
with time. This definition of steady-state is overly indicates the controlled and dependent parameters are
restrictive for the purposes of this Code. Steady-state maintained within agreed upon maximum operating
is defined by this Code as an operating condition in parameter deviations. The pretest agreement shall in-
which the system is at thermal and chemical equilibrium. clude a table of allowable maximum variations in
The criterion for thermal equilibrium is that, during operating parameters similar to Table 3.2-1. Values
the period of the test, there is no net change in energy shown in Table 3.2-1 are typical and may be used
stored inside the steam generator envelope. Energy can directly or modified by agreement between parties to
be stored in the water and steam, and in metal, refrac- the test. For units utilizing limestone or other sorbent for
tories, and other solid materials within the steam genera- reducing sulfur emissions, the SO, should be monitored
tor. If the steam generator is at thermal equilibrium continuously and used as an indication of chemical
during the test, the average input and average output equilibrium between the bed and recycled material, i.e.,
--
can be properly calculated and compared. For circulating the SO2 trend should be reasonably flat. For circulating
| ||| | || | ||
fluidized bed units, thermal equilibrium includes the fluidized bed units, complying with the pretest stabiliza-
requirement that size equilibrium of the recirculating tion period is the primary means of assuring chemical
solids be established. The ultimate criterion for steady- and mechanical equilibrium. Monitoring the dilute phase
|
| |||
state is that the average of the data during the test pressure drop provides a good indicator. Since relative
|||| | || ||| | || ||
represents equilibrium between the fuel input and steam changes are sought, plant instrumentation is acceptable
generator output. for these trend measurements.
Fluidized bed units that utilize limestone or other All parameters in Table 3.2-1, and any other condi-
||| | |---
sorbent for reducing sulfur (or other) emissions have tions designated by the parties to the test in which
a large inventory of reactive material that must reach variations might affect the results of the test, should
chemical equilibrium, including the recycled material be, as nearly as possible, the same at the end of the
from hoppers and hold-up bins. To achieve equilibrium run as at the beginning. However, the primary criterion
between the calcium oxide (Cao) in the unit and sulfur for steady-state is that the average of the data reflects
in the fuel (sulfation), the sorbent to fuel ratio during equilibrium between input from fuel and steam generator
the stabilization period shall be maintained within t5% output. Thus, gradual changes in the critical operating
of the targeted ratio for the test. parameters over a significantly long test period are not
The following are minimum pretest stabilization times necessarily grounds for rejecting a test.
typically required for various types of units: During a complete test run, each observation of an
operating condition shall not vary from the reported
pulverized coal and gadoil fired units - 1 hr
average for that operating condition by more than
0 stoker units - 4 hr
the allowable value under the “Long-Term Deviation”
0 fluidized bed units - 24 to 48 hr
column of Table 3.2-1, and the maximum variation
The purpose of the pretest stabilization period is to between any peak and an adjacent valley in the data
establish thermal, chemical, and recirculated material shall not exceed the limit shown in the “Short-Tem
size equilibrium of the system at the test conditions. Fluctuation” column. An illustration of the application
Minor adjustments to operating conditions are permitted of these limits is provided on Fig. 3.2-2. These limits
as long as they do not interfere with safe operation. may be modified by the parties to the test but, in any
However, the entire steam generator should be essen- event, the established limits shall be tabulated in the
tially at test conditions throughout the entire stabilization pretest agreeihent. If operating conditions vary during
period. The actual stabilization time required will depend any test run beyond the limits prescribed in that table,
upon the specific unit operating characteristics and the the test run is invalid unless the parties to the test agree
27
TABLE 3.2-2 to allow the deviation. Any such allowed deviations shall
MINIMUM TEST RUN DURATION be explained in the test report.
Type of Steam 3.2.6.2 Duration of Test Runs. The duration of a
Generating Energy Balance, Inputloutput, test run must be of sufficient length that the data reflect
Unit hr hr
the average efficiency andor performance of the unit.
Gas/Oil 2 This includes consideration for deviations in the measur-
Stoker 10 able parameters due to controls, fuel, and typical unit
Pulverized Coal 8
Fluidized Bed 8
operating characteristics. The test duration shall not be
less than that tabulated in Table 3.2-2.
The chief-of-test and the parties to the test may
determine that a longer test period is required. The
||| | |---
minimum times shown in Table 3.2-2 are generally
based upon continuous data acquisition and utilization
|||| | || ||| | || ||
| |||
|
| ||| | || | ||
--
+15
Pavg. Paverage
-1 5
Time -
Duration of run _I
GENERAL NOTE: From Table 3.2-1: controlled parameter steam pressure less than 500 psi
set point; peak to valley 20 psi maximum short term (peak to valley) fluctuation; maximum
long term deviation 215 psi; Pavg. is arithmetic average of data recorded.
FIG. 3.2-2 ILLUSTRATION OF SHORT-TERM (PEAK TO VALLEY)

FLUCTUATION AND LONG-TERM DEVIATION
28
STDIASME PTC 4-ENGL 1998 m 0759670 Ob34973 42b m
of composite gas sampling grids. Depending upon the fuel bed be accomplished some time before the run
personnel available and the method of data acquisition, starts and again the same length of time before the
it may be necessary to increase the length of a test run is completed. Normal cleaning of the fuel bed is
to obtain a sufficient number of samples of the measured permitted during the run. The ash pit must be emptied
parameters to achieve the required test uncertainty. either just after the initial and final cleaning and condi-
When point by point traverses of large ducts are utilized, tioning of the fuel bed or just before the start and end
the test run should be long enough to complete at least of the run so that the quantity of residue corresponds
two full traverses. Test runs using blended or waste to the quantity of fuel burned.
fuels may also require longer durations if variations in In the case of runs to determine the maximum output
the fuel are significant. at which the unit can be operated for a short period,
The duration of runs to determine the maximum the run should be started as soon as the maximum output
short period output, when the efficiency is not to be is reached and continue until the specified duration of
determined, shall be set by agreement of the parties the run is reached unless conditions necessitate terminat-
to the test. ing the run earlier. Refer to Subsection 3.2.6.2.
The actual duration of all runs from which the final
3.2.6.4 Frequency of Observations. The following
test data are derived shall be recorded.
measurement and sampling frequencies are recom-
mended for use during a test. The frequencies may be
3.2.6.3 Considerations for Conducting the Test.
increased or decreased based on a pretest uncertainty
Each test run should be conducted with the steam
analysis. Refer to Sections 4, 5, and 7 for additional
generator operating as closely as possible to the specified
information:
conditions to avoid the application of corrections to
the test results or to minimize the magnitude of the Readings should be taken at intervals of 15 min or less
corrections. Critical considerations include type of fuel, for all measurements except quantity measurements.
flow rates, pressures, and temperatures. For stoker and Continuous monitoring is permissible.
fluidized bed units, it is particularly important to main- If the amount of fuel or feedwater is determined from
tain constant coal quality and size distribution to ensure integrating instruments, the readings should be taken
stability of operating conditions. For units utilizing at 1 hr intervals.
sorbent, the sorbent to fuel ratio ( C d S molar ratio) is If the quantities to be determined are weighed, the
also particularly important. frequency of weighing is usually determined by the
The pretest stabilization period, deviation of critical capacity of the scales, but the intervals should be such
parameters during the test period, and criteria for rejec- that a total can be obtained for each hour of the test.
tion of tests are defined by the criteria in Subsection When differential pressure measurement devices are
3.2.6.1. used with venturi tubes, flow nozzles, or orifice plates
--
A test operations coordinator should be assigned to for subsequently determining quantity measurements,
| ||| | || | ||
facilitate communication between the steam generator the flow indicating element should be read at intervals
operator(s) and the parties to the test. The steam of 5 min or less.
generator operator(s) should be apprised of his responsi- Fuel and residue samples should be taken in accord-
|
| |||
bilities with respect to the test. This includes the ance with guidance in Section 4.
|||| | || ||| | || ||
requirements of the pretest stabilization period as well

3.2.6.5 Performance Curves. If runs are made at
as the specified maximum deviation of critical operating
different outputs, curves may be drawn to relate the
parameters. Communications between the test operations
test parameters to output. Such curves are useful in
coordinator and the operator(s) should be such that,
||| | |---
appraising the performance of the unit, because the

except under emergency operating situations, the test
desired outputs are seldom exactly obtained during
operations coordinator is consulted prior to changing
the test. If there are enough test points to establish
operating parameters.
characteristic curves, the performance corresponding to
If soot blowing would normally be used during the
intermediate levels of output may be read from the
period of a test run, it should be used during the
curves.
conduct of each test run. The pretest agreement shall
define the soot blowing plan for each run. Any soot 3.2.7 Corrections to Test Results. Operating condi-
blowing conducted during a test run shall be recorded tions at the time of the test may differ from the standard
and included in the analysis of the test results. or specified conditions which were used to establish
For stoker fired units with a stationary grate, it is design or guarantee performance levels. Section 5 pro-
essential that major cleaning and conditioning of the vides methods for applying corrections during the calcu-
29
~ ~
~~
~
STD-ASME PTC 4-ENGL 1998 W 0759670 Ob14972 3b2 W
lation of test results to account for many of these be used in conjunction with the following ASME
differences. Correction factors may be obtained from Performance Test Codes and Supplements on Instru-
various sources such as tables, correction curves, or ments and Apparatus and other pertinent publications
manufacturer’s design data. Parties to the test shall for detailed specifications on apparatus and procedures
record their agreement on the sources of any correction involved in the testing of steam generating units. These
factors to be used and the methods for their application. references are based upon the latest information avail-
This Code does not provide a method for calculating able when this Code was published. In all cases, care
the uncertainty of corrected results. Uncertainties calcu- should be exercised to refer to the latest revision of
lated in accordance with this Code apply to as-measured the document.
results only. A procedure for calculating the uncertainty
of corrected results will be provided in a future adden- 3.3.1 ASME Performance Test Codes
dum to this Code when related technical issues are General Instructions, PTC 1
resolved. Definitions and Values, PTC 2
3.2.8 Records and Test Reports. Computer data log- Diesel and Burner Fuels, PTC 3.1
ging is preferred to manual recording, provided all Coal and Coke, PTC 3.2
required points are recorded. Following completion of Gaseous Fuels, PTC 3.3
the test, a permanent record of the data shall be Coal Pulverizers, PTC 4.2
submitted in a mutually agreed upon format to each 0 Air Heaters, PTC 4.3
||| | |---
party of the test. Gas Turbine Heat Recovery Steam Generators, PTC
Any manually recorded data shall be entered on 4.4
|||| | || ||| | || ||
previously prepared forms which constitute original log Steam Turbines, PTC 6
sheets and shall be authenticated by the observers’ 0 Compressors and Exhausters, PTC 10
signatures. Each party to the test shall be given a Fans, PTC 11
| |||
complete set of unaltered log sheets, recorded charts, Instruments and Apparatus: Part 1 Measurement Un-
or facsimiles. The observations shall include the date
|
certainty, PTC 19.1
| ||| | || | ||
and time of day. They shall be the actual readings Instruments and Apparatus: Part 2 Pressure Measure-
without application of any instrument calibration correc- ment, PTC 19.2
tions. The log sheets and any recorded charts constitute Temperature Measurement, PTC 19.3
--
a complete record of the test. It is recommended that Application, Part II of Fluid Meters: Interim Supple-
sufficient space be left at the bottom of each log sheet ment on Instruments and Apparatus, PTC 19.5
to record average reading, correction for instrument NOTE: Ai the time this Code was published, a revision of F’ïC
calibration, and conversion to desired units for calcula- 19.5 was being prepared. This revised version or a later version
tions. should be consulted.
Records made during tests must show the extent of Measurement of Shaft Power, PTC 19.7
fluctuations (i.e., minimum and maximum values of Flue and Exhaust Gas Analyses, PTC 19.10
instrument readings) of the instruments so that data Steam and Water Sampling, Conditioning, and Analy-
will be available for use in determining the influence sis in the Power Cycle, PTC 19.11
of such fluctuations on the uncertainty of calculated Particulate Matter Collection Equipment, PTC 21
results. 0 Gas Turbine PTC 22
Every event connected with the progress of a test, 0 Determination of the Concentration of Particulate Mat-
however unimportant it may appear at the time, should ter in a Gas Stream, PTC 38
be recorded on the test log sheets together with the
time of occurrence and the name of the observer. 3.3.2 ASME Standards
Particular care should be taken to record any adjustments 0 Measurement of Fluid Flow in Pipes Using Orifice,
made to any equipment under test, whether made during Nozzle, and Venturi, MFC3M
a run or between runs. The reason for each adjustment Measurement of Gas Flow by Turbine Meters,
shall be stated in the test record. MFC-4M
3.33 ASTM Standard Methods
3.3 REFERENCES TO OTHER CODES AND
0 Test Method for Chemical Analysis of Limestone,
STANDARDS
Quicklime, and Hydrated Lime, C 25
The necessary instruments and procedures for making Test Method for Heat of Combustion of Liquid Hydro-
measurements are prescribed in Section 4 and should carbon Fuels by Bomb Calorimeter, D 240
30
~ ~
STDaASME PTC 4-ENGL 1448 m 0759b70 Ob14973 2 T 9 m
0 Practice for Collection and Preparation of Coke Sam- Test Method for Sulfur in Petroleum Products (High-
ples for Laboratory Analysis, D 346 Temperature Method), D 1552
0 Test Methods for Collection of a Gross Sample of 0 Test Method for Calorific Value of Gases in Natural
Coal, D 2234 Gas Range by Continuous Recording Calorimeter,
Test Method for Carbon Dioxide in Coal, D 1756 D 1826
0 Test Method for Gross Calorific Value, D 1989, D Test Method for Analysis of Natural Gas by Gas Chro-
2015, D 3286 matography, D 1945
0 Method of Preparing Coal Sample for Analysis, D Method for Calculating Calorific Value and Specific
2013 Gravity (Relative Density) of Gaseous Fuels, D 3588
0 Test Method for Heat of Combustion of Hydrocarbon 0 Practice for Automatic Sampling of Gaseous Fuels,
Fuels by Bomb Calorimeter, D 4809 D 5287
0 Test Methods for Forms of Sulfur in Coal, D 2492
0 Practice for Ultimate Analysis of Coal and Coke, D 3.3.4 IEEE Standards
3176
IEEE Master Test Guide for Electrical Measurements
0 Test Methods for Instrumental Determination of Car-
in Power Circuits. ANSIAEEE Standard 120-1989
bon, Hydrogen, and Nitrogen in Laboratory Samples
of Carbon and Coke, D 5373 3.3.5 National Institute of Standards and Tech-
0 Method for Calculating Calorific Value and Specific nology
Gravity (Relative Density) of Gaseous Fuels, D 3588
Test Method for Major and Minor Elements in Coal 0 Methods of Measuring Humidity and Testing Hygrom-
and Coke Ash by X-Ray Fluorescence, D 4326 eters, Circular 512
0 Test Method for Total Moisture in Coal, D 3302
3.3.6 International Organization for Standard-
Test Method for Ash in the Analysis Sample of Coal
ization
and Coke from Coal, D 3 174
Practice for Calculating Coal and Coke Analyses from 0 Flow Measurement, IS0 5167
As-Determined to Different Bases, D 3 180
Test Method for Total Sulfur in the Analysis Sample
of Coal and Coke, D 3177
3.4 TOLERANCES AND TEST
0 Test Method for Sulfur in the Analysis Sample of
Coal and Coke Using High Temperature Tube Furnace UNCERTAINTIES
Combustion Methods, D 4239
Test Method for the Proximate Analysis of the Analy- Tolerances or margins on performance guarantees
sis Sample of Coal and Coke by Instrumental Proce- are not within the scope of this Code. The test results
dures, D 5142 shall be reported as computed from test observations,
0 Practice for Manual Sampling of Petroleum and Petro- with proper corrections for calibrations. The uncertain-
leum Products, D 4057 ties of the test results shall be calculated in accordance
0 Test Method for Water in Petroleum Products and with Sections 5 and 7. The calculated uncertainties
Bituminous Materials by Distillation, D 95 shall be reported with the results of the test and the
Test Method far Ash from Petroleum Products, D 482 uncertainty analysis shall be part of the record of the
Practice for Density, Relative Density (Specific Grav- test. Test uncertainties are to be used only for evaluating
ity), or API Gravity of Crude Petroleum and Liquid the quality of the test and the accuracy of the test
Petroleum Products by Hydrometer Method, D 1298 results. They are not tolerances on performance.
31
-- | ||| | || | || | | ||| |||| | || ||| | || || ||| | |---
~~~
S T D - A S M E PTC 4-ENGL L99B W 0759b70 Ob14974 L35 W
||| | |---
|||| | || ||| | || ||
SECTION 4 - INSTRUMENTS AND METHODS OF
MEASUREMENT
| |||
|
| ||| | || | ||
4.1 GUIDING PRINCIPLES 0 exit flue gas and air entering temperatures
excess air
--
This Section provides guidance in test measurement.
0 waterhteam pressure drops
When planning a test, the engineer has many choices
0 aidflue gas pressure drops
regarding the parameters to be measured, the method
air infiltration
of measurement, calculations, assumptions, and values
0 sulfur capturehetention
for any assumed variables. Because the technology of
calcium to sulfur molar ratio
I test measurement is constantly improving, this Code
fuel, air, and flue gas flows
permits flexibility in the design and selection of test
instrumentation, yet maintains a prescribed quality level.
Tables 4.2-1 through 4.2-12 list the parameters re-
A test can be designed within the guidelines provided
quired to determine each of these performance character-
here to suit the particular needs and objectives of all
istics for typical units as defined by the Steam Generator
parties to the test.
System Boundaries on Figs. 1.4-1 through 1.4-7 in
This Section addresses three items:
Section 1. Each table lists the parameters required,
For each Code objective, the parameters needed to their relative importance, and the paragraph in this
compute the final result are identified. Section covering the applicable measurement procedure
0 The relative importance of each parameter is indicated, for the specific measurementhest objective. The user
and several methods for quantifying the parameter are of this Code is responsible for identifying any features
identified. of the unit to be tested that are not included in the
Appropriate bias limits are suggested for each method typical examples and for applying the principles of
used to measure the required parameters. this Code for measuring the appropriate parameters to
accomplish the objective of the test.
It is the test engineer’s responsibility to select the On the line with the major parameter, the “typical
method for measuring each parameter which, when influence” and “typical source” entries relate to the
considered with all the other parameters, produces major parameter. The typical sources are either mea-
results within the uncertainty requirements of the test. sured, calculated, or estimated. Measured is intended
In this Code, where there is a choice among several to indicate the parameter as determined from direct
methods, a preferred method is identified. If a preferred observation of a physical property such as voltage in
procedure is not selected, the increased bias is quantified a thermocouple or flow from a measured differential
for the chosen method. Section 7.5 discusses methods pressure. Calculared indicates the parameter is inferred
for estimating such biases. Bias limits shall be agreed from other measured parameters and calculated based
upon by all parties to the test. on engineering principles. Some examples are flow
calculated from an energy balance or a flow determined
by difference. Estimated indicates that the value of the
4.2 DATA REQUIRED parameter is estimated or agreed to by the parties to
the test. In general, estimated means that a reasonable
This Code addresses the methodology to determine
order of magnitude estimate can be made based on
separate performance characteristics including the fol-
experience from similar units, or, preferably, on previous
lowing:
.
tests on the unit. Examples are a contractually agreed
efficiency ash split or radiation loss.
output In these tables, the “Typical Influence” column desig-
0 capacity nates those parameters that typically have a major
steam temperaturekontrol range (primary) affect on the result and those items that are
33
Previous Page
is Blank
STD*ASME PTC 4-ENGL 3998 I0759670 Ob34975 073 H
TABLE 4.2-1
PARAMETERS REQUIRED FOR EFFICIENCY DETERMINATION BY ENERGY BALANCE METHOD
Calculation Reference Typical Typical
Acronym Parameter Section Influence [Note (113 Source [Note (2)l Remarks
QpLOFg DRY GAS LOSS 5.14.1 PRI

Fuel Analysis 4.12.3 PRI M
% O2 in Flue Gas 4.13.4 PRI M See Table 4.2-6
Flue Gas Temperature 4.4.3 PRI M See Table 4.2-5
MpUbc UNBURNED CARBON 5.10.3 SEC MIE See QpLUbc, Table 4.2.1
% Carbon in Residue 4.12.3.5 PRI M
Residue Split 4.7.8 PRI CIM
Sorbent Analysis 4.12.3.2 PRI M
||| | |---
Sorbent Rate 4.8 PRI M
Fuel Rate 4.7.7 PRI CIM See Table 4.2-12
|||| | || ||| | || ||
Yo CO, in Residue 4.12.3.5 PR I M
S0,/02 in Flue Gas 4.13.4 PRI M See Table 4.2-10
QpLHZF WATER FROM H2 I N FUEL LOSS 5.14.2 PRI M
| |||
|
| ||| | || | ||
QpLWF WATER FROM HO , I N FUEL LOSS 5.14.2 PR I M
QpL WvF Fuel Analysis 4.12.3 PR I M
~
--
QpLWA MOISTURE I N AIR LOSS 5.14.3 SEC MIE
Flue Gas O, 4.13.4 PRI M See Table 4.2-6
Dry-Bulb Temperature 4.15 PRI M
Wet-Bulb Temperature 4.15 PRI M
Or Relative Humidity 4.15 PR i M
Barometric Pressure 4.5.5 SEC M
QpLUbc UNBURNED CARBON RESIDUE 5.14.4 PRI M

LOSS
%O Carbon in Residue 4.12.3.5 PRI M
Residue Split 4.7.8 PRI M
Sorbent Analysis 4.12.3 PRI M
Sorbent Rate 4.8 PRI M See Table 4.2-12
Fuel Rate 4.7.5 PR I CIM
Yo CO2 in Residue 4.12.3 PRI M See Table 4.2-10
S02/02 in Flue Gas 4.13.4 PRI M
QpfHZRs UNBURNED H, I N RESIDUE LOSS 5.14.4 SEC E Normally zero

Items for Qpf übc PRI M See Qpf Ubc, Table 4.2-1
H2 in Residue 4.12.3 PRI M
QpLCO CO I N FLUE GAS LOSS 5.14.4 SEC MIE

Items for Excess Air PRI M See Table 4.2-6
CO in Flue Gas 4.13.3 PR I M
QpLPr PULVERIZER REJECTS LOSS 5.14.4 SEC E

Pulverizer Rejects Rate 4.7.5 PRI MIE
Pulverizer Rejects Analysis 4.12.3 PRI MIE
Pulverizer Outlet Temperature 4.4.3 PRI M
Fuel Rate 4.7.7 PR I CIM See Table 4.2-12
QpLUbHc UNBURNED HYDROCARBONS I N 5.14.4 SEC E

FLUE GAS LOSS
Hydrocarbons in Flue Gas 4.13.4 PRI M
HHV of Reference Gas ... PRI M
ícontinued)
34
TABLE 4.2-1 (CONT'D)

Acronym Parameter Section Influence [Note (1)l Source [Note (2)l Remarks
QpLRs SENSIBLE HEAT OF RESIDUE 5.14.5 PRI MIE
LOSS
Residue Split 4.7.8 PRI MICIE
Temp of Residue 4.4.5.1 PRI M
QpLAq HOT AIR QUALITY CONTROL 5.14.6 PRI M

EQUIPMENT LOSS
Flue Gas Temperature Entering 4.4.3 PRI M
Flue Gas Temperature Leaving 4.4.3 PRI M
?LO Oz in Flue Gas Entering 4.13.4 PRI M See Table 4.2-6
O h O2 in Flue Gas Leaving 4.13.4 PRI M See Table 4.2-6
~
Wet Gas Weight Entering 5.12.9 PRI C See Table 4.2-12

Wet Gas Weight Leaving 5.12.9 PRI C See Table 4.2-12
QpLALg AIR INFILTRATION LOSS 5.14.7 SEC M Normally NIA

Infiltrating Airflow 5.14.7 PRI M See Table 4.2-12
Infiltrating Air Temperature 4.4.3 PRI M
Exit Gas Temperature 4.4.3 PRI M See Table 4.2-6
QpLNO, FORMATION OF NO, LOSS 5.14.8 SEC MIE

NO, in Flue Gas 4.13.4 PRI MIE
Wet Gas Weight 5.12.9 PR I C See Table 4.2-12
QrLSrc RADIATION ANO CONVECTION 5.14.9 PRI M IE Normally estimated based

LOSS on suface area within
Steam Generator Surface Area ... PR I C envelope. See
--
Local Ambient Air Temperature 4.4.3 PRI MIE Subsection 5.14.9

| ||| | || | ||
Local Surface Temperature 4.4.3 PRI MIE

Local Surface Air Velocity 4.7 PRI E
Qrf WAd ADDITIONAL MOISTURE LOSS 5.14.10 SEC MIE

|
| |||
Mass Flow of Moisture 4.7.4 PRI MIE

|||| | || ||| | || ||
Feedwater Pressure 4.5.4 SEC M

Feedwater Temperature 4.4.4 PRI M
Fuel Flow 4.7.514.7.7 PR I CIM See Table 4.2-12
||| | |---
QrLClh CALCINATION DEHYDRATION OF 5.14.11 PRI M

SORBENTLOSS
Fuel Rate 4.7.514.7.7 PRI CIM See Table 4.2-12
Oho Carbon in Residue 4.12.3 PRI M
O h CO2 in Residue 4.12.3 PRI M
Residue Split 4.7.8 PRI MIE
S02/Oz in Flue Gas 4.13.4 PRI M See Table 4.2-10
QrL WSb WATER I N SORBENT LOSS 5.14.12 SEC M

QrLAp WET ASH PIT LOSS 5.14.13 SEC E Normally estimated.

QrAPW See Section 5.14.14
QrRsWL v for parameters
required when
measured.
QrL RY RECYCLED STREAMS LOSS 5.14.14 SEC M

Recycle Flow 4.7 PRI MIE
Recycle Temperature Entering 4.4.3 PRI M See Table 4.2-5
Recycle Temperature Leaving 4.4.3 PRI M
(continued)
35
~~~
STD-ASME PTC 4-ENGL 1998 0759670 Ob14977 944
TABLE 4.2-1 (CONT'D)

Acronym Parameter Section influence [Note (U1 Source [Note (2)l Remarks
QrLCw COOLING WATER LOSS 5.14.15 SEC MIE

Cooling Water Flow Rate 4.7.4 PRI MIE
Temperature of Water Entering 4.4.4 PRI M
Temperature of Water Leaving 4.4.4 PRI M
Fuel Rate 4.7.514.7.7 PRI CIM See Table 4.2-12
~
QrLAc AIR PREHEAT COIL LOSS (Energy 5.14.16 SEC M

Supplied from within Boundary)
APC Condensate Flow Rate 4.7.4 PRI MIC
APC Condensate Temperature 4.4.4 PRI M
APC Condensate Pressure 4.5.4 PRI M
~~
QpSDA ENTERING DRY AIR CREDIT 5.15.1 PRI M

Entering Air Temperature 4.4.3 PRI M See Table 4.2-5
EXCESS AIR 5.11.4 PRI M See Table 4.2-6
UNBURNED CARBON 5.10.4 SEC M/E See Qpf Ubc Table 4.2-1
SULFUR CAPTURE 5.9.5 PRI M See Table 4.2-10
QpBWA MOISTURE I N ENTERING AIR 5.15.2 SEC MIE

CREDIT
Items for QpSDA PRI M
Moisture in Air 4.15 PRI MIE
or Relative Humidity 4.15 PRI M
QPBF SENSIBLE HEAT I N FUEL CREDIT 5.15.3 SEC M

Fuel Temperature Entering 4.4 PRI MIE
QpSSlf SULFATION CREDIT 5.14.4 PRI M

S02/02in Flue Gas 4.13 PRI M See Table 4.2-10
Sorbent Rate 4.7.7 PRI M
Fuel Rate 4.7.5 PRI CIM See Table 4.2-12
% Carbon in Residue 4.12.3 PRI M
Oh COp in Residue 4.12.3 PRI M
QrüX AUXILIARY EQUIPMENT POWER 5.15.5 SEC MIClE

CREDIT
Steam Driven Equipment
Mass Flow of Steam 4.7.4 PR I M
Entering Steam Pressure 4.5.4 PRI M
Entering Steam Temperature 4.4.4 PR I M
Exhaust Pressure 4.5.4 PRI M
Drive Efficiency NA PRI EIM PTC 19.7
Electrical Driven Equipment
For Large Motors:
Watt Hour Reading NA PRI M I E E E Standard 120
Drive Efficiency NA PRI EIM PTC 19.7
For Small Motors:
Volts NA SEC M
Amps NA SEC M
QrBSb SENSIBLE HEAT I N SORBENT 5.15.6 SEC M

CREDIT
Sorbent Rate 4.7.5 PR I M
Sorbent Temperature 4.4.5 PRI M
ícontinuedl
36
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~~ ~
STD.ASME PTC 4-ENGL 1978 m 0759b70 Ob14978 880 m
TABLE 4.2-1 (CONT‘D)

QrBWAd ENERGY SUPPLIED BY 5.15.7 SEC MIE
ADDITIONAL MOISTURE
CREDIT
Mass Flow Rate 4.7.4 PRI M
Entering Temperature 4.4.4 PRI M
Entering Pressure 4.5.4 PRI M
NOTES:
(1) Typical influence: PRI = Primary, SEC = Secondary.
( 2 ) Typical Source: M = Measured, C = Calculated, E = Estimated.
TABLE 4.2-2
PARAMETERS REQUIRED FOR EFFICIENCY DETERMINATION BY INPUT-OUTPUT METHOD
Acronym Parameter Section influence [Note (111 Source [Note (2)l Remarks
QrF HEAT I N P U T FROM FUEL 5.5 PRI M

Fuel Rate 4.7.514.7.7 PRI M
Heating Value of Fuel 4.12 PRI M
--
QrO OUTPUT 5.4 PRI C See Table 4.2-3

| ||| | || | ||
NOTES:
(1) Typical Influence: PRI = Primary, SEC = Secondary.
|
| |||
|||| | || ||| | || ||
required but have a lesser (secondary) affect on result. starting with “Sorbent Analysis” and separated within
||| | |---
In some cases, the general parameter may have a the major parameter with a line.
secondary impact on the results, but the items required
to determine the parameter have a primary impact on
the parameter itself. For example, see “Unburned H2 4.3 GENERAL MEASUREMENT
in Residue Loss” in Table 4.2-1. REQUIREMENTS
The “Typical Source” column identifies acceptable
The methods for obtaining the required data detenhine
options for determining the parameter. These options are
the quality of the test. There are usually several ways
“measured,” “cakulated,” and “estimated.” “Typical”
to measure any given parameter. Each of these ways
indicates what is usual or common industry practice
has inherent measurement errors attributable to both
for this measurement. In many cases, the typical source
the process involved and the measurement system used.
choice may not be relevant for a particular unit; the
The test engineer must take all of this into account
test engineer’s responsibility is then to choose a method
when designing the test program.
which is consistent with the principles of this Code.
The method of obtaining the data typikally involves
The determination of some parameters such as flue
the use of a measurement system. This measurement
gas constituents can be extensive. Either a table or
system consists of four parts:
portion of a table is devoted to these types of parameters.
When these items are required to determine other 0 primary element
characteristics, the general parameter is noted, and the 0 sensing device
applicable table referenced. When sorbent is used, 0 data collectiodmeasurement device
parameters related to sorbent are grouped separately data storage device
37
~
STD-ASME PTC 4-ENGL 1998 0759670 Ob14979 717
TABLE 4.2-3
PARAMETERS REQUIRED FOR CAPACITY DETERMINATION
Typical
Influence Typical
Calculation Reference [Note Source
Acronym Parameter Section (111 [Note (2)l Remarks
QrO OUTPUT 5.4 PRI C

Saturated Steam Generator 5.4.1.1
Saturated Steam Flow 4.7.4 PRI M
Feedwater Flow 4.7.4 PRI M
Blowdown Flow 5.4.5 PRI MIE
Extraction Flow 4.7.4 PRI M
Saturated Steam Pressure 4.4.4 PRI M
Superheated Steam Generator 5.4.1.2
Main Steam Flow 4.7.4 PRI M
Blowdown Flow 4.7.4 SEC MIE
Extraction Flow 4.7.4 PRI M
Desuperheating Spray Flow 4.7.4 PRI CIM
Main Steam Temperature 4.4.4 PRI M
Main Steam Pressure 4.5.4 PRI M
Desuperheating Spray Water Temperature 4.4.4 PRI M
Desuperheating Spray Water Pressure 4.5.4 SEC M
Reheat Steam Generator 5.4.2
Reheat Steam Flow 5.4.2.1 PRI CIM See PTC 6
Reheat Desuperheating Spray Water Flow 4.7.4 PRI M
Feedwater Heater Extraction Flow 5.4.2.1 PRI CIM
Feedwater Heater Extraction Temperature 4.4.4 PRI M
Feedwater Heater Extraction Pressure 4.5.4 PRI M
Feedwater Heater Entering Water Temperature 4.4.4 PRI M
Feedwater Heater Leaving Water Temperature 4.4.4 PRI M
Feedwater Heater Water Pressure 4.5.4 SEC M
Feedwater Water Drain Temperature 4.4.4 PRI M
Turbine Leakage NA SEC E
Steam Extraction Flow (Other) 4.7.4 PRI M
Reheat Out Steam Temperature 4.4.4 P RI M
Reheat Out Steam Pressure 4.5.4 PR I M
Reheat I n Steam Temperature 4.4.4 PRI M
Reheat I n Steam Pressure 4.5.4 PRI M
Reheat Desuperheating Spray Water Temperature 4.4.4 PRI M
Reheat Desuperheating Spray Water Pressure 4.5.4 SEC M
Auxiliary Steam 5.4.3
Auxiliary Steam Flow 4.7.4 PRI MIE
Auxiliary Steam Temperature 4.4.4 PRI M
Auxiliary Steam Pressure 4.5.4 PRI M
Feedwater Temperature 4.4.4 PR I M
NOTES:
(2) Typical Source: M = Measured, C = Calculated, E = Estimated.
38
-- | ||| | || | || | | ||| |||| | || ||| | || || ||| | |---
TABLE 4.2-4
PARAMETERS REQUIRED FOR STEAM TEMPERATURUCONTROL RANGE DETERMINATION
~ ~~ ~~

Acronym Parameter Section Influence [Note (111 Source [Note (211 Remarks
--
Superheated Steam Generators 5.4.1.2 The primary

Main Steam Flow 4.7.4 PR I M measurements are listed
| ||| | || | ||
Blowdown Flow 4.7.4 PRI MIE here. All items needed

Extraction Flow 4.7.4 PRI M for output are required.
Main Steam Temperature 4.4.4 PRI M
|
Main Steam Pressure

| |||
4.5.4 PRI M
Drum Pressure (if applicable) 4.5.4 PRI M
|||| | || ||| | || ||
Drum Level
Feedwater Temperature 4.4.4 P RI M
Desuperheated Spray Water Flow 4.7.4 PRI M
||| | |---
Desuperheated Spray Water

Temperature 4.4.4 PRI M
Desuperheated Spray Water Pressure 4.5.4 SEC M
Other Items Required to Determine
output 5.4 SEC MICIE
Reheat Steam Generators 5.4.2 See Table 4.2-3
Reheat Steam Flow 5.4.2.1 PR I C IM
Reheat Out Steam Temperature 4.4.4 PRI M
Reheat Out Steam Pressure 4.5.4 PRI M
Reheat I n Steam Temperature 4.4.4 PRI M
Reheat Out Steam Pressure 4.5.4 PRI M
Reheat Desuperheating Spray Water
Flow 4.7.4 PRI M
Temperature 4.4.4 PRI M
Pressure 4.5.4 SEC M
Related Parameters
Excess Air 5.11.4 M
Gas Proportioning Damper M
Flue Gas Recirculation Flow M
Blowdown 5.4.4
NOTES:
The primary element provides access or causes an recording instruments may increase test uncertainty
effect which the sensing device measures, typically by beyond agreed-upon limits. All instruments must be
converting it to a proportional electrical signal. This checked to verify that they are the specified type,
electrical signal is then either converted to a digital properly installed, working as designed, and functioning
value and stored electronically or sent to a chart recorder over the range of input expected.
or analog meter.
4.3.2 Calibration. The parties to the test shall agree
4.3.1 Type of Equipmentnnstallation. In general, on which instruments will be calibrated for the test.
measuring equipment should be selected to minimize This Code requires that, as a minimum, relevant compo-
test uncertainty. In particular, critical parameters should nents of ail instrumentation loops have been initially
be measured with instruments that have sufficient accu- aligned (the zero offsets or spans have been adjusted
racy to ensure that target uncertainties will be achieved. to their respective specifications). Calibrations prior to
Typical station recording instruments are designed for and following the tests shall be against standards whose
reliability and ease of use and maintenance, rather than calibrations are traceable to the National Institute of
for accuracy. Therefore, measurements made by station Standards and Technology (NIST) or other recognized
39
ASME Fl'C 4-1998 FRED STEAM GENERATORS
TABLE 4.2-5
PARAMETERS REQUIRED FOR EXIT FLUE GAS AND AIR ENTERING
TEM PERATURE DETER MI NATIONS
Typical Typical
Calculation Reference Influence Source
Acronym Parameter Section CNote (111 CNote (2)l Remarks
No Air Heater
Flue Gas Temperature Leaving Steam Generator 4.4.3 PRI M
Air Temperature Entering Steam Generator 4.4.3 PRI M
Single Bisector Type Air Heater

O2 Entering Air Heater 4.10 PRI M
Oz Leaving air Heater 4.10 PRI M
Flue Gas Temperature Entering Air Heater 4.4.3 PRI M
Flue Gas Temperature Leaving Air Heater 4.4.3 PRI M
Air Temperature Entering Air Heater 4.4.3 PRI M Flue gas temperature enter-
ing is ony required for
correction to reference.
Primary Secondary Air Heaters

Items Above for Bisector Air Heater PRI
Plus:
Air Temperature Leaving Each Air Heater 4.4.3 PRI M
Primary Air Flow Leaving Air Heater 4.7.3 PRI CIM
Tempering Air Flow 4.7.3 SEC C
Tempering Air Temperature 4.4.3 PRI M
Mixed Air Flow 4.7.3 PRI CIM
Mixed Air Temperature 4.4.3 PRI M
Items Required for Efficiency PRI See Table 4.2-1
Items Required for Output PRI See Table 4.2-3
Trisector Type Air Heders

Items Above for Single Air Heater PRI
Secondary Air Temperature Entering Air Heater 4.4.3 PRI M
Secondary Air Temperature Leaving Air Heater 4.4.3 PRI M
Primary Air Temperature Entering Air Heater 4.4.3 PRI M
Primary Air Temperature Leaving Air Iieater 4.4.3 PRI M
Primary Air Flow Leaving Air Heater 4.7.3 PRI CIM
Tempering Air Flow 4.7.3 PRI M
Tempering Air Temperature 4.4.3 PR I M
Mixed Air Flow 4.7.3 PRI M
Mixed Air Temperature 4.4.3 PRI M
Items Required for Efficiency PRI See Table 4.2-1
Items Required for Output PRI See Table 4.2-3
NOTES:
--
| ||| | || | ||
international standard. All measurements should be used plus other bias influences. These influences may
corrected for any calibrations before use in the perform- include environmental influences on the instrument as
|
ance calculations; otherwise, the bias estimate must be well as bias introduced due to nonuniformity of mea-
| |||
increased to the reference accuracy plus other bias sured medium.

|||| | || ||| | || ||
influences described below. Reference accuracy is the Certain insirumentation should be calibrated immedi-
bias a user may expect to achieve in the absence of ately prior to and immediately following the testing
a calibration after the instrument is initially adjusted period to determine the amount of drift. If the pretest
||| | |---
in accordance with the manufacturer's specification. and post-test calibrations differ, the amount of drift
This bias is reduced when adjustments are made to an shall be determined and one half added to the bias
instrument to align it to a reference standard. The bias estimate for the instrument. Drift is assumed to be
then becomes the accuracy of the reference standard linear with time. Therefore, the average of the pretest
40
~
STD-ASME PTC 4-ENGL 1998 = 0757670 0614982 2 0 1 W
TABLE 4.2-6
PARAMETERS REQUIRED FOR EXCESS AIR DETERMINATION
XPA EXCESS AIR 5.11.4 M

MpUbc UNBURNED CARBON 5.10.3 PRI CIE

YO Carbon in Residue 4.12.3 PRI M
% O, in Flue Gas 4.13.4 PRI M
Oz W E T BASIS
MFr WA MOISTURE I N AIR 5.11.2 PRI CIE
Or Relative Humidity 4.15 P RI M
Additional Moisture 4.7.4 PRI M
MoFrCaS Sorbent Analysis 4.12.3 PRI M

CdS MOLAR RATIO 5.9.6 PRI CIE
Fuel Rate 4.7.5f4.7.7 PRI CfM See Table 4.2-12
MFrCIhk CALCINATION 5.10.8 PRI CIE

YOCOz in Residue 4.13.4 PRI M
MFrSc SULFUR CAPTURE 5.9.5 PRI CIE

SO2fO2 in Flue Gas 4.13.4 P RI M See Table 4.2-10
NOTES:
and post-test calibrations shall be used for the calibration device should be calibrated against a standard which
value. has a calibration traceable to the NIST or other intema-
In general, the best methodology for calibrating the tionally recognized standard. The sensing element
test instrumentation is to calibrate the entire system. should be compared to at least four different tempera-
This is accomplished by introducing a known input to tures. The temperatures selected for calibration should
a sensing device and comparing the result on the span the range of the anticipated values expected during
recording device to the known value. An example of the test. Thermocouples must be heat soaked prior to
this is the introduction of a known pressure to a calibration to ensure that shifts in output do not occur
transmitter mounted at its measurement location and after calibration.
connected to the data acquisition, measurement, and
recording system. Using this approach, effects of the 4.3.2.2 Pressure or Differential Pressure. The
installation such as a high temperature environment or sensing device should be calibrated with an NIST
wiring connections are thus included in the calibration traceable pressure standard at five different pressures.
experiment. Any calibration should be performed at a The pressures should be recorded at atmospheric (zero),
minimum of three different points bracketing the highest 25% full scale, 50% full scale, 75% full scale, and
and lowest value in the range expected to be measured full scale. The pressure should be recorded at each point
during the test. while pressure is increased and again while pressure is
decreased and the average should be used. The differ-
4.3.2.1 Temperature. Temperature sensing devices ence should be considered in the bias estimate.
can be calibrated when it is desired to reduce the
uncertainty of the parameter. The level of the standard 43.23 Flue Gas Analysis. Analyzers used to mea-
(interlaboratory, transfer, etc.) used in the calibration sure oxygen, carbon monoxide, oxides of nitrogen, and
sets the reference accuracy. The temperature sensing total hydrocarbons shall be calibrated immediately prior
41
-- | ||| | || | || | | ||| |||| | || ||| | || || ||| | |---
STDmASNE PTC 4-ENGL 3998 9 0759b70 Ob14983 I148 9
ASME Pn= 4-1998 FRED STEAM GENERATORS
TABLE 4.2-7
PARAMETERS REQUIRED FOR WATEWSTEAM PRESSURE DROP DETERMINATIONS
Acronym Parameter Section Influence [Note (U1 Source [Note (211 Remarks
SUPERHEATER PRESSURE DROP 5.17 MIC
Superheater Outlet Pressure 4.5.4 PR I M
Superheater Inlet (Drum) Pressure 4.5.4 PRI M
Main Steam Flow 4.7.4 PRI M
Blowdown Flow 4.7.4 SEC MIE
Exraction Flow 4.7.4 PR I M
Superheater Spray Flow 4.7.4 PRI CIM
Superheater Outlet Steam 4.4.4 SEC M
Temperature
Superheater Inlet Steam 4.4.4 SEC M Supercritical Units
Temperature
REHEATER PRESSURE DROP 5.17 MIC
||| | |---
Reheater Inlet Steam Pressure 4.5.4 P RI M
Reheater Outlet Steam Pressure 4.5.4 PR I M
|||| | || ||| | || ||
Reheater Steam Flow 5.4.2.1 PRI CIM See Table 4.2-3
Feedwater Heater Extraction Flow 5.4.2.1 PRI CIM
Turbine Leakage NA SEC E
Steam Extraction Flow 4.7.4 PRI M
| |||
Reheater Spray Water Flow 4.7.4 PR I M
|
Reheater Inlet Steam Temperature 4.4.4 SEC M
| ||| | || | ||
Reheater Outlet Steam Temperature 4.4.4 SEC M
ECONOMIZER PRESSURE DROP 5.17 MIC

Economizer Water Inlet Pressure 4.5.4 PRI M
--
Economizer Water Outlet (Drum) 4.5.4 PR I M
Pressure
Feedwater Flow 4.7.4 PR I M
Superheated Spray Water Flow 4.7.4 PRI MIC
Economizer Water Inlet 4.4.4 SEC M
Temperature
Economizer Water Outlet 4.4.4 SEC M
Temperature
NOTES:
to a test, and calibration shall be checked for drift calibrated on one range and the measurement during
immediately following a test. These calibrations are the test is performed on another, a post-test Calibration
performed using certified calibration gases for zero, check shall be performed on the second range. Potential
full span, and midpoint. Calibration gases must be EPA biases introduced by the sampling system should be
Protocol I quality gases or gases which have been verified by the introduction of calibration gases into
compared to EPA Protocol I gases on a calibrated the sampling system at the probe after the instrumenta-
analyzer. Additionally, no calibration gas shall be used tion has been properly calibrated. Any deviation from
when the pressure in the cylinder is lower than 100 what the instruments read when the gas is introduced
psi to ensure that atmospheric air does not contaminate directly versus when fed through the sampling system
it. The calibration gas used for full span standard must indicates a sampling system bias. If significant bias is
exceed the largest expected value by 10%. The span observed, the sampling system design should be re-
gas used for the post-test calibration check must exceed viewed to reduce or eliminate this bias. Certain materials
the largest measured value by 10%. If the analyzer is may absorb gases until saturated and then release them
42
~
STD-ASME PTC 4-ENGL 1778 0759b70 Ob14984 O84
FìRED STEAM GENERATORS ASME PTC 4-1998
TABLE 4.2-8
PARAMETERS REQUIRED FOR AIWFLUE GAS PRESSURE DROP DETERMINATIONS
Typical Typical
Calculation Parameter Reference Influence Source
Acronym [Note (1)l Section [Note (211 [Note (3)l Remarks
AIR SIDE RESISTANCE 5.17.3 MIC
Forced Draft Fan Discharge Pressure 4.5.3 PRI M
||| | |---
Air Heater Air Inlet Pressure 4.5.3 PRI M
Air Heater Air Outlet Pressure 4.5.3 PRI M
|||| | || ||| | || ||
Windbox Pressure 4.5.3 PR I M
Furnace Pressure 4.5.3 PRI M
Air Flow 5.11.6 PRI C See Table 4.2-12
[Note (4)l
| |||
Main Steam Flow 4.7.4 SEC M
|
Air Temperature 4.4.3 SEC M
| ||| | || | ||
GAS SIDE RESISTANCE 5.17.3 MIC
Furnace Pressure 4.5.3 PRI M
Superheater Inlet Pressure 4.5.3 PRI M
--
Superheater Outlet Pressure 4.5.3 PRI M
Reheater Inlet Pressure 4.5.3 PRI M
Reheater Outlet Pressure 4.5.3 PR I M
Generating Bank Inlet Pressure 4.5.3 PRI M
Generating Bank Outlet Pressure 4.5.3 PRI M
Economizer Inlet Pressure 4.5.3 PRI M
Economizer Outlet Pressure 4.5.3 PRI M
Air Quality Control Equipment Inlet Pressure 4.5.3 PRI M
Air Quality Control Equipment Outlet Pressure 4.5.3 PRI M
Air Heater Gas inlet Pressure 4.5.3 PRI M
Air Heater Gas Outlet Pressure 4.5.3 PRI M
Flue Gas Flow Rate 5.12.9 PRI C See Table 4.2-12
[Note (413
Main Steam Flow 4.7.4 SEC M
Flue Gas Temperature 4.4.3 SEC M
NOTES:
( 1 ) Typical intermediate pressures are shown for evaluation of system resistance.
( 2 ) Typical Influence: PRI = Primary, SEC = Secondary.
( 4 ) Air gas side flow rates are required for corrections to reference conditions.
when concentrations are lower. This hideout phenome- tant parameters during the time data are being collected
non can be resolved by replacing the offending materials at greater than 2 minute intervals, the time interval
with more inert material. between data collections should be decreased to no
4.3.3 Frequency of Measurements. Because of fuel longer than 2 minutes. The resulting increase in the
variability, control system tuning, and other factors, quantity of data provides a greater statistical base
variations in operational parameters are inevitable. To from which to determine performance, and reduces the
minimize the uncertainty, more measurements are taken precision component of uncertainty.
during the test to reduce precision errors in the data The use of automated data collection devices is
collected. The frequency of data collection has a direct preferred. In most modem data acquisition devices,
correlation to the test uncertainty. Quantity measure- AID accuracy is no longer an issue; most have at least
ments, e.g., fuel measured by volumetric or weigh 14 bit accuracy. The major issue involves Distributed
tanks, are made at a frequency dictated by the collection Control Systems (DCS) which use exception-based re-
device. Other data collection should be at a maximum porting. This method utilizes a deadband approach with
interval of 15 minutes and a preferred interval of 2 which no change in the value is reported unless it
minutes or less. If fluctuations are noted on any impor- exceeds a given percentage. This type of system is
43
ASME FIT 4-1998 FIRED STEAM GENERATORS
TABLE 4.2-9
PARAMETERS REQUIRED FOR AIR INFILTRATION DETERMINATION
Typical Typical
Calculation Reference Influence Source
Acronym Parameter Section [Note (1)l [Note (211 Remarks
INFILTRATION BASE0 ON MEASURED O:, 5.17.6

EXGESS AIR ENTERING COMPONENT 5.11.4 PRI C See Table 4.2-6
Flue Gas O, Entering Component 4.13.4 PRI M
EXCESS AIR LEAVING COMPONENT 5.11.4 PRI C See Table 4.2-6
Flue Gas O2 Leaving Component 4.13.4 PRI M
INFILTRATION BY ENERGY BALANCE 5.17.6 C
FLUE GAS RATE ENTERING AIR HEATER 5.12.9 PRI C See Table 4.2-12
Flue Gas O2 Entering Air Heater 4.13.4 PRI M
Fuel Analysis 4.12.3 SEC M
Flue Gas Temperature Entering Air Heater 4.4.3 PR I M
Flue Gas Temperature Leaving Air Heater 4.4.3 PRI M
Air Temperature Entering Air Heater 4.4.3 PR I M
Air Temperature Leaving Air Heater 4.4.3 PRI M
Moisture in Air 4.15 SEC MIE
NOTES:
||| | |---
unacceptable unless the deadband can be set to approxi- point-by-point data results in fewer complete sets of
|||| | || ||| | || ||
mately zero for test measurements. data being obtained. Therefore, this Code only recom-
mends flow weighting when the bias limit due to flow
4.3.4 Weighted Parameters. The flue gas temperature
weighting is significantly large.
is needed to determine the sensible heat in a flue gas
| |||
stream. Because the temperature varies across the duct 43.4.1 Applicability of Flow Weighting. The exis-
|
cross section, the proper temperature to use is an
| ||| | || | ||
tence of stratification of the flue gas and its effect on
integrated average (see Subsection 7.2.3). Because the uncertainty can be determined by a temperature or by
sensible heat is the objective, the variation in mass a preliminary traverse.
flow or stratification should be taken into account.
--
The temperature traverse is useful when an existing
Ideally, this is done by simultaneously measuring the temperature grid is available to eliminate concerns of
flue gas velocity, oxygen, pressure, and temperature at stratification. Using the temperature data from the grid,
all points in the grid. Weighting factors based on the an estimate for the flow weighted temperature is made
relative mass flow in the local area can be applied to using the ratio of absolure temperatures to approximate
the measured temperatures. Weighting factors based on the velocity weighting factors:
velocity are also applied to flue gas oxygen concentra-
tion measurements.
Although the theoretically correct weighting is by
-VI TI + 459.7
mass flow (weighting factors are the product of density -=- -
V T + 459.7
and velocity) for temperature and by volume flow
(weighting factor is velocity) for oxygen, this Code
recommends that only velocity weighting be used in If the difference between the weightec. and unweighted
either case so that the procedure is as simple and as temperatures (AT) calculated using this approximation
practical as possible. exceeds 2°F @e., if the bias estimate exceeds 4"F,
In some cases, flow weighting can decrease the error refer to Subsection 7.5.3.3), the parties to the test may
in the results of a performance test; in other cases, wish to consider a preliminary velocity traverse to aid
flow weighting can increase the error. This latter case in deciding whether to employ flow weighting.
can occur when velocity is not determined simultane- A preliminary velocity traverse can also be performed
ously with temperature and oxygen data, when velocity to determine if stratification will result in high bias
data are inaccurate, or when the time required to obtain limit and if flow weighting should be considered. First,
44
STD.ASME PTC 4-ENGL 1998 0759670 OhL4ïôb 957 H
FIRED STEAM GENERATORS ASME pM3 4-1998
TABLE 4.2-10
PARAMETERS REQUIRED FOR SULFUR CAPTURURETENTION DETERMINATION
Acronym Parameter Section Influence [Note (111 Source [Note (213 Remarks
--
MFrSc SULFUR CAPTURE RETENTION 5.9.5

SOz in Flue Gas 4.13.4 PRI M
| ||| | || | ||
O, in Flue (Same Location as SOz) 4.13.4 PRI M

~ ~ ~
MFrWA GAS ANALYSIS WET BASIS 5.11.2 PRI CIE

|
MOISTURE I N AIR
| |||
Dry-Bulb Temperature 4.15 PR I M

|||| | || ||| | || ||
Wet-Bulb Temperature 4.15 PR I M

Or Relative Humidity 4.15 PRI M
Additional Moisture 4.7.4 PRI MIE
Fuel Analysis 4.12.3 PRI MIE
||| | |---
~~
MpUbc UNBURNED CARBON 5.10.3 PRI CIE

% Carbon in Residue 4.12.3 PRI M
~ ~ ~~ ~
MoFrCaS Cals MOLAR RATIO 5.9.6 PRI CIE

Fuel Rate 4.7.5 PRI C
MFrClhk CA LC INAT1O N 5.10.8 PRI CIE

% CO2 in Residue 4.12.3 PRI M
NOTES:
TABLE 4.2-11
PARAMETERS REQUIRED FOR CALCIUM TO SULFUR MOLAR RATIO DETERMINATION
MoFrCaS CdS MOLAR RATIO 5.9.6 C

YO CO2 in Residue 4.12.3 PRI M
OO
/ Carbon in Residue 4.12.3 PRI M
Residue Split 4.7.8 PRI FIM
Fuel Analysis 4.7.514.7.7 PRI M
Sorbent Rate 4.7.7 P RI M
Fuel Rate 4.7.5 PRI C
SULFUR CAPTURE 5.9.5 SEC CIE See Table 4.2-10
S02102 in Flue Gas 4.13.4 PRI M
NOTES:
45
STD.ASME PTC II-ENGL 1998 = 0759670 Ob14987 893 9
TABLE 4.2-12
PARAMETERS REQUIRED FOR FUEL, AIR, AND FLUE GAS FLOW RATE DETERMINATIONS
--

| ||| | || | ||
Qrl INPUT FROM FUEL 5.5

|
Fuel Rate (measured) 4.7.7 PRI M

| |||
Fuel Rate (calculated) 5.7.7 PRI C

|||| | || ||| | || ||
QrO output 5.4 PRI M See Table 4.2-3

EF Fuel Efficiency 5.7.1 PRI C See Table 4.2-1
@?A WET AIR FLOW RATE 5.11.6 C

||| | |---
MrA EXCESS AIR 5.11.4 PRI C See Table 4.2-6

MOISTURE I N AIR 5.11.2 PRI C See Table 4.2-6
Wfg WET GAS FLOW RATE 5.12.9 C

MrFg Fuel Analysis 4.12.3 PR I M
UNBURNED CARBON 5.10.3 PRI MIE
YO Carbon in Residue 4.12.3.5 PRI M
EXCESS AIR 5.11.4 PRI MIE See Table 4.2-6
MOISTURE I N AIR 5.11.2 PRI M/E
Additional Moisture 4.7.4 PRI M/E

C d S MOLAR RATIO 5.9.6 PRI MIE
CALCINATION 5.10.8 PRI MIE
SULFUR CAPTURE 5.9.5 PRI MIE
NOTES:
the differences between flow-weighted averages and to flow weight, flow weighting shall be applied as
non-weighted averages are calculated: fol10ws.
Prior to any weighting, the “velocity” raw data
(typically velocity pressure and pitch and yaw angles)
should be reduced to determine velocity normal to the
traverse plane. The (space and time) average velocity
should be calculated so that the weighting factors are
V;lV.
where ABS is the absolute value function. (These Two approaches may be considered for flow
differences estimate the bias due to not flow weighting using velocity factors. The first is to use the
weighting.) Then: preliminary velocity weighting factors with the test
0 If AT is less than 3°F and/or AO2 is less than 0.2%, measurements for temperature and (less frequently)
flow weighting should not be used. oxygen, as discussed in the previous Subsection. The
0 If AT is greater than 3’F or AO2 is greater than 0.2%, second is to traverse each grid point during the test to
three or more complete traverses are required to vali-
measure temperature, velocity, and oxygen. (Sometimes,
date the velocity distribution, else flow weighting may only temperature and velocity are measured, with oxy-
not be used. If the velocity factors have been verified, gen measured as a composite sample and therefore not
then the parties to the test shall decide if flow flow weighted.) Each method has the potential for
weighting is to be used. introducing error in the averages calculated from the
data. In addition to the error in velocity determination,
43.4.2 Flow Weighting Method.If it is determined the first method introduces error by assuming that the
that flow weighting is applicable and the parties elect test-time velocities are identical to those measured in
46
STD*ASME PTC 4-ENGL 1998 = 0759b70 ObL49öô 72T
FIRED STEAM GENERATORS ASME FTC 4-1998
the preliminary traverse(s). The error associated with sample. Obviously, all leaks should be found and
the second method is more subtle. The time required repaired prior to the beginning of the test, although it
to traverse each point is usually sufficiently large that is recognized that a small leak could occur during the
only a few repeated measurements at each point (that test, or a very small leak may not be found prior to
is, only a few repeated traverses) are made, thus testing. All of these biases must then be combined into
increasing the precision error. An additional error may a single value for the parameter.
be introduced by the variation of the test conditions Since data collection and storage are often the same
over time so that values measured at a point near the for many parameters, the biases associated with these
end of a traverse do not correspond to those measured portions of the measurement system warrant discussion
at another point near the beginning of the traverse. next. Following the discussion of the data collection
The following rules should be used when performing system, each of the different types of process measure-
simultaneous velocity, temperature, and oxygen tra- ments will be discussed along with the biases associated
verses during a test run: with their primary elements and sensing devices. Other
sources which may be referenced for typical values of
0 There should be no fewer than three complete traverses bias include other ASME publications such as MFC-
per test run. 3M, Measurement of Fluid Flow in Pipes Using Orifice,
0 Flow weighting of O2 should be considered only if Nozzle, and Venturi; FTC 19.2, Instruments and Appara-
AO2 is greater than 0.2% and three or more complete tus: Part 2 Pressure Measurement; PTC 19.3, Tempera-
traverses have been performed during the test run. ture Measurement; I S 0 5 167, Flow Measurement; ap-
0 The values of ATand AO2must be repeatable between propriate ASTM standards; and instrument manufacturer
the test runs. If the value for either AT or AO2 for specifications.
any traverse differs by more than 33% from the aver- Estimating the bias in a measurement involves the
age value for all traverses, the most likely cause is evaluation of all components of a measurement system,
bad velocity data and data from that traverse must be such as those listed in Tables 4.3-1 through 4.3-5.
rejected. These biases, however, may not be representative of
During each test run, a velocity probe should be any specific measurement situation and tend to be
located at a fixed point where the velocity is approxi- conservative. It would be misleading for this Code to
mately equal to the average value, the temperature is mandate specific values for bias and values must be
approximately equal to the average value, and the agreed upon by parties to the test.
oxygen content is approximately equal to the average Many instrument specifications provide a reference
--
value. The velocity, temperature, and oxygen at this accuracy. This accuracy is only a part of the potential
| ||| | || | ||
point should be recorded with the same frequency as bias of that instrument. Other factors such as drift,
the traverse points (that is, the data should be recorded nonuniformity of flowing fluid, vibration, and differ-
ences between assumed and actual water leg density
|
each time the data at any traverse point is recorded).

| |||
The resulting large number of data for the single point can influence the measurement. Often the reference
|||| | || ||| | || ||
can be used to estimate the precision error of the accuracy of an instrument can be improved through
weighted average, as described in Subsection 7.4.1.3 calibration. After a calibration, the accuracy of the
and Subsection 5.2.4.2. reference standard and the repeatability of the instrument
can be combined to determine the new accuracy of the
||| | |---
4.3.5 Determination of Bias Due to Measurements. instrument.

Estimating the bias is a key step in designing the test The assignment of the appropriate bias requires the
and selecting instrumentation. The total bias associated full knowledge of the test measurement system, the
with a particular measurement is the result of several process being tested, and all other factors which may
biases in the measurement system. Section 7.5 describes influence the bias of the measurement. The test engineer
the process of combining the biases. For each parameter is in the best position to evaluate these factors, and
in the test program, all possible sources of measurement can use Tables 4.3-1through 4.3-5 as a tool to assist
system error associated with that parameter should be in assigning values for measurement biases.
determined. All of the components of the system should When parameters are estimated rather than measured,
be examined to estimate their bias. the values for estimates and for bias limits shall be
Outside factors which influence the measurement agreed upon by the parties to the test. The test engineer
should be considered. Factors such as an air leak into can usually arrive at reasonable values by considering
a flue gas analyzer should be considered and included that the probability is approximately 19:l (95% confi-
as a one-sided bias, since a leak can only dilute the dence level) that the upper and lower limits will not
47
~~
STD-ASME PTC 4-ENGL 1798 0759b70 Obi14789 bbb m
ASME F K 4-1998 FIRED STEAM GENERATORS
TABLE 4.3-1
POTENTIAL INSTR U M ENTATION BIAS LIMITS
Instrument Bias Limits [Note (1)l
Data Acquisition Note (2)
Digital Data Logger Negligible
Plant Control Computer i 0.1%
Hand-Held Temperature Indicator 5 0.25%
Hand-Held Potentiometer (including reference junction) 2 0.25%
Temperature Note (3)

Thermocouple
NIST Traceable Calibration Note (4)
Premium Grade Type E
32-600°F i 2OF
600-1,600°F 2 0.4%
Premium Grade Type K
32-53OoF i 2°F
530-2,300°F i 0.4%
Standard Grade Type E
32-6OO0F i 3OF
600-1,6OO0F i 0.5%
Standard Grade Type K
32-530'F i 4°F
530-2,3OO0F 2 0.8%
Resistance Temperature Device (RTD)
NIST Traceable Calibration Standard Note (4)
32OF 2 0.3%
200OF i 0.0%
4OOOF 2 1.3%
57OoF i 1.8%
750°F i 2.3%
93OOF i 2.89b
l,lOO°F 2 3.3%
1,30OoF i 3.8%
Temperature Gauge i 2% of span
Mercury-in-Glass Thermometer i 0.5 gradation
Pressure Note (5)

Gauge
Test i 0.25% of span
Standard i 1%of span
Manometer & 0.5 gradation
Transducer and Transmitter
High Accuracy i O . 1 % of span
Standard I 0.25% of span
Aneroid Barometer I 0.05 in. Hg
Weather Station Note ( 6 )
~~
(continued)
48
-- | ||| | || | || | | ||| |||| | || ||| | || || ||| | |---
FIRED STEAM GENERATORS ASME F E 4-1998
TABLE 4.3-1 (CONT’D)

POTENTIAL INSTRUMENTATION BIAS LIMITS
Instrument Bias Limits [Note (111
Vel oc ity
Standard Pitot Tube
Calibrated 2 5 % [Note ( 7 ) l
Uncalibrated I 8% [Note (713
S-Type Pitot Tube
Calibrated 2 5% [Note (713
Uncalibrated i 8% [Note ( 7 ) l
3-Hole Probe
Calibrated i 2% [Note (7)1
Uncalibrated 2 4 % [Note ( 7 ) l
Hot Wire Anemometer I 10%
Turbometer I 2%
Flow (Air and Gas)

Multipoint Pitot Tube (Within Range)
Calibrated and Inspected (Directional Velocity Probe) i 5%
Calibrated with S-Type or Standard 2 10%
Uncalibrated and Inspected i 8%
Uncalibrated and Uninspected I 20%
Airfoil
Calibrated 2 5%
Uncali brated I20%
~~~ ~
Flows (Steam and Water) Note ( 8 )

Flow Nozzle
PTC 6 (With Flow Straighteners)
Calibrated and Inspected I0.25%
Uncalibrated and Inspected 2 2.5%
Uncalibrated and Uninspected i 5%
Pipe Taps
Calibrated and Inspected I 0.50% steam 2 0.40% water
Uncalibrated and Inspected i 2.2% steam I 2.1% water
Uncalibrated and Uninspected New plant: see above
Existing plant: variable
Venturi
Throat Taps
Calibrated and Inspected i 0.50% steam i 0.40% water
Uncalibrated and Inspected I 1.2% steam I 1.1% water
Orifice
Calibrated and Inspected I0.50% steam t 0.40% water
Uncalibrated and Inspected i 0.75% steam I 0.70% water
Weir t 5%
Blowdown Valve I15%
(continued)
49
-- | ||| | || | || | | ||| |||| | || ||| | || || ||| | |---
~~
STD=ASME PTC 4-ENGL 1998 m 0759670 Ob14991 214 m

POTENTIAL INSTRUMENTATION BIAS LIMITS
Liquid Fuel Flow (Calibrated)
Flow Meter
Positive Displacement Meter 2 0.5%
Turbine Meter 2 0.5%
Orifice (for larger pipes, uncalibrated) z 1.0%
Weigh Tank 2 1%
Volume Tank 2 4%
Gaseous Fuel Flow Note (1)

Orifice
Calibrated and Inspected 20.5%
Calibrated and Uninspected 2 2%
Uncalibrated and Inspected 2 0.75%
||| | |---
Turbometers
Non Self-correcting t 1.0%
|||| | || ||| | || ||
Self-correcting 2 0.75%
Solid Fuel and Sorbent Flow

Gravimetric Feeders
Calibrated with Weigh Tank 2 2%
| |||
Calibrated with Standard Weights t 5%
|
Uncalibrated t 10%
| ||| | || | ||
Volumetric Feeders
Belt
Calibrated with Weigh Tank _t 3%
--
Uncal i brated t 15%
Screw, Rotary Valve, etc.
Calibrated with Weigh Tank t- 5%
Uncalibrated 2 15%
Weigh Bins
Weigh Scale f 5%
Strain Gauges t 8%
Level t 10%
Impact Meters t 10%
Residue Flow
Isokinetic Dust Sampling t 10%
Weigh Bins
Weigh Scale 2 5%
Strain Gauges 2 8%
Level 2 20%
Screw Feeders, Rotary Valves, etc.
Calibrated with Weigh Tank 2 5%
Uncalibrated 2 15%
Assumed Split (Bottom Ash/Fly Ash) 10% of total ash
Solid Fuel and Sorbent Sampling Tables 4.3-2 and 4.3-3
Stopped Belt ? 0%
Full Cut 2 1%
“Thief” Probe 2 29b
Time-Lagged 2 5%
Liquid and Gaseous Fuel Sampling Tables 4.3-4 and 4.3-5
(continued)
50
FIRED STEAM GENERATORS ASME pM3 4-1998

POTENTIAL INSTRUMENTATION BIAS LIMITS (Continued)
Flue Gas Sampling
Point-by-Point Traverse Section 7
Composite Grid Section 7
Residue Sampling
Isokinetic Dust Sampling 59/0
”Thief” Probe I 200%
Bottom Ash I50% [Note ( 9 ) l
. Bed Drain I20%
Fuel Handling and Storage - 10% of Moisture Value

Limestone Handling and Storage + 5% of Moisture Value
Residue O
Flue Gas Analysis
Oxygen Analyzer
Continuous Electronic Analyzer I1.0% of span
Orsat Analyzer i 0.2 points
Portable Analyzer I5% of reading
I2% of span
Calibrated on Air
Calibrated on Cal Gas
Carbon Monoxide
Continuous Electronic Analyzer I20 ppm
Orsat Analyzer I0.2 points
Sulfur Dioxide
Continuous Electronic Analyzer I 10 ppm
CEM Electronic Analyzer 2 50 ppm
Oxides of Nitrogen
Chemiluminescent 2 20 pprn
CEM Electronic Analyzer 2 50 ppm
Hydrocarbons
Flame ionization Detector 2 5%
Electric Power
Voltage or Current
Current Transformer 2 10%
Potential Transformer ?lo%
Hand-Held Digital Ammeter 2 5%
Watts
Wattmeter I2%
Humidity
Hygrometer Z 2 % RH
||| | |---
Sling Psychrometer 2 0.5 gradation
Weather Station Note ( 6 )
|||| | || ||| | || ||
NOTES:
All bias limits are percent of reading unless noted otherwise.
For thermocouples, error may be introduced depending on the method of correcting for a reference junction.
Also, the algorithm for conversion of thermocouple millivolts to temperature may introduce errors.
| |||
See ASM E PTC 19.3,Temperature Measurement, for applicability.

|
NIST traceable instruments have a bias limit equal to the accuracy of the calibration device. These bias
| ||| | || | ||
limits do not include drift.

See ASME PTC 19.2, Pressure Measurement, for applicability.
Must be corrected for elevation and distance from weather station.
These bias limits include user-induced errors such as probe location.
--
Calibrations at test Reynold’s number or use ASME PTC 6 nozzle for extrapolation. For uncalibrated
devices, flow coefficients and uncertainties can be taken from PTC 19.5, MFC-3M, or I50 5167.
Bottom ash carbon content should be very low.
51
TABLE 4.3-2
POTENTIAL BIAS LIMITS FOR COAL PROPERTIES
Coal Property Analysis Procedure Bias Limit Comments
Sampling ASTM D 2234 i 10% of Ash Content e 5% ash i 0.5%

I2 % of other constituents
Sample Preparation ASTM D 2013 None
Air Dry Moisture ASTM D 3302 t 0.31% Bituminous

i 0.33% Subbituminous
Ash Content ASTM D 3174 t 0.15% Bituminous with no carbonate

i 0.25% Subbituminous with carbonate
t 0.5% > 12% ash with carbonate and pyrite
Proximate ASTM D 5142 Moisture = 0.12 + 0 . 0 1 7 ~ Automated Method
Ash = 0.07 + 0.0115~
VM = 0.31 + 0.0235X
~~ ~~~
Total Moisture ASTM D 3173 i 0.15% for fuels < 5 % moisture

-r: 0.25% for fuels > 5% moisture
Carbon ASTM D 5373 i 1.25% (1 - %HZ0/100) > 100 mg sample

ASTM D 3178 2 0.3% CNote il)]
~ ~~
Hydrogen ASTM 0 5373 -

0.15% (i %H,0/100) > 100 mg sample
ASTM D 3178 i 0.07% [Note i l ) ]
Nitrogen ASTM D 5373 i 0.09% (1 - %H,0/100) > 100 mg sample

ASTM D 3179 I0.205X- 0.13 Method B
Sulfur ASTM D 4239 2 0.05% Bituminous

i 0.07% Subbituminous
ASTM D 3177 i 0.5% for fuels < 2 % sulfur
2 0.1% for fuels > 2% suifur
HHV ASTM D 2015 t 54 Btdlb dry basis-Anthracite/Bituminous

2 70 Btu/lb dry basis-Subbituminous/Lignite
Converting Analysis to ASTM D 3180 None

Different Basis
GENERAL NOTE:
All bias limits are absolute unless otherwise indicated.
NOTE
(1) Estimated based on repeatability.
be exceeded, and by noting that most processes are Data measurement devices must be allowed to reach
governed by well-known physical principles (e.g., radi- thermal equilibrium in the environment where the mea-
ant heat transfer occurs from a hotter object to a colder surements will be taken. Thermocouple lead wires shall
object; air can only leak into a sample train held under be placed in a nonparallel position relative to electrical
vacuum). sources to avoid possible electrical interference.
RTDs have a narrower operating range and a slower
response time than thermocouples, but are potentially
4.4 TEMPERATURE MEASUREMENT more accurate.
||| | |---
Mercury-in-glass thermometers are limited to mea-

4.4.1 General. Temperature is typically measured with surement of temperatures lower than the boiling point
|||| | || ||| | || ||
thermocouples (Tcs), resistance temperature devices of mercury and to visual reading only.
(RTDs), temperature gauges, or mercury-in-glass ther- Each of these devices has advantages and constraints
mometers. These devices produce either a direct reading to its use. Users of this Code are referred to PTC 19.3
or a signal which can be read with a hand-held meter for further information on temperature measurement
| |||
or data logger. techniques.

|
| ||| | || | ||
52
--
STDaASME PTC 4-ENGL 3998 m 0759670 Ob34994 T23 m
TABLE 4.3-3
POTENTIAL BIAS LIMITS FOR LIMESTONE PROPERTIES
' Limestone Property Analysis Procedure Bias Limits Comments
Limestone Constituents ASTM C 25 Calcium Oxide t 0.16% Test Method 31
Magnesium Oxide I 0.11% Test Method 31
||| | |---
Free moisture t 1 0 % Value
Inert by difference C 5.0% of Value
|||| | || ||| | || ||
Sampling Subsection 4.8.2 I2.0% thief sample
I5.0% other
GENERAL NOTES:
| |||
(a) All bias limits are absolute unless otherwise indicated.
|
(b) Free moisture, inerts, and sampling bias are suggested values.
| ||| | || | ||
--
TABLE 4.3-4
POTENTIAL BIAS LIMITS FOR FUEL OIL PROPERTIES
Fuel Oil Analysis Procedure Bias Limits Comments
~~
Sampling ASTM D 4057 t 0.5% for multiple samples

i 1%for single sample
f 2% for supplier analysis
API Gravity ASTM D 1298 f 0.25 API for Opaque (Heavy Oil)
2 0.15 API for Transparent (Distillate)
I 5 API if estimated
Water Content ASTM D 95 f 0.1% for fuels c 1% Water

i 5 % of measured value for > 1%Water
Ash ASTM D 482 2 0.003% for fuels < 0.08% Ash

f 0.012% for fuels 0.08-0.18% Ash
Sulfur ASTM D 1552 %S
_. -
IR Iodate
< 0.5 0.07% 0.04%
0.5 - 1 0.11% 0.06%
1-2 0.14% 0.09%
2-3 0.19% 0.13%
3-4 0.22% 0.20%
4-5 0.25 '/o 0.27%
Carbon ASTM D 5291 t ( x + 48.48) 0.009

ASTM D 3178 [Note (1)l C 0.3% [Note (211
Hydrogen ASTM D 5291 I 0.1157
ASTM D 3178 [Note (1)l 2 0.07% [Note (2)l
Nitrogen ASTM D 5291 -C 0.23 Reported to 0.00

ASTM D 3228 i 0.095 4 ~~~~~~~~~ ~~ ~ ~
Heating Value ASTM D 240 86 Btu/lbm

ASTM D 4809 I 49 BtuAbm all fuels
I 51 BtuAbm non-volatiles
I 44 BtuAbm volatiles
GENERAL NOTE:
NOTES:
(1) Modified for oil.
( 2 ) Estimated based on repeatability.
53
TABLE 4.3-5
POTENTIAL BIAS LIMITS FOR NATURAL GAS PROPERTIES
Natural Gas Analysis Procedure Bias Limits Comments
Sampling ASTM D 5287 f 0.5% for multiple sample
f 1.0% for single sample
I 2.0% for supplier analysis
on-line analysis-use supplier specification
for Guidance
Gas Constituents ASTM D 1945 Mole Oh of constituent:
0.0 - 0.1 I 0.01%
0.1 - 1.0 I 0.04°/o
1.0 - 5.0 I 0.05%
5.0 - 10.0 I 0.06%
> 10 I 0.08%
Higher Heating ASTM D 3588 None Perturbated with

Value, calculated fuel constituents
Higher Heating Value ASTM D 1826 0.3 - 0.55%
GENERAL NOTE:
4.4.2 Bias for Temperature Measurement. When temperature uncertainty can be reduced either by sam-
estimating the bias of a temperature measurement, pling more points or by using more sophisticated calcu-
test personnel should consider the following potential lation methods. To compensate for stratification and to
sources. Not all sources are listed, and some of those obtain a representative average, multiple points must
listed may not be applicable to ail measurements. These be sampled in a plane perpendicular to the flow. The
factors should be considered in conjunction with the measurement plane should be located away from bends,
--
factors listed in Table 4.3-1: constrictions, or expansions of the duct. If the stratifica-
| ||| | || | ||
tion is severe, mass flow weighting as described in

0 TC type
Subsection 4.3.4should be applied to reduce potential
RTD type
errors in the average temperature. Thermocouples shall
|
calibration
0
| |||
be read individually and not be grouped together to

0 lead wires
|||| | || ||| | || ||
produce a single output.

thermoweil location/geometry/condition
0 pad weid (insulatduninsulated) If flue gas temperature is measured at a point where
0 stratification of flowing fluid the temperature of the gas is significantly different
||| | |---
0 grid size from the temperature of the surrounding surface, an

O grid location error is introduced. This situation occurs when the gas
0 ambient conditions at junctions temperature is high, and the surface is cooled well
0 ambient conditions at meter below the gas temperature. The thermocouple is cooled
0 intermediate junctions by radiation to the surrounding surface, and this reduc-
0 electrical noise tion in measured temperature should be taken into
0 heat conduction and radiation account. A High Velocity Thermocouple (HVT) probe
.
potentiometer/voltmeter can be used to reduce this error.
0 reference junction accuracy
drift 4.43.1 Method of Measurement. This Code recog-
o thermometer nonlinearity nizes three different methods for calculating average
parallax values from multiple point samples as discussed in
Subsection 5.2.3:
4.43 Air and G-as Temperatures. Air and flue gas
flowing through a duct have nonuniform velocity,.tem- O multiple midpoint
perature, and composition. This is especially true near a 0 triple midpoint
flow disturbance, such as a bend or transition. Generally, O composite midpoint
54
STD=ASME PTC 4-ENGL 1998 W 0759b70 ObL499b 8 T b
All of these methods require specific placement of (c) Additional Rules for Using the Triple Midpoint
sampling points. The minimum number of points is Calculation Method. When the triple midpoint sampling
given; in all cases, uncertainty can be reduced by method is being used to determine average value, the
increasing the number of points. The following rules guidance regarding rectangular ducts is followed. How-
should apply to location of sampling points in all cases. ever, the grid must contain a multiple of three points in
( a ) Rectangular Ducts. Rectangular ducts shall be di- each direction, and a circular duct must have six equal
vided to form a grid with equal areas. Samples shall be sectors.
taken at the centroid of each equal area. For ducts larger If the parties to the test agree to use a greater number
than 9 sq ft, there should be four to 36 sampling points, of points there must still be a multiple of three in
based on the cross-sectional area of the duct. Each equal each direction for rectangular ducts and three in each
area should be no larger than 9 aq ft unless there arc sector for circular ducts.
more than 35 points. In such cases, the equal arcas may (d) Additional Rules for Using the Composite Mìd-
be larger than 9 sq ft. The Code does not require more point Calculation Method. To use the composite midpoint
than 36 points. method to determine the average value, the number of
There should be a minimum of two points spanning grid points must be a multiple of three in one direction
each dimension (height and width) of the duct cross only. This may be in either direction for rectangular ducts.
section. In ducts with severe stratification, it is recom- If six sectors arc used, there may be any number of points
mended that points be added in the direction of the in the sector. If either four or eight sectors arc used,
steepest gradient. the number of points in each sector must be a multiple
According to the bias models suggested in Subsection of three.
7.5.3.2, the bias due to numerical integration decreases If the parties to the test agree to use a greater number
as the square of the number of points; therefore, using of points, a multiple of three must be used in one
more points has a significant effect on that component direction.
of the uncertainty.
The shape of the equal areas should be one of the 4.43.2 Estimating Bias. An estimate of the bias
following: from a temperature measurement grid is a combination
of bias limits from temperature primary element and
0 a rectangle with the ratio of height to width the same sensor type, data acquisition, grid size, temperature
as that of the cross section of the duct, so that it is of distribution, averaging method, and flow weighting.
the same geometrical shape as the cross section, as Potential sources of these biases are described in Section
shown on Fig. 4.4-1 sketch (a). This is the preferred 4.3 and Subsection 4.4.2. Models for the estimation of
method biases due to flow weighting, grid size, and averaging
e any rectangle, as shown on Fig. 4.4-1 sketch (b), that method are suggested in Section 7.5.
is more nearly square than the geometric shape on When the average entering air temperature or exiting
Fig. 4.4-1 sketch (a) gas temperature is a mass weighted average of two or
o a square, as shown on Fig. 4.4-1 sketch (c) more streams at different temperatures, the impact of
the bias associated with the determination of the mass
If the shape of the equal area is not square, the flow rate shall be included in the overall bias for the
long dimension should align with the long dimension average aidgas temperature.
of the cross section. If a greater number of measurement
points are being used than is recommended, the addi-
4.4.4 Steam and Water Temperatures. Steam and
tional points may be added without concern for the water flowing in pipes typically have an approximately
aspect ratio. uniform temperature distribution. A potential exception
(b) Circular Ducts. Circular ducts should be divided
is in the piping from a desuperheater in which spray
into equal areas of 9 sq ft or less. There should be four
impingement could cause nonuniformity.
to 36 sampling points based on the cross-sectional area
of the duct. Parties to the test may agree to divide the 4.4.4.1 Method of Measurement. Selection of the
cross section into either 4, 6, or 8 sectors. The location method of measurement and the temperature measuring
of each sampling point must be at the centroid of each instruments depends upon the conditions of the individ-
equal area. The location of these sampling points may ual case. Steam and water temperatures are usually
be determined by the method shown in the example on measured by insertion of the sensing device into a
Fig. 4.4-2, which shows the use of 20 points and four thermowell located in the piping. Alternatively, “pad”
sectors. There must be at least one point per sector. or “button” thermocouples can be located around the
55
-- | ||| | || | || | | ||| |||| | || ||| | || || ||| | |---
STD.ASME PTC Li-ENGL 1998 0759b70 Ob14997 732
ASME PTC 4-1998

--
| ||| | || | ||
|
| |||
|||| | || ||| | || ||
||| | |--- FiRED STEAM GENERATORS
(a) Same Geometric Shape as Cross Section
a _,
(b)More Nearly Square Than Shown in sketch (a) above

-A> A a n d 8 r b
B b
~~
S T D = A S f l E PTC 4-ENGL 1998 0759670 0614998 6 7 9
||| | |---
|||| | || ||| | || ||
GENERAL NOTE: Indicates points
| |||
of location of sampling tube.
|
| ||| | || | ||
--
I /
Formula for determining location points in circular duct:
rp = J2Rz(2p-n I)
7 a x
where
rp = distance from center of duct to point p
R = radius of duct
p = sampling point number. To be numbered from center of duct
outward. All four points on same circumference have same hum
n = total number of points
NOTE: rp will be in same units as R.

Example: Duct radius = R; 20 points total;
distance to point 3 = 4.
r3 = -,JT
JT JZ = = = Q.7Q7R
FIG. 4.4-2 SAMPLING GRID - CIRCULAR DUCTS
57
STDmASME PTC 4-ENGL Lîîô 0 7 5 î b 7 0 0 b L 4 î î î 505
pipe and insulated, but use of this method substantially should be assigned. If stratification is suspected in the
increases the uncertainty of the measurement. solid stream, this should be incorporated into the bias
estimate.
4.4.4.2 Estimating Bias. An estimate of the bias
from a temperature measurement is a combination of 4.4.6 Liquid and Gaseous Fuels. Liquid or gaseous
bias limits from the temperature primary element, sensor fuels flowing in pipes usually have approximately uni-
type, and data acquisition. Potential sources of these form temperature distribution.
biases are discussed in Section 4.3 and Subsection 4.4.2.
4.4.6.1 Method of Measurement. A temperature
4.4.5 Solid Streams. The temperatures of solid measuring instrument should be inserted into the fuel
streams entering or leaving the unit are often difficult stream at the entrance to the unit, preferably near the
to measure. The parties te, the test should decide whether flow measurement device. If the fuel is heated by a
the temperature of these streams will be assigned a source external to the unit being tested, the inlet tempera-
value or measured. If temperatures are to be measured, ture shall be measured after this heater. If the fuel is
the temperature probe should be inserted into a flowing heated directly from the unit being tested, the tempera-
stream. The average temperature of multiple solid tures shall be measured before the heater.
streams should be mass flow weighted.
4.4.5.1 Method of Measurement. The following from a temperature measurement is a combination of
locations and methods of measurement shall be used: bias limits from temperature primary element, sensor
(a) Fuel. A rigidly supported temperature measuring type, and data acquisition. Section 4.3 and Subsection
instrument should be inserted into the solid fuel stream 4.4.2 discuss potential sources of these biases.
as close as practical upstream of the point where the
primary/transport air is mixed with the fuel.
(b) Sorbent. A rigidly supported temperature measur- 4.5 PRESSURE MEASUREMENT
ing instrument should be inserted into the solid sorbent
4.5.1 General. Total pressure is the sum of static
stream as close as practical upstream of the point where
pressure and velocity pressure. Change in static head
the transport air is mixed with the sorbent or the fuel/
is calculated based on the average fluid conditions and
sorbent mixture.
local ambient conditions. Velocity pressure is usually
(c) Residue. Residue that carries over in the flue gas
calculated from average fluid velocity and density. If
stream (fly ash) can be considered to be the same tempera-
velocity is to be measured, refer to Section 4.6 for
ture as the gas at the extraction point. An exception is
guidance in making these measurements. This section
ash leaving an air heater. The temperature of the gas
addresses the measurement of static pressure.
leaving the air heater excluding leakage shall be used.
For bed drains in fluidized bed combustors, the bed tem- 4.5.2 Bias for Pressure Measurement. When estimat-
perature may typically be used unless bed drain coolers ing the bias of a pressure measurement, test personnel
return heat to the boundary. In that case, the temperature should consider the following list of potential sources.
of the bed drain leaving the cooler should be measured. Not all sources are listed, and some of those sources
Refer to Section 5.14 for estimating bottom ash tempera- listed may not be applicable to ail measurements. These
ture. If the residue temperature is measured (such as factors should be considered in conjunction with the
residue leaving a grate), a rigidly supported temperature factors listed in Table 4.3-1.
measuring instrument should be inserted into each flow- e
ing residue stream as close as practical to the point where gauge type
e manometer type
the residue leaves the boundary. e transducer type
4.4.5.2 Estimating Bias. An estimate of the bias e calibration
from a temperature measurement is a combination of e tap location/geometry/fiow impact
bias limits from temperature primary element, sensor e probe design
type, and data acquisition. Section 4.3 and Subsection e stratification of flowing fluid
4.4.2 discuss potential sources of these biases. When e number and location of measurements
||| | |---
biases are assigned to parameters which are assumed, e water leg

typically a larger value for bias is chosen than if the e specific gravity of manometer fluid
|||| | || ||| | || ||
parameter is directly measured. If the mass flows of e ambient conditions at sensor

multiple streams are not approximately equal and the e ambient conditions at meter
average temperature is not flow weighted, a higher bias e hysteresis
| |||
|
58
| ||| | || | ||
--
0 electrical noise 0 Pressure measurement connections should be short and

0 potentiometerholtmeter direct.
0 drift o All pressure measurement connections should be leak-
0 transducer nonlinearity proof, with provisions for cleaning and drainage.
parallax 0 Pressure connections should be located and installed
with care to exclude velocity effects.
4.53 Air and Gas - Static and Differential Pres- o Connections from the instrument to the pressure tap
sure. The static pressure in air and gas ducts may should be purged and condensate allowed to fill the
be required to determine pressure drop. Pressure drop lines. Condensate water legs shall be included in the
determinations should be performed using differential calculations.
measuring apparatus rather than two separate instru-
ments. 4.5.4.2 Estimating Bias. An estimate of the bias
from a pressure measurement is a combination of
4.53.1 Method of Measurement. Pressure is mea- .bias limits from primary element, tap type, and data
sured with gauges, manometers, or transducers. The acquisition. Potential sources of these biases are dis-
output of these devices is either visual or a signal cussed in Section 4.3 and Subsection 4.5.2.
which can be read with a hand-held meter or data logger.
PTC 19.2 provides further information on pressure 4.5.5 Barometric Pressure. Barometric pressure is
measurement techniques. required to determine ambient conditions.
4.5.5.1 Method of Measurement. The preferred
Static pressure connections must be installed to mini- method for determining barometric pressure is from a
mize errors resulting from gas velocity impingement. barometer at the test site. An alternate method is the
This may be accomplished by proper location of taps use of the barometric pressure, not corrected to sea
around the perimeter of the duct or by use of specially level, reported at the nearest weather station. The
designed probes. Measurements should be made at more elevation of the weather station's reading and the test
than one location in or around the plane. Piping or site should be noted and corrections made for any
tubing should be specifically installed for the test, and differences in elevation.
should be verified leakproof. Provisions should be made
for cleaning and draining. Connections from the instru- 4.5.5.2 Estimating Bias. The use of a barometer
ment to the pressure tap should slope downwarä to or other such measurement device at the site will be
allow condensate to flow back into the duct. When considered to have a negligible bias limit. Data from
this is not possible, provisions must be made to account a weather station are considered the least accurate, and
for condensate water legs. Purging may be used to if used an appropriate bias should be assigned.
keep pressure sensing lines clear. If purging is used,
a constant low flow should be maintained.
4.5.3.2 Estimating Bias. An estimate of the bias 4.6 VELOCITY TRAVERSE

from a pressure measurement is a combination of bias 4.6.1 General. A velocity traverse consists of mea-
limits from primary element, installation effects, and surements taken at numerous locations in a plane perpen-
data acquisition. Potential sources of these biases are dicular to the flow. These measurements should include
--
addressed in Section 4.3 and Subsection 4.5:2. at least velocity pressure, static pressure, and tempera-
| ||| | || | ||
ture, and may also include velocity vector angles. The

4.5.4 Steam and Water - Static and Differential user should refer to Sections 4.4 and 4.5 related to
Pressure. The static pressure in steam and water piping temperature and pressure measurements for guidelines
|
may be required to determine fluid properties or pressure

| |||
and specific instructions.

drop. To minimize uncertainty, pressure drop determina-
|||| | || ||| | || ||
A probe is inserted into the duct, and measurements

tions should be performed using differential measuring
are made at a number of locations corresponding to
apparatus rather than two separate instruments.
the centers of equal areas. The probe is usually one
4.5.4.1 Method of Measurement. Pressure mea- of several types which sen% the velocity pressure and
||| | |---
surement devices should be located to minimize the pressure differentials indicating yaw and pitch. Users
effects of temperature and vibration. Adhere to the of this Code are referred to PTC 19.5 (see Note below)
following in the installation of pressure measuring and PTC 11, Fans, for further information on velocity
devices: measurement techniques.
59
NOTE: At the time this Code was published, a information on flow measurement techniques. These
revision of PTC 19.5 was k i n g prepared. This revised sources include design, construction, location, and instal-
version or a later revision should be consulted. lation of flowmeters, the connecting piping, and compu-
tations of flow rates. If an individual stream flow
4.6.2 Bias for Velocity Traverse. When estimating
rate is to be determined by velocity traverse refer to
the bias of a velocity traverse, test personnel should
Section 4.6.
consider the following potential sources. Not all sources
are listed, and some of those listed may not be applicable For multiple streams where the total flow can be
to all measurements. These factors should be considered calculated more accurately than measured (e.g., air,
in conjunction with the factors listed in Table 4.3-1 flue gas, residue, etc.), all but one stream may be
and Subsections 4.4.2 and 4.5.2: measured and the unmeasured stream flow rate calcu-
probe type lated by difference. If all streams are measured, the
0 calibration mass flow fraction of each stream shall be calculated
0 stratification of flowing fluid from the measured mass flow rate. The mass flow rate
0 turbulendlaminar flow conditions of the individual streams is then determined from the
0 yaw product of the mass flow fraction of the individual
0 pitch streams and the total calculated mass flow rate.
0 grid size 4.7.2 Bias for Flow Measurement. Flow is often
0 grid location measured indirectly, ¡.e., using measured differential
ambient conditions at measurement location pressure, pressure, and temperature; therefore, the mea-
0 parallax sured inputs to the flow calculation must be examined
0 pressure errors for sources of bias and combined into the bias of the
fluctuation of pressure in time flow measurement. When estimating the bias of a
0 temperature errors
flow measurement, test personnel should consider the
4.63 Method of Measurement. Measurements are following potential sources. Not all sources are listed,
taken at the centers of equal areas. The traverse points and some of those listed may not be applicable to all
must correspond to the temperature or oxygen measure- measurements. These factors should be considered in
ment points. FTC 19.5 and ASME PTC 11 may be conjunction with the factors listed in Table 4.3-1:
consulted for information on velocity measurement.
Numerous types of probes are used for velocity measure- 0 calibration of primary element, e.g., orifice, nozzle,
ment, such as standard pitot, S-type, three-hole and venturi, airfoil, and differential sensing probes
0 stratification of flowing fluid
five-hole, turbometer mass flow probe, and others.
Determination which accounts for the direction of flow temperature biases
at the plane of measurement is preferred. pressure biases
0 installation
4.6.4 Estimating Bias. An estimate of the bias from condition of nozzle or orifice
a velocity traverse is a combination of bias limits from pressure correction (compensation)
probe type, measurement methods, and data acquisition. 0 temperature correction (compensation)
Section 4.3 and Subsection 4.6.2 include potential 0 Reynolds number correction
sources of these biases. If the probe used for the 0 measurement location
velocity traverse does not account for the approach 0 fadpump curve
angle to the plane of measurement, the velocity may 0 valve position
be overestimated, and an appropriate bias limit should 0 level accuracy/difference
be included. heat balance inputslequations
0 weir
0 tap location
4.7 FLOW MEASUREMENT

4.73 Air and Flue Gas. The total mass flow of air
4.7.1 General. Numerous methods are employed in and flue gas crossing the steam generator boundary is
industry to detemine the flow rate of solid, liquid, or calculated stoichiometrically. It may be necessary to
gaseous streams. FTC 19.5 is the primary reference measure the air or flue gas flow in addition to the
for flow measurements. ASME document MFC3M, temperature of the stream to account for an individual
FTC 6, Steam Turbines, and I S 0 5167 provide further air or gas stream that crosses the steam generator
-- | ||| | || | || | | ||| |||| | || ||| | || || ||| | |---
STDSASME PTC 4-ENGL 3998 M 0757b70 Ob35002 7T8 W
boundary. The energy crossing the boundary in that that the differential produced by the orifice or nozzle
air or gas stream then may be calculated. is at the lower range of the system, a measuring device
and transmitter which is accurate at the spray flow rate
4.7.3.1 Methods of Measurement. There are nu-
or an energy balance calculation should be used.
merous methods for the measurement of air and gas
flow (e.g., venturi, airfoil, velocity traverse, heat balance, 4.7.4.1 Method of Measurement. The following
etc.). If plant instrumentation is used, it should be methods of measurement are typically used to determine
calibrated. The flow may be calculated from velocity, steam and water flows:
as measured according to Section 4.6, the density of
the fluid, and the duct cross-sectional area. The use of Flow masurement through a nozzle, venturi, or orifice.
sophisticated traversing strategies such as Gauss or One method of measuring flow is to measure pressure
Tchebycheff distribution of points as described in PTC drop across a flow nozzle, venturi, or orifice plate..
19.5 generally leads to more accurate determination of This method is usually the most accurate and should
flows. be used for all critical flow measurements.
Energy and mass balance calculation. Certain flows
4.73.2 Estimating Bias. The most accurate way may be quantified by energy balance calculations.
to determine the flow of air or gas in most applications These flows typically include reheat extraction flow
is by calculation. The steam generator efficiency, total to feedwater heaters, and possibly, superheater desup-
output, flue gas weight per pound of fuel, and heating erheating spray flow. The method of calculation is
value of the fuel can all be determined accurately. The outlined in Section 5.6. Enthalpies shall be determined
measurement of air and flue gas flow is subject to from the ASME 1967 Steam Tables, using pressures
significant error. Using a standard pitot tube or a and temperatures measured with test instrumentation.
Stauschibe (S-type or forward-reverse) tube can result Estimated flows. In some cases, it may not be feasible
in overestimating the flow if the flow is not perpendicu- to quantify a flow using any of the methods listed
lar to the plane of measurement. The area of the duct above. In these cases, flow curves relating to either a
may also be difficult to determine accurately because known flow or a valve position may be used. Steam
of obstructions within the duct or inaccurate dimensions. flow based on first-stage pressure, estimated turbine
An estimate of the bias from an air or gas flow leakage based on main steam flow, or blowdown flow
measurement is a combination of bias limits from based on valve turns are examples of this type of flow.
measurement methods and data acquisition. Section.4.3 Design performance data also may be used. All parties
and Sub section 4.7.2 discuss potential sources of these involved in the performance test must agree to the
biases. If the probe used for velocity traverse does method of calculation prior to the test, and an appro-
not account for the approach angle to the plane of priate uncertainty must be assigned.
measurement, the velocity may be overestimated, and
an appropriate bias limit should be included.
from a flow measurement is a combination of bias
4.7.4 Steam and Water. Certain steam and water limits from primary element type, sensor type, and
flow measurements may be required, depending on the data acquisition installation effect. Section 4.3 and
objective of the test. When the determination of output Subsection 4.7.2 discuss potential sources of these
is required, the preferred method is to use a calibrated biases.
and inspected flow element such as the ASME throat 4.7.5 Liquid Fuel. The input-output method for effi-
tap nozzle, as described in F'TC 6, Steam Turbines. ciency determination requires the quantity of liquid fuel
On large units, the F'TC 6 nozzle is preferred because
burned.
of the potentially high Reynolds numbers of the mea-
sured flow. The requirement for the PTC 6 nozzle is 4.7.5.1 Method of Measurement. The quantity of
eliminated if the flow element can be calibrated at the fuel may be determined by flow measurement device,
Reynolds numbers that will be encountered during the weigh tank, or volume tank. Refer to Subsection 4.7.4.1
test. The F'TC 6 flow nozzle should be used if flow for discussion of the use of flow nozzles and thin plate
coefficients need to be extrapolated to higher Reynolds orifices. If a level change in a volume tank is utilized
numbers. While an energy balance calculation is accept- to determine the flow measurement, accurate density
able for determining the superheat desuperheating spray determination is required. ASTM D 1298 provides
flow, reheat desuperheating spray flow should be directly procedures to determine API Gravity and density.
measured rather than calculated by energy balance. If Recirculation of fuel between the point of measure-
the reheat desuperheating spray flow is low enough ment and point of firing shall be measured and accounted
61
-- | ||| | || | || | | ||| |||| | || ||| | || || ||| | |---
~
~- ~ ~
STD-ASME PTC 4-ENGL L99A W 0759b70 Obl15003 b34
for in the flow calculation. Branch connections on the It is even more difficult to assess the accuracy of
fuel piping shall be either blanked off or provided with volumetric feeders. This assessment requires assump-
double valves. tions about the volume of material passed per revolution
and the density of the material. The rotor may not be
4.7.5.2 Estimating Bias. An estimate of the bias full, the density may vary as a result of size distribution
from a flow measurement is a combination of bias or other factors, and all these parameters may vary
limits from primary element type, sensor type, and data over time.
acquisition. Section 4.3 and Subsection 4.7.2 discuss Calibrations of solid flow measurement devices
potential sources of these biases. should be conducted just prior to the testing and at
frequent intervals to ensure the minimum bias.
4.7.6 Gaseous Fuel. For the input-output method, the
quantity of gaseous fuel burned must be determined. 4.7.7.2 Estimate of Bias. The bias from a solid
4.7.6.1 Method of Measurement. Measurement of flow measurement is one of the most difficult parameters
the relatively large volumes of gaseous fuel normally to determine. Bias limits from instrument response
encountered while testing steam generators requires the variation resulting from size distribution, uneven loading
use of an orifice, flow nozzle, or turbine meter. The on the weigh scale, or varying densities should be
pressure drop shall be measured using a differential considered. Section 4.3 and Subsection 4.7.2 discuss
pressure gauge or differential pressure transmitter. Out- other potential sources of biases.
puts from these devices can be read manually, via 4.7.8 Residue Splits. The amount of residue leaving
hand-held meters, or with data loggers. When gas flow the steam generator boundary is required to determine
is measured, the temperature and pressure used in the the sensible heat loss in the residue streams and the
calculation of density are extremely important. Small weighted average of unburned carbon (and CO, on
variations can cause significant changes in the calculated units that utilize sorbent) in the residue. Typical loca-
gas density. In addition, the supercompressibility factor tions where the residue is removed periodically or
has a significant effect on the determination of gas continuously are furnace bottom ash (bed drains), econo-
density. mizer or boiler hoppers, mechanical dust collector re-
jects, and fly ash leaving the unit.
from a flow measurement is a combination of bias 4.7.8.1 Method of Measurement. The calculated
limits from primary element type, sensor type, and data total residue mass flow rate is used since it is normally
acquisition. Section 4.3 and Subsection 4.7.2 discuss more accurate than a direct measurement. Therefore,
potential sources of these biases. The impact of pressure the percent of the total residue that leaves each location
and temperature measurements on the gas density should must be determined. Several methods can be used to
be evaluated at the test operating conditions because determine the split between the various locations:
a 10 psi deviation or a 2°F variation can impact flow
as much as 1%. 0 The mass flow rate should be measured at each lo-
cation.
4.7.7 Solid Fuel and Sorbent Flow Measurement. The residue at one or more locations should be mea-
The accurate measurement of solid flow is difficult sured (usually the locations with the highest loading)
because of solid material variabilitv. and the quantity at the other locations should be calcu-
lated by difference. Where there is more than one
4.7.7.1 Method of Measurement. Numerous meth- unmeasured location, the split between these locations
ods are available to measure the flow of solids, such should be estimated.
as gravimetric feeders, volumetric feeders, isokinetic The residue percentage leaving each location may be
particulate sample, weigh bindtimed weights, impact estimated based on the typical results for the type of
meters, etc. To reduce uncertainty of any of these fuel and method of firing.
methods below 5 to 10% requires extensive calibration
against a reference. The calibration can involve the The parties to the test shall reach agreement on what
collection of the solid material into a container which streams are to be measured and values for any estimated
can be weighted rather than placing weights on the splits prior to the test.
belt. For example, the output of a gravimetric feeder The fly ash concentration leaving the unit, determined
can be directed to a container suspended by load cells, in accordance with Section 4.11, is used to calculate
and the rate of feed indicated by the feeder can then residue mass flow rate leaving the unit. See Section 5
be compared to the timed catch in the container. for calculating the mass flow rate from the grain loading.
62
-- | ||| | || | || | | ||| |||| | || ||| | || || ||| | |---
= 0757670 Ob15004 570
~
STD.ASME PTC 4-ENGL L998
The mass flow rate of residue discharged from hop- a flowing stream as near to the steam generator as
pers or grates in a dry state may be determined from practical to ensure that samples are representative. If
weigh bindtimed weights, e.g., the number of rotations it is not possible or practical to sample near the steam
of rotary feeders, screw speed, impact meters, etc. generator, a time lag may be incurred between when
See Subsection 4.7.7.1 for considerations regarding the sample is taken and when it is actually injected
calibration and sources of uncertainty. or removed from the steam generator. This time lag
Determining the mass flow rate of residue discharged must be determined based on estimated flow rates
from sluice systems is even more difficult than determin- between the sample location and the steam generator.
ing the dry state. Generally, the total discharge flow It is important that the time-lagged sample be representa-
must be captured in bins or trucks, free-standing water tive of the actual material injected or removed from
drained off, and the bin or truck weighed and compared the steam generator. ‘Thief’ sampling or taking a partial
against the tare weight. Since residue is considered to cut sample from silos or hoppers have large associated
leave the unit in a dry state, moisture content of the bias errors. One possible exception to this is sorbent,
sample must be determined, and the measured wet which in most cases is homogenous. Parallel streams
mass flow rate corrected for moisture. such as coal feed with belt feeders have the potential
for variation from stream to stream because of different
4.7.8.2 Estimating Bias. When splits are estimated, flow rates, particle sizes, and chemical composition.
a mean value should be selected such that the same
Therefore, unless the chemical constituents of the sam-
positive and negative estimate of bias can be used. A ples can be shown to be uniform, the samples must
bias that would produce a split of less than zero or be taken from each of the parallel streams and combined.
more than 100% must not be used. Refer to Section If the flows for the parallel streams are unequal, the
4.1 1 regarding bias for dust loading (residue sampling). amount of samples of each parallel stream must be
Where mass flow is determined from volumetric devices, flow weighted for the composite sample. The flow for
considerations include repeatability of the fullness of each of the parallel streams must be continuous through-
the volume chamber and density and size distribution out the test.
of the material. Also refer to Subsection 4.7.7.2. Depending on the costs associated with laboratory
||| | |---
analyses and the availability of a historical data base,
different options may be selected for different sample
|||| | || ||| | || ||
4.8 SOLID FUEL AND SORBENT SAMPLING constituents (Le., coal, sorbent, residue).
4.8.1 General. The methods of sampling shall be Fuel or sorbent samples collected from upstream of
agreed upon by all parties to the test and must be silos, tanks, or hoppers typically have larger biases
| |||
described in the test report. An appropriate uncertainty than samples collected downstream from the silos, tanks,
|
must be assigned for the method of sampling used for and hoppers. Samplings from upstream of silos, tanks,
| ||| | || | ||
and hoppers are classified as alternate procedures be-
a test.
The sampling program conducted during the perform- cause of the possibility of samples not being representa-
ance test has a significant effect on the steam generator tive of fuel fired during the test. Alternate procedures
--
efficiency result. Of all the data collected during a test, should not be used for acceptance tests. For other test
the higher heating value (“V) of the solid fuel is the purposes, if alternate procedures are used, the parties
variable having the most influence on steam generator to the test shall assign appropriate biases.
efficiency. Further, on some units, unburned combusti-
bles loss in the residue (based on carbon concentration) 4.8.2.1 Sample Size. As stated previously, it is
is a major energy loss. If samples are not representative extremely important that any sample be as representative
of the respective solid streams, the steam generator of the composition of the actual stream as possible.
efficiency result is questionable. In addition, the varia- In addition, since there is a direct correlation between
individual sample weight and variance, sufficient weight
tion in the composition of solids directly affects the
of .individual samples is required to minimize the
uncertainty of the steam generator efficiency. In this
variance.
Section, the methods used to determine variances, stan-
dard deviations, and precision indices for the samples Generally, a complete cross section of the flowing
stream is the most representative. This criterion, how-
obtained during the test are discussed. The estimation
of bias limits is also addressed. ever, can mean different sample size requirements for
different types of solid streams. For example, the fly
4.8.2 Methods of Solid Sampling. Fuel, sorbent (if ash residue stream sample should be obtained from
applicable), and residue solids shall be sampled from isokinetic particulate sampling. This sample is typically
63
~~ ~
STD-ASME PTC 4-ENGL 1998 m 0759670 Ob15005 407
ASME PTC 4- 1998 FIRED S v GENERATOS
very small. However, since it is taken from a complete nel. The procedure used must be d e v e l o w and carefully
and controlled traverse of the flue gas duct, the sample implemented to ensure that representatjk samples are
is representative. In this case, the small quantity is a obtained and to prevent contaminat@ in samplin$
minor factor in regard to the reliability of the sample. devices and storage containers. S collected opt-
Another example of the acceptability of a small doors must be protected from ex efivironmentd
quantity of sample is sorbent sampling. The size of influences during collection. Airtight, noncorrosive stor-
sorbent may vary, but it is likely that the chemical age containers prevent degradation of &e sample until
composition does not vary across the size range or it is analyzed. Each sample should be s@d immediately
among different lots of sorbent. Therefore, a small after being taken. Samples should no0 be mixed’ in
sample can be representative of the entire sorbent feed open air prior to analysis for moisture because of the
during the test. potential for moisture loss.
In summary, the actual sample size must be based Samples must be properly labeled qnd described in
on several factors, including size distribution, chemical terms of their significance to the test. The label should
composition variability, feed methods, flow capacities, include, as a minimum, the date, tiqe, location, and
and number of samples. In general, larger size samples type of sample taken.
result in lower variances. However, as sample size ASTM Standards D 2013 and D 3302 should be
increases, so do sample preparation costs for reducing followed in the preparation of coal samples. Sorbent
to a size for laboratory analysis. For manual sampling analysis procedures are addressed by ASTM D 25.
of coal or sorbent, samples typically weighting from
4.8.3 Bias for Solid Fuel and Sorbent Sampling.
2 to 8 Ib are collected. For automatic sampling devices,
When the bias of a sampling procedure is estimated,
much larger samples can be collected.
the test engineer should consider the following potential
The weight of the individual test sample must be
sources. There may be other sources, and not all sources
equal to or greater than the weight of the samples used
listed are applicable to all measurements:
from a historical database. Otherwise, the variance of
the test database could be greater than the variance of sampling locatiodgeometry
the historical data. probe design
The factors previously noted, combined with good stratification of flowing stream
engineering judgment, costs, agreement between parties, number and location of sample points
and desired accuracy of sample analyses, should be ambient conditions at sample location
used by the testing participants to determine the proper fueysorbent variability
sample size. Table 2 of ASTM Standard D 2234 fueilsorbent size
provides more information about sample size. sample handlinghtorage
0 duration of test
4.8.2.2 Sample Collection. ASTM D 2234 provides
quantity of sample obtained
guidance on sample collection. The “stopped belt”
technique is the preferred or reference method. Zero An estimate of the bias from a sample is a combina-
sampling bias should be assigned if the “stopped belt” tion of bias limits from sample acquisition, location,
technique is used. Using this method, a loaded conveyor and stream consistency.
is stopped, and a full cross-section cut normal to the Sampling methods other than those recommended
flow stream is taken. The width of this cut should not must be assigned higher biases.
be less than three times the top size of the solid. In Before conducting a performance test, it is mandatory
many cases, however, stopped belt sampling is not that parties to the test make a pretest inspection of the
practical; therefore, full-cut sampling should be used. sampling locations, identify the sampling methodology,
Using full-cut sampling, the sample is taken from a and make the sampling probes available. Careful atten-
full diverted cut of a moving stream. Figure 4.8-1 tion should be paid to areas where samples might not
||| | |---
shows a typical “full-cut’’ sampling method. A “thief” be representative. Sampling of coal and other solid
probe, as shown on Fig. 4.8-2, may be used for taking materials from a moving stream can result in more of
|||| | || ||| | || ||
a sample from a flowing stream if a full-cut sampling one size range of particles during collection. If system-
device is not available. A pretest run is recommended atic (bias) errors are present in the sampling system,
to identify and alleviate potential problems in the the errors must be corrected, or the parties must assign
| |||
sampling techniques. conservative (higher) bias limits.

|
| ||| | || | ||
4.8.2.3 Handling Samples. Sampling must be car- 4.8.4 Type of Samples. Coal or sorbent samples
ried out only under the supervision of qualified person- may be individual, partial-composite, or full-composite
--
64
Solids storage bin
v Solids conveyor
J
Solenoid valve
Air cylinder
actuator
Limit switch in
To sample
collection container
There are five methods for obtaining sample.

(1) Close isolation gate on dust suppression system.
This will eliminate fines removal.
(2) Initiate sample diverter gate to sample position.
This is done pneumatically.
(3) Adjust timer to obtain a proper sample size.
(4) Throw away the first sample.
(5) Collect 5 gallon bucket and seal container. Prepare for riffling,
crush, and size.
FIG. 4.8-1 FULL-CUT SOLIDS SAMPLING METHOD
65
-- | ||| | || | || | | ||| |||| | || ||| | || || ||| | |---
~~
STDOASME PTC 4-ENGL 3998 m 0759670 Ob35007 28T m

--
-
| ||| | || | ||
Typical thief probe sampling location.

Care must be taken to get a
|
| |||
representative sample.
|||| | || ||| | || ||
A n n A
II
||| | |---
I,-
I 1 I/
L
Section A -A
DESIGN:
Consists of two concentric pipes with the same sample hole configuration.
The probe is inserted into a flowing solids stream with the sample ports
closed. (The inner tube rotates 180 deg relative to the outer tube from the
sample position.) The inner tube is rotated to align the sample holes and is
rotated back with the inner tube now full of material.
FIG. 4.8-2 TYPICAL “THIEF” PROBE FOR SOLIDS SAMPLING ON A SOLIDS STREAM
66
STD=ASME PTC 4-ENGL 1998 W 0759b70 Ob15008 L L b
samples. Residue samples other than for fly ash should 0 the historical and test coal (sorbent) are from the same
be individual samples. Fly ash samples are covered in mine/quarry and seam
Section 4.1 1. 0 historical data are the analyses of individual (not
mixed) sample’increments for the coal (sorbent)
4.8.4.1 Individual Samples. Separate analysis sam-
the historical and test samples arc collected and pre-
ples are prepared from individual samples, referred to
pared in accordance with ASTM Standards D 2234,
as “increments” in the terminology of ASTM D 2234,
Test Methods for Collection of a Gross Sample of
Standard Methods for Collection of a Gross Sample
Coal, and D 2013, Method of Preparing Coal Sample
of Coal. The analysis samples are individually analyzed
for Analysis
for the applicable constituents, heating value, carbon
0 the types of increments of the historical data and the
content, moisture, etc. The average value and precision
test data are ASTM D 2234 Type 1, Condition A
index of each constituent are calculated using Eqs.
(Stopped-Belt Cut) or Condition B (Full-Stream Cut),
(5.2-1) and (5.2-10). This procedure must be used when
with systematic spacing
there are no historical data available to estimate the
0 the size of the historical samples is the same as the
precision index of the samples.
size of the samples collected during the test
4.8.4.2 Partial-Composite Samples. This is an al-
ternative to analyzing individual samples, predicated If the historical samples were taken at a different
on the availability of valid historical data. The objective location, an additional bias likely has been introduced.
is to reduce laboratory costs. The constituents are Two sets of individual analysis samples are prepared.
grouped into “composite” (e.g., carbon, hydrogen, and One set is individually analyzed for the variable constit-
nitrogen) and “variable” (e.g., water, ash, and possibly uents, such as ash and moisture. The average value
sulfur) constituents. The precision indices of the “com- and precision index of each variable constituent are
posite” constituents are taken from valid historical data. calculated using Eqs. (5.2-1) and (5.2-10).
The precision indices of the “variable” constituents are The second set of individual analysis samples is
based on individual analysis made for the specific test. thoroughly mixed and analyzed for the composite con-
The underlying premise for this alternative is that stituents. The average value of each variable constituent
“composite” constituents for both the historical and test is the measured value of the mixed analysis sample.
data are from the same statistical population. As the The historical analyses are converted to the dry-and-
constituents are from the same population, a precision ash-free (daf) basis by multiplying the as-received
index derived from historical data may be used for the percentages (other than the variable constituents, ash
test uncertainty analysis. Subsection 7.4.1.4 provides and moisture) by
additional background for this alternative.
To simplify this discussion, coal constituents and 1O0
terminology are used; sorbent constituents and terminol- (4.8- 1)
100 - MpH2OF; - MpAsFi
ogy can be substituted as appropriate.
As coal is typically stored outdoors, the moisture
content of as-fired coal may have greater variability where
than as-received coal. This increased variability may MpH20Fi = moisture content, in percent, of historical
invalidate the premise that the historical as-received sample increment i
data and the test data are from the same statistical MpAsFi = ash content, in percent, of historical sam-
population. However, changes in moisture content do ple increment i
not affect constituents on a dry-and-ash-free basis. For carbon content, the conversion equation is
Where sulfur retention is an important consideration
in the test, sulfur content should be included in the MpCFdafi
variable constituents. The variability of sulfur content
is often relatively large.
This alternative is not suitable for residue samples.
= MpCFj
( 100 - M p H 12O00 F ;- MpASFi (4.8-2)
The composition of residue is affected by operating

conditions within the steam generator. There is no where
simple way to ensure that historical and test data for MpCFi= carbon content of the fuel in percent,
residue would be from the same statistical population. as-fired basis
Historical data should satisfy the following criteria MpCFdaf;= carbon content of the fuel in percent,
to be valid for estimating precision: dry-and-ash-free basis
67
-- | ||| | || | || | | ||| |||| | || ||| | || || ||| | |---
STD-ASME PTC 4-ENGL 1998 m 0 7 5 ï b 7 0 Ob15009 052 =
MpH@F,= moisture content of the fuel in percent, TABLE 4.8-1

as-fired basis (average of test analysis) f DISTRIBUTION
MpAsF,= ash content of the fuel in percent, as-
fl-1 L i
fired basis (average of test analysis)
The conversion equations for heating value, hydrogen, 1 3.8415
nitrogen, sulfur, and oxygen are similar. ASTM D 3180 2 2.9957
addresses the conversion of analysis from one basis to 3 2.6049
another and should be used.
Using the dry-and-ash-free values of the individual 4 2.3719
historical samples, estimate the maximum probable 5 2.2141
standard deviation, soj, of each composite constituent. 6 2.0896
Use Appendix A2, Method of Estimating the Overall
Variance for Increments, of ASTM D 2234 to deter- 7 2.0096
mine s,]. 8 1.9384
The use of this Appendix requires for each composite 9 1.8799
constituent 20 or more analyses of individual increments.
If fewer than 20 are available, calculate the standard 10 1.8307
deviation, STDDEV,, of each composite constituent 12 1.7522
using Q. (5.2-11).
~~
15 1.6664
The precision index for each composite constituent,
Prj, is for 20 or more analyses: 20 1.5705
40 1.3940
120 1.2214
(4.8-3)
Infinity 1.0000
or for less than 20 use:
F,,- *STDDEV:)”I
PIj = ( N (4.8-4) constituents. The average value of each constituent is
the measured value of the mixed analysis sample.
The criteria and calculations given above for partial-
where composite samples are applicable to full-composite sam-
F distribution
Fn-1,3=the upper 5% point of the ples except that the conversion factor (4.8-1) and Eq.
for n - 1 and CD degrees of freedom. (4.8-2) are excluded.
Table 4.8-1 provides selected values of
the distribution 4.8.4.4 Systematic Sampling. With one exception,
n = the number of sample increments in the the samples shall be collected at uniform, not random,
historical data intervals. The exception is when it is known that the
N = the number of sample increments taken collection sequence corresponds with “highs” or “lows”
during the test in the fines content. In that instance, random time
The degrees of freedom of this precision index are intervals should be used. Each sample should be of
infinite. the same weight. The elapsed time to collect all coal
samples must equal the duration of the test run.
4.8.4.3 Full-Compite Samples. This is also an
alternative to analyzing individual samples. For full- 4.8.4.5 Number of Samples. The number of sam-
composite samples, none of the constituents are classi- ples to take during a test can be set by trial and error
fied as variable constituents. This alternative may be using the precision indices of the constituents. The
applicable for sorbents and coal when historical data preferred method uses a complete pretest uncertainty
are available and changes in moisture or ash content analysis, as discussed in Section 7.3. The number of
are either very small or of minor concern. samples is varied parametrically. A number of samples
A composite analysis sample is prepared from the is selected such that the target test uncertainty can
samples taken during the test and aflalyzed for ail be met.
68
-- | ||| | || | || | | ||| |||| | || ||| | || || ||| | |---
FIRED STEAM GENERATORS ASME PTC J-199X
An alternative method is to examine the direct effect by Gas Chromatography. should be consulted for the
of changing the number of samples on the precision proper procedures and equipment for sampling liqiiid
index of a resultant. The result may be steam generator or gas. The type of sample vessel and procedure is
efficiency, a heat credit or loss, or the value of the illustrated for various cases and types of liquid fuels
constituent. A heat credit or loss is a way of highlighting in PTC 3.1.
the effect of a constituent. For example, the carbon An estimate of the bias from a sample is ;i combina-
content of residue has ;i primary effect on the unburned tion of bias limits from sample acquisition. location,
carbon loss and relatively lower effect on efficiency. and stream consistency.
The contribution of constituent j to the precision index
of a resultant PiRj is
PI, = R q * PI, (4 8 5 ) 4.10 SAMPLING OF FLUE GAS

where 4.10.1 General. Flue gas flowing through a duct hai
R o/
= the absolute senFitivity coefhcient of nonuniform composition distribution. In a plane across
constituent i on resultant K the flowing flue gas, this variation i n composition oi
The absolute sensitivity coefficients are obtained from stratihcation also changes with tirne becauie of slight
a sensitivity analysis, a i detailed in Sections 5 and 7 changes fuel and tiow The goal of nue gas
When the test sample\ are to be allalYLed, iampling is to obtain the integiated average in both
the standard deviation used to set the number of samples time and space across that plane of the flue gis
is estimated. Several powble sources of data for emmat- tion This is accomplished by repeatedly \ampling
ing the standard deviation are the following number of representative points in a cross section of
prior individual analysis the duct
the maximum and minimum values of the constituent.
4.10.2 Bias for Flue Gas Sampling. The bias of a
If the data are from analysis of sample increments, flue gas sampling procedure is similar to the bias for
an approximation of the standard deviation is to divide
solid fuel and sorbent sampling. Refer to Subsection
the range by six.
4.8 3 for potential sources of bias for flue gas sampling
if the data for the ranges are from
An estimate of the bias from a sample is a combination
an approximation of the standard deviation is to divide of bias limits from sample acquisition, location, and
the range by three stream consistency Section 4 3 provides potential
When composite samples are to be analyzed for the sources of these biasei If sampling proceduies are
test, the precision indices described above are used performed using a composite sample, the bias error
due to spatial nonuniformity may be estimated by
making individual measurements at the grid sampling
4.9 LIQUID AND GASEOUS FUEL SAMPLING points and computing the spatial distribution index
according to Subsection 5 16.4 A sampling system
presentative Of the which operates at subatmospheric pressure has a poten-
mance test be Obtained tial for in-leakage which will result in a one-sided bias.
gas is severely stratified, the possibility of
natural gas typically have more bias is increased,
n than coal or other solid fuels,
ethoàs of Flue Gas Sampling. Multiple
--
the sampling plane shall be sampled to

| ||| | || | ||
for stratification and to obtain a representa-

representative samples. tive sample. The flue gas samples must be taken from
the same measurement points used for temperature
|
or Gas Sampling. The bias

| |||
determination. The number of sampling points is chosen

is similar to the bias of solid
|||| | || ||| | || ||
as described in Subsection 4.4.3 To minimize the

uncertainty, the individual sample points should be
combined to form a composite sample, which is then
or Gas Sampling. PTC continuously analyzed dunng the test. The flow from
||| | |---
should be equal. Analysis at individual

be utilized (along with using a greater bias)
S T D - A S M E PTC 4-ENGL 1998 M 0759670 Ob15011 700
when the number of points is not so large as to reduce on the filter. The weight of the sample and the flue
the number of complete traverses during the test. gas volume recorded during this process determine the
particulate concentration in the Aue gas stream. To
4.10.3.1 Sample Collection and Transport. The
avoid altering the concentration of the gas stream, the
flue gas should be collected from a sampling grid, and
velocity of the stream entering the sample nozzle must
combined into a single sample for each duct or location.
equal the velocity of gas at that point in the duct. This
The layout of points in the grid must be the same as
process is known as isskinetic sampling. Multiple points
temperature points described in Subsection 4.4.3.1. The
are sampled in the testing plane to compensate for
sampling rate from each probe must remain equal, and
nonuniform velocity distributions and stratification of
the system must be checked for leaks prior to and
the particulate concentration.
throughout the test.
Large numbers of grid points are not required for 4.11.2 Bias for Residue Sampling. Isokinetic sam-
SO2 and total hydrocarbons (THC). These samples pling is the reference method prescribed by this Code,
require heated sample lines and, therefore, a large The bias associated with this method is assumed to be
number of points is impractical. The parties to the test zero. There is stili an associated bias for the ash
shall agree on sampling procedures for these two gases. collected in the bottom ash as well as any hoppers
It should be noted that filtering the sample may cause located upstream of the fly ash collection point. If
a bias for SO2 if C a 0 is present in the particulate multiple samples are analyzed using multiple analysis
filter. Ca0 reacts with the SOz and reduces it. In this for the bottom ash, an estimate of the associated bias
case the filters should be cleaned frequently. can be made from this information. The procedure
should also be reviewed to determine if other sources
of bias may also be present.
4.1 1 RESIDUE SAMPLING 4.11.3 Methods of Sampling Fly Ash. All apparatus
Those fuels which contain ash necessitate a sample and test procedures shall be in accordance with either
of the various streams leaving the unit containing the PTC 38, Determination of the Concentration of Particu-
ash. These streams typically include fly ash and bottom late Matter in a Gas Stream, or US EPA Reference
ash. Obtaining representative samples from each of Method 17 as described below:
these streams is a difficult task. Fly ash may be collected e PTC 38. The particulate sampling train generally con-
in several hoppers as the flue gas makes its way to sists of a nozzle, probe, filter, condenser, dry gas me-
the stack. The heaviest particles fall out first, with the ter, orifice meter, and vacuum pump or aspirator. PTC
smaller particles being removed by mechanical forces 38 illustrates different configurations of sampling
resulting from the turning of the gas stream. Unfortu- trains, and should be consulted for the type of train
nately, the carbon is not uniformly distributed through- to be used on specific installations.
out the particle size range. The relative distribution of e US EPA Method 17.The US Environmental Protection
the ash into the various hoppers is also not accurately Agency has established two methods for particulate
known. The best method for obtaining a representative sampling. These reference Methods 5 and 17 are simi-
fly ash sample is to isokinetically sample the ash in lar except that Method 17 uses an in-stack filter,
the flue gas upstream of as many ash collection hoppers whereas Method 5 uses an external filter. Method 17
as possible. This usually means at the economizer is preferred since all of the particulate catch remains
outlet. This obtains a sample which has a representative in the filter holder. Method 5 requires an acetone wash
cross section of particle size and carbon content. It of the probe assembly, which may not be suitable
also ensures that the sample is representative of the for analysis for carbon. Detailed procedures for these
testing period. methods are contained in 4oCFR60 Appendix A.
The bottom ash also presents challenges in the form
of large chunks and poor distribution. A number of Isokinetic sampling of the flue gas is both the refer-
samples and several analyses of each sample may be ence and the preferred method for sampling fly ash.
required to obtain representative results. A single sample The number of grid points on the traverse sampling plane
may contain a chunk of coal not typically found in must be in accordance with PTC 38, Determination of
other samples or may have no carbon content. the Concentration of Particulate Matter in a Gas Stream.
4.11.1 General. Fly ash may be sampled isokinetically 4.11.4 Methods of Sampling Bottom Ash. For a
as particulate by drawing a flue gas sample through a bottom ash sluice stream, the preferred method of
filter and weighing the amount of particulate gathered sample collection is to take the sample with a multiholed
70
-- | ||| | || | || | | ||| |||| | || ||| | || || ||| | |---
~
STDmASME PTC 4-ENGL 1796 D 0759b70 ObL50L2 647 D
probe extending the width of the sluice stream. Pages and may be required for other test objectives. Appendix
2-3, 2-4, and 2-5 of EPRI Report EA-3610 illustrate E, Coal Properties, offers additional information.
a multihole probe. Alternatively a portion of the sluice
4.12.3.2 Sorbent and Other Additives. The mini-
stream may be diverted to a collection device where
mum information needed to determine the sulfur capture
the ash is allowed to settle and a sample then taken.
and efficiency is the sorbent ultimate analysis (calcium,
4.11.5 Other Residue Streams. In some cases, the magnesium, moisture, and inert). The determination of
parties to the test may decide not to sample from a other solid sorbent qualities such as sorbent sizing
residue stream that does not contribute significantly to may be required, depending on the objectives of the
the energy loss. Possible examples of such streams are particular test.
air heater disposal drains or vent lines, where the flow 4.12.3.3 Liquid Fuel. For liquid fuel fired steam
rate is negligible, or bottom ash drains, which may generators, the minimum fuel information needed to
have insignificant sensible heat and unburned combusti- determine efficiency is the ultimate analysis and higher
ble losses. Alternatively, samples of bottom ash sluiced heating value of the fuel. The determination of other
to a settling pond can yield a result which is no more liquid fuel qualities such as API Gravity and density
certain than using an assumed value. If a solid stream may be required depending on the objectives of the
is not sampled, the appropriate bias limit shall be test. The procedures for these determinations are found
assigned and the historical evidence documented in the in ASTM D 1298.
final report.
4.12.3.4 Gaseous Fuel. For gaseous fuel fired steam
generators, the minimum fuel information needed to
4.12 FUEL, SORBENT, AND RESIDUE determine efficiency is the constituent volumetric analy-
ANALYSIS sis of the fuel. ASTM D 1945 is used for this determina-
tion. This analysis is converted to an elemental mass
4.12.1 General. It is the intent of this Code that the analysis as detailed in Subsection 5.8.2. Higher heating
samples be analyzed in accordance with the latest value may be determined by a continuous online calo-
methods and procedures. When choosing a laboratory, rimeter as defined in ASTM D 1826. The parties to
the parties to the test should choose a certified labo- the test shall agree on which method will be used.
ratory.
4.12.3.5 Residue. Particulate residue samples shall
4.12.2 Bias for Fuel, Sorbent, and Residue Analysis. be analyzed for total carbon content according to ASTM
ASTM provides guidelines for typical lab to lab repro- D 5373, Instrumental Method, or equivalent, and cor-
ducibility. These values are listed in Tables 4.3-2 to rected for carbon dioxide as determined in accordance
4.3-5 for use in estimating the bias of a sample analysis. with ASTM D 1756. Use of a loss on ignition (LOI)
In general, the bias limit is taken as one-half the analysis is not permitted for the determination of un-
reproducibility. burned combustible loss, because several reactions may
occur in the combustion process which reduce or in-
4.12.3 Methods of Fuel, Sorbent, and Residue
crease the weight of the sample and which have no
Analysis
heating value.
4.12.3.1 Solid Fuels. For solid fuel fired steam The test for total carbon in the residue includes the
--
generators, the minimum fuel information required to determination of hydrogen, and the hydrogen result
| ||| | || | ||
determine efficiency is the ultimate analysis, proximate may be reported in addition to the carbon. This portion
analysis, and the higher heating value. Tables 4.3-2 to of the test is not mandatory for testing carbon in
4.3-5 identify the ASTM procedures to be used for residue, and experience indicates that H2 in fuel volatil-
|
analysis. ASTM D 3180 defines the procedures for izes readily and no significant quantity of H2 exists in
| |||
converting the analysis from one basis to another. The residue in the normal combustion process. This test
|||| | || ||| | || ||
latest versions of these procedures shall be utilized. If may result in a measured hydrogen content on the
ASTM adds a new or revised procedure which is order of 0.1%or less. Hydrogen quantities of this order
agreeable to both parties to the test, that procedure of magnitude should be considered as zero in the
||| | |---
may be used. combustion and efficiency calculations. A potential

The determination of other solid fuel qualities such source for error in the determination of free hydrogen
as fusion temperature, free swelling index, grindability, is that, as with carbon, this test method yields the total
ash chemistry, and fuel sizing are important to judge percentage of hydrogen in the residue as analyzed and
the equivalence of the test fuel and the specified fuel the results present the hydrogen present in the free
71
moisture accompanying the sample as well as hydrogen manual instruments are permitted, operator skill, chemi-
present as water of hydration of silicates or calcium cal freshness, and other factors related to manual instru-
oxide [Ca(OH).J. ments contribute to potentially high biases. In addition,
it is recommended that flue gas composition be moni-
tored on a continuous basis throughout the test. Fuel
4.13 FLUE GAS ANALYSIS variations, control system tuning, and other factors
cause variations in flue gas constituents. Therefore, a
4.13.1 General. It is the intent of this Code that the continuously analyzed composite sample taken from a
samples be analyzed in accordance with the latest representative grid best represents the true average gas
methods and procedures. composition.
4.13.2 Bias for Flue Gas Analysis. A number of 4.13.4.1 Oxygen. Several methods are employed
factors need to be considered in determining the bias to measure oxygen; among them are paramagnetic,
of a flue gas analysis system. Some of the potential electrochemical cell, fuel cell, and zirconium oxide.
sources of bias for the flue gas system are the following: The test engineer must ensure that the method selected
||| | |---
analyzer accuracy is appropriate for the application employed. When an
0 sampling system interference electrochemical cell is being used, care must be taken
|||| | || ||| | || ||
0 analyzer drift to ensure that other gases such as CO, do not interfere
spatial variation with the oxygen measurement. An interfering gas in
time variation the calibration gas of the approximate concentration
found in the flue gas can be used to minimize the error.
| |||
0 cal gas accuracy
|
0 sample temperature and pressure influence on analyzer 4.13.4.2 Carbon Monoxide. The most common
| ||| | || | ||
0 undetected leaks method for carbon monoxide analysis is nondispersive
interference gases infrared. The main disadvantage of this methodology
0 ambient temperature influence on analyzer is that CO, CO2, and H20 all have similar infrared
--
0 sample moisture influence on analyzer wavelength absorption. For accurate CO readings, the
accuracy of dilution ratio, if used sample must be dry and the analyzer must compensate
4.13.3 Methods of Flue Gas Analysis. The following for CO, interference. Better quality instruments deter-
Subsections describe methods and equipment operation mine CO,, then compensate CO for that value; others
for measurement of flue gas oxygen (O,), carbon monox- use a preset CO, interference factor. For determining
ide (CO), sulfur dioxide (SO2), oxides of nitrogen heat loss due to CO, the inaccuracy resulting from
(NO,), and total hydrocarbons (THC). neglecting CO, (approximately 20 ppm) is minimal.
The equipment needed to conduct a flue gas analysis However, an overestimate of 20 ppm may be significant
by extractive sampling is composed of two parts: the in relation to environmental protection regulations.
sample collection and transport system and flue gas 4.13.4.3 Sulfur Dioxide. The analysis of sulfur
analyzers. The sample collection and transport system dioxide (SO,) is typically performed using one of two
is composed of a grid of probes, sample lines, flue accepted methods: pulsed fluorescent or ultraviolet. SO2
gas mixing device, filter, condenser or gas dryer, and is very reactive, and only glass, stainless steel, or teflon
pump. The flue gas analyzers each measure a particular can be used in the sampling and analysis system.
flue gas constituent. Since an extractive sample removes
water vapor from the sample prior to analysis, this 4.13.4.4 Oxides of Nitrogen. Chemiluminescent an-
type of analysis is on a dry basis. A nonextractive or alyzers are the preferred method of analysis. These
“in situ” analysis produces results on a wet basis. Flue analyzers first convert NO, to NO in a thermal converter,
gas constituents are analyzed on a volumetric or molar then mix the NO with ozone (O3)and produce NOz
basis, in which the moles of the constituent of interest in the reaction chamber. This reaction process emits
are divided by the total moles present. The difference light, which is measured to determine the concentration
between the wet and dry basis is that the wet basis of NO,. Even though NOz represents a very small
includes both the dry moles and water vapor moles in percentage of the NO, emissions (typically less than
the denominator. 5%), NO, is reported as NOz. This has negligible effect
on steam generator efficiency.
4.13.4 Flue Gas Analysis. The types of analyzers
currently in use are continuous electronic analyzers and 4.13.4.5 Total Hydrocarbons. Total hydrocarbons
manual instruments such as the Orsat analyzer. Although (”C) measurement by flame ionization detector (FID)
72
STD-ASME PTC 4-ENGL 1998 0759b70 Ob15014 4 1 T
based instrument is the preferred method. Either methane limits from primary sensor type, wattmeter, and data
or propane should be used for calibration and the acquisition. Section 4.3 and Subsection 4.14.2 provide
resulting THC value reported as THC ppm methane potential sources of these biases. The uncertainty of
or THC ppm propane. protection CTs is typically ?10 to 20%. Measurement
CTs vary but usually have uncertainty in the range of
1 to 5%. These CTs are used to send a signal to the
4.14 ELECTRIC POWER operator. Usually only one phase uses a measurement
CT and the assumption is made that the power used
4.14.1 General. The accurate measurement of three- on the other two phases is the same (balanced load).
phase power is a complex issue. Fortunately, highly This assumption is not necessarily accurate due in part
accurate electrical measurement is of minor importance to varying power factors.
for determining steam generator efficiency. If power
measurements are used to determine auxiliary power
consumption a more exhaustive procedure should be 4.15 HUMIDITY
used. The best approach is to measure the current and
voltage in each phase of the circuit and sum the power 4.15.1 General. The moisture carried by the entering
in each phase to determine the total. In practice this air must be taken into consideration in calculations of
is difficult and costly. steam generator efficiency.
4.14.2 Bias for Electrical Power Measurement. 4.15.2 Bias for Humidity Measurement. When esti-
When estimating the bias of an electric power measure- mating the bias of a humidity measurement, test person-
ment, test personnel should consider the following list nel should consider the following potential sources.
of potential sources. Not all sources are listed, and Not all sources are listed, and some of those listed
some of those listed may not be applicable to all may not be applicable to all measurements:
measurements: 0 hygrometer
current transformer (CT) accuracy wet/dry bulb thermometer type
0 potential transformer (FT) accuracy 0 calibration
power factor on each phase 0 drift
0 wattmeter accuracy 0 thermometer nonlinearity
0 load imbalance 0 parallax
0 frequency of sampling 4.15.3 Method of Measurement. The dry-bulb and
wet-bulb temperatures should be determined at the
4.14.3 Method of Measurement. For the measure-
atmospheric air inlet to the unit. Since the specific
ment of electrical power for steam generator efficiency,
humidity does not change with heat addition unless
measurement of a single phase current and voltage
there is a moisture addition, the specific humidity of
along with the assumption of balanced load for the
the combustion air leaving the air heater is the same
auxiliaries is sufficiently accurate. Should a highly
--
as the specific humidity entering. To determine specific

accurate determination of auxiliary power be required
| ||| | || | ||
humidity, either dry-bulb and wet-bulb, or dry-bulb and

for other purposes, the determination shall be made in
relative humidity, are needed. Subsection 5.1 1.2 ad-
accordance with the 2 wattmeter or 3 wattmeter methods.
dresses absolute or specific humidity (pounds of mois-
IEEE 120 should be consylted for methods to use in
|
| |||
ture per pound of dry air). The moisture may be

making electrical power measurements.
determined with the aid of a sling type psychrometer,
|||| | || ||| | || ||
4.14.4 Estimating Bias. An estimate of the bias from hygrometer with temperature or similar device, and an
an electrical measurement is a combination of bias observed barometric pressure reading.
||| | |---
73
STDOASME PTC 4-ENGL L998 0759b70 ObL50L5 35b -
ASME FIT 4-1998
SECTION 5 - COMPUTATION OF RESULTS
5.1 INTRODUCTION error correlation versus mv determined for a thermocou-

ple in a laboratory should be applied to the measured
This Section describes the data required and the
result prior to averaging.
computation procedures for determining the perform-
In this same category is any dependent variable, which
ance of steam generators covered by this Code. Data
is a result of multiple measurements. Measurement of
acquisition principles, instruments, and methods of mea-
fluid flow is a common example. The flow result is
l surement are given .in Sections 3 and 4. Derivations
of certain equations are detailed in Appendix C.
a square root function of differential pressure and
approximately linear function of temperature and pres-
The computation equations use acronyms for variables
sure. The calculated result should be used in the data
which consist of alphanumeric characters that may be
average. The bias and precision error of the instruments
used directly in computer programs without loss of
required to determine flow should be incorporated in
interpretation. The format for these acronyms, definition
the total precision and bias uncertainty of the measured
of letters or letter combinations, and a summary of
flow parameter (refer to sensitivity coefficient in Sec-
developed acronyms are described in Section 5.20.The
tion 5.16).
alphanumericaldesignations which identify the locations
of gaseous, liquid, and solid streams in relation to the 5.2.2 Outliers. The first step in determining the aver-
steam generator components are listed on the Steam age value for a measurement is to reject bad data
Generator Boundary Data Identification List in Section points or outliers. Outliers are spurious data that are
i and shown schematically on Figs. 1.4-1 through 1.4-7. believed to be not valid and should not be included
This Section is generally arranged in the sequence as part of the calculations and uncertainty analyses.
required to compute steam generator performance after Causes of outliers are human errors in reading and
completion of a test. The test measurements recorded writing values and instrument errors resulting from
during a performance test must be reduced to average electrical interference, etc. Several documents provide
values before performance and uncertainty calculations guidance and statistical methods for determining outli-
are completed. Section 5.2provides guidance for reduc- ers; among them are ASME F'TC 19.1 and ASTM
ing test measurements to average values. Section 5.2 E178. This Code does not recommend a particular
also presents the equations to determine the precision statistical method for determining outliers. It is important
index for uncertainty analysis calculations. Sections 5.3 to note that the use of statistical methods to determine
through 5.15 present the equations to determine steam outliers can produce unrealistic results depending on
generator performance. Section 5.16 presents the equa- the method and criteria used. Most outliers are obvious
tions to determine the bias component of the uncertainty when all data recorded for a given parameter are
and the remaining equations required to complete the compared. The rejection of outliers based on engineering
test uncertainty analysis. Sections 5.17 through 5.19 judgment and/or pretest agreements by the parties in-
present guidance for determining other operating param- volved in the test is recommended. It is also recom-
eters, corrections to standard or guarantee conditions, mended that the test engineer and all parties involved
and enthalpy calculations. determine the likely cause of any outliers.
5.2.3 Averaging Test Measurement Data. The aver-
age value of a parameter measured during a performance
5.2 MEASUREMENT DATA REDUCTION
test is determined before or after the rejection of outliers.
5.2.1 Calibration Corrections. When an instrument The average value can provide important information
has been calibrated, the calibration correction should which can be used to determine outliers. If the average
be applied prior to data reduction. An example is a value is calculated before determining outliers, it must
pressure transducer for which an actual pressure versus be recalculated after all outliers are rejected.
output reading (e.g., mv output) has been determined Parameters measured during a performance test can
statistically via laboratory measurements. Similarly, an vary with respect to time and spatial location. The
7'5
Previous Page
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COPYRIGHT 2002; American Society of Mechanical Engineers Document provided by IHS Licensee=Fluor Corporation/2110503105, User=, is Blank
STD-ASME PTC 4-ENGL 1998 0759b70 ObLSOLb 292
ASME PTC 4-1998 F R E D STEAM GENERATORS
majority can be averaged on the basis that the parameter 5.23.2 Summary Data. It is common for data
has perturbations about a constant value. This includes acquisition systems to print out (and store on electronic
any parameter measured at a single point to determine media) average values and standard deviations for mea-
the value such as steam temperature or pressure. During sured parameters several times during a test period.
a steady-state performance test (as defined in Section These are called summary data. The total set of measure-
3), some single-point parameters may exhibit time ments for a test consists of m sets of measurements.
--
dependency. However, for purposes of this Code, such Each set has n readings. The average value, XAVEk,
for set k is given by Eq. (5.2-1) with the addition of
| ||| | || | ||
parameters are assumed to have a constant value equal

to the arithmetic average. a subscript to denote the set. The overall average value
However, some parameters, measured during a test of such parameters is:
|
run, must be considered with respect to space as well

| |||
as time (i.e., parameters which are not uniform within

|||| | || ||| | || ||
a plane perpendicular to the direction of flow). This 1 '"

XAVE = - XAVEk (5.2-2)
would include any measured parameter determined from mk=l
more than one point at a given location. Air heater
||| | |---
flue gas outlet temperature measurements using a grid

of thermocouples is a typical example. Parameters which Summary data can only be used if individual mea-
vary with space as well as time are averaged differently sured parameter data and standard deviation information
from parameters which vary only with time. are available for each set of measurements. If this
The average value of the parameters, along with information is not available, the subsets should be
their standard deviations of the mean and degrees of treated as individual samples.
freedom, are used to calculate the overall precision
uncertainty. 5.2.3.3 Average Value for Spatially Nonuniform
Average Parameters. The average value of parameters
5.2.3.1 Average Value for Spatially Uniform Pa- having spatial variations can be determined using numer-
rameters.' The average value of a parameter that is ical integration methods. This Code recognizes three
not expected to exhibit spatial variations is calculated methods for this calculation:
by averaging readings taken over time.
For parameters modeled as constant irdover space multiple midpoint
(e.g., feedwater temperature or pressure), or values of triple midpoint
a parameter at a fixed point in space (e.g., exit flue 0 composite midpoint
gas temperature at one point in the thermocouple grid),
the equation used to calculate average values is: Numerical integration methods are used to average
the spatial variations of a parameter. First, the average
value at each grid point is determined using either Eq.
1 1 "
XAVE = - (xi + XZ + ~3 + . . . + x,) =- 2 X; (5.2-1) (5.2-1) or (5.2-2). Next, if the parties to the test agree
n n ;=i
to use weighted averages, the individual point averages
are multiplied by a weighting factor,
where
&IVE= arithmetic average value of a measured pa-
rameter xi, = Fix; (5.2-3)
xi= value of measured parameter i at any point
in time
n = number of times parameter x is measured where
Xi= arithmetic average value of parameter at mea-
surement point i
' Some parameters measured at a single point in space may exhibit [NOTE: If Xi is temperature, it must be in
a time dependency, e.g., combustion air temperature due to ambient
air temperature changes. This Code recommends the use of F.q.(5.2- absolute terms]
I ) to calculate the average value of such parameters and increasing Xjw= weighted average value of parameter at mea-
the number of readings to reduce the precision index. However, at
the option of the parties to the test, a polynomial may be fitted to surement point i
the data for a fixed point in space. If a cume fit is utilized, the Fi= weighting factor for point i
user must (1) statistically validate the model; (2) mathematically This Code uses only one type of weighting factor:
integrate the fitted curve to determine the average value of the
parameter; and (3) develop the method for calculating the variance velocity.
of the average value for determining the precision index. The individual weighting factor is:
76
STD-ASME PTC 4-ENGL L998 0759670 ObL501’7 it29
FIRED STEAM GENERATORS ASME Yl’C 4-1998
vi The integrated average value of a parameter using the

Fi= = (5.2-4)
triple midpoint method is obtained using the following
V
equations:
where
V i = velocity normal to traverse plane at measure-
- ment point i
V = average velocity at traverse plane
and
-
v = -1r , v i ”
(5.2-5)
=
P- I
[3 (U3j.k + 2U3j+i,tl (5.2-7)
n i=i zk
j=O
u 3 j + 2 , k ) -b
where
where
p = number of rows in grid
n= number of points on the traverse measuring
4 = number of columns in grid
plane
Up,4= arithmetic (or flow/velocity weighted if appli-
This Code does not require that integrated-average
cable) average value of each row, p , and
parameters be mass flow or velocity weighted. If the
column, q. measurement point
parameter average is not weighted, an appropriate bias
( c ) Composite Midpoint Averaging Method. The com-
must be assigned in the uncertainty analysis. Subsection
posite midpoint numerical integration method can be used
7.5.3 provides guidance for estimating the bias.
if the number of grid points in either the horizontal or
Finally, after averaging the parameter at each grid
vertical direction are multiples of three. The integrated
point and applying the weighting factors (if applicable),
average value of a parameter using the composite mid-
spatial averaging is computed in accordance with the
point method is obtained using the following equation:
following methods:
( a ) Multiple Midpoint Averaging Method. The multi-
ple midpoint is the simplest and most commonly used (5.2-8)
numerical integration method. The multiple midpoint in-
tegrated average value is the same as the arithmetic aver-
age of all individual point measurements, as shown in and
the following equation:
= ( X w i+ X,, + Xw3 + .... + X,,)/n

or (5.2-6)
= (Xi+ X z + X 3 + .... + X n ) / n
5.2.4 Precision Uncertainty. General guidelines for
calculating the precision index for individual measure-
where ment parameters are given below. A more detailed
U = integrated average value of measured pa- description of uncertainty analysis calculations along
rameter with derivations is included in Section 7. Section 7
(b) Triple Midpoint Averaging Method. The triple should be reviewed prior to beginning any uncertainty
midpoint numerical integration method can be used if the calculations. The precision component of uncertainty
number of grid points in both the horizontal and vertical must be calculated using several steps. Each measured
directions are multiples of three. The following is a sche- parameter has a precision index and a certain number
matic of points in a grid with the number of columns and of degrees of freedom. There is also an overall precision
rows being multiples of three: index and number of degrees of freedom for all measure-
ment parameters combined. These cannot be calculated
until after the steam generator performance computa-
tions shown in Sections 5.3 through 5.15 are completed.
29 2.1 22 2.3 ... 24 - 1 The calculation of the overall test precision index and
... ... ... ... ... ... the precision component of uncertainty are presented
p-1.0 ~ - 1 , l p-1.2 p-1.3 ... p-1.q-1 in Section 5.16.
77
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STD-ASME PTC 4-ENGL L9q8 = 0759b70 Ob15018 Ob5
The first step in determining the precision index and programs calculate the population standard deviation
degrees of freedom for a measured parameter is to while others calculate the sample standard deviation.
||| | |---
calculate the average value and standard deviation using Some also calculate the standard deviation of the mean.
the data recorded during a test. The average value, It is important that the individual calculating the preci-
|||| | || ||| | || ||
standard deviation, and degrees of freedom for a mea- sion index understands the difference between popula-
sured parameter are calculated differently for parameters tion standard deviation, sample standard deviation, and
which vary in both time and space and those parameters standard deviation of the mean. With the use of a
| |||
which vary only in time. computer or scientific calculator, if the function for
|
“sample standard deviation” is used with the measured
| ||| | || | ||
5.2.4.1 Precision Index for Spatially Uniform Pa-
values of the parameter, the result would be STDDEV.
rameters. For multiple measurements of a parameter
If the function for “population standard deviation” is
which is not expected to exhibit spatial variations, the
used on these values, the result would be PSTDDEV.
--
standard deviation and precision index for the parameter
If the function for standard deviation for the mean or
are calculated from:
“standard error of the mean” is used, the result would
be STDDEVMN. An understanding of the differences
PI = STDDEVMN (5.2-10) will help in the use of the correct functions and
formulae.
The degrees of freedom for the precision index of
a spatially uniform parameter is determined from the
ISTDDEVZJ”~ (5.2-1 following equation:
STDDEVMN =
ì n l
-- [n (n’- 5 I) i =I
(xi-XAVE)’
1 DEGFREE = n -1 (5.2- 14)
where
DEGFREE = number of degrees of freedom
For summary data (refer to Subsection 5.2.3.2), the
STDDEV = -’[ (n- I);=¡
i ( x i - XAVE)2
1 (5.2- 12)
associated standard deviation of set k is:
or
STDDEVk = .,[ 1 “
i=, (xi - XAVE# ] (5.2- 15)
(PSTDDEV)’ -
I’”
(n - 1)
(5.2-13) where n is the number of measurements within each set.
The precision index is given by Eq. (5.2-lo), where
the standard deviation of the mean is:
where
PI=precision index for a measured pa- STDDEVMN =
rameter m
1
STDDEVMN= standard deviation of the mean for ( mn(mn-l)n=i
E
( ( n - i STDDEV;
a measured parameter
STDDEV = standard deviation estimate from the
sample measurements
+ nXAVE;) - mnXAVE2
Y (5.2- 16 )
PSTDDEV= population standard deviation for a where m is the number of sets of data.
measured parameter The degrees of freedom for the precision index and
n=number of times parameter is mea- standard deviation of the mean are:
sured
xj=value of measured parameter i at DEGFREE = m n -1 (5.2- 17)
any point in time
XAVE=arithmetic average value of a mea- The overall averages and the standard deviations of
sured parameter the mean of both the summary data and the total m . n
The equations are presented in the above format measurements have to be the same. The model is a
because some electronic calculators and spreadsheet constant value parameter for both.
78
~
STD-ASME PTC 4-ENGL 1998 0759b70 Ob35039 T T 3 m
5.2.4.2 Precision Index for Spatially Nonuniform If weighted averages are to be employed in perform-
Parameters. The precision index and degrees of free- ance calculations, with only a small number of simulta-
dom for a parameter with spatial variations must be neous traverses (fewer than six), giving only a small
determined in a manner consistent with the integration number of readings at each point, then the precision
methods discussed in the previous Sections and the index of the weighted average is estimated using a
use of weighted or unweighted averages. The most single probe as described in Subsection 7.4.1.3. This
common integration method is the multiple midpoint probe is arranged to simultaneously measure velocity
rule, for which calculation of the precision index is as and the parameter of interest (temperature or oxygen)
shown below. The equations used to calculate precision at a fixed point. There are n readings at the single
index and degrees of freedom with the triple midpoint point. The readings are multiplied:
and composite midpoint are presented in Section 7.
The precision index for multiple midpoint rule aver-
age is:
XfW,i = [LIxi
VAVE
(5.2-20)
The sample standard deviation of X,,, STDDEV, is

(5.2- 18)
calculated from Eq. (5.2-12) or (5.2-13). The precision
index for the weighted average parameter is:
The associated degrees of freedom are:
F,,-i,,STDDEV
PI = (5.2-21 )
D I14
I
N’/2
DEGFREE = (5.2- 19)
-
m
PI4
x m4 DEGFREEi
i=I
where
n = readings at the single point
N = number of traverses
where
Fn-l,cc= F distribution as read in Table 4.8-1
PI = precision index for average parameter
PI,= precision index of the parameter at The standard deviation is determined from the stan-
point i dard deviation of the single point. The degrees of
freedom for the single point are taken as infinite;
DEGFREE= degrees of freedom for average pa-
rameter therefore, the F-distribution table is used.
If weighted averages are to be employed in perform-
DEGFREEi= degrees of freedom of the parameter at
point i ance calculations with weighting factors (velocities)
m = number of grid points determined separately from the weighted parameter, then
The degrees of freedom must fall between a minimum the precision index of the weighted average parameter is
calculated from:
and maximum value based on the number of readings
taken at each grid point and the number of grid points.
The minimum possible degrees of freedom is the smaller PI = [PIUW* + (PARAVEUW - PARAVEFW)’
of the following: x PI V 2 N AVE2] (5.2-22)
number of points in the grid, m

where
number of readings taken at each grid point minus 1,
PIUW=precision index of the unweighted
N-1
average
The maximum possible degrees of freedom is the PARAVEUW= the unweighted average value of the
product of the two items listed above. parameter
Equations (5.2-18) and (5.2-19) are for unweighted PARAVEFW=’the weighted average value of the
averages and also for weighted averages when the parameter
weighting factors are measured simultaneously with the PIV=the precision index of the velocity
parameters so that the precision indexes at the grid VAVE =the average velocity
points are calculated by using weighted parameters If the velocity distribution is determined by a limited
[X,, = Fi X i , see Eq. (5.2-3)]. This calculation should number of traverses, PIV can be estimated from a large
be used for weighted averages only when there are a number of velocity readings taken over time at a single
large enough number of readings at each grid point to point, as described immediately above, with Vi used
assure statistical significance. in place of X , ¡ .
79
-- | ||| | || | || | | ||| |||| | || ||| | || || ||| | |---
5 3 CAPACITY Q r O = MrSt3I(HSt31 - HW24), Btulh (W) (5.4-2)

--
| ||| | || | ||
5.3.1 Capacity. Capacity is the maximum main steam

mass flow rate the steam generator is capable of produc- 5.4.1.2 Superheated Steam Generators. Output in
ing on a continuous basis with specified steam conditions main steam is equal to the difference between the main
|
and cycle configuration (including specified b h ~ d o w n

| |||
steam and spray mass flow rates multiplied by the

and auxiliary steam). This is also frequently referred
|||| | || ||| | || ||
difference between the main steam and feedwater enthal-

to as maximum continuous rating (MCR). pies and added to the spray mass flow rate multiplied
by the difference between the main steam and spray
5.3.2 Capacity, Peak. Peak capacity is the maximum water enthalpies:
||| | |---
main steam mass flow rate the steam generator is

capable of producing with specified steam conditions
and cycle configuration (including specified blowdown Q r O = (MrSt32 - MrW25)(HSt32 - HW24) (5.4-3)
and auxiliary steam) for intermittent operation, i.e., for + MrW25tHSt32 - HW25), Btulh (W)
a specified period of time without affecting future
operation of the unit.
5.4.2 Reheat Steam Generators. For reheat steam,
a term for each stage of reheat must be added to the
output equation. (Refer to Subsection 5.4.2.1 for the
5.4 OUTPUT (@O), Bhini (W) logic for determining reheat flow.) The additional output
from the first-stage reheat is the reheat mass flow
Output is the energy absorbed by the working fluid rate times the difference between the reheat enthalpies
that is not recovered within the steam generator enve- entering and leaving and added to the reheat spray
lope, such as energy to heat the entering air. It includes mass flow rate times the difference between the reheat
the energy added to the feedwater and desuperheating steam and reheat spray water enthalpies:
water to produce saturatedsuperheated steam, reheat
steam, auxiliary steam (refer to Subsection 5.4.3) and
blowdown. It does not include the energy supplied to QRh = MrSt33(HSt34 - HSt33) (5.4-4)
preheat the entering air such as air preheater coil steam + MrW26(HSt34 - HW26), Btulh(W)
supplied by the steam generator.
The general form of the output equation is:
5.4.2.1 Reheat Flow. For purposes of this Code,
first-stage reheat flow is calculated by subtracting from
the main steam flow the sum of the extraction flow(s)
to feedwater heater(s), turbine shaft and seal leakages,
where and any other flows extracted after the main steam
MrStz2= mass flow rate of fluid leaving location flow leaves the steam generator boundary and prior to
22, lbmlh (kgW returning to the reheater, and by adding reheat spray
HLvz2 = enthalpy of fluid leaving location 22, flow. The preferred method for determining extraction
B t d b m (Jkg) flow to feedwater heaters is calculated by energy bal-
HEnzl= enthalpy of fluid entering location z l , ance. Turbine shaft and seal, leakages may be estimated
Btu/lbm ( J k g ) from the manufacturer’s turbine heat balances or recent
turbine test data. Extraction flows that cannot be calcu-
5.4.1 Output in Main Steam. The output energy in lated by energy balance must be measured, or, if minor,
main steam is the energy added to the entering high- estimated with appropriate uncertainty factors applied.
pressure feedwater (and superheater spray water for The logic for calculating second-stage reheat flow
superheat units). Refer also to auxiliary steam and is similar to first-stage reheat flow except the calculated
blowdown, which are outputs generated from the enter- first-stage reheat flow leaving the unit is used in lieu
ing high-pressure feedwater. of main steam flow.
Consult FTC 6, Steam Turbines; for guidance in
5.4.1.1 Saturated Steam Generators. Output in
determining reheat flow.
main steam is equal to the steam mass flow rate leaving
the unit times the difference between the enthalpy of 5.43 Auxiliary Steam. Auxiliary steam includes
the steam leaving the unit and the feedwater entering steam which exits the steam generator envelope as well
the unit: as miscellaneous steam, such as atomizing steam and
80
~
STD-ASME PTC 4-ENGL 1998 = 0759670 Ob15021 b5T

FIRED STEAM GENERATORS ASME ITC 4-1998
soot blowing steam, and is included in the boiler output. QEn = QLv, Btulh (W) (5.6-1)
It does not include steam utilized to heat the entering
air. For each extraction point, add the following term
Energy entering the system is the energy associated
to the output equation:
with the entering mass flow streams and auxiliary
equipment motive power. Energy leaving the system
QrAxSt = MrSi46A(HSt46A (5.4-5) is the energy associated with the leaving mass flow
- HW24). Btülh (W) streams and heat transfer to the environment from the
steam generator surfaces.
where MrSt46A and HSt46A are the mass flow rate Expressing the energy balance in terms that can be
and enthalpy at the extraction point. readily measured and calculated, Eq. (5.6-1) becomes:
5.4.4 Blowdown. The term added to the output

equation when blowdown is utilized is: Qrf = QrO + Qb, Btulh (W) (5.6-2)
QrBd = MrW35(HW35 (5.4-6) where

- HW24), Btulh (W) Qb = the energy balance closure. Energy balance
closure is the net sum of the energy associated
with entering and leaving mass flow streams
(excluding input and output), energy due to
5.5 INPUT chemical reactions that occur within the steam
Input is the potential combustion energy. It is the generator envelope, motive power energy, and
maximum amount of energy available when the fuel radiative and convective heat transfer to the
is completely burned: environment.
In keeping with conventional practice, energy balance
closure may be divided into credits and losses:
Qr! = QrF = MrF HHVF, Btulh (W) (5.5-1)
where Qb = QrL - QrB, Btulh (W) (5.6-3)

Qrí= input, Btdh (W)
QrF= input from fuel, Btuh (W) where
MrF= mass flow rate of fuel, Ibm/h (kg/s) Q r L = losses, Btu/h (W). Losses are the net sum of
HHVF= higher heating value of fuel, BtuAbm (Jkg). energy transferred from the system (excluding
Refer to Section 5.8. external steam output) by mass flow streams
leaving the envelope plus endothermic chemi-
cal reactions that occur within the steam gener-
5.6 ENERGY BALANCE ator envelope and radiative and convective heat
transferred to the environment from envelope
In accordance with the first law of thermodynamics, surfaces.
the energy balance around the steam generator envelope Q r B = credits, Btuh (W). Credits are the net sum
can be stated as: of energy transferred to the system by mass
flow streams entering the envelope (excluding
Energy entering the system - Energy leaving the system fuel combustion energy) plus exothermic
= Accumulation energy in the system chemical reactions and motive power energy of
auxiliary equipment within the steam generator
||| | |---
Since a steam generator should be tested under envelope.

steady-state conditions, such that accumulation is zero, Substituting the above in Eq. (5.6-2), the overall energy
|||| | || ||| | || ||
the equation is: balance becomes:
Energy entering the system QrF + QrB = QrO + QrL, Btulh (W) (5.6-4)
| |||
= Energy leaving the system

|
where
| ||| | || | ||
or Q r F + Q r B = the total energy added to the system
81
--
~
~
STD-ASME PTC 4-ENGL 1998 0759b70 Ob15022 59b =

5.7 EFFICIENCY While most losses and credits can be calculated

conveniently on a percent input from fuel basis as they
Efficiency is the ratio of energy output to energy
are a function of the input from fuel, some losses and
input, expressed as a percentage:
credits are calculated more readily on a Btuh (W)
basis. The expression for fuel efficiency using mixed
output = I O 0 -
QrO units for losses and credits is:
EF = 100 - (5.7-1)
Input QrI
EF = (100 - SmQpL (5.7-6)
= loo=,%
QrF QrO
+
(QrO + SmQrL - SmQrB
When input (&I) is defined as the total energy of
--
combustion available from the fuel (QrF), the resulting where

| ||| | || | ||
efficiency is commonly referred to as fuel efficiency

(EF). SmQpL and SmQpB are the sum of the losses and
Fuel efficiency is the preferred method in this Code credits calculated on percent input from fuel basis
|
for expressing efficiency. Another method for expressing SmQrL and SmQrB are the sum of the losses and credits
| |||
efficiency is to consider the total energy input to the calculated on a Btuh (W) basis (refer to Appendix C
|||| | || ||| | || ||
steam generator envelope (QrF + QrB). This is com- for derivation)

monly referred to as gross efficiency (EGr). Appendix The mass flow rate of fuel ( M r F ) may be calculated
D addresses calculation of gross efficiency. from output and fuel efficiency determined by the
||| | |---
5.7.1 Efficiency -
Energy Balance Method. In the energy balance method:
energy balance method, the energy closure losses and
credits are used to calculate efficiency. Equation (5.6-
4) can be rewritten as follows:
MrF = 100 (EFQro
HHVF
), Ibm/h (kgís) (5.7-7)
QrF = QrO + QrL - QrB, Btulh (W) (5.7-2) The calculated mass flow rate of solid fuel is generally
more accurate than the measured flow.
The energy balance method is the preferred method
Thus, fuel efficiency expressed in terms of the losses
for determining efficiency. It is usually more accurate
and credits becomes:
than the input-output method (refer to Subsection 5.7.2)
because measurement errors impact the losses and
EF = 100-QrO = 100 QrO
(5.7-3) credits rather than the total energy. For example, if
QrF QrO + QrL - QrB the total losses and credits are 10% of the total input,
a 1% measurement error would result in only a 0.1%
QrF - QrL + QrB error in efficiency, where a 1% error in measuring fuel
= 100 ,%
QrF flow results in a 1% error in efficiency. Another major
advantage to the energy balance method is that reasons
Most losses and credits can be calculated on a percent for variations in efficiency from one test to the next
input from fuel basis in accordance with the following can be identified. Also, it is readily possible to correct
equations: the efficiency to reference or contract conditions for
deviations from test conditions such as the fuel analysis.
QrL
QpL = 100 -and
QrF
-
QpB = 100 QrB %
Q~F’
(5.7-4) -
5.7.2 Efficiency Input-Output Method.Efficiency
calculated by the input-output method is based upon
measuring the fuel flow and steam generator fluid side
thus, combining Eqs. (5.7-3) and (5.7-4), fuel efficiency conditions necessary to calculate output. The uncertainty
can also be expressed as: of efficiency calculated by the input-output method is
EF = 100 (a;:
---+- QrL
QrF
QrB) = 100
QrF
(5.7-5)
directly proportional to the uncertainty of determining
the fuel flow, a representative fuel analysis, and steam
generator output. Therefore, to obtain reliable results,
extreme care must be taken to determine these items
accurately:
82
output is normally expressed on a volume basis, Btdscf (J/

EF = 100- = 100 % (5.7-8)
Input MrF HHVF’ Nm3), HHVG. For compatibility with the units used
in the calculation procedure, the higher heating value
where MrF is the measured mass flow rate of fuel. must be converted to a energy per unit mass basis,
Btdlbm (Jkg):
5.7.3 Efficiency Calculation Convergence. The cal-
culation procedure is iterative for most types of units.
That is, an efficiency or fuel rate (input) is estimated HHVF = HHVGF, BtuAbm (J/kg)
~ (5.8-2)
to initiate the efficiency calculations. The calculations DnGF
are repeated until the efficiency (fuel ratehnput) is
within an acceptable limit. The calculation process is where
relatively insensitive to the initial estimate and con- DnGF = density of gas at the standard temperature and
verges easily. pressure conditions used for HHVGF, Ibm/scf
For calculations to determine efficiency only, where (kg/Nm3)
the efficiency result is only required for the first or For fossil fuels, the reasonableness of the higher
second decimal place, a convergence limit of 0.1% heating value can be checked based on the theoretical air
efficiency is sufficient (1.O% for hand calculations). calculated from the ultimate analysis (refer to Subsection
For calculations to develop sensitivity coefficients 5.1 1.3). Higher heating value based on typical theoretical
(refer to Section 5.16), the sensitivity coefficient is air values can be estimated using the following equation:
determined from the difference between the base effi-
ciency and the efficiency calculated with the perturbed MFrThA
data. Since the perturbation may be small, the change HHVF = IO6- Btullbm (J/kg) (5.8-3)
MqThA F’
in efficiency may be small. For developing sensitivity
coefficients, an efficiency convergence limit on the
where
order of efficiency is recommended.
MFrThA = theoretical air, l b d b m (kgkg) fuel
as-fired
MqThAF= normal value of theoretical air for fuel
5.8 FUEL PROPERTIES being checked, IbnúMBtu. (Refer to Sub-
5.8.1 Heating Value of Fuel. Higher heating value, section 5.1 1.3 for typical ranges.)
HHVF refers to the as-fired higher heating value on a
5.8.2 Chemical Analysis of Fuel. An ultimate analysis
constant pressure basis. For solid and liquid fuels,
of solid and liquid fuels is required to determine
HHVF is determined in a bomb calorimeter, which is
the mass of the individual elements involved in the
a constant volume device. Since fuel is burned in
combustion process, and the mass of inert ash. The
a steam generator under essentially constant pressure
total as-fired moisture content must also be determined.
conditions, the bomb calorimeter values must be cor-
When the ultimate analysis is on an air dried or moisture
rected to a constant pressure basis:
free basis, it must be converted to an as-fired basis.
A gaseous fuel analysis is usually reported on a dry
HHVF = HHVFcv + 2.644 MpHZF, (5.8-1) or saturated basis. The amount of moisture as-fired
BtuAbm (J/kg) should be determined and the chemical analysis and
HHVGF should be adjusted to the as-fired condition.
where HHVFcv is the higher heating value of the fuel The ultimate analysis of the fuel is used to calculate
on a constant volume basis as determined from a bomb the quantity of air and products of combustion. When
calorimeter and MpH2F is the mass percent of H2 in the ultimate analysis is expressed on a percent mass
the fuel. basis, the constituents considered in the calculations
The user should ensure that the laboratory performing are carbon (CF), hydrogen (H2F), nitrogen (N,F), sulfur
the fuel analysis has not made this correction. For (SF), oxygen (02F),water (H20F), and ash (AsF).
gaseous fuels, the higher heating value is determined Trace gaseous elements, such as chlorine, which is not
under constant pressure conditions; therefore, the calo- considered in the calculations, should be added to the
rimeter values do not need correction. nitrogen in the fuel for calculation purposes. Note that
The calculations throughout this Code utilize higher hydrogen is considered on a dry or moisture free basis,
heating value expressed in units on a mass basis, Btu/ ¡.e., it does not include the hydrogen in the water in
lbm (Jkg). For gaseous fuels, the higher heating value the fuel.
83
-- | ||| | || | || | | ||| |||| | || ||| | || || ||| | |---
For some combustion processes, those involving solid VpCj Mokj

fuels in particular, all of the carbon may not be MvFk = M w k 2 (5.8-6)
100 ’
burned. When there is unburned carbon, the combustion Ibmlmole fuel (kg/mole)
calculations utilize the carbon burned, Cb, rather than
the actual carbon in the fuel (refer to Subsection 5.1 1.3).
Similarly, if it is ascertained that there is a significant where
quantity of unburned hydrogen (greater than 1% of the k = fuel constituents expressed on a mass basis.
actual hydrogen in the fuel), the hydrogen burned, H2b, For this Code, these are C, H2, N2, S, 0 2 ,
should be used in the calculations rather than the actual H20. For a gaseous fuel, it is assumed that
hydrogen available in the fuel. (Refer to Subsection water is in a vaporous state and the acronym
--
5.10.3.) H20V is used throughout the calculatioqs.

| ||| | || | ||
A proximate analysis for solid fuels (typically coal) j = fuel components expressed on a by volume
includes the determination of volatile matter, fixed or mole basis, such as CH4, C&, etc.
carbon and ash, as weil as the as-fired moisture. The
|
VpCj=.as-fired fuel components (such as CH,, C2&),

| |||
sulfur content may also be reported. A complete proxi- percent by volume

|||| | || ||| | || ||
mate analysis is not necessarily required for determina-

Mo&= moles of constituent k in component j. For
tion of efficiency. Typical applications for a proximate
example:
analysis include:
For component j = C2H6, and k = C, Mokj
||| | |---
A cost-effective means for obtaining the variations in = 2.

ash, moisture, and sulfur during a test, to better quan- For component j = C2H6, and k = H2, Mokj
tify the uncertainty of these constituents.A large num- = 3.
ber of proximate analyses can be used to determine Mwk= molecular weight of constituent k, lbdmole
ash, moisture, and possibly sulfur in lieu of a large (kg/mole)
number of ultimate analyses. MwCF=molecular weight of the gaseous fuel, l b d
For coal, the volatile matter and fixed carbon are re- mole (kg/mole). This is the sum of each MVkF
quired to determine enthalpy of the entering coal. If value on a mass per unit mole (or volume)
not determined, dry ash free values may be agreed basis, lbdmole (kghole).
upon prior to the test and adjusted for the measured MvFk= mass of constituent k per unit volume of fuel,
ash and moisture content of the as-fired fuel. lbdmole or lbm/ft3 (kg/mole or kg/m3)
Volatile matter and fixed carbon (frequently expressed MpFk= mass percentage of constituent k
as the ratio of fixed carbon to volatile matter) are an
indication of how difficult a coal is to burn. In general, 5.8.3 Multiple Fuels. When more than one fuel is
the lower the volatile matter with respect to the fixed fired, the ultimate analysis and higher heating value is
carbon, the more difficult the fuel is to bum. For the weighted average based upon the mass flow rate
guarantee tests, this ratio may be considered when of each fuel. For the initiai calculation, the total fuel
evaluating whether the test fuel is suitably equivalent input is estimated from measured fuel flow or calculated
to the contract fuel. from output and estimated efficiency. The input from
the primary fuel (fuel with the major input) is calculated
A gaseous fuel analysis expresses the individual
by difference from the total input and the input calcu-
hydrocarbon compounds and the other constituents on
lated for the fuel(s) for which the measured mass flow
a volumetric percentage basis. For the combustion
rate is used. The mass flow rate of the unmeasured
calculations in this Code, the gaseous fuel analysis is
fuel is then calculated from the HHV and input from
converted to a mass basis. The Gaseous Fuel Calculation
that fuel. The efficiency calculations must be reiterated
Form included in Appendix A may be used for this
conversion. The calculations follow the general logic until the estimated input and the input calculated from
below: measured output and efficiency are within the conver-
gence tolerance discussed in Subsection 5.7.3.
MpFk = 100- MvFk %mass (5.8-4)

MWCF’ 5.9 SORBENT AND OTHER ADDITIVE
PROPERTIES
This Section addresses solid andior gaseous material
MwGF = 2 MvFk, Ibm/mole (kg/mole) (5.8-5) other than fuel that is added to the gas side of the
84
~
STDmASME PTC 4-ENGL 1998 0759b70 ObL5025 2T5
steam generator envelope. Additives can impact the MrF= mass flow rate of fuel, Ibmh (kg/s). Repeat
efficiency and combustion process in several ways: efficiency calculation until the calculated MrF
converges within the guidelines of Subsec-
additives may increase the quantity of residue and
tion 5.7.3.
“sensible heat of residue” losses
0 additives may introduce moisture which increases 5.9.2 MFrSbk - Mass of Constituents in Sorbent,
“moisture in flue gas” losses and alters the flue gas Ibm/lbm Fuel (kgíkg). The important constituents in
specific heat the sorbent are the reactive products, the moisture, and
additives may undergo a chemical change and alter the the inerts. The mass of each constituent is converted
flue gas composition or may alter the air requirement to a masdmass from fuel basis:
chemical reactions that are endothermic require heat
which is an additional loss
chemical reactions that are exothermic add heat which MFrSbk = MFrSb MpSbk,
-Ibm/lbm fuel (kg/kg) (5.9-2)
1O0
is an additional credit where
Since limestone is widely used for sulfur removal, k = constituent in the sorbent. The reactive constituents
this Code specifically addresses the impact of the specifically addressed are:
addition of limestone on the efficiency and combustion CUCO,= calcium carbonate (Cc)
calculations. The term “sorbent” is used throughout the M g C 0 3 = magnesium carbonate (Mc)
Code to refer to any material added to the flue gas CU(OH)~ = calcium hydroxide (Ch)
(within the steam generator envelope) that is not fuel. Mg(Orn2= magnesium hydroxide (Mh)
The calculations for limestone demonstrate the princi- MpSbk= percent of constituent k in the sorbent
ples of calculation required for the effect of most 5.93 MqCO2Sb - Gas From Calcination of Sor-
additives on efficiency and combustion products. If the bent, lbm/Btu (kglJ). When heat is added to calcium
effects of other additives on flue gas constituents or carbonate and magnesium carbonate, CO2 is released.
particulates are independently demonstrated and rneasur- This increases the dry gas weight:
able or calculable, the parties to the test may include
the associated credits and/or losses. In addition to
limestone, the calculations address hydrated lime, which
MoCOZSb = ZMoFrClhk -MFrSbk, (5.9-3)
consists of calcium hydroxide, Ca(OH)2,and magnesium Mwk
hydroxide Mg(OH),, as a potential sorbent for reducing moles/lbm fuel (moleslkg)
SOz. When inert materials such as sand are added, the
calculations below should be made as if limestone
containing only inert material and moisture were used.
--
5.9.1 MFrSb - Mass Fraction of Sorbent, lbm/

M F r C 0 2 S b = 44.01 MoCOZSb, (5.9-4)
| ||| | || | ||
Ibm Fuel (kgkg). Combustion and efficiency calcula- lbm/lbm fuel (kg/kg)
tions are sensitive to the measured sorbent mass flow
|
rate. Therefore, the mass flow rate of sorbent must be

| |||
determined accurately.
|||| | || ||| | || ||
To simplify the combustion and efficiency calcula-

tions, the sorbent mass flow rate is converted to a MFrC02Sb
MqC02Sb = , lbm/Btu (kg/J) (5.9-5)
mass of sorbent/mass of fuel basis. The mass flow rate HHVF
||| | |---
of fuel is measured or estimated initially. The efficiency

calculations are repeated until the estimated and calcu- where
lated fuel mass flow rates are within the convergence k = constituents that contain carbonates, typi-
tolerance of Subsection 5.7.3: cally calcium carbonate (Cc) and magne-
sium carbonate (Mc)
M F r S b = MrSb, Ibmlibm fuel (kg/kg fuel)
~ (5.9-1) MoFrClhk = calcination fraction for constituent k,
MrF moles CO2 released/mole of constituent.
Two constituents are addressed directly
where by this Code. Magnesium carbonate
MrSb= measured mass flow rate of sorbent, Ibmh (Mc) calcines readily at partial pressures
(kgW of CO2 typical of combustion with air
85
and normal operating temperatures of MqWSb= mass of total water from sorbent on an
atmospheric fluidized bed steam genera- input from fuel basis, Ibm/Btu (kg/J)
--
tors and thus the calcination fraction is MrWSb= mass flow rate of total water from sor-
| ||| | || | ||
normally considered to be 1.0. Not all bent, lbm/h (kgls)

of the Caco3 (Cc) is converted to C a 0
5.9.5 MFrSc - Sulfur Capture/Retention Ratio,
and CO2, however. Refer to Subsection
|
I b d b m (kgkg). The sulfur capturehetention ratio is

| |||
5.10.8 for determination.

the mass of sulfur removed divided by the total mass
|||| | || ||| | || ||
Mwk= molecular weight of constituent k, lbm/

of sulfur available. The sulfur capturehetention ratio
mole (kglmole)
is determined from the measured 0, and SO, in flue gas.
MuCO2Sb= moles of gas (CO,) from sorbent, moles/
Ibm fuel (moles/kg) 5.9.5.1 MFrSc When SO2 and O2 Are Measured
||| | |---
MFrCO2Sb = mass fraction of gas (CO2) from sorbent, on a Dry Basis

lbdlbm fuel (kg/kg), and where 44.01
is the molecular weight of carbon dioxide
MqCO2Sb= mass of gas (CO,) from sorbent on an MFrSc =
input from fuel basis, Ibm/Btu (kg/J)
1 - (DVpSO2 (MoDPcu + 0.7905 MoThAPcu)\
5.9.4 MqWSb - Water From Sorbent, lbm/Btu \ 100 ( I - DVp02/20.95)MoSO2 /
(kg/J). The total moisture added due to sorbent is the
sum of the moisture in the sorbent and the moisture (1 + 0.887 ( 1 Dvpso2/100
DVp02/20.95
-
))
released due to the dehydration of calcium hydroxide
and magnesium hydroxide: Ibm/lbm (kg/kg) (5.9-1 O)
MFrH20Sb + MFrSbk
MoWSb = (5.9-6) MoThAPcu =
18.015 Mwk
rnoles/lbm fuel (moiedkg) +---
rnoles/mass fuel (5.9-1 I )

MFrWSb = 18.015MoWSb, Ibm/lbm fuel (kglkg) (5.9-7)
MpCb MpSF MpN2F

MODPCU= -+ -+ - (5.9-12)
1201 3206.4 2801.3
MqWSb = -
MFrWSb, Ibrn/Btu (kg/J) (5.9-8)
HH VF + MoC02Sb, moles/rnass fuel
MrWSb = MFrWSb MrF, Ibrn/h (kgls) (5.9-9) Mos02 = -

MpSF rnoles/lbrn fuel (rnoles/kg) (5.9- 13)
3206.4’
where
where MuDPcu = moles of dry products from the combus-
k = constituents that contain water or hydrox- tion of fuel (CO,, SO2, N2 from fuel)
ides that are dehydrated, typically cal- with 100% conversion of the sulfur to
cium hydroxide (Ch) and magnesium SO2 plus the dry gas from sorbent (CO,),
hydroxide (Mh) moledmass fuel
MFrH2OSb= mass fraction of the water in sorbent, MuThAPcu= moles of theoretical air required for the
l b d b m fuel (kgkg) gasified products in the fuel with total
MoWSb = total moles of water from sorbent, moles/ conversion of the sulfur in fuel to SO,,
Ibm fuel (moleskg) moleslmass of fuel. The constituents in
MFrWSb = mass fraction of total water from sorbent, the fuel, CB (carbon burned), H2, S, and
IbmAbm fuel (kgkg) 0, are on a percent mass basis.
86
~ ~
STD-ASME PTC 4-ENGL 1998 W 0759b70 Ob15027 078 W
FIRED STEAM GENERATORS ASME Pl'C 4-1998
MoSO2= moles of SO2 per Ibm fuel that would vp02,

be produced with 100% conversion of VpS02= measured O2 and SO2 in the flue gas,
the sulfur in the fuel to SO2, moledibm percent volume. They must be measured
fuel (moles/kg) at the same location and expressed on
DVpO2, a wet basis. SO2 is usually measured in
DVpSO2= measured O2 and SO2 in the .flue gas, ppm. To convert to a percent basis,
percent volume. They must be measured divide ppm by 10,OOO.
at the same location and expressed on 5.9.6 MoFrCuS -
Calcium to Sulfur Molar Ratio,
a dry basis. SO2 is usually measured in moledmole
ppm. To convert to a percent basis,
divide ppm by 10,000.
MwS MpCak
MoFrCaS = MFrSb -2- (5.9-18)
5.9.5.2 MFrSc When SO2 and O2 Are Measured M p S F MwCak'
on a Wet Basis
moleshole
MFrSc =
where
VpSO2 [MoWPcu + MoThAPcu (0.7905 + M o W A ) ] MpCak= percent of calcium in sorbent in form
- ( 100[1 - ( i + M o W A ) Vp02/20.95]MoS02 of constituent k, percent mass
MwCuk = molecular weight of calcium compound
VpS02/I O0
1 - (1 + MoWA ) Vp02/20.95 k, lbdmole (kg/mole)
CuCû3= calcium carbonate (Cc) MW = 100.089
Ibm/lbm (kglkg) (5.9-i 4) Ca(0H,ì2= calcium hydroxide (Ch) MW = 74.096
MwS= molecular weight of sulfur, 32.0ó4
Ibnúmole
5.9.7 MFrSsb - Mass Fraction Spent Sorbent, I b d
||| | |---
MpH2F MpWF
MOWPCU = MODPCU+
+
~ - (5.9-15) Ibm Fuel (kgkg). Spent sorbent is the solid residue
201.6 1801.6
|||| | || ||| | || ||
remaining from the sorbent after evaporation of the
moisture in the sorbent, calcination/dehydration and
+ MFrWAdz + M ~ W S B moies/mass
, fuel
mass gain due to sulfation:
18.016
| |||
|
| ||| | || | ||
K = 2.387 (0.7905 + M o W A ) - 1.0 (5.9-16) MFrSsb = M F r S b - M F r C 0 2 S b
- MFrWSb + MFrS03, (5.9- 19)
Ibmlibm fuel (kgkg)
--
M o W A = 1.608 MFrWA, moles/mole (5.9-17)
M o WPCU = MoDPcu plus moles of water from flue, M F r S 0 3 = 0.025 MFrSc MPSF, (5.9-20)
plus moles of water from sorbent, plus Ibm/lbm fuel (kg/kg)
moles of additional water, moles/mass
fuel
MFrWA = mass of moisture in air per mass of dry where
air, Ibnúlbm (kgkg) MFrSO3= mass fraction of SO3 formed in the
MoWA = moles moisture per mole of dry air, sulfation (sulfur capture) process, I b d
moles/mole Ibm fuel (kgkg). The constant 0.025 is
MFr WAdz = additional moisture at location z, such as the molecular weight of sulfur divided
atomizing steam and sootblowing steam, by the molecular weight of SO3 and
lbdlbm fuel as-fired. Also refer to Sub- divided by 100 to convert percent mass
section 5.12.7. to mass fraction.
87
~ ~ ~~
STD-ASME PTC Li-ENGL 3998 0759670 Ob35028 TO4
ASME F'TC 4-1998 FIRED STEAM GENERATORS
5.10 RESIDUE PROPERTIES mass flow rate of fuel should be measured or

estimated initially and the calculations repeated
Residue is the ash and unburned fuel removed from
until the calculated mass flow rate of fuel
the steam generating unit. When a sorbent such as
based on efficiency is within the guidelines
limestone or an inert material such as sand is introduced,
of Subsection 5.7.3.
the residue includes the spent sorbent (solid sorbent
The most universal measurement location for the
products remaining after evaporation of the moisture
mass of residue is the dust loading or fly ash leaving
in the sorbent, calcinatioddehydration, and weight gain
the unit, refer to Section 4.1 1. The results of this test
due to sulfation). Residue is analogous to refuse when
procedure are normally reported on a mass per volume
used to refer to the solid waste material removed from
of flue gas basis. While the dust loading result from
a fossil fuel fired steam generator.
this test is considered accurate, the flue gas mass flow
5.10.1 MFrRs - Mass of Residue, Ibmhbm Fuel calculation from this test is not considered as accurate
(kgkg). The ash in fuel and spent sorbent are converted as the gas mass flow calculated stoichiometrically by
to a mass of residue per mass of fuel basis: this Code. Accordingly, the mass flow rate of residue
based on dust loading results is calculated as follows:
MpAsF + 100 MFrSsb
MFrRs = (5.10-1)
(100 - M p C R s ) ' MvRs MrFg
MrRsz = , Ibm/h (kg/s) (5.10-4)
lbm/ibm fuel (kg/kg) Ci DnFg
where where
MpAsF= ash in fuel, percent mass MvRs = dust loading results tested in accordance with
MFrSsb= mass fraction of spent sorbent per mass Section 4.1 1, grains/ft3 (g/m3)
of fuel, lbdlbm fuel (kgkg) MrFg = mass flow rate of wet flue gas, refer to Subsec-
MpCRs = unburned carbon in the residue, per- tion 5.12.9, Ibm/h (kg/s)
cent mass DnFg= density of wet flue gas at conditions MVR
above reported, Ibm/ft3 (kg/m3)
5.10.2 MqRsz - Mass of Residue at Location z,
CI = 6,957 grains/lbm (US Customary), 1,000
Ibm/Btu (kg/J). The mass of residue exiting the steam
generator envelope must be determined for the energy g k g (SI)
balance calculations and for the intermediate residue 5.10.3 MpCRs -
Unburned Carbon in the Residue,
calculations below: percent. The unburned carbon in the residue, MpCRs,
refers to the free carbon and is used to determine
MpRsz MFrR unburned carbon from fuel. The residue contains carbon
MqRsz = , lbm/Btu (kg/J) (5.10-2)
1O0 HHVF in the form of carbonates as well as free carbon when
limestone is utilized, as well as from fuels with a high
where MpRsz is the percent of total residue exiting carbonate content in the ash. The standard tests for
the steam generator envelope at location z, percent. carbon in the residue determine total carbon (MpToCRs).
It may be impractical to measure the residue collected It is also necessary to determine the carbon dioxide
at all extraction points. In such cases, the unmeasured content in the residue ( M P C O ~ R S )and
, correct the
residue may be calculated by difference from the total total carbon results to a free carbon basis (MpCRs).
calculated residue and the measured residue. The esti- Refer to Section 4.12 regarding the analysis methods
mated split between the unmeasured locations must be to be specified. If the lab analysis is not clear whether
agreed upon by all parties to the test: total carbon (MpToCRs) or free carbon (MpCRs) is
reported, it should be clarified. When sorbent with
calcium carbonate is utilized, the CO, in residue is
MpRsz = 100 MrRsz , % mass (5.10-3) required to calculate the quantity of Caco3 in the
MFrRs MrF
residue and the calcination fraction of calcium carbonate
in the sorbent:
where
MpRsz = residue collected at location z, percent
MrRsz= measured mass flow rate of residue at location MpCRs = MpToCRs (5.10-5)
z, Ibmh (kg/s) --
12.01
MpCOZRs, lbm/100 ibm residue
MrF= mass flow rate of fuel, lbmíh (kg/s). The 44.01
88
-- | ||| | || | || | | ||| |||| | || ||| | || || ||| | |---
~
STD.ASME PTC 4-ENGL i1998 W O759670 Ob35029 940
When residue is collected at more than one location, MpCb

M p C b o = 100 - % (5.1 O- 1O)
the weighted average of carbon and carbon dioxide in MPCF'
residue is calculated from:
5.10.7 ECm - Combustion Efficiency, percent. The

combustion efficiency is 100 minus the unburned com-
(5.10-6)
bustible losses on Section 5.14 (excluding the loss due
to pulverizer rejects):
ECm = 100 - QpLUbC - QpLCO (5.10-11)

MpRsz MpCOZRsz, % mass
MpC02Rs = 2 (5.10-7) - QpLH2Rs - QpLUbHc, %
1O0
5.10.8 MoFrCZhCc - Calcination Fraction of Cal-

NOTE: if measured, unburned hydrogen is to be reported on a dry cium Carbonate, moles C02/mole Caco3. Calcination
--
basis. On units utilizing limestone sorbent, there is a strong potential is the endothermic chemical reaction when carbon diox-
that hydrogen in the residue is from the water of hydration of ide is released from compounds containing carbonate
| ||| | || | ||
calcium oxide which will not be detected by the normal method of

testing for free moisture. if it is ascertained that unburned hydrogen (CO,) such as calcium carbonate to form calcium oxide
in the residue is real and significant and it cannot be corrected by and magnesium carbonate to form magnesium oxide.
operating techniques, the hydrogen in the fuel should be corrected
|
Magnesium carbonate, MgCO, (Mc), calcines readily

| |||
for unburned hydrogen for the combustion and efficiency calculations

in the same manner as unburned carbon. Refer also to Subsection under- the normal operating conditions of atmospheric
|||| | || ||| | || ||
5.105 fluidized bed boilers. However, not all of the calcium

carbonate, Caco3 (Cc), is converted to C a 0 and COz.
5.10.4 MpUbC - Unburned Carbon in Fuel, per-
The calcination fraction is determined from the mea-
cent mass. The unburned carbon in the residue is used
||| | |---
sured COz in the residue. Assuming that the principal

to calculate the percent of the carbon in the fuel that
carbonates in the sorbent are magnesium carbonate and
is unburned:
calcium carbonate, these calculations assume that the
COz in the residue is in the form of calcium carbonate.
M p U b C = MpCRs MFrRs, % mass (5.10-8) If a sorbent is used that contains significant amounts
of a carbonate that is more difficult to calcine than
calcium carbonate, the principles of this Code should
5.10.5 MpCb - Carbon Burned, percent mass. The be followed but the amount of CO2 in the residue
actual percent carbon in the fuel that is burned is the should be proportioned among the carbonate compounds
difference between the carbon in the fuel from the in view of the difficulty of calcination:
ultimate analysis and the unburned carbon. The actual
carbon burned ( M p C b ) is used in the stoichiometric MrRs MpCO2Rs M w C c
MoFrClhCc = 1 - (5.10- 12)
combustion calculations in lieu of carbon in fuel MFrSb MpSbCc M w C 0 2
(MpCF):
where
M p C b = MpCF - MpUbC, % mass (5.10-9) MpCO2Rs = mass of CO2 in residue, percent mass
MFrSb = mass fraction of sorbent, lbdlbm fuel
(kg/kg)
NOTE: If it is determined that there is unburned hydrogen, MpUbH2, MpSbCc= mass of C a c o 3 (Cc) in sorbent, percent
the actual hydrogen burned, MpHZb, must be used in the combustion
and efficiency calculations in lieu of MpH2F;
MwCc = molecular weight of Caco3 (Cc),
100.089 Ibmímole (kghole)
M w C 0 2 = molecular weight of CO2, 44.01 I b d
M p H 2 b = MpH2F - MpUbH2 mole (kglmole)
Refer to Subsection 5.10.3.

5.11 COMBUSTION AIR PROPERTIES
5.10.6 MpCbo - Carbon Burnout, percent. Carbon
burnout is the carbon burned divided by the carbon 5.11.1 Physical Properties. The calculations and deri-
available and expressed as a percentage: vation of constants used in this Code are based upon
89
~~~ ~~
STD-ASME PTC 4-ENGL 3998 = 0759b70 Ob35030 bb2
ASME PM: 4-1998 FRED STEAM GENERATORS
a composition of air as follows [i]: 0.20946 02,0.78102 bulb temperature (PsWvTdb), psia. The
N2, 0.00916 Ar, 0.00033 CO2 moles per mole of air curve fit is valid for temperatures from
(and other trace elements), yielding an average molecu- 32°F to 140°F:
lar weight of 28.9625. For simplification of the calcula- C1 = 0.019257
tions (N2) includes the argon and other trace elements, C2 = 1.289016E-3
and is referred to as “atmospheric nitrogen” (NZa), C3 = 1.211220E-5
having an equivalent molecular weight of 28.158. C4 = 4.534007E-7
Below is a summary of the nominal properties of C5 = 6.841880E-11
air used in this Code: C6 = 2.197092E-11
Pu = barometric pressure, psia. To convert in.
0 volumetric composition: 20.95% oxygen, 79.05% ni-
Hg to psia, divide by 2.0359.
||| | |---
trogen
Tdbz = temperature of air (dry-bulb) at location
0 gravimetric composition: 23.14% oxygen, 76.86% ni-
z, “F
|||| | || ||| | || ||
trogen
Twb = temperature of air (wet-bulb) at location
5.11.2 MFrWDA - Moisture in Air, I b d b m Dry z, O F
Air (kgkg). The moisture in air is determined from Rhmz = relative humidity at location z
| |||
measured inlet air wet-bulb and dry-bulb temperature
5.11.3 MqThACr - Theoretical Air (Corrected),
|
or dry-bulb temperature and relative humidity in con-
| ||| | || | ||
Ibm/Btu (kg/J). Theoretical air is defined as the ideal
junction with psychrometric charts, or calculated from
minimum air required for the complete combustion of
vapor pressure as determined from Carrier’s Eq. (5.11-
the fuel, i.e., carbon to CO2, hydrogen to H20, and
2) when wet-bulb temperature is measured or Eq. (5.1 1-
--
sulfur to SO2. In the actual combustion process, small
3) when relative humidity is measured:
amounts of CO and nitrous oxides (NO,) are formed
and commonly measured. Also, small amounts of SO3
and gaseous hydrocarbons are formed but less frequently
Pp WvA measured. The impact of these minor species is negligi-
MFrWDA = 0.622 (5.11-1)
(Pa - PPWVA)’ ble on the combustion calculations addressed by this
Code. Refer to Appendix C for a rigorous treatment
Ibm H20/lbm dry air (kg/kg)
of CO and NO, which may be used if CO andor NO,
is significant (greater than 1,000 ppm):
PpWvA = PsWTwb (5.1 1-2)
- ( f a - PsWvTwb)(Tdbz - Twbz), psis MqThAf MFrThA, lbm/Btu (kglJ)

~
HHVF
(5.1 1-5)
2830 - 1.44 Twbz
MFrThA = O. 1 15 1 MpCF (5.1 1-6)

PpWvA = 0.01 RHMz PsWvTdb, psia (5.11-3)
+ 0.3430 MpHZF + 0.0431 MpSF
- 0.0432 Mp02F, lbm/lbm fuel (kg/kg)
PsWvTz = CI + C 2 T + C3T2 + C4T3 (5.11-4)
+ C5T4 + C6T5, psia where fuel constituents MpCF, MpH2F, MpSF, and
Mp02F are on a percent mass basis.
For typical fossil fuels, the value of calculated theoret-
where ical air is a good check on the reasonableness of the
PpWvA = partial pressure of water vapor in air, fuel analysis. Expressed on a Ibdmillion Btu (MBtu)
psia. This may be calculated from rela- basis (MQTHA x lo6), a valid fuel analysis should fall
tive humidity or wet- and dry-bulb tem- within the ranges of theoretical air shown below:
perature. Coal (Vhf,,,,f > 30%) 735-775 Ibm/MBtu
PsWvTz= saturation pressure of water vapor at Oil 735-755 Ibm/MBtü
wet-bulb temperature (PsWvTwb) or dry- Natural Gas 715-735 I b m B t ü
90
STDOASME PTC 4-ENGL 1998 0 7 5 î b 7 0 Ob1503L 5 T î 9
RRED STEAM GENERATORS ASME PTC 4-1998
The theoretical air for carbon and hydrogen, 816 the steam generator envelope. Refer to
and 516 lbm/MBtu respectively, are the practical maxi- Subsection 5.9.5 for calculation.
mum and minimum values for hydrocarbon fuels.
5.11.4 XpA - Excess Air, percent. Excess air is
For monitoring operation and analysis of combustion,
the actual quantity of air used, minus the theoretical
the theoretical air required to produce the gaseous
air required, divided by the theoretical air, and expressed
products of combustion is more meaningful than the
as a percentage:
ideal value defined above. In commercial applications,
particularly for solid fuels, it is not feasible to bum
the fuel completely. The gaseous products of combustion (MFrDA - MFrThACr)
XpA = 100 (5.1 1-10)
are the result of the fuel that is burned or gasified. MFrThACr
When additives are used, secondary chemical reactions
(MqDA - MqThACr)
may also occur. For example, when C a 0 reacts with = 100 ,%
MqThA Cr
SO2 in the flue gas to form Caso4 (a method of sulfur
reduction), additional O2 supplied from air is required.
Therefore, for purposes of the calculations in this Code, In this Code, corrected theoretical air [Eq.(5.11-7)]
corrected theoretical air which accounts for the actual is used as the basis for calculating excess air. Defined
--
combustion process is used. as such, zero percent O2 in the flue gas corresponds
to zero percent excess air. Excess air may also be
| ||| | || | ||
Corrected theoretical air is defined as the amount of

defined based on ideal theoretical air, and calculated
air required to complete the combustion of the gasified
by substituting ideal theoretical air [Eq. (5.11-5) or
fuel and support secondary chemical reactions with
|
(5.11-6)] in Eq. (5.11-10) above.

| |||
zero excess 02.By definition, the theoretical products of

For efficiency calculations, excess air must be deter-
|||| | || ||| | || ||
combustion would have no CO or gaseous hydrocarbons:

mined at the steam generator exit (14), as well as air
heater exits (15), (15A), and (15B), if applicable; and
MqThACr = MFrThACr, Ibrn/Btu (kg/J) (5.1 1-7) air heater gas inlets (14A) and (14B), if different from
||| | |---
HHVF the steam generator exit. Refer to Figs. 1.4-1 through

1.4-7, and Section 1.4 for boundary data identification
numbers. Excess air is determined from the volumetric
MFrThACr = 0.1 151 MpCb + 0.3430 MpH2F (5.11-8) composition of the flue gas. It may be calculated
+ 0.043 1 MpSF ( 1 + 0.5 MFrSc) stoichiometrically based on O2 or CO2, and analytically
based on COz and MpCb/S ratio in the fuel. Measure-
- 0.0432 MpO2F. Ibrn/lbrn fuel as-fired ment of O2 is the most common and preferred continuous
analysis method. O2 is used as the basis for calculation
of excess air in this Code. An additional advantage of
using measured O2 is that for a given type of fuel
MFrThACr
MoThACr = (5.1 1-9) (coal, oil, gas, etc.), excess air depends only on O2 and
28.963 ' not on the specific analysis. Conversely, the relationship
rnoleslrnass fuel as-fired between CO2 and excess air is strongly dependent on
the fuel analysis due to the amount of CO2 produced
being dependent on the carbonhydrogen ratio of the
where
fuel. When Oz is measured on a wet basis, an additional
MqThACr = theoretical air (corrected), IbmA3tu. Note
variable is introduced (H20 in the flue gas). However,
that when a sulfur removal process is
even on a wet basis, O2 versus excess air is essentially
employed, the excess air and combustion
constant for typical variations in moisture in flue gas
calculations are dependent upon where
produced from a given fuel source.
the sulfur removal occurs in relation to
the flue gas composition measurements. 5.11.4.1 O2 Analysis on DRY BASIS Where the
MoThACr = theoretical air (corrected), moledmass Moisture in the Flue Gas Is Condensed Such as
fuel as-fired When an Extractive Sampling System Is Used
MpCb= MpCF - MpUbC = carbon burned on
a mass percentage basis
MFrSc= sulfur capture ratio, I b d b m . This item DVpOZ(MoDPc + 0.7905 MoThACr)
XpA = 100 ,%
is normally assumed to be zero when MoThACr(20.95 - DVpO2)
the sulfur removal occurs external to (5.1 1 - 1 1)
91
STD=ASME PTC 4-ENGL 1998 m 0759670 Ob15032 435 m
MpSF DVpN2a = 100 - DVpO2 (5.1 1 - 17)

Mpcb + (1
MoDPc = - - MFrSc) -
1201 3206.4 - DVpCO2 - DVpSO2 - DVpN2J 9%
F
-MpN2
i - (5.1 1-12)
2801.3
+ MoCOZSb, moleslmass fuel
MoDFg = MoDPc + MoThACr
rnoles/mass fuel (5.11-18)
where
DVpO2 = oxygen concentration in the flue gas,
percent by volume, dry basis where
MoDPc= moles of dry products from the combus- DVpCO2= carbon dioxide in the flue gas, percent.
tion of fuel (CO, from carbon burned, Note that for comparison to an Orsat
actual SO2 produced (excluding sulfur analysis, DVpSO2 must be added.
retained due to SO, capture techniques), DVpSO2= sulfur dioxide in the flue gas, percent
N, from fuel and the dry gas from volume
sorbent, CO2, moledmass fuel DVpN2f = nitrogen from fuel in the flue gas, percent
MFrSc = mass fraction of sulfur capture, lbm/lbm volume. This term is shown separately
fd (kg/kg)
from the atmospheric nitrogen from the
MoCO2Sb= moles of gas from sorbent, moles/lbm air to note the technical distinction be-
fuel (moleskg). Refer to Section 5.9 for tween the two. Since the quantity of
calculation. nitrogen from the fuel is generally insig-
nificant compared to the nitrogen in the
5.11.4.2 Calculation of DVpO2, DVpCO2, air, calculation of this term is sometimes
DVpSO2, DVpN2J and DVpN2a on a DRY BASIS omitted.
When Excess Air Is Known DVpN2a = atmospheric nitrogen (refer to Subsection
5.1 1.1) in the flue gas, percent volume
MoDFg= moles of dry gas per Ibm of fuel as-fired
5.11.4.3 O2 Analysis on WET BASIS Where the
XpA MoThACr 0.2095 Flue Gas Sample Includes Moisture, Such as In-
DVp02 = ,% (5.1 1-13)
MoDFg Situ Monitors and Heated Extractive Systems
XpA = (5.1 1-19)
[ MpCb + 100 M o C 0 2 S b
100 [
V p 0 2 [ M o W P c + MoThACr(0.7905 + MoWA)]
MoThACr(20.95 - V p 0 2 ( 1 + M o W A ) )
DVpCO2 =
12.01
MoDFg j,
%
(5.1 1 - 14)
MoWA = I .608 MFrWA, rnoles/rnole dry air (5.1 i -20) ||| | |---
MpSF
(1 - MFrSc) +M p H2 F
|||| | || ||| | || ||
32.064 MoWPC = MoDPc -

DVpSO2 = ,% (5.11-15) 201.6
MoDFg
+-MpWF
' + MFrWAdz
(5.1 1-21)
| |||
1801.5 18.015
|
| ||| | || | ||
+ MoWSb, rnoles/lbrn fuel
28.013 1 where
--
DVpN2f = ,% (5.1 1-16)

MoDFg MFrWA= moisture in air, lbm H20Abm dry air
92
STD-ASME PTC 4-ENGL 1998 0759b70 Ob15033 3 7 1
FIRED STEAM GENERATORS ASME I'TC 4-1998
MoWA= moles of moisture in air, moles H201

mole dry air \ 28.013 I
1.608= molecular weight of dry air divided by VpN2f = ,% (5.11-26)
MoFg
the molecular weight of water
MpWF= H,O in fuel, percent mass basis
MFrWAdz = additional moisture at location z, such as
atomizing steam and sootblowing steam, VpN2a = 100 - V p 0 2 - VpCO2 (5.1 1-27)
lbm/lbm fuel as-fired. Refer to Subsec- - V p S 0 2 - VpH2O - VpNZf, %
tion 5.12.7. Measured values of steam
and fuel flow are usually sufficiently
accurate for this calculation. If the mass
flow rate of fuel is reiterated based on MoFg = MoWPc
calculated efficiency, this item should
be included. 0.7905 + MoWA (5.1 1-28)
MoWPc = MoDPc plus moles of wet products from
the combustion from fuel, plus the wet + XPA
-( i + MoWA)
products from sorbent, plus any addi- 100
tional moisture, moles/mass fuel
V p 0 2 = oxygen concentration in the flue gas,
percent by volume, wet basis where
MoFg= moles of wet gas per lbm fuel as-fired
MoWSb = total water from sorbent, molesílbm fuel..
Refer to Section 5.9. 5.11.5 MqDAz -
Dry Air, lbm/Btu (kg/J). The
--
quantity of dry air entering the steam generator ahead

| ||| | || | ||
5.11.4.4 Calculation of Vp02, VpCO2, VpSO2,

VpH20, VpN2f, and VpN2a on a WET BASIS When of location z is calculated from the excess air determined
to be present at location z as follows:
Excess Air Is Known
|
| |||
|||| | || ||| | || ||
X p A MoThACr 0.2095 (5.1 1-22) MqDAz = MqThACr (5.1 1-29)

vp02 = ,%
Mo Fg
lbrn/Btu (kglJ)
||| | |---
12.01 + ;:F;C02Sb
vpco2 = ,% (5.11-23) MFrDAz = MFrThACr (5.1 1-30)
lbmllbm fuel (kglkg)
MpSF ( i - M F r S c ) 5.11.6 MrAz - Wet Air, lbmh (kg/s). The quantity

32.064 of wet air at any location z is, the sum of the dry air
vpso2 = ,% (5.11-24)
M oW G plus moisture in air:
MqAz = (1 + M F r W A ) MqDAz, (5.1 1-31)

Ibm/Btu (kglJ)
+ MFrWAdz + 100 MoWSb

0.18015 MrAz = MqAz QrF, lbmlh (kgls) (5.1 1-32)
where
(5.1 1-25) QrF= input from fuel, Btu/h (w)
93
-~
STDaASME PTC 4-ENGL 1978 m 0759b70 Ob15034 208 W
ASME WC 4-1998 FIRED STEAM GENERATORS
Note that to determine the air mass flow rate leaving Wet flue gas is required for calculations such as air
the air heaters (to the burners), the excess air leaving heater leakage, hot air quality control equipment energy
the boiler or economizer must be reduced by the losses and draft loss corrections. The total gaseous
estimated amount of setting infiltration. products excluding moisture are referred to as “dry
flue gas,” and are used in the energy balance efficiency
5.11.7 DnA -
Density of Air, lbm/ft3 (kg/m3). The calculations. The general logic of this Section is that
density of wet air is calculated using the ideal gas wet flue gas is the sum of the wet gas from fuel
relationship: (fuel less ash, unburned carbon and sulfur captured),
combustion air, moisture in the combustion air, and
any additional moisture, such as atomizing steam and
DnA = cr(c2 Ibm/ft3 (kg/m3) (5.11-33) moisture and gas added from the addition of sorbent.
Rk (C3 + TAz)
+
Dry flue gas is determined by subtracting all moisture

from the wet flue gas.
5.12.1 MqFgF - Wet Gas From Fuel, lbm/Btu

Rk=-,- f t . Ibm -
Mwk 1 b m . R k g . K
( ) (5.11-34) (kg/J)
MqFgF =
(100 - MpAsF - MpUbC - MFrSc M p S F )
100 HHVF
MwA = -+ MFrwA Ibm/mole (kglmole) (5.11-35) ibmmtu (kglJ) (5.12-1)
1 MFrWA’
+-
28.963 18.015
where
where MpAsF= ash in fuel, percent mass
R = universal molar gas constant, 1,545 ft . Ibf/lbm- MpUbC= unburned carbon, percent mass
-
mole R (8314.5 Jkg . mole . K) MFrSc = mass fraction of sulfur capture, lbdlbm
Rk= specific gas constant for gas k, (kgkg)
MpSF = sulfur in fuel, percent mass
“““(3
Ibm . R kg . K
MwA= molecular weight of wet air, lbdmole (kg/
5.12.2 MqWF, MqWvF - Moisture From H,O
(water) in Fuel, IbmíBtu (kg/J)
mole)
Pu = barometric pressure, psia (Pa). . To convert in.
Hg to psia, divide by 2.0359. M pW F
MqWF = 1bmlBtu (kg/J) (5.12-2)
PAZ= static pressure of air at point z, in. wg (Pa) 100 HHVF’
TAz= temperature of air at point z, O F (OC)
CI = 5.2023 Ibf/ft (US Customary), 1.0 J/m3 (SI)
C2= 27.68 in. wg/psi (US Customary), 1.0 Pa/Pa where MpWF is the water in the fuel, percent mass.
For gaseous fuels, moisture is assumed to be in a
(SI)
C3= 459.7”F (US Customary), 273.2”C (SI) vaporous state. Water vapor from fuel (MpWvF) must
be accounted for separately from liquid water for the
energy balance calculations.
5.12 FLUE GAS PRODUCTS 5.12.3 MqWH2F - Moisture From the Combustion
Flue gas quantity is calculated stoichiometricallyfrom of Hydrogen in the Fuel, 1bmíBtu (kg/J)
the fuel analysis and excess air. Computations are not
valid if significant quantities (in comparison to flue
gas weight) of unburned hydrogen or other hydrocarbons M q WH2F = 8‘937 MpH2F, IbrnBtu (kg/J) (5.12-3)
100 HHVF
are present in the Rue gas.
The total gaseous products are referred to as “wet
flue gas.” Solid products, such as ash from the fuel,
unburned carbon, and spent sorbent, are considered 5.12.4 MqCO2Sb - Gas From Sorbent, Ibm/Btu
separately and are not a part of the wet flue gas mass. (WJ)
94
-- | ||| | || | || | | ||| |||| | || ||| | || || ||| | |---
STDmASME PTC 4-ENGL 1998 M 0759b70 ObL5035 L44 D
MqCOZSb =
MFrC02Sb
, lbm/Btu (kg/J) (5.12-4)
MqWFgz = M q W F + M q W v F + MqWH2F
HHVF + MqWSb + MqWAz (5.12-9)
+ MqWAdz, 1bmlBtu (kg/J)
5.12.5 MqWSb - Water From Sorbent, I b d t u
WJ) 5.12.9 MqFgz - Total Wet Flue Gas Weight,
IbmíBtu (kg/J). The total wet gas weight at any location
MqWSb = MFrwsb, lbm/Btu (kg/J)
~ (5.12-5) z is the sum of the dry air, moisture in air, wet gas
HHVF from the fuel, gas from sorbent, water from sorbent
and any additional moisture:
5.12.6 MqWAz - Moisture in Air, lbm/Btu (kg/J).
Moisture in air is proportional to excess air and must MqFgz = MqDAz + MqWAz + MqFgF
be calculated for each location z where excess air is + MqCOZSb + MqWSb (5.12-10)
determined. + MqWAdz, lbm/Btu (kg/J)
MqWAz = M F r W A MqDAz, IbmlBtu (kg/J) (5.12-6) The mass flow rate of wet flue gas at any location
z may be calculated from:
5.12.7 MqWAdz - Additional Moisture in Flue
MrFgz = MqFgz QrF (5.12-11)
Gas, IbmlBtu (kglJ). This item accounts for any mois-
ture added to the flue gas not accounted for above. = MqFgz M r F HHVF, lbm/h (kgls)
Typical sources are atomizing steam and sootblowing
Steam. Additional moisture measured on a mass flow 5.12.10 M ~ D - F D~
~ ~Flue Gas Weight, lbm/Btu
basis is converted to a mass Per unit mass Of (kg/J). The dry flue gas weight is the difference between
--
basis for the stoichiometric calculations. For the initiai the wet flue gas and the total moisture:
| ||| | || | ||
calculations, either the measured or an estimated fuel

rate is used. Where the quantity of additional moisture (5.12-12)
MqDFgz = MqFgz - MqWFgZ,
is small compared to the total moisture, this is usually
|
Ibm/Btu (kg/J)
| |||
sufficiently accurate. If the efficiency calculations are

|||| | || ||| | || ||
reiterated for other purposes, the mass fraction of

additional moisture with respect to mass rate of fuel 5-12-11 MpWFgz - Moisture in flue Gas, percent
should be also corrected: mass. The percent moisture in wet flue gas is required
for determining the flue gas enthalpy:
||| | |---
MqWAdz = MFrWAdz, Ibm/Btu (kg/J) (5.12-7)

HHVF MpWFgz =z -
100 MqWFgz, % mass (5.1 2- 13)
MqFgz
5.12.12 MpRsFg - Residue (Solids) in Flue Gas,

MrStz
MFrWAdz = - , Ibmllbm fuel (kglkg) (5.12-8) percent mass. The solids in flue gas add to the enthalpy
MrF of flue gas. When the mass of residue exceeds 15 lbm/
MBtu input from fuel or when sorbent is utilized, the
where MrStz is the summation of the measured addi- mass of solids in gas should be accounted for:
tional moisture sources entering the steam generator
upstream of location z, lbm/h. MpRsz M F r R s
MpRsFgz = , % mass (5.12-14)
Moisture due to evaporation of water in the ash pit MqFgz H H V F
is considered negligible with regard to the mass flow
rate of flue gas, and ignored in this calculation. However, where MpRsz is the percent of total residue (solids)
if measured, it should be included here. in the flue gas at location z, percent wet gas.
5.12.8 MqWFgz - Total Moisture in Flue Gas, 5.12.13 DnFg - Density of Wet Flue Gas, l b d
lbm/Btu (kg/J). The total moisture in flue gas at any ft3 (kg/m3). The density of wet flue gas is calculated
location z is the sum of the individual sources: using the ideal gas relationship. Refer to Section 5.11
95
STDmASME PTC 4-ENGL 1998 m 0759b70 Ohla5036 080 m
ASME FIT 4-1998 FIRED STEAM GENERATORS
for calculation of the flue gas constituents on a volumet- MwFg= molecular weight of wet flue gas, I b d
ric basis and calculation of the density of air: mole (kg/mole)
MwDFg= molecular weight of dry flue gas, I b d
mole (kghole)
DnFgz = Pa P F g ) , Ibm/ft3 (kg/m3) (5.12-15)
+ Pu= barometric pressure, psia (Pa). To con-
Rk(C3 + TFg) vert in. Hg to psia, divide by 2.0359.
PFgz= static pressure of flue gas at point z, in.
wg- P a )
Rk=---- f t . lbf - ( ')
MwFg' lbm . R kg . K
(5.12-16)
TFgz = temperature of flue gas at point z, "F (OC)
MoDFg = moles dry gas. Refer to Eq. (5.1 1-18)
for calculation.
MoFg= moles wet gas. Refer to Q. (5.11-28)
When the flue gas constituents have been calculated for calculation.
on a wet basis, the molecular weight of wet flue gas CI = 5.2023 lbf/ft (US Customary), 1.0 J/m3
is calculated as follows: Pa (SI)
C2= 27.68 in. wg/psi (US Customary), 1.0
MwFg = 0.32 V p 0 2 + 0.4401 VpCO2 (5.12- 17) Pa/Pa (SI)
C3 = 459.7"F (US Customary), 273.2"C (SI)
+ 0.64064 VpSO2 + 0.28013 VpN2F
+ 0.28158 VpN2a + 0.18015 V p H 2 0 , 5.13 AIR AND FLUE GAS TEMPERATURE
rnass/mole 5.13.1 TRe - Reference Temperature, "F ( O C ) . The
reference temperature is the base temperature to which
When the flue gas constituents have been calculated streams (air, fuel, and sorbent) entering he steam
on a dry basis? the mokcular weight of wet flue gas generator envelope are compared for calculation of
can be calculated as follows: sensible heat losses and credits. The reference tempera-
ture for this Code is 77°F (25°C).
MoDFg
MwFg = MwDFg-, (5.12- 18) 5.13.2 TMnAEn - Average Entering Air Tempera-
--
MoFg ture, OF ("C). The air temperature entering the steam

generator envelope is required to calculate the credit
| ||| | || | ||
Ibm/mole ( k g h o l e ) due to the difference between the entering air tempera-

ture and the reference temperature. When air preheating
|
coils are utilized and the energy is supplied from

| |||
+ 0.4401 DVpCO2 outside the envelope, the entering air temperature is

|||| | || ||| | || ||
MwDFg = 0.32 DVpO2 (5.12-19)

the temperature leaving the air preheating coils (TA8).
+ 0.64063 DVpSO2 + 0.28013 DVpN2F When the energy to an air preheating coil is supplied
from within the envelope (steam from the steam genera-
+ 0.28158 DVpN2a + 0.18015 D V p H 2 0 ,
||| | |---
tor), the entering air temperature is the temperature

masslmole entering the air preheating coils (TA7). W h p there is
more than one fan of the same type, such as two
forced draft fans, it is normally sufficiently accurate
to assume balanced air flows between the fans and use
MOFg - MODFg the arithmetic average of the air temperatures in each
D V p H 2 0 = 100 , %O2 dry (5.12-20)
MoDFg stream. When there is evidence of unbalance, weighted
averages should be used. When there is more than one
source of air entering at different temperatures, the
where average entering air temperature must be determined.
R = universal molar gas constant, 1,545 ft . The general philosophy for determining the mass frac-
IbfAbm-mole . R (8,314.5 Jkg-mole K) tion of individual streams is that all air streams may
Rk= specific gas constant for gas k, be measured or some streams may be measured (and
or calculated by energy balance) and the balance calcu-
lated by difference from the total air flow (calculated
96
STDmASME PTC 4-ENGL 3998 m 0759670 Oh35037 TL7 m
FIRED STEAM GENERATORS ASME FT

' C 4-1998
stoichiometrically).It should be noted that some amount are repeated until the estimated and cal-
of air (usually not more than 2 or 3% at full load) culated fuel mass flow rates are within
enters the unit as leakage through the setting and the the convergence tolerance of Subsec-
actual temperature is indeterminate. Unless otherwise tion 5.7.3.
specified or agreed to by the parties to the test, the MqA14= total wet air entering steam generator
infiltration air is considered to enter the unit at the envelope upstream of location (14),
same temperature as the measurable air streams and lbm/Btu (kg/J)
the uncertainty accounted for in the measurement bias. MrAII = measured primary air flow to pulverizers,
Typical examples of units with multiple air sources lbmh (kg/s)
are pulverized coal fired units with cold primary air where secondary air is the only other significant source
fans (TA8A) or pulverizer tempering air supplied from of air, the mass flow fraction of the remaining air
the environment (TA5). The weighted average air tem- equals (i - MFrAII). For the equation above, it is
perature entering the unit TMnAEn, must be calculated: assumed that the tempering air to the pulverizers is
the same temperature as the air entering the primary
TMnAEn = MFrAzl T A z l + MFrAz2 TAz2 . .. (5.13-1) air heater. Refer to the tempering air calculation below
+ MFrAzi TAzi, OF (OC) if it is not.
For units with hot primary air fans or exhauster fans,
and where pulverizer tempering air is supplied from
When the entering air temperature at the various
the environment (TA5), the mass flow rate of the
locations differs significantly, it is more correct to
tempering air may be calculated as follows:
determine the average entering air temperature from
the average entering enthalpy of the entering air:
MrA5
HMnAEn = MFrAzl H A z l + MFrAz2 HAz2 . . . (5.13-2) MFrA5 =
M q A l 4 MrF HHVF'
(5.13-4)
+ MFrAzi HAzi, Btu/lbm (J/kg)
Ibm/lbm (kglkg)
where
HMnAEn= average enthalpy of wet air entering the
boundary, Btu/lbm (Jíkg). The average
air temperature is determined from the MrAII(HA9A - H A I I )
MrA5 = (5.13-5)
average enthalpy. HA9A - HAS
MFrAz= mass flow rate fraction of wet air enter- Ibm/h (kg/s)
ing at location z to total wet air flow
leaving the steam generator based on
where
excess air at location (14), lbdlbm
MrAS= pulverizer tempering air mass flow rate,
(kgkg) Ibmh (kg/s)
TAz = temperature of wet air at location z ,
O F (OC) 5.13.3 TFgLvCr - Corrected Gas Outlet Tempera-
HAZ= enthalpy of wet air at temperature TAz, ture (Excluding Leakage), O F (OC).On units with air
Btdlbm (Jíkg) heaters, air leakage within the air heater depresses the
For pulverized coal units with cold primary air fans, exit gas temperature without performing any useful
the mass flow fraction of the primary air, MFrAl1, work. For the efficiency calculations, the measured gas
may be calculated as follows: temperature leaving the air heater must be corrected
to the temperature that would exist if there were no
MrAll air heater leakage, TFgLvCr.
MFrAl1 = (5.13-3) The correction calculation method below utilizes the
M q A l 4 MrF HHVF'
nomenclature and products of combustion calculated in
lbmllbm (kg/kg) the preceding Section. Refer to Appendix C for the
derivation of the Eq. (5.13-6). For alternate calculation
where methods, refer to PTC 4.3, Air Heaters.
MrF= fuel mass flow rate, lbmh (kg/s). Esti- When there are two or more air heaters with approxi-
mate or use the measured mass flow mately the same gas flow through each, the air and
rate initially. The efficiency calculations gas temperatures may be averaged, and one corrected
97
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~
STD-ASME PTC 4-ENGL L998 = 0759b70 Ob15038 953

ASME PTC 4-1998 RRED STEAM GENERATORS
gas temperature calculated. However, when there are from Subsection 5.12.8 using the excess
two or more air heaters with different gas flows, such air entering the air heater, lbm/Btu
as a primary and secondary air heater, the corrected MqFgLv= wet gas weight leaving the air heater
gas temperature must be calculated separately for each from Subsection 5.12.8 using the excess
and a weighted average used for efficiency. Refer to air leaving the air heater, lbm/Btu
Subsection 5.13.4 below.
5.13.4 TMnFgLvCr - Average Exit Gas Tempera-
ture (Excluding Leakage), O F (OC).The average exit
gas temperature (excluding leakage) is used to calculate
TFgLvCr = TFgLv the losses associated with constituents leaving the unit
in the flue gas (e.g., dry gas loss, water from fuel
(5.13-6) loss, etc.). On units where the flue gas exits at more
than one location, the weighted average gas temperature
x (TFgLv - TAEn), O F (OC) must be determined. The general philosophy for de-
termining the mass fraction of individual flue gas
streams is that all gas streams may be measured or
some streams may be measured (andor calculated by
energy balance) and the balance calculated by difference
HATFgLv - HAEn
MnCpA = (5.13-7) from the total (calculated stoichiometrically). On units
TFgLv - TAEn ' with two or more air heaters of the same type and
Btullbrn F (J/kg K) size, it is normally sufficiently accurate to assume equal
gas flows, and use the arithmetic average of the gas
--
temperature leaving each air heater (excluding leakage),

| ||| | || | ||
where TFgLvCr. When there is evidence of unbalance,

MnCpA= mean specific heat of wet air between weighted averages should be used. For units with
multiple air heaters not of the same type where the
|
TAEn and TFgLv, Btdibm, OF (Jíkg K).

| |||
This is equal to the enthalpy of wet air gas mass flow and gas temperature leaving the air
|||| | || ||| | || ||
at the measured gas outlet temperature heaters is not the same, for example, separate primary
minus the enthalpy of wet air at the air and secondary air heaters for pulverized coal fired units
inlet temperature divided by the tempera- with cold primary air fans, the gas flow distribution
||| | |---
ture difference. between the air heaters must be determined to calculate

MnCpFg= mean specific heat of wet flue gas be- a weighted average exit gas temperature (excluding
tween TGLv and TFgLvCr, Btdlbm, OF leakage). On some units, gas may be extracted upstream
(Jkg K). If using the curves of Section of the air heater(s) or other stream generator heat trap(s)
5.19 (as opposed to the computer code and must be included in the determination of the average
that calculates specific heat), use the exit gas temperature.
instantaneous specific heat for the mean The following addresses pulverized coal fired units
temperature. with separate primary air heater@) (used to heat the
TAEn = air temperature entering the air heater, air to the pulverizers) and secondary air heater(s) and
O F (OC). Location (7), (7A), (8), or @A), is a typical example of how the calculations for two
Figs. 1.4-1 through 1.4-7. For air heaters different types of air heaters might be handled. The
that have two air inlets and one gas methodology is based upon measuring the primary air
outlet (a trisector air heater, for example), flow to the pulverizers and calculating the gas flow
this item is the weighted average of the through the primary air heaters by energy balance:
air temperature leaking to the gas side
of the air heater. Use the manufacturer's
TMnFgLvCr = MFrFgl4B TFglSBCr (5.13-8)
estimated leakage split to calculate the
average air temperature of the leakage + ( I - MFrFglBB)TFglSACr, O F ( O C )
air.
TFgLv = gas temperature leaving the air heater, When there is a significant difference in the gas
OF (OC). Location (15) or (15A), Figs. temperature at the various exiting locations, the average
1.4-1 through 1.4-7. gas temperature, TMnFgLvCr, should be determined
MqFgEn= wet gas weight entering the air heater from the average enthalpy of the exiting wet gas:
98
-~ ~
~
STD-ASME PTC r(-ENGL 3998 0759670 Ob35039 89T
HMnFgLvCr = MFrFgl4B HFglSBCr measured and conveniently calculated. In the first cate-
+ ( i -MFrFg14B)HFgl5ACr, (5.13-9) gory are losses that are a function of input from fuel
and can be readily expressed in terms of loss per unit
Btu/lbm (Ukg)
of input from fuel, i.e., expressed as a percentage of
fuel input. Losses due to products of combustion (dry
MrFg14B gas, water from fuel, etc.), are expressed in these units.
MFrFg148 = (5.1 3- 1O) In the second category are losses not related to fuel
MqFgl4 MrF HHVF'
input, which are more readily calculated on an energy
Ibm/ibm (kg/kg) per unit of time basis, such as the loss due to surface
radiation and convection. The losses in each category
are grouped generally in order of significance and
where
universal applicability with applicability taking pref-
HMnFgLvCr =average enthalpy of wet gas leaving the
erence.
boundary (excluding leakage), Btdlbm
The logic for calculating losses that are a function
(Jkg). The average temperature is deter-
of fuel input is described below:
mined from the average enthalpy.
MFrFgl4B = mass fraction of wet gas entering the
primary air heater to total wet gas enter-
ing the air heaters, Ibmílbm (kgkg) QpLk = 100 Mqk x (HLvk - HRek) (5.14- 1)
M q F g l 4 = total wet gas entering air heaters, Subsec- = 100 Mqk x MnCpk x (TLvk - TRe), ?6
tion 5.12.8, lbm/Btu (kglJ)
M r F = fuel mass flow rate, lbmlh (kg/s). Esti-
mate or use the measured mass flow
rate initially. Refer to Subsection 5.7.3 Ibm constituent
QpLk = 1OOx X- Btu x "F (5.14-2)
regarding convergence tolerance. Btu fuel input Ibm OF
M r F g l 4 B = mass flow rate of wet gas entering the
primary air heater, lbmh (kg/s). This - Btu loss ,%
item may be calculated by energy 100 Btu In
balance.
where
MrFgl4B = MrAII (HAI I - HA8A) (5.13-1 I ) Q p U = loss from constituent k, percent of input
(HFgl4B - HFglSBCr)? from fuel, Btu/lûû Btu input from fuel
(J/lOO J)
Ibm/h (kgls)
M q k = mass of constituent k per Btu input
in fuel. This is the unit system used
where
throughout this Code for items that are
M r A l l = measured primary air mass flow rate,
related to the fuel such as air and gas
lbm/h (kg/s)
quantities.
HFglSBCr = enthalpy of wet gas for the gas tempera-
TLvk= temperature of constituent k leaving the
ture leaving the primary air heater ex-
steam generator envelope, O F ( O C )
cluding leakage (corrected), using the
TRe = reference temperature, O F ( O C ) . The refer-
moisture in wet gas entering the air
ence temperature is 77OF (25OC).
heater
MnCpk= mean specific heat of constituent k be-
HA1 I = average enthalpy of wet air entering
tween temperatures TRe and TLvk, B t d
pulverizers. If the pulverizers are not
lbm, "F (Jkg . K). Whenever practical,
operating at the same primary air flow,
enthalpy is used in lieu of the mean
this should be a flow weighted average
specific heat and the difference in tem-
rather than an arithmetic average.
perature.
HLvk= enthalpy of constituent k at temperature
TLvk, Btu/lbm (Jkg)
5.14 LOSSES HRek= enthalpy of constituent k at temperature
The calculation of losses falls into two categories TRe, Btu/lbm (Jkg). For water that enters
in accordance with the method in which they are the steam generator envelope as liquid
99
-- | ||| | || | || | | ||| |||| | || ||| | || || ||| | |---
ASME €TC 4-1998
~
STD-ASME
~ ~~~~
PTC 4-ENGL 2996 0759b70 Ob15040 502

~
-
and leaves the envelope as steam (water QpLWvF = 100 MqWvF HWvLvCr, % (5.14-6)
vapor), the ASME Steam Tables are
used for enthalpy and are based on a where
32°F reference temperature for enthalpy. HStLvCr= enthalpy of steam (water vapor) at 1 psia
The enthalpy of water at TRe is 45 at temperature TFgLvCr or TMnFgLvCr.
Btu/lbm (105 kJ/kg). For all other con- The enthalpy of steam (water vapor)
stituents, the enthalpy is based upon does not vary significantly at the low
the Code reference temperature of 77°F partial pressures of water vapor in air or
(25°C). Thus, the reference enthalpy is flue gas, and thus, specifically calculating
zero and does not appear in the loss/ the actual partial pressure of water vapor
credit energy balance equation as shown is not warranted. Refer to Subsection
above. 5.19.5 for curve fit.
HWvLvCr= enthalpy of water vapor at TFgLvCr or
5.14.1 gpLDFg - Dry Gas Loss, percent TMnFgLvCr, Btu/lbm (Jkg). The dis-
tinction of enthalpy of steam (HSr) ver-
QpLDFg = 100 MqDFg HDFgLvCr, 16 (5.14-3) sus the enthalpy of water vapor (HWv),
is that HSr is the enthalpy of vapor with
where respect to liquid water at 32°F (OOC) as
MqDFg= dry gas mass flow leaving the steam the reference in accordance with ASME
generator based on the excess air at Steam Tables, and includes the latent
heat of vaporization of water, where
location (13) or (14). Note that when
hot air quality control equipment (e.g., HWV is the enthalpy of water vapor with
precipitator) is located between the steam respect to the enthalpy of water vapor
at 77'F (25OC) as the reference (which
generator exit and the air heater gas
inlet, there may be a dry gas loss due is zero). Refer to Subsection 5.19.4 for
to air infiltration. This loss is included curve fit.
in the loss calculated for the hot AQC HWRe= enthalpy of water at the reference tem-
equipment. perature TRe, BtuAbm (Jkg)
HDFgLvCr = enthalpy of dry gas at the temperature HWRe= TRe - 32 = 45, Btu/lbm
leaving the boundary corrected for !eak- 5.14.3 QpLWA - Loss Due to Moisture in Air,
age (excluding leakage). Refer to Sub- percent
section 5.19.3 for curve fit.
QpLWA = 100 MFrWA MqDA HWLvCr, % (5.14-7)
5.14.2 QpLH2F, QpLWF, QpLWvF - Water From
Fuel Losses, percent
where
5.14.2.1 b s Due
~ to Water Formed From the MqDA = mass of dry air corresponding to the excess
Combustion of H2in the Fuel air used for dry gas loss, Ibm/Btu (kg/J)
5.14.4 QpLSmUb - Summation of Losses Due to
QpLH2F = 100 MqWH2F (HStLvCr - HWRe), % Unburned Combustibles, percent. The loss due to
(5.14-4) unburned combustibles is the sum of the applicable
losses for the individual unburned constituents.
5.14.4.1 Loss Due to Unburned Carbon in Resi-
5.14.2.2 Loss Due to Water (H20) in a Solid or due, percent
Liquid Fuel. This may also be applicable to manufac-
tured gaseous fuels:
HHVCRs
QpLUbC = MpUbC- .% (5.14-8)
HHVF
QpLWF = 100 MqWF (HSrLvCr - HWRe), % (5.14-5)
where HHVCRs is the heating value of carbon as it
occurs in residue.
5.14.23 Loss Due to Water Vapor in a Gas- When unburned hydrogen in the residue is considered
mus Fuel insignificant (normal case, refer to unburned hydrogen
100
-- | ||| | || | || | | ||| |||| | || ||| | || || ||| | |---
STD-ASME PTC 4-ENGL 1998

0759b70 Ob15041 448 - ASME R C 4-1998
below), a value of 14,500 Btu/lbm (33,700 I d k g ) 5.14.4.4 Loss Due to Pulverizer Rejects, percent.
should be used for HHVCRs. Any unburned carbon is This loss includes the chemical and sensible heat loss
expected to be in an amorphous form. The NBS Techni- in pulverizer rejects:
cal Notes does not list the heat of formation of carbon
in the amorphous form; only the heats of formation
of carbon in the graphite and diamond forms &e listed QpLPr = 100 M q P ï (HHVPï + HPr), % (5.14-1 i )
[2]. The higher heating value for carbon in the residue
adopted by ASME PTC 4.1-1964 has been retained in
this Code. When it is determined that unburned hydro-
gen is present in the residue and is accounted for MrPr
separately, a value of 14,100 Btu/lbm (32,800 W k g ) MqPr = Ibm/Btu (kg/J) (5.14-12)
MrF HHVF’
shall be used based on the heat of formation of CO2.
5.14.4.2 Loss Due to Unburned Hydrogen in Resi- where
due, percent. Refer to Subsection 5.10.3. Where it is M r P r = measured mass flow rate of pulverizer
established that unburned hydrogen is present and cannot rejects, lbmh (kg/s)
be eliminated by operating adjustments: HHVPr = higher heating value of pulverizer rejects
from laboratory analysis of representa-
MrRs MpH2Rs HHVH2 tive sample, Btu/lbm (Jkg)
QpLHZRs = ,% (5.14-9)
MrF HHVF H P r = sensible heat or enthalpy of pulverizer
rejects leaving the pulverizer, Btdlbm
where MpH2Rs is the mass weighted average of un- (Jkg). Use the enthalpy of ash at the
burned hydrogen in residue, percent, and HHVH2 = mill outlet temperature.
61,100 Btullbm (142,120 Idkg). 5.14.4.5 Loss Due to Unburned Hydrocarbons in
5.14.4.3 Loss Due to Carbon Monoxide in Flue Flue Gas,percent. Where it is established that unburned
||| | |---
Gas, percent hydrocarbons are present and cannot be eliminated by
operating adjustments:
|||| | || ||| | || ||
HHVCO %
Q p L C O = D V p C O MoDFg M w C O - HHVHc %
HHVF QpLUbHc = DVpHc MoDFg MWHC -
HHVF ’
| |||
or (5.14- 1O )
or (5.14-13)
|
| ||| | || | ||
HHVCO
Q p L C O = V p C O MoFg MwCO - HHVHc
HHVF ’ % QpLUbHc = VpHc MoFg MWHC - ,%
HHVF
--
where where
D V p C O = quantity of CO measured on a dry basis, DVpHc = quantity of hydrocarbons in flue gas
percent volume measured on a dry basis, percent volume
VpCO = quantity of CO measured on a wet basis, VpHc= quantity of hydrocarbons in flue gas
percent volume measured on a wet basis, percent volume
MoDFg= moles of dry gas with excess air mea- HHVHc = higher heating value of the reference gas
sured at the same location as the CO, used to determine the volume percentage
moles/lbm fuel (moleskg). Refer to Sec- of total hydrocarbons, Btu/lbm (Jkg)
tion 5.1 1 for calculation.
MoFg= moles of wet gas with excess air mea- 5.14.5 QpZXs - Loss Due to Sensible Heat of
sured at the same location as the CO, Residue, percent. For units with a wet furnace ash
moles/ìbm fuel (moleskg). Refer to Sec- hopper, refer to Subsection 5.14.13:
tion 5.11 for calculation.
MwCO = molecular weight CO, 28.01 lbdmole
(kg/mole)
HHVCO= higher heating value of CO, 4,347 where
Btu/lbm (10,111 kJkg) MqRsz = mass flow rate of residue at location z, lbm/Btu
101
STD.ASME PTC 4-ENGL 3998 = 0759b70 Ob35042 384
ASME PTC 4-1998 FiRED STEAM GENERATORS
(kg/J) from Section 5.10. For units with a wet 5.14.7 &Z.,AZg - Loss Due to Air Infiltration,
furnace ash hopper, when the total ash pit percent. This item refers to air infiltration between the
losses are tested, the wet ash pit loss, QrLAp, point where dry gas weight is determined (normally
includes the sensible heat of residue, and the the boiler exit) and the air heater flue gas inlet, excluding
sensible heat of residue to the ash hopper air infiltration in hot AQC equipment which is accounted
should be omitted here. When the loss due for separately:
to radiation to the wet ash pit is estimated,
QrLRsAp, the loss due to sensible heat in QpLALg = 1O0 MqA Lg ( H ALvCr (5.14- 16)
residue leaving the ash pit is calculated in
accordance with this paragraph. - HALgEn), %
HRsz= enthalpy of residue at location z, Btdlbm
(Jkg). For locations other than bottom ash, where
the residue can be assumed to be at gas MqALg= mass rate of wet infiltration air, lbm/Btu
temperature. For dry bottom ash, use 2,000"F (kg/J). Refer to Subsection 5.1 1.6.
(1,IOO"C) if not measured. For wet bottom HALgEn = enthalpy of infiltrating wet air, normally
ash, a typical enthalpy of 900 Btdlbm (2,095 air inlet temperature, Btdlbm (Jkg).
kJkg) is recommended. Refer to Subsection
5.14.8 a>LNo, - Loss Due to the Formation of
5.19.3 for curve fit.
NO,, percent. This item refers to the loss associated
with the formation of NO, during the combustion
5.14.6 I3pLAq - Loss From Hot Air Quality Con-
process. This loss is usually small, 0.04% for 0.5 lb/
trol Equipment, percent. This item refers to flue gas
million Btu (335 ppm) NO,, and may be estimated if
cleanup equipment located between the boiler exit and
air heater gas inlet, such as a mechanical dust collector not measured. This calculation procedure assumes that
or hot precipitator. The calculation below is the total the analyzer converts the NO2 in the gas sample to
NO and gives a total reading of NO, as NO. The
of the dry gas loss due to air infiltration, moisture in
infiltration air loss, and surface radiation and convection equations below assume that NO2 is negligible and are
loss. Refer to Appendix C for derivation. based on the heat of formation of NO. For most
units, N 2 0 is also considered negligible. If measured
separately, the loss may be calculated by substituting
QpLAq = 100 [MqFgEn (HFgEn - HFgLv) (5.14-15)
the heat of formation of N 2 0 in the equation below:
- (MqFgLv - MqFgEn) (HAAqLv HrNOx
- HALvCr)], % QpLNOx = DVpNOx MûDFg - (5.14-17)
HHVF
HrNOx
where or VpNOx MoFg -,%
HHVF
MqFgEn= mass of wet gas entering with excess
air entering, Ibm/Btu (kg/J)
MqFgLv= mass of wet gas leaving with excess air HrNûx
leaving, Ibm/Btu (kg/J) QpLNOx = 100 MqNOx ~ ,% (5.14-18)
MwNOx
HFgEn= enthalpy of wet gas entering with a
moisture content entering and a residue
content leaving, Btdlbm (Jkg) where
HFgLv = enthalpy of wet gas leaving with a mois- DVpNO,= quantity of NO, as NO on a dry basis,
ture content entering and a residue con- percent volume. NO, is normally mea-
tent leaving, Btu/lbm (Jkg) sured on a ppm basis. Divide by 10,OOO
HAAqLv= enthalpy of wet air at a temperature to convert to percent.
corresponding to the gas temperature VpNO,= quantity of NO, as NO on a wet basis,
leaving the hot AQC device, Btu/lbm percent volume
(JW MqNO,= quantity of NO, expressed on an energy
HALvCr= enthalpy of wet air at the average gas basis, IbmíBtu (kg/J). When expressed
temperature (excluding leakage) leaving on an energy basis, the units used are
the steam generator envelope, Btu/lbm usually MBtu (J). Divide by 1E6 to
(J49 convert to Btu (J).
102
-- | ||| | || | || | | ||| |||| | || ||| | || || ||| | |---
STDmASME PTC 4-ENGL 1998 0759670 Ob15043 210
MoDFg= moles of dry gas with excess air mea- Hraz = 0.841 + 2.367E-3 TDi (5.14-21)
sured at the same location as the NO,, + 2.94E-6 TDi2 + 1.37E-9 TDi3
moles/lbm fuel (moleskg)
MoFg= moles of wet gas with excess air mea-
sured at the same location as the NO,, where
moledlbm fuel (moleskg) Hcaz = convection heat transfer coefficient for
HrNO,= heat of formation of NO, 38,600 Btullb area z, Btu/ft2 . h F. The constants e
mole (89,850 Wkg). The heat of forma- used in this correlation are based upon
||| | |---
tion of N 2 0 is 35,630 Btu/lb mole using US Customary Units. The charac-
(82,880 Idkg). teristic length is approximately 10 ft. A
|||| | || ||| | || ||
MwNO,= molecular weight of NO, 30.006 Ib/mole bias uncertainty for the correlation of
(kg/mole). The molecular weight of N 2 0 +20% is suggested.
is 44.013 lblmole (kg/mole). Hraz = radiation heat transfer coefficient for area
z, Btu/ft2 . h . F. The constants used in
| |||
5.14.9 QrLSrc - Loss Due to Surface Radiation this equation are based upon using US
|
| ||| | || | ||
and Convection. This loss is determined indirectly by Customary Units ( O F ) . This correlation
measuring2 the average surface temperature of the steam is based on an ambient temperature of
generator and the ambient conditions near it. Surface 77°F (25OC) and an emissivity of 0.80.
temperature, ambient temperature, and ambient air ve-
--
A bias uncertainty for the correlation
locity should be determined at a sufficient number of of 120% is suggested. The uncertainty
locations to determine representative average values. includes variations in emissivity and the
Alternatively, the parties to the test may decide to impact of surrounding objects such as
determine this loss based on the actual area of the support steel.
unit and the standard surface and ambient conditions Afz= flat projected surface area of the casing/
described below. The parties to the test shall decide lagging over the insulation (circumferen-
whether to measure the surface and ambient conditions? tial area for circular surfaces) for location
including the number and location of measurements, z, ft2. For protuberances such as buck-
or to use the standard conditions described below. Use stays, only the flat projected area of the
of surface and ambient conditions as specified for face adjacent to the hot surface is to be
design of unit insulation shall not be permitted for included in the flat projected surface
loss evaluation; test conditions or the standard values area. The areas to be considered are the
specified herein are the only allowable options. steam generator, flues and ducts within
The loss is calculated by: the envelope, major piping (Le., size
with respect to the steam generator), and
QrLSrc = Ci 2 (Hcaz + H r a z ) Afz (TMnAfz major equipment such as pulverizers.
Hot air quality control equipment (such
- TMnAz), Btu/h (W) (5.14- 19) as hot precipitators) should not be in-
cluded if this loss is accounted for sepa-
rately.
where
TMnAfz= average surface temperature of area z
TMnAz = average ambient air temperature at loca-
tion z, “F.The local ambient air tempera-
Hcaz = the larger of 0.2 (TMnAfz - T M ~ A z ) ”or
~ ture is the temperature within 2 to 5 ft
of the surface.
0.35VA2’5 (5.14-20)
TDi= (TAfz - TAz) = temperature difference
VAz = average velocity of air near surface, typi-
2“Measure” is used in the general sense in this paragraph and does cally within 2 to 5 ft of the surface, ft/
not preclude estimation of parameters by qualified personnel. sec (m/s)
)It is not mandatory that this test be performed in conjunction with
the efficiency test. It may be performed separately to establish the
CI= 1.0 (US Customary Units); CI = 0.293
actual setting heat loss and the results corrected to standard or W NBtu (SI Units).
guarantee conditions in accordance with Section 5.18 for use with If values for TA$ TA, and VA are not measured,
an efficiency test performed at a different time. When so used, the
corrected QrLRc results shall meet the criteria for repeatability in this loSS be using the
Section 3. areas and the following standard values:
103
STDmASME PTC 4-ENGL 1998 0759670 Obi15044 1 5 7
(a) VA = 1.67 ft/sec (100 fvmin); MFrCZhk= mass fraction of calcination of constit-
--
(b) TDi,the differential temperature, should be 50°F uent k. Refer to Subsection 5.10.8 for
| ||| | || | ||
or, if the situation warrants it for components where Caco3. Use 1.0 for other constituents.
personnel safety is not a problem, a larger value used. Heats of reaction were calculated from the heats of
For example, where it is not practical to design for a formation and the molecular weights given in the NBS
|
temperature differential of 50°F or less (PC piping and Technical Notes [2]. MgCo, is assumed to be in its
| |||
hot cyclones, for example), the expected differential most common form, dolomite, Caco3 MgC03.
|||| | || ||| | || ||
should be used.
This calculation method applies to estimation of the 5.14.12 QrLWSb - Loss Due to Water in Sorbent,
efficiency loss and is not intended for use in designing Btuh (W)
||| | |---
casing insulation. If the standard conditions are used,

a bias limit of rf: 50% is suggested for QRLRC.
QrLWSb = MrWSb (HStLvCr - HWRe), (5.14-24)
5.14.10 QrLWAú - Loss Due to Additional Mois-
ture, Btuíh (W). Additional moisture is water or steam Btu/h (W)
injected in the gas side of the steam generator and not
accounted for separately. Typical examples of additional
moisture are atomizing and soot blowing steam. It is 5.14.13 QrLAp - Wet Ash Pit Loss, Btu/h (W).
noted that when air is utilized as the atomizing or soot On units with a wet ash pit, there is a loss due to
blowing medium, the loss is included in the dry gas heat absorbed. by the water from radiation through the
and moisture in air loss since it is included in the furnace hopper throat, in addition to the sensible heat
measured O2 in the flue gas: in residue loss. The test procedure for this loss requires
the measurement of the mass flow rate and temperature
QrLWAd = ZMrStz(HStLvCr - HWRe), of the water entering and leaving the ash pit, the mass
Btu/h (W) (5.14-22) flow rate of the residue/water mixture leaving the ash
pit, and a laboratory determination of the water in the
where residue leaving the ash pit.
MrSrz= mass flow rate of additional moisture at Due to the difficulty of determining the mass flow
location n, lbmh (kg/s) rate of the residue leaving the ash pit and the uncertainty
HStLvCr= enthalpy of steam in gas leaving the of determining the water in the residue, the parties to
boundary (excluding leakage), Btdlbm the test may agree to estimate this loss. The procedure
(Jkg). Refer to Subsection 5.14.2. for estimating this loss is described in Subsection
HWRe = enthalpy water at the reference tempera- 5.14.13.2
ture, Btdlbm (Jkg)
5.14.13.1 QrLAp - Wet Ash Pit Loss When
5.14.11 QrLCih - Loss Due to Calcination and Tested. By energy balance, the ash pit loss is the sum
Dehydration of Sorbent, Btu/h (W) of the energy gain by the water leaving the ash pit,
energy loss due to evaporation of pit water and sensible
QrLCih = L? MrSbk MFrCIhk Hrk, heat in the residue/water mixture as it leaves the pit.
Btu/h (W) (5.14-23) Note that if measured, the sensible heat loss of residue
to the ash pit in Subsection 5.14.5 should be omitted:
where
MrSbk =mass flow rate of reactive constituents
k, l b d h (kg/s) Q r U p = QrApW + QrApEv (5.14-25)
Hrk= heat of reaction for calcination of cal- + QrRsWLv, Btu/h (W)
cium or magnesium carbonate or dehy-
dration of calcium or magnesium hy-
droxide
Caco, (Cc) 766 Btu/lbm (1,782 kJkg) 5.14.13.1.1 Energy Increase in Ash Pit Water
MgC03 (Mc) 652 BtuAbm (1,517 Hkg)
Ca(OH), (Ch) 636 Btdlbm (1,480 kJkg)
Mg(OH)* (Mh) 625 Btdlbm (1,455 QrApW = MrW39(HW39 (5.14-26)
Id/kg) - HW38). Btdh ( W )
104
~
~
STD-ASME PTC Li-ENGL i1998 0759670 ObL5045 O93
FiRED STEAM GENERATORS ASME PTC 4-1998
5.14.13.1.2 Loss Due to Evaporation of Pit QrLRy = QrLRyRs + QrLRyFg, Btu/h (W) (5.14-30)
Water
5.14.14.1 Recycled Solids. Residue may be recy-
(5.14-27)
cled to utilize unburned carbon in the residue and/or
+ MrRsW37 ( I M+FrMjWRs
WRs
)) (HSrLvCr reduce the amount of sorbent added. If the recycle
piping and hold up bins are included in the area used
to calculate the surface radiation and convection loss
- HW38), B t d h (W)
(QrLSrc), Subsection 5.14.9, then this calculation is
omitted.
5.14.13.1.3 Sensible Heat in ResidueNater
Mixture Leaving the Ash Pit QrLRyRs = MrRyRs (HRsLv - HRsEn), (5.14-31)
Btu/h (W)
37
QrRsWLv = MrRsW (HRs37
1 +MFrWRs where
MrRyRs= mass flow rate of recycled residue,
+ MFrWsR (HW31 (5.14-28) Ibmh (kg/s)
- HW38)), Btu/h (W) HRsLv= enthalpy of the residue where it is col-
lected, Btdlbm (Jkg)
HRsEn= enthalpy of the residue when it is read-
where
mitted to the steam generator, Btdlbm
MrRs W 3 7 = mass flow rate of the residue/water mix-
ture leaving the ash pit, Ibmh (kg/h) (JA&
MFrWRs= mass fraction of water in residue in the 5.14.14.2 Recycled Gaseous Streams. An example
residue/water mixture leaving location of a recycled gaseous stream is flue gas recirculation
(37), Ibm H20/lbm dry residue (kgkg) after the air heater (typically ID fan gas recirculation).
HRs37= enthalpy of dry residue at the temperature However, this loss is applicable to any gaseous stream
of the residue/water mixture leaving the added to the steam generator from an external source.
ash pit, Btdlbm (Jkg) Refer to Appendix C if the excess air in the recycled
H W z = enthalpy of water at location z, gaseous stream is different from the excess air upon
Btuílbm (Jkg) which the dry gas weight is based.
5.14.13.2 Q r U p -Estimated Loss Due to Radia-
tion to the Ash Pit. If agreed to by the parties to the QrLRyFg = MrRyFg (HFgCr - HFgEn), (5.14-32)
||| | |---
test, the loss due to radiation to the ash pit may be Btulh (W)
estimated. When the loss due to radiation to the ash
|||| | || ||| | || ||
pit is estimated, the sensible heat in residue loss must where
also be calculated (estimated) in accordance with Sub- MrRyFg= mass flow rate of the recycled gas,
section 5.14.5. lbm/h (kg/s)
| |||
HFgLv= enthalpy of wet flue gas at the average
|
QrLAp = QrAp ApAJ Btulh (W) (5.14-29) gas temperature leaving the unit (exclud- | ||| | || | ||
ing leakage), Btdlbm (Jkg)

where HFgEn = enthalpy of the recycled flue gas entering
Q r A p = equivalent heat flux through furnace hopper the steam generator, Btdlbm (Jkg)
--
opening absorbed by ash pit water. Based

5.14.15 QrLCw - Loss From Cooling Water, Btu/h
on limited data of apparent water usage, an
(W). This loss occurs when cooling water (external to
estimated equivalent heat flux of 10,000 B t d
the steam generator steadwater circuits) removes en-
ft2h (31,500 W/m2) is recommended. A bias
ergy from the steam generator envelope. Typical equip-
limit of I 5 0 % is suggested.
ment that uses cooling water are water cooled doors,
ApAf= flat projected area of hopper opening, ft2 (m2)
ash coolers, and boiler circulating pumps. Care should
5.14.14 QrLRy - Loss From Recycled Streams, be taken not to consider a loss twice. For example, if
Btdh (W). The loss due to recycled streams is the the sensible heat in residue is based upon the temperature
sum of the loss due to recycled solids and recycled gas. of residue entering the ash cooler, there would be no
105
~~ ~~
STD-ASME PTC 4-ENGL 1998 m 0759b70 ObL504b T2T m
loss associated with the ash cooler; however, if the QpBDA = 100 MqDA HDAEn. % (5.15-1)
temperature of the residue is measured after the ash
cooler, the energy absorbed by the ash cooler must be where
added to the steam generator losses: MqDA = total dry air entering the steam generator
corresponding to the excess air leaving
QrLCw = Z M r C w n (HWLv - HWEn), (5.14-33) the boiler used to calculate dry gas
Btulh (W) weight, Ibm/Btu (kg/J)
HDAEn= enthalpy of dry air at the average air
where temperature entering the steam generator
MrCwz= mass flow rate of cooling water at loca- envelope (TMnAEn), Btu/lbm (Jkg).
tion z, Ibmh (kg/s) This is the weighted average of the
various sources of the airflow contribut-
5.14.16 @ZAC- Loss Due to Internally Supplied ing to MqDA as defined above. Note
Air Preheater Coil, Btuh (W). When an air preheater
||| | |---
that when an air preheating coil is sup-
coil is supplied by steam from the steam generator, plied from the steam generator, the air
|||| | || ||| | || ||
the steam generator envelope is defined to include the temperature entering the air preheater
air preheat coils. The loss is the product of the conden- coil is used for that portion of the air
sate flow from the air preheat coils and the difference entering the steam generator.
in enthalpy of the air preheat coils condensate and
| |||
entering feedwater. The condensate flow should not be 5.15.2 @BWA - Credit Due to Moisture in Enter-
|
ing Air, percent
| ||| | || | ||
included in the boiler output:
Q r U c = MrSt36 (HW36 - HW24), (5.14-34) QpBWA = 100 MFrWA MqDA HWvEn, % (5.15-2)
--
Btu/h (W)
where
HWvEn= the enthalpy of water vapor at the aver-
5.14.17 Conversion of Loss on Rate Basis to Percent age air temperature entering the steam
Input Fuel Basis. The loss calculated on a rate or generator envelope (TMnAEn),
unit of time basis may be used to calculate efficiency. BtuAbm ( J k g )
If the loss on a percent input from fuel basis is desired,
it may be calculated after completion of the efficiency 5.15.3 QpBF - Credit Due to Sensible Heat in
calculations using the calculated fuel input: Fuel, percent
(5.14-35) QpBF = -loo HFEn, % (5.15-3)

HHVF
where
5.15 CREDITS HFEn= enthalpy of the fuel at the temperature of
fuel entering the steam generator envelope at
As in the loss section, the calculation of credits falls
locations (l), (3), or (4), Btdlbm (Jkg)
into two categories in accordance with the method in
which they are measured and conveniently calculated. 5.15.4 QpBSíf- Credit Due to Sulfation, percent.
In the first category are those credits that can be readily Sulfation is the reaction of sulfur dioxide (SO,) with
expressed as a percent of input from fuel, such as calcium oxide (Cao) and oxygen to form calcium
energy in entering air; and second, those which are sulfate (Caso,). The reaction is exothermic:
more readily calculated on an energy per unit of time
basis, such as energy supplied by auxiliary equipment
power. The credits are arranged in approximate order QpBSlf = MFrSc -
MpSF HRSIJ; % (5.15-4)
HHVF
of significance and universal applicability, with the
latter taking precedence.
where
5.15.1 QpBDA - Credit Due to Entering Dry Air, HrSlf= heat generated in the reaction of sulfur dioxide,
percent oxygen, and calcium oxide to form calcium
106
STD-ASME PTC 4-ENGL 1998 0759b70 Ob15047 9bb W
FiRED STEAM GENERATORS ASME F'TC 4-1998
sulfate per pound of sulfur capture, 6,733 5.15.7 QrBWAd - Credit Due to Energy Supplied
BtuAbm (1 5,660 kJkg) by Additional Moisture, Btuh (W). Typical examples
MFrSc = mass fraction of sulfur capture, lbdlbm of additional moisture are soot blowing and atomizing
(kgkg) steam:
5.15.5 QrBX - Credit Due to Auxiliary Equipment
Power, Btuh (W). Typical auxiliary equipment in- QrBWAd = Z M r S t z (HSrEnz - HWRe). (5.15-8)
cludes pulverizers, gas recirculating fans, hot primary Btu/h (W)
air fans, and boiler circulating pumps. Note that credits
shall not be calculated for forced draft fans, cold where
primary air fans, and other equipment when credits are MrSrEnz= mass flow rate of additional moisture,
calculated based on the measured fluid temperature Ibmh (kg/s) at location z
exiting the equipment. For example, when a credit is HSrzEnz = enthalpy of additional moisture entering
calculated for entering air in accordance with Subsection the envelope, Btdibm (Jkg)
5.15.1, the energy added by the forced draft and primary HWRe= enthalpy of water at the reference tem-
air fans is included; thus, adding the credit for fan perature, Btu/lbm (Jkg)
power would be accounting for the energy added twice.
5.15.8 Conversion of Credits on Rate Basis to Per-
5.15.5.1 For Steam Driven Equipment cent Input Fuel Basis. The credit calculated on a rate
or unit of time basis may be used to calculate efficiency
MrSrX (HStEn - HStLv) EX directly. If the credit on a percent input from fuel basis
QrBX = (5.15-5)
1O0 is desired, it may be calculated after completion of the
Btu/h (W)
efficiency calculations using the calculated fuel input:
where QrBk
QpB = 100 -, % (5.15-9)
HSrEn= enthalpy of the steam supplied to drive the QrF
auxiliaries, Btu/lbm (Jkg)
HSrLv = enthalpy at the exhaust pressure and the initial
entropy of steam supplied to drive the auxilia- 5.16 UNCERTAINTY
ries, Btdlbm (Jkg)
Section 5.2, Data Reduction, discussed calculation
EX= overall drive efficiency, percent; includes tur-
of the precision index and degrees of freedom for
bine and gear efficiency
individual parameters. This Section presents calculations
5.15.5.2 For Electrically Driven Equipment for overall precision index and degrees of freedom for
the test. This Section also presents calculation methods
EX for sensitivity coefficients and the precision and bias
QrBX = QX CI -, Btu/h (W) (5.15-6)
1O0 components of uncertainty. For post-test uncertainty
calculation, all steam generator performance calculations
||| | |---
where must be complete prior to the beginning of the uncer-
QX= energy input to the drives, kWh (J) tainty calculations presented in this Section. The uncer-
tainty calculations presented in this Section, as well as |||| | || ||| | || ||
EX= overall drive efficiency, percent; includes such
items as motor efficiency, electric and hydrau- those presented in Subsection 5.2.3, can be used for
lic coupling efficiency, and gear efficiency pretest as well as post-test uncertainty analysis.
| |||
CE= 3,412 Btu/kWh (1 J/J) The pretest uncertainty analysis can provide important
information and reduce the effort required to calculate
|
5.15.6 QrBSb - Credit Due to Sensible Heat in

| ||| | || | ||
uncertainty after completion of a performance test.

Sorbent, Btu/h (W) Refer to Section 7 for additional guidance on pretest
uncertainty analysis. The majority of bias limit estimates
--
QrBSb = MrSb HSbEn, Btu/h (W) (5.15-7) can be made prior to starting a performance test.
Precision indexes can be estimated based on preliminary
where observation of equipment operating conditions. Pretest
M r S b = mass flow rate of sorbent, Ibmh (kg/s) estimates of the parameter standard deviation and de-
HSbEn=enthalpy of the sorbent entering the steam grees of freedom can be used to determine the frequency
generator envelope, BtuAbm (Jkg) and number of measurements required for a given
107
STD.ASME PTC 4-ENGL 1998 075îb30 ObLSO4B B T 2 D
ASME F'TC 4-1998 RRED STEAM GENERATORS
variable during the test. This Code does not require a RECALEF - EF
ASENSCO = (5.16-2)
pretest uncertainty analysis; however, it is important CHGPAR
to note that waiting until after a performance test is
complete to calculate uncertainty can result in actual where
test uncertainties in excess of expected or agreed upon ASENSCO = absolute sensitivity coefficient for a mea-
values. sured parameter, percent efficiency per
This Section provides general guidelines for calculat- measured parameter units
ing the uncertainty associated with a steam generator EF= steam generator fuel efficiency, calcu-
performance test. A more detailed description of uncer- lated for the actual (measured) parameter
tainty analysis calculations along with derivations is RECALEF = recalculated steam generator fuel effi-
included in Section 7, which should be reviewed prior ciency using (X + CHGPAR) or (U +
to beginning any uncertainty calculations. CHNGPAR) in place of X (or U >while
5.16.1 Sensitivity Coefficients. Sensitivity coefficients all other measured parameters are held
represent the absolute or relative effect of a measured fixed
parameter on the calculated steam generator efficiency. In no case shall an absolute sensitivity coefficient
||| | |---
Sensitivity coefficients can also be used for determining smaller than the efficiency convergence tolerance be
the effect of a parameter on an intermediate calculation considered. If smaller, it should be considered zero.
|||| | || ||| | || ||
such as steam generator output. Sensitivity coefficients Refer to Subsection 5.7.3 regarding the efficiency con-
are important for pretest uncertainty analysis to deter- vergence tolerance.
mine what parameters have the largest impact on the The above equation gives the sensitivity coefficient
associated with steam generator efficiency. However,
| |||
desired result (e.g., efficiency, output, gas temperature).
this form of equation can be used for any calculated
|
Sensitivity coefficients are calculated by arbitrarily
| ||| | || | ||
perturbing the value of a parameter. The change in the result such as output, fuel flow, calciumísulfur ratio,
value of a measured parameter can be calculated from: etc., by substituting the result for EF and RECALEF.
Relative sensitivity coefficients are calculated for
--
(PCHGPAR XAVE)
each measured parameter from the following equation:
CHGPAR = or (5.16-1)
1O0
(ASENSCO XA V E ) or
(PCHGPAR ü) RSENSCO = (5.16-3)
PFE
1O0
(ASENSCO ü)
where PFE
CHGPAR= incremental change in the value of a
measured parameter
PCHGPAR= percent change in the value of a mea- where
sured parameter. The recommended RSENSCO = relative sensitivity coefficient for a mea-
value of PCHGPAR is 1.0%. If the sured parameter, percent change in result
average value of the measured parameter per percent change in measured pa-
is zero, enter any small incremental rameter
change. The above equation is shown for efficiency but can
XAVE= arithmetic average value of a measured be used for other calculated results.
parameter. For development of sensitiv- 5.16.2 Precision Index and Degrees of Freedom.
ity coefficients, care must be taken to The precision index of the calculated steam generator
use units that will not be zero such as efficiency is obtained by combining the precision in-
absolute temperature and pressure. dexes of all measured parameters according to the root-
U = integrated average value of a measured sum-square rule:
parameter. Refer to note above regard-
ing units. N
Alternatively, such as when XAVE is very small or PIR = (ASENSCOiPIi)2]"2 (5.1 6-4)
i= 1
zero, CHGPAR can be any convenient small increment
of XAVE. where
Absolute sensitivity coefficients are calculated for PIR= overall precision index of test
each measured parameter from the following equation: Pli = precision index for measured parameter i
108
STDeASME PTC 4-ENGL 1998 D 0759b70 Ob15049 739
ASENSCOi = absolute sensitivity coefficient for mea- TABLE 5.16-1

sured parameter i TWO-TAILED STUDENT’S t-TABLE FOR THE
N = number of measured parameters 95% CONFIDENCE LEVEL
The number of degrees of freedom for the overall Degrees of Degrees of
test result is calculated from the following equation: Freedom t Freedom t
1 12.706 16 2.120
PIP 2 4.303 17 2.110
DEGFREER = (5.16-5)
3 3.182 18 2.101
x (ASENSCOi
PI
i=i DEGFREE,
Pli )4
4
5
2.776
2.571
19
20
2.093
2.086
where 6 2.447 21 2.080

DEGFREER =overall number of degrees of free- 7 2.365 22 2.074
8 2.306 23 2.069
dom for test
9 2.262 24 2.064
DEGFREE, =degrees of freedom for measured 10 2.228 25 2.060
parameter i
11 2.201 26 2.056
5.16.3 Precision Component of Uncertainty. The 12 2.179 27 2.052
precision component of uncertainty is calculated from 13 2.160 28 2.048
the precision index and degrees of freedom of the 14 2.145 29 2.045
result using the following equation: 15 2.131 30 or more 1.960
UPC = STDTVAL PIR (5.16-6)
where BIASi= bias limit of measured parameter i. The units

UPC = precision component of uncertainty of bias are the same as the units of the
STDTVAL = two-tailed Student’s r-value. measured parameter.
The two-tailed Student’s r-value is based on the 95th BZASj= bias limit of individual components used to
percentile point distribution and the degrees of freedom determine the value of parameter i. Refer to
of the result. Table 5.16-1 shows the Student’s r-value note on units above.
||| | |---
as a function of degrees of freedom. Interpolation in M = number of components in the measurement
the table is done using reciprocal degrees of freedom.
|||| | || ||| | || ||
system of parameter i
A curve fit for f is:
NOTE: ‘‘Measure’’ and “measurement syjtem” are used in a general
sense and do not exclude estimation of parameters.
2.3717 3.1213
r = 1.9588 +
| |||
+
(5.16-7)
DEGFREE DEGFREE2
|
5.16.4.1 Bias Limit Associated With Spatially
| ||| | || | ||
0.7993 4.4550 Nonuniform Parameters. The bias limits associated
+ +
with spatially nonuniform parameters which vary in

DEGFREE3 DEGFREE4
both space and time are discussed in detail in Sections
--
4 and 7. Section 7 presents models which can be used
5.16.4 Bias Limit. Bias limits for uncertainty calcula- to estimate the bias limit associated with these types
tions are estimated based on the method used to deter- of parameters. These models use a variable called
mine the values of a measured parameter. Recommended Spatial Distribution Index (SDZ).Spatial Distribution
procedures for estimating bias limits are presented in Index is calculated from the following equation:
Sections 4 and 7. Elementary bias limits for each
measured parameter are combined according to the
root-sum-square rule:
1 (5.16-9)
(5.16-8)
Eq. (5.16-10) is suggested for multiple midpoint

where average:
109
~~ ~~
STD.ASME PTC 4-ENGL 1998 m 0759b70 Ob15050 q50 m
ASME PTC 4-1998 FiRED STEAM GENERATORS
SDI recommendations in Subsections 3.2.5.2, 3.2.5.3, and

Multiple Midpoint BIAS; = (5.16-10) 3.2.6.
( N - i)’
~
5.17.1 Peak Capacity. Peak capacity is defined as

where the maximum steam mass flow rate, at a specific
SDI = spatial distribution index pressure and temperature, that the steam generator is
N = number of points in the measurement grid capable of producing (including specified blowdown
z = time averaged value of the measured parameter and auxiliary steam) for a limited time period without
Z= integrated average value of z damaging the steam generator components.
It should be noted that although SDI is calculated Peak capacity can be either measured directly (MrSt31
identically to standard deviation, there is a significant for saturated steam generators, MrSt32 for superheated
statistical difference between the two variables. steam generators) or calculated from feedwater, desuper-
5.16.4.2 Bias Limit of Result. The bias limit of heater water, and blowdown mass flow rates.
a result is also calculated according to the root-sum- When desuperheater water flow is not measured, it
square rule: may be determined by an energy balance. When blow-
down flow is not measured, it may be determined from
--
3’” the setting of a calibrated valve or by energy balance

| ||| | || | ||
(ABSENCO; BIAS;)2 (5.16-11) around a blowdown heat recovery system.

i=l
Data required for peak capacity determination are
summarized in Table 4.2-3.
|
where Prior to the test, the following shall be defined and

| |||
BIASR= overall bias limit of the test result agreed upon:

|||| | || ||| | || ||
The bias limit of the result can be positive andor

negative. If the positive and negative bias limits are 0 Duration of the “limited time period.” This determines
not symmetrical, the positive and negative values must the minimum run time.
||| | |---
be calculated separately. The sign of the product Steam pressure and temperature for superheated steam
(ABSENCO, x BIASi) determines whether the term is generators
summed with the positive or negative bias limits. Steam pressure for saturated steam generators
Feedwater pressure and temperature
5.16.5 Total Uncertainty. The total uncertainty of a
Blowdown rate
test is calculated from the overall test precision aqd
bias limit components: 5.17.2 Steam Temperature. Data required for the
determination of superheater andor reheater steam tem-
UNC = ( U P @ +BIASR~)‘~~ (5.16-12) perature characteristics and control ranges are given in
Table 4.2-4.
where 5.17.3 Pressure Loss. Instruments and methods of
UNC= total uncertainty measurement for steam and water differential pressure
The uncertainty be tests, Le., pressure loss across the steam generator or
for both positive and negative ranges if the bias limits a particular section of the generator, are given
are not symmetrical. in Subsection 4.5.4. Instruments and methods of mea-
surement for air or flue gas differential pressure tests,
i.e., draft loss across the steam generator or a particular
5.17 OTHER OPERATING PARAMETERS section of the generator, are given in Subsection 4.5.3.
It is sometimes desirable to test a steam generator 5.17.4 Static Pressures. Instruments and methods of
for performance parameters other than rated capacity measurement for steam water static pressure tests are
and efficiency. This Section covers such tests. given in Subsection 4.5.4. Instruments and methods of
Instruments to be used, methods of measurement, measurement for air and gas static pressure tests are
and acceptable values for uncertainty of results shall given in Subsection 4.5.3.
be the subject of pretest agreements. Instruments and
methods of measurement are described in Section 4. 5.17.5 Exit Gas Temperature. Data required for exit
To ensure that operating and equipment condition, gas temperature tests are given in Table 4.2-5. Instru-
and control system adjustments do not adversely affect ments and methods of gas temperature measurement
the tests, particular attention should be given to the are given in Subsection 4.4.3.
110
STDmASME PTC 4-ENGL 1998 0759670 O,bL5051 397
FìRED STEAM GENERATORS ASME FTC 4-1998
Computational procedures for obtaining the corrected 5.18 CORRECTIONS TO STANDARD OR

gas outlet temperature (TFgLvCr)are given in Subsec- GUARANTEE CONDITIONS
tion 5.18.2. Computational procedures for obtaining the
average exit gas temperature (TMnFgLvCr)are given It is usually not possible to test a unit with the
in Subsection 5.13.3. standard or guarantee fuel and at the exact standard
or guarantee operating conditions. By correcting the
5.17.6 Air Leakage or Air Infiltration. Determina- test results to standard or contract conditions, it is
tion of the amount of air leakage (as across an air heater), possible to make a more meaningful comparison and
or infiltration through the steam generator casing, or evaluation of efficiency and performance.
any section of the casing downstream of the furnace The corrections to efficiency described in this Section
exit, is accomplished by comparing excess air or air specifically address efficiency calculated by the energy
mass flow rate. Data required for excess air determina- balance method. Subsection 5.18.10 discusses correcting
tion are given in Table 4.2-9. Excess air and mass flow input-output efficiency test results to contract conditions.
||| | |---
rate computational procedures are given in Section 5.1 1. Corrections to efficiency described in this Section
The amount of air infiltration, or leakage, is expressed consist of using the standard or guarantee air inlet
|||| | || ||| | || ||
in terms of the increase in percent excess air: temperature, correcting air heater gas outlet temperature
for deviations between the test and standard conditions,
MpAhLg = 100 ( X p A z 2 - X p A z I ) , % (5.17-1) and repeating the efficiency calculations utilizing the
| |||
standard or guarantee fuel and other operating variables
|
described below. The corrections described herein are
| ||| | || | ||
where
for the most common variables. In accordance with
MpAhLg = mass percent air infiltration
Subsection 3.2.3, the parties to the test shall agree
XpAz2= mass percent of excess air at the down-
upon other corrections for a specific unit, including
stream sampling location
--
correction curves.
XpAz1= mass percent of excess air at the up-
The corrections address off-design test conditions,
stream sampling location
not changes in load. Variations between the targeted
The previous paragraph addressed calculating air
test load and actual test load should not be more than
infiltration between two points where the O2 in the
5%. It is expected that the difference between the test
flue gas can be measured entering and leaving the
efficiency and corrected efficiency will usually be no
section in question, for example, a hot precipitator. On
more than two to three percentage points.
units with recuperative air heaters (air to gas heat
exchangers), the setting infiltration between the air
heater air exit and the point of measuring O2 in the 5.18.1 Entering Air Temperature. Corrections to the
flue gas can be calculated. The combustion airflow to credits for changes in test entering air temperature to
the burners (and pulverizers, if applicable) can be standard or guarantee conditions are made by substitut-
calculated by energy balance around the air heater ing the standard or guarantee temperature for the test
based on the flue gas flow entering the air heater(s) temperature in the applicable credit equations.
and measured air and gas temperature entering and
leaving the air heater(s). Setting infiltration between
5.18.2 Exit Gas Temperature. When correction of
the air heater air outlet and the point of measuring O2
the exit gas temperature is applicable, corrections to
(excess air) in the flue gas (usually boiler or economizer
the losses are made by substituting the corrected exit
gas outlet) can be calculated from the difference between
gas temperature for the test conditions in the applicable
the wet airflow determined at the point of O2 measure-
loss equations.
ment and the wet airflow leaving the air heater. All
airflows and gas flows are calculated stoichiometrically 5.18.2.1 Units Without Air to Gas Heat Ex-
in accordance with Sections 5.11 and 5.12. When there changer Type Air Heater(s). The exit gas temperature
is more than one air heater of the same type, it is may be corrected based upon the manufacturer’s correc-
usually sufficiently accurate to assume equal flows tion curves for deviations from design conditions if
between the air heaters. If gas flow or airflow is agreed upon between the parties to the test. Examples
measured to determine the imbalance, the ratio of the of deviation from design conditions when in excess of
results should be used to correct the gas flow/airflow those for which the thermal performance is unaffected
calculated stoichiometrically. For pulverized coal fired (refer to Subsection 5.18.3) might include deviations
units with cold primary air systems, refer to Section from design fuel, significant difference in entering air
5.13 for calculation of air and gas weights. temperature, and feedwater inlet temperature.
111
STD.ASME PTC CI-ENGL L778 m 0757b70 Ob35052 223
ASME FTC 4-1998 FiRED STEAM GENERATORS
5.18.2.2 Units With Air to Gas Heat Exchanger TDiTAEn = (5.18-2)

Type Air Heater(s). The exit gas temperature shall
be corrected for the standard or guarantee conditions TAEnd(TFgEn - TFgLvCr) + TFgEn(TFgLvCr - TAEn)
based upon the test air heater performance for deviations (TFgEn - TAEn)
from standard or guarantee conditions. The parties to
the test may agree to use PTC 4.3, Air Heaters, as - TFgLvCr, OF ( O C )
described below, or a different model if the corrections
described can be accomplished: where
TAEnd= design entering air temperature, OF (OC).
Refer to Subsection 5.18.1.
TAEn = air temperature entering air heater(s),
O F (OC)
TFgLvCrd = TFgLvCr + TDiTAEn + TDiTFgEn
TFgEn = gas temperature entering air heater(s),
+ TDiMrFgEn + TDiXr, ( O C )
O F (5.18-1) OF (OC)
(b)Entering Gas Temperature. Correction for entering
gas temperature shall be agreed upon by the parties to
the test. Examples for which corrections due to the enter-
where ing gas temperature may be applicable include:
TFgLvCrd = exit gas temperature corrected to design (1) Equipment within the steam generator envelope
conditions, OF (OC) not supplied by the steam generator vendor, such as hot
TFgLvCr = exit gas temperature corrected for air air quality control equipment. The specified temperature
heater leakage and used for calculation drop across the terminal points shall be used to determine
of efficiency (as tested), OF (OC) the corrected air heater entering gas temperature based on
TDiTAEn = temperature correction for entering air the measured gas temperature entering such equipment.
temperature, O F (OC) (2) Feedwater inlet temperature. The entering feed-
TDiTFgEn = temperature correction for entering gas water temperature is significantly different from the stan-
temperature, O F (“C) dard or guarantee conditions.
TDiMrFgEn = temperature correction for entering gas (3) Deviations from contract fuel. The test fuel is
mass flow, O F (OC) significantly different from the contract fuel.
TDiXr = temperature correction for off-design X- The exit gas temperature correction due to off-design
ratio, O F (OC) entering gas temperature may be calculated from the
PTC 4.3-1968, Air Heaters, does not cover corrections following equation:
to trisector air heaters (partitioned sections to separate
primary and secondary air). Until PTC 4.3-1968, Air
TDiTFgEn = (5.18-3)
Heaters, is revised, this Code will handle the corrections
as a standard bisector air heater. The airflow is the TFgEnCrd(TFgLvCr - TAEn) + TAEn(TFgEn - TFgLvCr)
sum of the primary and secondary air leaving the air ( TFgEn - TAEn)
heater. The entering air temperature is the mass weighted
average air temperatures entering the primary and sec- - TFgLvCr, O F (OC)
ondary air heaters, weighted on the basis of the airflow where
mass flow rates leaving the primary and secondary air TFgEnCrd = entering gas temperature corrected to
heaters. The corrected air temperature leaving the air design conditions, O F (OC)
heater is required for some calculations such as pulver- (e) Entering Gas Mass Flow. For determining cor-
izer tempering airflow for the corrected conditions. It rected efficiency, the air heater exit gas temperature may
is sufficiently accurate for these correction calculations be corrected for the difference in the gas mass flow enter-
to assume the primary and secondary air temperatures ing the air heater for the test conditions and the gas mass
||| | |---
leaving the air heater change by the same amount as flow entering the air heaters for the contract conditions.
|||| | || ||| | || ||
the predicted change in average air temperature leaving An example of when this correction may be necessary
the air heater. is when equipment between the steam generator air
The terms for Eq. (5.18-1) and other considerations inlet and gas outlet is not supplied by the steam
for determining this correction are shown in (a) through generator vendor and the equipment does not perform
| |||
(0 below: as specified. An example is hot air quality control

|
( a ) Entering Air Temperature:

| ||| | || | ||
equipment in which the tested air infiltration across
112
--
~~
STD-ASME PTC 'I-ENGL 3998 = 0759b70 Ob35053 LbT W

the equipment may be different than specified. The air flow and corresponding corrected secondary airflow
heater gas outlet temperature shall be corrected for the should be determined for the corrected air temperature
gas mass flow entering the air heater that would occur leaving the air heater and test or design pulverizer inlet
using the specified infiltration and the gas mass flow that air temperature (Subsection 5.18.3). The revised X-ratio
would occur with efficiency and operating conditions correction and revised corrected air heater exit gas tem-
corrected to guarantee conditions. perature should be determined. This process is iterative
For units with separate primary air heaters and sec- and should be repeated until the corrected exit gas temper-
ondary air heaters (for the remainder of the combustion ature is within 0.5"F (0.3"C).
air), it is recommended for simplification of the calcula- (j) Correctionsfor Pulverizer TemperingAirflow, Units
tions that the test gas mass flow be used for the primary With Primary Air Heater. When required, this correction
air heater for the corrected conditions (assuming normal should be performed before the entering gas flow and
operation); thus, no correction is required for the primary X-ratio corrections. Refer to Subsection 5.18.2.2(e) and
air heater. The balance of the difference in the gas Subsection 5.18.3 regarding when corrections for pulver-
mass flow is used to correct the secondary air heater izer tempering airñow may be required. Corrections for
exit gas temperature. tempering airflow can generally be solved directly (as
Because of the possibility of abnormal coal or other opposed to iteratively) for units with separate primary
operating considerations during the test, the parties to air heaters that are controlled to a fixed exit gas tempera-
the test should agree upon how to determine the split ture. The parties to the test shall agree upon the controlled
between the air heaters for the corrected conditions. primary exit gas temperature (normally the test tempera-
TDiMrFgEn is obtained from a correction curve, ture) and design pulverizer entering air temperature. Since
usually provided by the air heater vendor. the primary airflow to the pulverizers is constant and the
(d) Heat Capacity or X-Ratio. For determining cor- primary air heater inlet and outlet flue gas temperatures
rected efficiency, the air heater exit gas temperature may are known, the required primary air heater gas flow can
be corrected for the difference in the heat capacity ratio be solved for directly as follows:
for the test conditions and the heat capacity ratio calcu-
lated for the corrected efficiency and the contract steam H A l l d - HA8Ad
generator output. The most typical reason for the heat MrFgI4BCr = MrAIl
H F g l 4 B d - HFglSBd'
capacity ratio to be different from design is air bypassing
the air heater(s). Examples of cases in which this may Ibm/h (kg/s) (5.18-4)
occur are excessive setting infiltration (normally older
units) and excessive pulverizer tempering airflow. For where
units with separate primary and secondary air heaters (as MrFgl4BCr= corrected mass flow rate of flue gas
described above), if the test is conducted with the target entering primary air heater, Ibmh (kg/s)
primary air heater exit gas temperature and corrections MrA11= primary airflow entering pulverizers,
to pulverizer tempering airflow are not required because Ibm/h (kg/s)
of the difference in the moisture between the test and HAlld= enthalpy of the design air temperature
contract coal, it is recommended for simplification of the entering the pulverizer, BtuAbm (Jkg)
calculations that the test X-ratio be used for the secondary HA8Ad = enthalpy of the design air temperature
air heater. This eliminates the need for calculating a pri- entering the air heater, BtuAbm (Jkg)
mary air heater correction. Subparagraph (f) below ad- HFg14Bd = enthalpy of the design gas temperature
dresses calculation of corrected pulverizer tempering air- entering the primary air heater,
flow and corrected mass flow rate of flue gas entering B t d b m (Jkg)
the primary air heater. HFglSBCrd = enthalpy of the design gas temperature
TDiXr is obtained from a correction curve, usually leaving the primary air heater (excluding
provided by the air heater vendor. leakage), BtuAbm (Jkg)
( e ) Corrections for Pulverizer Tempering Airflow, This energy balance procedure is only valid if the
Units Without Primary Air Heater. The air temperature air heater surface and performance characteristics are
leaving the air heater may be significantly different from capable of producing the design air temperature leaving.
the test conditions which could impact the amount of This can be verified by calculating the corrected air
pulverizer tempering air required. When tempering air is heater exit gas temperature utilizing the design boundary
normally utilized, the corrected air temperature leaving conditions. If the corrected exit gas temperature is
the air heater shall be calculated by energy balance based higher than the desired control exit gas temperature,
on the corrected conditions. A corrected tempering air- the actual air temperature leaving will be lower than
113
-- | ||| | || | || | | ||| |||| | || ||| | || || ||| | |---
STDmASME PTC 4-ENGL 1998 m 0759h70 Ob15054 OTh
ASME FTC 4- 1998 FIRED STEAM GENERATORS
the required pulverizer inlet temperature. This indicates water in coal) the pulverizer tempering airflow and air
that the air heater is not capable of performing in heater performance should be corrected for the mill
accordance with the energy balance, and the actual inlet temperature required for the design coal. High
expected performance will have to be calculated itera- moisture coals generally do not require pulverizer tem-
tively using the correction procedure parameters as the pering air, and corrections for coal moisture are not
air heater model. required unless tempering air is utilized during the test.
The parties to the test shall agree upon whether this
5.18.3 Fuel Analysis. Corrections to credits, losses correction is required, and if it is required, either agree
(efficiency), and air and flue gas mass flow rates for upon a design mill inlet air temperature or a method
differences in fuel constituents between the test and of correcting the test mill inlet temperature for off-
contract fuel are made by utilizing the standard or design moisture in coal.
contract fuel analysis in the applicable computations.
Corrections to air heater performance for pulverized 5.18.4 Sorbent Analysis and Sorbent Reactions. The
coal fired units (units with controlled air temperature actual sulfur content of the coal during a test is not
known until after the test. Therefore, the calcium to
--
for drying the fuel) and air and gas resistance resulting
from differences in air and flue gas mass flow rates sulfur molar ratio during the test is likely to be different
| ||| | || | ||
are described below. Additional corrections should not from the agreed upon target value for the test. Deviation
be required if the test and contract fuels are equivalent; from the target calcium to sulfur molar ratio impacts
|
i.e., have similar ultimate and proximate analyses and the sulfur capturehetention result. Also, differences
| |||
similar slagging, fouling, and combustion characteristics. between the test and the standard or contract sulfur
|||| | || ||| | || ||
Refer to Appendix E for guidance regarding equiva- content of the fuel and sorbent analysis impact the
lent fuels. sorbent mass flow rate required (Ca/S ratio) as well
Equivalent fuels do not affect the thermal performance as the sulfur capturehetention. These differences also
||| | |---
of the steam generator. Thermal performance with impact efficiency and air and flue gas mass flow rates.
regard to efficiency refers to the gas temperature exiting 5.18.4.1 Corrections for Sorbent Analysis and
the steam generator pressure parts, but also applies to Sorbent Reactions. In accordance with Subsection
furnace, superheat, and reheat absorption and may 5.18.4.2, agreed upon values for the calcium to sulfur
include other parameters such as steam temperature (Ca/S) molar ratio and sulfur capture are used to make
and spray attemperation. the corrected combustion and efficiency calculations.
The differences in the slagging and fouling character- The calcium to sulfur molar ratio is used in conjunction
istics have the most significant impact on thermal with the standard or contract fuel analysis to calculate
performance. Differences in fuel moisture content (on the corrected sorbent rate, lbm/lbm fuel (kgkg fuel).
the order of 1 5 points) and ash content (210 points) The corrected sorbent rate, agreed upon sulfur capture/
have minimal impact on the gas temperature leaving the retention, standard or contract sorbent analysis, and
pressure parts, but may affect component absorptions. calcination fraction determined from the test are all
For manufactured or process gases and/or synthetic substituted for the test values to calculate the required
fuels, differences in constituents may impact flue gas input data for the corrected efficiency calculations.
mass flow rate and yet have a minimal impact on the
gas temperature leaving the pressure parts. However, 5.18.4.2 Guidelines for Establishing a Standard
if the corrected flue gas mass flow rate is different by or Reference C d S Molar Ratio and Sulfur Capture.
more than 2 or 3%, absorptions may be affected. It is desirable that the sorbent rate versus sulfur capturd
This Code requires that the parties to the test agree retention characteristics of the unit be determined prior
that the test fuel is equivalent to the contract fuel, or to an efficiency test. This allows the parties to the test
that they reach a pretest agreement as to a method for to establish a target calcium to sulfur molar ratio for
correcting the thermal performance of the steam genera- operating the unit during the test. This agreed upon value
tor for differences between the test fuel and the standard would normally be used as the value for corrections to
or contract fuel. standard or contract conditions in conjunction with the
On pulverized coal fired units, the air temperature tested sulfur capturdretention result. There may be
entering the pulverizer is controlled to maintain a design occasions when the target value for the test does not
pulverizer air-coal outlet temperature. The required reflect steam generator capability such as off-design
pulverizer inlet air temperature is a function of the fuel sulfur content, sorbent characteristics versus the
moisture in the coal. If the test coal is appreciably off design sorbent, overfeeding of sorbent to meet a lower
design (more than two or three percentage points of than contract sulfur emissions level, etc. In such cases,
114
~~
STD-ASME PTC 4-ENGL 3998 0757b70 Ob35055 T32
FIRED STEAM GENERATORS ASME WC 4-1998
it may be necessary for the parties to the test to agree to excess air are made by substituting the target value
upon calcium to sulfur molar ratio and sulfur capture/ in the applicable equations.
retention values to use for the corrected efficiency If the unit must operate at an excess air level other
results. The test calcium to sulfur molar ratio ( C d S ) than the standard or contract value to meet other
may be corrected for the changes between the test and performance parameters such as unburned carbon, emis-
the standard or contract sulfur capture and sulfur content sions, steam temperature, etc., then no correction to
of the fuel by use of correction curves or equations the “as tested” excess air value should be applied.
agreed to by the parties to the test. Note that the
purpose of this Section is to calculate a normalized 5.18.7 Other Entering Streams
efficiency that reflects the unit’s capability. 5.18.7.1 Moisture in Air. Substitute the standard
or guarantee value for the test value in the applicable
5.18.5 Residue. The considerations for residue are calculations.
losses related to unburned combustible in the residue,
sensible heat of residue losses, residue split between 5.18.7.2 Fuel Temperature. Substitute the standard
the various boiler collection points, the quantity of ash or guarantee value for the test value.
in the fuel, and the quantity of spent sorbent, which
are discussed in the following sections. 5.18.7.3 Sorbent Temperature. Substitute the stan-
dard or guarantee value for the test value.
5.18.5.1 Unburned Carbon Loss. Unless otherwise
agreed to, the test unburned carbon loss is to be used 5.18.8 Surface Radiation and Convection Loss.
for the corrected conditions. The unburned carbon mass When this item is measured, the results shall be cor-
--
per mass of fuel basis for the standard or guaranteed rected to the standard or guarantee ambient conditions
| ||| | || | ||
fuel is calculated by multiplying the unburned carbon (air temperature and velocity). This is a three step
measured during the test by the ratio of the higher process. For each incremental area measured:
heating value of the standard or guarantee fuel divided
|
Solve for the insulation and lagging heat transfer coef-

| |||
by the higher heating value of the test fuel. ficient, Hwz, based on the measured parameters.
|||| | || ||| | || ||
5.18.5.2 Residue Quantity. The residue quantity Based on the assumption that Hwz is constant, solve
is the sum of the ash in the fuel, unburned carbon, for the corrected surface temperature, TMnAfCrz, for
and spent sorbent, and is calculated for the standard the standard or guarantee ambient conditions.
||| | |---
or guarantee conditions using the reference fuel and With the corrected surface temperature and standard or
sorbent analysis, and other corrected conditions in the guarantee ambient conditions, solve for the corrected
same manner as calculated for the test conditions. surface convection and radiation loss, QrUrcCrz.
5.18.5.3 Residue Split. The residue split between 5.18.8.1 Insulation and Lagging Heat Transfer
the various collection locations should be assumed to Coefficient, Hwz
be the same as tested unless otherwise agreed upon.
For fluidized bed units, the quantity of ash in the fuel
and sorbent used can impact the ash split. In cases
where this may be significant, a correction curve or
Hwz =
(QrLSrcz\
Thfz
Afz
- TMnAfz
’ , Btu/ft2hoF (W/m2soC) (5.18-5)
procedure should be agreed upon.

5.18.5.4 Sensible Heat in Residue Loss. The sensi- where Thfz is the hot face temperature of the insulation
ble heat in residue loss at each location is calculated and lagging (steam generator wall, flue, duct, etc.).
based upon the total mass of residue calculated for the
standard or guarantee conditions, using the residue split 5.18.8.2 Corrected Surface Temperature,
in accordance with Subsection 5.18.5.3 and temperatures TMmifCrz The corrected surface temperature requires
(corrected to standard or guarantee conditions, if appli- the solution of the following equation:
cable).
5.18.6 Excess Air. Minor deviations in excess air
between the test and standard or contract value that
are due to variability of establishing test conditions
may be corrected to the standard, contract, or other where Hrcaz is the sum of the radiation and convection
agreed upon value. Corrections to losses or credits due heat transfer coefficients for TMnAfCrz and the reference
115
ambient air temperature, TMnARe, and reference surface typically fuel analysis, entering air temperature and exit
velocity. gas temperature corrected for entering air temperature
An iterative solution is required to solve Eq. (5.18- (for unit with air-to-gas-heat exchangers). Correcting
6) using the standard method for calculating Hrcuz. for the test fuel versus the design fuel requires that
The solution can be simplified by using a linear curve the ultimate analysis be determined for the test fuel
fit for Hrcuz in the range of the corrected surface as well as the heating value. For units with air to gas
temperatures and reference ambient air temperature and heat exchangers, if the entering air temperature is
reference velocity. The following curve fit predicts a measured, the exit gas temperature (expected tempera-
surface temperature within 0.5% for a range of surface ture if not measured) should be corrected in accordance
temperatures from 130°F to 280°F for standard reference with Subsection 5.18.2. Any other corrections discussed
ambient conditions: above can be applied if measurements of necessary
parameters are made.
Hrcaz = 1.4254 (5.18-7) 5.18.11 Air and Gas Resistance. The measured resist-
+ 0.00593 (TMnAfCrz - TMnARe) ance shall be corrected to standard or guarantee condi-
tions for the difference in mass flow of the flowing
The user should develop a similar curve fit if different fluid and the specific volume of the fluid between the
standard conditions are used. This simplification allows test condition and the standard conditions. The general
for solving for the corrected surface temperature directly equations for correcting air resistance or draft loss are:
from the following equation:
- B + -./B2 - 4 A C
MrAFg )2+ S e ) .
(MrA
TMnAfCrz = , OF (OC) (5.18-8) Fg C r
2A
where in. wg (Pa) (5.18-11)

A = 0.00593
B = 1.4254 - 2.0 x 0.00593 TMnARe
+ Hwz (5.18-9)
C = - 1.4254 TMnARe - Hwz Thfz 2.31
+ 0.00593 TMnARe2 (5.18-10) Se = c2 -Ht(DnAFg - DnA),
12
where TMnARe is the reference surrounding air temper-
ature. in. Wg (Pa) (5.18.i 2 )
5.18.8.3 Corrected Surface Radiation and Con-

vection Loss, QrLSrcCrz. Solve for the corrected sur-
face radiation and convection loss in accordance with where
Subsection 5.14.9 using the corrected surface tempera- PDiAFgCr = corrected air resistance or draft loss, in.
ture and the standard or guarantee ambient conditions. wg (Pa)
5.18.9 Miscellaneous Efficiency Corrections. Other PDiAFg= measured air resistance or draft loss, in.
minor losses and/or credits that are measured should wg (Pa)
be reviewed by the parties to the test and agreement MrAFg= mass flow rate of air or flue gas for
reached as to whether corrections to the efficiency are test conditions, lbmh (kg/s)
applicable. MrAFgCr= corrected mass flow rate of air or flue
gas, lbmh (kg/s)
5.18.10 Corrected Input-Output Efficiency. When Se= stack effect or difference in static pres-
efficiency is determined by the input-output method, sure between the aidgas side of boiler
the test result is corrected to the standard or guarantee and surrounding ambient air. Se will be
conditions by adding the difference between the cor- negative if the fluid is flowing upward.
rected efficiency and test efficiency (both as calculated Ht= height between the pressure locations,
by the energy balance method) to the input-output test i.e., the difference in elevation between
results. Design boundary conditions (such as entering the downstream and upstream pressure
air and exit gas temperatures) shall be used if they locations, ft (m). Ht will be positive if
are not measured. The most significant corrections are the fluid is flowing upward.
116
-- | ||| | || | || | | ||| |||| | || ||| | || || ||| | |---
STD-ASME PTC 4-ENGL 1998 0759670 Ob15057 805 4
-(
[[(TT sr]
Cl = unit conversion factor, 1.0 for in. wg
(2.4884E + 02 for Pa) VhCr = C2- 1 (5.18-14)
DnSt
C2= unit conversion factor, 1.0 for in. wg
(2.4884E + 02 for Pa) + vhcf(-)l].
MrStd psi (pa)
DnAFg= density of air or flue gas, Ibm/ft3 (kg/ Aidd
m3). For the furnace shaft, use a value
of 0.0125 Ibm/ft3 (0.20 kg/m3). where
DnA = density of ambient air in vicinity of VhCf= loss coefficient for the change in cross section
pressure measurement, Ibm/ft3 (kg/m3) geometry involved based on the diameter of
The pressure drop characteristics of each system must the pipe at the terminal point. Parties to test to
be examined in detail and a detailed pressure drop agree upon value based on geometry involved
correction procedure for the specific system be devel- utilizing fluid flow reference text.
oped. The above general pressure drop equation may Ai&= area of the pipe at the contractual terminal
not be applicable for all equipment (pulverizers, for point, ft2 (m2)
example) and systems (for example, where pressure Aid= area of the pipe where pressure tap is installed,
drop is controlled, such as cyclone furnaces). ft2 (m2)
C2 = unit conversion factor, 8.327E-12 for psi
5.18.12 Steam or Water Pressure Loss. The general (5.741E-8 for Pa)
equations for correcting steardwater pressure drop be- The measured pressure differential across a steam
tween the test and design or contract conditions are generating unit or a portion of the unit shall be corrected
--
as follows: to standard or guarantee conditions due to the difference

| ||| | || | ||
in mass flow of the flowing fluid and the specific

volume between the test condition and the reference
conditions. A correction for velocity pressure may also
|
PDiStCr = (PDiSt
| |||
o be required if the static pressure measurement tap is

|||| | || ||| | || ||
- CI H t DnSt) - -
DnSt MrSrd (5.18-13) located at a point with a cross sectional area different
DnStd MrSt from the terminal point for the guarantee.
+ CI H t DnStd - VhCr, psi (pa)
5.18.13 Steam Temperature and Desuperheating
||| | |---
Spray. Steam temperature and desuperheating spray

guarantees must be evaluated based on actual and design
where
superheater (and reheater if applicable) absorptions
PDiSt= the measured pressure drop, psi (Pa)
rather than actual temperature due to potential deviations
PDiStCr= the corrected pressure drop, psi (Pa)
from the target steam temperature during the test andor
Hr = height between the pressure locations,
deviations from the design cycle conditions. The actual
¡.e., the difference in elevation between
main steam and reheat mass flow rates utilized to
the downstream and upstream pressure
calculate actual absorptions are corrected for off-design
locations, ft (m). Hr will be positive if
test conditions. In general:
the fluid is flowing upward.
DnSt= density of the s t e d w a t e r at the test 0 The steam temperature shall be evaluated by compar-
conditions, lbm/ft3 (kg/m3) ing the actual superheaterheheater absorption to the
DnStd= density of the s t e d w a t e r at the design design required superheaterheheater absorption.
conditions, ibm/ft3 (kg/m3) 0 Desuperheating spray shall be evaluated based on the
Cl = unit conversion factor, 0.00694 for psi calculated spray required for the actual versus design
(4.788026E + O1 for Pa) required superheaterheheater absorption.
MrSt= mass flow rates of the stearrúwater at 0 The test main steam and reheat mass flow rates utilized
the test condition, lbmh (kg/s) to calculate actual absorptions are corrected for off-
MrSrd= mass flow rates of the stearrúwater at design load by multiplying by the ratio of the design
the design condition (for feedwater flow main steam flow divided by the test main steam flow,
and intermediate superheater flows, cal- MfStCr.
culated based on the corrected spray 0 Main steam temperature and superheater spray attemp-
water flow), Ibmh (kg/s) eration for once-through steam generators are not
VhCr = velocity head correction (if applicable) functions of surface arrangement, and corrections are
calculated as follows: not necessary. Main steam temperature is a matter of
117
S T D - A S M E PTC 4-ENGL 1998 0759b30 Ob15058 7 4 1
ASME F'TC 4-1998 FIRED STEAM GENERATORS
steam generator controls and should be acknowledged 5.18.133 Reheater Absorption Corrected,
as achievable unless there are other limiting design QrRhCr. The reheater absorption corrected for design
considerations. main steam flow is calculated from:
Certain designs, such as divided gas flow units, may
require test andor correction procedures not addressed QrRhCr = M ~ t C ~r ~ (H.334
~ - HSt33)
~ 3 3 17)
(5.18-
by this Code (a simplified approach for divided gas
flow units is presented below). + MrW26 (HSt34 - HW26). Btulh ( W )
Actual and design required superheat and reheater where MfsrCr is the ratio of the design main steam
absorptions are defined below. The main steam and flow divided by the test main steam flow
reheat steam mass flow rates used to calculate actual
absorptions are corrected for off-design main steam 5.18.13.4 Required Reheater Absorption,
flow by multiplying the test main steadreheat steam RqQrRh. The required reheater absorption for the design
flow by the ratio of the design main steam flow divided main steam flow is calculated from:
by the test main steam flow (MfsrCr). The resulting
absorption term generally referred to as "actual absorp- RqQrRh = MrSt33d (HSt34d - Hst33d),
tion" above is referred to as corrected absorption in
the following Sections. While a second stage of reheat Btulh (W) (5.18- 18)
is not addressed directly, the same principles apply as
for the first stage of reheat. where all terms are the contract or design conditions
for the design main steam flow.
--
5.18.13.1 Superheater Absorption Corrected,

5.18.13.5 Corrected Superheat and Reheat Steam
| ||| | || | ||
QrShCr. The superheater absorption corrected for design

main steam flow is calculated from: Temperature and Desuperheating Spray. When the
corrected component absorption is equal to or exceeds
|
the required component absorption, the corrected steam

| |||
QrShCr = MrSt32d (HSt32 - HSt3I) (5-18- 15) temperature is considered to be the design temperature.
|||| | || ||| | || ||
+ MrW25 (HSt31 - HWZS) The required superheat and reheat spray is based on
+ MrSt46A (HSt46A - HSt31). Btulh ( W ) excess absorption of the specific component and is
calculated in accordance with the following equations:
||| | |---
where
MrSt32d= design main steam flow, Ibh (kg/s) QrShCr - RqQrSh
MrW25= desuperheating water flow for the test
conditions, lb/h (kg/s)
MrWZSCr =
HSt3ICr - HW2Sd ' )
MrSt46A = superheater extraction flow for the test Ibm/h (kg/s) (5.18- 19)
conditions, Ibh (kg/s)
5.18.13.2 Required Superheater Absorption,
RqQrSh. The required superheater absorption for the
design main steam flow is calculated from:. MrW26Cr = (QrRhCr - RqQrRh
HSt34d - HW26d
Ibm/h (kg/s) (5.18-20)

RqQrSh = MrSt32d (HSt32d - HSt31Cr) (5.18- 16)
+ MrSt46Ad (HSt46A - HSt31 Cr), B t d h ( W )

Subsection 5.18.13.6 discusses divided gas flow units
where steam temperature is controlled by exchanging
where energy between the reheater and superheater.
HSt46A = enthalpy of auxiliary or extraction steam If the corrected component absorption is less than
at the test conditions, BtuAbm (Jkg) the required absorption, the corrected spray flow is
HSr31 Cr= enthalpy of saturated steam calculated zero. The corrected outlet temperature is determined
from the design superheater outlet pres- from the outlet enthalpy calculated from the corrected
sure and corrected superheater pres- component absorption, design steam and extraction
sure drop flows, and the design (or corrected) inlet conditions as
Other terms are based on design conditions. follows:
118
~
STD.ASME PTC 4-ENGL 1998 = 0759670 Ob15059 688 H

HSt32Cr = HSt3lCr the required superheat and required reheat absorption

and the reheat absorption is controllable.
+ QrShCr - QrAxStCr The reheat absorption is deemed to be controllable
MrSt32d if the gas biasing dampers are within an operating
range capable of achieving the required change in reheat
Btu/lbm (J/kg) (5.1 8-21) absorption. The required change in reheat absorption
is the difference between the corrected reheat absorption
and the required reheat absorption, QrRhCr - RqQrRh.
Based upon these assumptions, the corrected super-
QrAxStCr = MrSt46Ad (HSt46A - HStJICr), heater spray is calculated from the following equation:
Btulh (W) (5.18-22)
MrW25Cr = (5.18-24)
(QrShCr - RqQrSh) + (QrRhCr -

HSt3lCr - HW25d
HSt34Cr = HSt33d (5.18-23)
Ibmlh (kgls)
+- QrRhCr , Btullbm (J/kg)
MrSt34d
For corrected steam temperature for under absorption
conditions, the main steam temperature is normally
where deemed to be met and the reheat outlet steam tempera-
QrAxStCr = energy in the superheated auxiliary or
ture determined from the enthalpy calculated based
extraction steam, Btu/h (W) upon the design reheat inlet conditions and the difference
5.18.13.6 Corrected Superheat and Reheat Steam in the sum of the corrected reheat and superheat absorp-
Temperature and Desuperheating Spray, Divided tion less the required superheat absorption.
Gas Flow Units. On divided gas flow units, reheat
steam temperature is controlled by exchanging energy HSt34Cr = (5.18-25)
between the reheater and superheater by biasing gas
flow between the reheat and superheat pass. Tests are HSt33d + QrRhCr + (QrShCr - RqQrSh)
normally conducted by controlling to the design reheat MrSt33
temperature. Superheat absorption can be impacted if
Btu/lbm (J/kg)
the reheat boundary conditions are different from the
design conditions. Therefore, superheat and reheat ab-
sorption must be evaluated collectively. 5.18.14 Uncertainty of Corrected Results. The un-
For differences in corrected versus required reheat certainty values calculated and used in this Code are
absorption on the order of 5%, a direct exchange in for the as-measured test results only. Several technical
energy between the superheat and reheat can be as- issues need to be resolved regarding uncertainty of
sumed. The following corrected results are based on corrected results. So as not to delay the issuance of
this assumption. this Code, this calculation is not included. When such
An alternate test method is to control to a target a procedure is developed, it will be issued as an
reheat outlet steam temperature andor reheater attemper- addendum and become a part of this Code.
ation flow equivalent to the design required reheat
absorption, RqQrRh. This method may be required if
the differences between the corrected and required
5.19 ENTHALPY OF AIR, FLUE GAS, AND
reheat absorption are larger than 5%. Due to normal
OTHER SUBSTANCES COMMONLY
deviations between the desired set point and actual
REQUIRED FOR ENERGY BALANCE
performance, a minor correction in accordance with
CALCULATIONS
this Section is still expected. The disadvantage of this
test method is that the required versus corrected reheat The specific energy (energy per unit mass) of many
absorption may not be known at the time of the test. different flow streams is required to evaluate energy
Main steam and reheat steam temperature are deemed losses and credits for efficiency calculation. A few of
to be met if the sum of the corrected superheat and the streams are steam, water, air, flue gas, sorbent,
corrected reheat absorption is greater than the sum of coal, and residue (ash and spent sorbent). Specific
119
-- | ||| | || | || | | ||| |||| | || ||| | || || ||| | |---
energy of a flow stream is evaluated by the enthalpy are recommended for users interested in general heat
of the flowing material. transfer calculations involving air and flue gas.
The measured quantities that allow determination of Unless otherwise noted, the reference source is the
enthalpy of substances are the temperature and pressure. JANAF Thermochemical Tables [3], and curve fit coef-
Enthalpy is related to temperature and pressure by ficients developed in accordance with NASA Publication
relationships that are simple for some ranges of tempera- SP-273 [4]. Abbreviated JANAFNASA correlations are
ture and pressure and complicated for other ranges. presented below.
Accurate determination of enthalpy at all values of For convenience in hand calculations, curves are
temperature and pressure requires the use of tables, provided at the end of this Section for calculating
charts, or computer software. Engineers who deal with enthalpy of air, flue gas, water vapor, and residue.
steam almost invariably obtain the enthalpy of steam Refer to Subsection 5.19.12 for a description of how
using tables or software. these curves are used.
Frequently, changes of specific energy of streams Unless otherwise noted, the curve fits for enthalpy
other than steam are evaluated using the specific heat in this Section are in US Customary Units of Btdlbm.
and temperature difference: To convert to Jíkg, multiply the result by 2,326.
5.19.1 Enthalpy of Air, Btdbm (Jag). Enthalpy of
Hn - Hp = MnCpk (Tn - Tp) air is a function of the mass of the mixture of dry air
and water vapor in air. To determine the enthalpy of
||| | |---
where dry air, use a water vapor content of zero:
MnCpk= the mean specific heat between the two
|||| | || ||| | || ||
temperatures
The mean specific heat is usually taken as the value HA = ( i - MFrWA) HDA (5.19- 1)
at the mean temperature:
+ MFrWA HWV, Btu/lbm (Jlkg)
| |||
Tmn = (Tn + T p ) / 2
|
| ||| | || | ||
In reality, specific heat and enthalpy are both nonlin-
ear functions of temperature and are related by: MFrWA = MFrWDA I (1 + MFrWDA), (5.19-2)
--
Ibm/lbm (kg/kg)
Hn - Hp =
IrT: MnCpk dT
As specific heat is usually nonlinear, MnCpk is not where

equal to the specific heat at temperature Tmn. The HA = enthalpy of wet air, Btdlbm (Jíkg)
differences are slight for small temperature differences; HDA = enthalpy of dry air, B t d b m ( J k g ) . Refer
however, a steam generator test may require evaluation to Subsection 5.19.10 below.
of enthalpy differences between temperatures typical HWv= enthalpy of water vapor, Btulibm (Jkg).
of inlet air (50°F)and of flue gas leaving an economizer Refer to Subsections 5.19.4 and 5.19.10
(700’F). below.
To gain accuracy, as well as be more “theoretically” MFrWDA = mass fraction of water vapor in dry air,
correct, this Code requires that enthalpy of substances lbm H201ibm dry air (kgkg). This is
other than steam be evaluated directly from temperature the standard method for expressing mois-
via enthalpy-temperature curve fits. Pressure effects are ture in air.
neglected because all streams other than watedsteam MFrWA = mass fraction of water vapor in wet air,
are at low and nearly constant pressure: lbm H20/lbm wet air (kgkg)
When the mean specific heat is required, it is ob-
5.19.2 Enthalpy of Flue Gas, Btu/lbm (Jkg). “Wet
tained from
flue gas” as defined by the calculations in this Code
is composed of dry gaseous products of combustion
MnCpk = [H(Tn) - H(Tp)]/(Tn- T p ) and water vapor. Solid residue may also be entrained
in the gas stream. The enthalpy of wet flue gas accounts
The enthalpy correlations presented in this Section for the enthalpies of all of these components. If the
120
STDmASME PTC 4-ENGL 1998 W 0759670 0635063 23b
enthalpy of dry flue gas is desired, the water and solid 5.19.4 Enthalpy of Water Vapor, Btdlbm. The coef-
residue components are zero: ficients for the JANAF/NASA fifth order curve fit
are given in Subsection 5.19.10 below. The following
HFg = ( 1 - MFrWFg) HDFg + MFrWFg HWV
simplified curve fit for calculating credits and losses
due to moisture may also be used. The results are
+ MFrRsFg HR, Btu/lbm J/kg) (5.19-3) within 0.3% of the -JANAF values for temperatures
between 0°F and 1,000"F (-2O"C-54O0C):
where
HFg= enthalpy of wet flue gas, BtuAbm (Jkg) HWV = 0.4408 T + 2.381E-5 T2 (5.19-5)
HDFg= enthalpy of dry flue gas, Btdlbm (Jkg). + 9.638E-9 T 3 - 34.1, Btullbm
Refer to Subsection 5.19.10 below.
HRs= enthalpy of residue, Btu/lbm (J/kg). Re- where
fer to Subsections 5.19.3 and 5.19.10 T = temperature, "F
||| | |---
below. NOTE: The reference temperature is 77°F (25°C).
MFrWFg= mass fraction of water in wet gas, Ibm
|||| | || ||| | || ||
H20/ibm wet gas (kgkg). Refer to Sub- 5.19.5 Enthalpy of Steadwater at 1 psia, Btul
section 5.12.10 for calculation. lbm. The enthalpy of steam at 1 psia is required to
MFrRsFg= mass fraction of residue in wet gas, determine the losdcredit of water that enters the bound-
| |||
Ibdlbm wet gas (kgkg). Refer to Sub- ary in the liquid state and leaves the boundary in the flue
|
section 5.12.11 for calculation. The sen- gas in a vaporous state. An example is the calculation of
| ||| | || | ||
sible heat of residue may be omitted if the water from fuel losses. The following equation
sorbent is not utilized and the ash in may be used in lieu of the ASME Steam Tables for
the fuel is less than 15 lbm/MBtu input temperatures from 200°F to 1,000"F (95°C to 540°C):
--
(i.e., where 10,oOO x MpAsF/HHVF is
less than 15).
HSt = 0.4329T+ 3.958E - 5T2 (5.19-6)
5.19.3 Enthalpy of Dry Residue, Btdlbm. Residue
is composed of numerous complex compounds and may
+ 1062.2. Btullbm
include spent sorbent products when sorbent is utilized.
One approach for determining enthalpy of residue would
be to determine or estimate (calculate) the major constit- HW = T - 32, Btullbm (5.19-7)
uents in the residue and use a mass weighted average
of the enthalpy for each component to determine the
average enthalpy. In the interest of simplicity and where
considering the insignificant impact of inaccuracies in T= temperature, "F
calculating the enthalpy of residue on the energy balance NOTE: The reference temperature is 32°F (0°C).
calculations within the scope of this Code compared
5.19.6 Enthalpy of Coal, Btdlbm. The correlation
to the error in measuring the mass flow rate of residue
for enthalpy of coal is based upon the constituents in
streams, this Code adopts the curve fit below for all
coal as determined from a Proximate Analysis. It is
dry residue streams. It was developed from data for
developed from N.Y. Kirov's correlation as reported
SiO2, 77°F (25°C) reference temperature and is applica-
in Chemistry of Coal Utilization [ 5 ] . The original
ble from 0°F to 2,000"F (-20°C to 1,100"C). This
specific heat equations were integrated to obtain en-
Code adopts the fifth order correlations described in
thalpy at a reference temperature of 77°F (25°C). The
Subsection 5.19.10 for all dry residue streams. The
polynomial for fixed carbon was reduced by one order
following abbreviated equation developed from the fifth
for simplicity. The enthalpy of ash was developed from
order curve fit may be used for hand calculations:
Si02 for consistency with enthalpy of residue.
The correlation is not applicable for frozen coal or
HRs = 0.16T + 1.09E-4 T2 (5.19-4) for temperatures above which devolatization occurs:
- 2.8438-8 T3 - 12.95. Btu/lbm
where HCoal = MFrFc HFc (5.19-8)

T = temperature, "F + MFrVml HVml + MFrVm2 HVm2
121
STD-ASME PTC II-ENGL 1998 = 0759b70 Ob35062 372 H
ASME ITC 4-1998 FRED STEAM GENERATORS
+ MFrWF HW + MFrAsF HR, Btullbm MFrVml = MFrVm - MFrVm2 (5.19- 19)
where
MFrFc= mass fraction of fixed carbon, ibdlbm
HFc = 0.152T + 1.95 E-4 T 2 (5.19-9)
coal as-fired
- 12.860, Btullbm MFrAsF= mass fraction of ash, lbdlbm coal as-
fired
M F r W F = mass fraction of water, Ibnúibm coal
as-fired
HVml = 0.38T + 2.25E-4 T2 (5.19-10) MFrVm= mass fraction of volatile water, Ibdlbm
- 30.594, Btullbm coal as-fired
MFrVmZ = mass fraction of primary volatile matter,
lbdlbm coal as-fired
MFrVm2= mass fraction of secondary volatile mat-
HVm2 = 0.70T + 1.70E-4 T2 (5.19-1 1) ter, lbdlbm coal, as-fired
- 54.908, Btullbm M F r V m C r = mass fraction of volatile matter on a dry
and ash free basis, Ibnúlbm coal, dry-
ash free
T= temperature, OF
HRs = 0.17T + 0.80E-4 T 2 (5.19-12) Hk= enthalpy of coal component k, Btu/lbm
- 13.564, Btullbrn 5.19.7 Enthalpy of Fuel Oil, BtuAbm. The enthalpy
of fuel oil has been con-elated as a function of specific
gravity at 60°F (16°C) in "AP1[6].
HW = T - 77, Btu/lbm (5.19- 13)

HFO = CI + C2 API + C3 T + C4 API T (5.19-20)
+ (C5 + C6 API)T2, Btu/lbm
MFrVm = MFrVml (5.19- 14)
+ MFrVm2, Ibmllbm fuel as-fired
API = (141.5 - 131.5Sg)/Sg (5.19-21)
MFrVmCr = MFrVml(1 - MFrAsF - MFrWF),

Sg = Dn162.4 (5.19-22)
lbrn/lbm fuel dry-ash free (5.19-15)
where
If MFrVmCr 5 0.10, then H F o = enthalpy of fuel oil, Btdlbm
T = temperature, OF
API= density at 60°F (16"C), "API
MFrVm2 = MFrVm (5.19- 16) Dn= density at 60°F (16"C), 1bdft3
Sg = specific gravity at 60°F (16"C), lbdlbm
CI = -30.016
C2= -0.11426
MFrVml = 0.0 (5.19- 1 7) c3=M.373
C4 = +O. 143E-2
C5 = 4 . 2 184E-3
If MFrVmCr > 0.10, then
C6= +7.0E-7
5.19.8 Enthalpy of Natural Gas, BtuAbm. The fol-
MFrVm2 = O.lO(1 - MFrAsF (5.19- 18) lowing curve fit was developed from the JANAFDJASA
- MFrWF) data for a typical natural gas fuel analysis of 90%
122
-- | ||| | || | || | | ||| |||| | || ||| | || || ||| | |---
methane (CH,), 5% ethane (Czi&), and 5% nitrogen. TK = temperature, K

It is valid from 0°F to 500°F. Natural gas is normally Coefficients for dry air are based upon the composi-
near the reference temperature of 77°F (25"C), and tion of air as defined in this Code.
thus utilizing a typical analysis for natural gas is Coefficients for dry air for temperatures from 255 K
sufficiently accurate for efficiency calculatians. For to 1,Ooo K:
manufactured gases that enter the steam generator at an
elevated temperature, the enthalpy should be determined
CO = -0.1310658E+03 CI = +0.45813048+00
based upon the actual constituents in the gas.
C2 = -0.10750338-O3 C3 = +0.1778848E-06
HGF = 0.4693 T + O. 17523E-3 T Z (5.19-23) C4 = -0.9248664E-10 C5 = +0.168203148-13
+ 0.4326 E-7 T 3 - 37.2, Btullbm
Coefficients for dry air temperature above lo00 K:
where
T = temperature, "F CO = -0.11777238+03 CI = +0.37167868+00
5.19.9 Enthalpy of Limestone Sorbent, B M b m . C2 = +0.8701906E-04 C3 = -0.2196213E-07
The following correlation is based upon JANMAVASA C4 = +0.29795628-11 C5 = -0.1630831E-15
data for Caco3 with a correction for water. It is valid
from 0°F to 200°F:
Coefficients for water vapor temperatures from 255
K to loo0 K:
HSb = ( i - MFrH20Sb) HCc (5.19-24)
+ MFrH20Sb ( T - 77), Btu/lbm CO = -0.2394034E+03 CI = +0.82745898+00
C2 = -0.17975398-03 C3 = +0.39346148-O6
C4 = -0.24358738-09 C5 = +0.60692648-13
HCc = 0.179T+ 0.11288 (5.19-25)

Coefficients for water vapor temperatures above
- 3 T 2 - 14.45, Btu/lbm
lo00 K:
where
CO -0.15734608+03 CI = +0.5229877E+OO
MFrWSb= mass fraction of water in sorbent,
I b d b m sorbent C2 +0.30895918-03 C3 = -0.5974861E-07
T = temperature, OF C4 = +0.62905158-11 C5 = -0.2746500E-15
5.19.10 Enthalpy Coefficients for Abbreviated

JANAF/NASA Correlation. The enthalpyhemperature Coefficients for dry flue gas are based on a flue gas
curves in this Section are based upon the following composition of 15.3% COz, 3.5% Oz, 0.1% SO,, and
abbreviated enthalpy correlation and the coefficients 8 1.1% atmospheric nitrogen by volume. The enthalpy
tabulated below. The reference temperature is 77°F of dry flue gas does not vary significantly for fossil
(25°C): fuels because atmospheric nitrogen is the predominant
component. It varies between 80% for coal to approxi-
mately 88% for natural gas. The difference is predomi-
nately CO, and O,, which have similar heat capacity
H k = CO + CI TK + C2 TK2 + C3 TK3 (5.19-26)
characteristics which are not significantly different from
+ C4 TK4 + C5 TK5. Btu/lbm those of atmospheric nitrogen. For typical hydrocarbon
fuels combusted with less than 300% excess air, the
following coefficients are sufficiently accurate for most
heat transfer calculations. For unusual fuels such as
TK = (T + 459.7)/1.8, K (5.19-27)
manufactured gases, hydrogen and/or combustion
processes utilizing an oxidizing medium other than air,
where refer to Subsection 5.19.1 1 below.
H k = enthalpy of the constituents, Btdlbm Coefficients for dry flue gas for temperatures from
T= temperature, OF 255 K to 1,OOO K:
123
-- | ||| | || | || | | ||| |||| | || ||| | || || ||| | |---
STDOASME PTC 4-ENGL $998 0759b70 Ob15064 T 4 5
CO = -0.1231899E+03 CI = +0.4065568E+00 to calculate the dry flue gas coefficients once for an
C2 = +0.5795050E-05 C3 = +0.6331121E-07 average fuel.
Coefficients for O, temperatures from 255 K to
C4 = -0.29244348-10 C5 = +0.2491009E-14
1,OOO K:
Coefficients for dry flue gas for temperatures above
1,000 K: CO = -0.1189196E+03 CI = +0.4229519E+00
C2 = -0.16897918-03 C3 = +0.3707174E-06
CO = -0.1 180095E+03 CI = +0.36350958+00 C4 = -0.27439498-09 C5 = +0.7384742E-33
C2 = +0.1039228E-03 C3 = -0.2721820E-07
C4 = +0.3718257E-11 C5 = -0.2030596E-15 Coefficients for O2 temperatures above 1,000 K:
Coefficients for residue of unknown composition and CO = -0.1338989E+03 CI = +0.4037813E+00

sand for temperatures from 255 K to 1,OOO K. The C2 = +0.4183627B-04 C3 = -0.73853208-08
following coefficients are based upon a smoothed curve C4 = +0.9431348B-12 C5 = -0.5344839E-16
fit for Sioz around the discontinuous point at approxi-
mately 1,000 K.
Coefficients for N2 (elemental) temperatures from
255 K to 1,Oûû K.
CO = -0.3230338E+02 CI = -0.2431404E+00
C2 = +0.1787701E-02 C3 = -0.2598230E-05 CO = -0.1358927E+03 CI = +0.4729994E+00
C4 = +0.2054892E-08 C5 = -0.6366886E-12 C2 = -0.9077623E-04 C3 = +0.1220262E-06
C4 = -0.38397778-10 C5 = -0.3563612E-I5
Coefficients for residue of unknown composition and
sand for temperatures above 1,OOO K:
Coefficients for N2 (elemental) temperatures above
1,000 K:
CO = +O. 1822637E+02 CI = +0.3606155E-01
c 2 = +0.4325735E-03 C3 = -0.1984149E-06
CO = -0.1 136756E+03 CI = +0.3643229E+OO
c 4 = +0.4839543E-30 C5 = -0.4614088E-14
C2 = +0.1022894E-03 C3 = -0.2678704E-07
C4 = +0.3652123E-11 C5 = -0.1993357E-15
5.19.11 Enthalpy Coefficients for Gaseous Mix-
tures - General. For normal flue gas mixtures, refer Coefficients for N,, (atmospheric) temperatures from
to coefficients for dry flue gas above. The enthalpy 255 K to 1,OOO K:
coefficients for gaseous mixtures not covered above
may be calculated from the mass fraction of the constit-
uents, MFr,, in the gaseous mixture in accordance with: CO = -O.l34723OE+03 CI = +0.4687224E+OO
||| | |---
C2 = -0.8899319E-04 C3 = +O.] 198239E-06
C4 = -0.3771498E-10 C5 = -0.35026408-I5
|||| | || ||| | || ||
CAmix= Zh4Fr-k CAk (5.19-28)
where Coefficients for Nh (atmospheric) temperatures above

CAk=coefficient i for the constituent k as listed in 1,OOO K:
| |||
this text or derived from an appropriate source

|
| ||| | || | ||
If the long procedure is used to derive coefficients CO = -0.1129166E+03 CI = +O,3620126E+OO

for a specific flue gas mixture from a specific fuel (or C2 = +0.1006234E-03 C3 = -0.2635113E-07
oxidant), it is recommended that the mixture be on a
C4 = +0.3592720E-11 C5 = -0.1960935E-15
dry gas basis based on a typical excess air. The moisture
--
content (and residue, if applicable) at the location in

question can then be used in conjunction with the dry Coefficients for CO2 temperatures from 255 K to
flue gas to calculate the enthalpy of wet flue gas 1,OOO K:
in accordance with Subsection 5.19.2. The enthalpy
coefficients for dry flue gas are applicable over a wide CO = -0.8531619E+02 CI = +O.l951278E+OO
range of excess air; therefore, it is usually only necessary C2 = +0.3549806E-03 C3 = -0.1790011E-06
124
STD-ASME PTC Li-ENGL 1398 = 0753b70 ílbL50b5 981 W
R R E D STEAM GENERATORS ASME PTC 4-1998
C4 = +0.40682858-10 C5 = +0.1028543E-16 CO = -0.17340278+04 CI = +O.S222199E+01
||| | |---
C2 = +0.3088671E-02 C3 = -0.4596273E-05
Coefficients for CO2 temperatures above 1,ûûû K: C4 = +0.3326715E-08 C5 = -0.8943708E-12
|||| | || ||| | || ||
CO = -0.1327750E+03 CI = +0.3625601E+00 Coefficients for H2 temperatures above 1,ooO K
C2 = +0.1259048E-03 C3 = -0.3357431E-07
| |||
C4 = +0.4620859E-11 C5 = -0.25238028-15
|
CO = -0.1529504E+04 CI = +0.54219508+01
| ||| | || | ||
C2 = +0.5299891E-03 C3 = -0.99050538-O9
Coefficients for Ar temperatures from 255 K to
C4 = -0.9424918E-11 C.5 = +0.8940907E-15
1,ûûû K:
--
CO = -0.6674373E+02 CI = +0.2238471E+00
Coefficients for H2S temperatures from 255 K to
1,ûûû K:
C2 = +0.0000000E+00 C3 = +0.0000000E+00
C4 = +0.0000000E+00 C5 = +0.0000000E+00
CO = -0.1243482E+03 CI = +0.41272388+00
Coefficients for Ar temperatures above 1,ûûû K: C2 = -0.2637594E-04 C3 = +0.1606824E-06
C4 = -0.83459018-IO C5 = -0.1395865E-13
CO = -0.6674374E+02 CI = +0.2238471E+00
C2 = +0.0000000E+00 C3 = +0.0000000E+00 Coefficients for H,S temperatures above 1,OOO K
C4 = +0.0000000E+00 C5 = +0.0000000E+00
CO = -0.1001462E+03 CI = +0.28812758+00
Coefficients for SO2 temperatures from 255 K to C2 = +0.21219298-03 C3 = -0.5382326E-07
1,ûûû K: C4 = +0.7221044E-11 C5 = -0.3902708E-15
CO = -0.6741655E+02 CI = +0.18238448+00
C2 = +0.1486249E-03 C3 = +0.3273719E-07 5.19.12 Curves for Calculating Enthalpy. The abbre-
viated JANAFNASA correlations for air and flue gas
C4 = -0.7371521E-30 C5 = +0.2857647E-13
are fifth order polynomials. For convenience in hand
calculations, specific heat curves for dry air, water
Coefficients for SO2 temperatures above 1,ûûû K vapor, dry flue gas and residue are provided on Figs.
5.19-1 through 5.19-4. These curves show the mean
CO = -0.1037132E+03 CI = +0.2928581E+00 specific heat of the constituent between the temperatures
CZ = +0.5500845E-04 C3 = -0.1495906E-07 desired and 77°F (25°C). To obtain enthalpy (H) for
C4 = +0.2114717E-11 C5 = -0.1178996E-15 any of the constituents (77'F reference), multiply the
mean specific heat times the temperature (T) minus 77°F:
Coefficients for CO temperatures 255 K to 1,OOO K:
Hk = MnCpk (T- 77). Btullbm (5.19-29)
CO = -0.1357404E+03 CI = +0.4737722E+00
C2 = -0.10337798-03 C3 = +0.1571692E-06 The resolution of the curves is such that the calculated
C4 = -0.6486965E-10 C5 = +0.6117598E-14 result will be within 0.1 Btdlbm of the actual correla-
tions. Explanations are given above for calculation of
Coefficients for CO temperatures above 1,ooO K: enthalpy of mixtures such as wet air and wet flue gas.
For some calculations, the instantaneous specific heat
(as an approximation of mean specific heat over a
CO = -0.1215554E+03 CI = +0.3810603E+OO
small temperature band) at a specific temperature is
C2 = +0.9508019E-04 C3 = -0.24645628-07 required, such as for the calculation of corrected air
C4 = +0.3308845E-11 C5 = -0.1771265E-15 heater exit gas temperature. Instantaneous specific heat
can be obtained from the mean specific heat curves
Coefficients for H2 temperatures from 255 K to by entering the curve with a temperature (Tc) equal
1,ooO K: to two times the temperature (T) desired minus 77°F:
125
ASME F'TC 4- 1998
~
0759b70 ObL50bb 818 -

Dry air (77°F reference)
FIG. 5.19-1 MEAN SPECIFIC HEAT OF DRY AIR VERSUS

T E M PERATU RE
i 26
-- | ||| | || | || | | ||| |||| | || ||| | || || ||| | |---
~~
STD-ASME PTC 4-ENGL 1998 0759670 Ob15067 754 W
Water vapor (77°F reference)

0.458
0.457
0.456
0.455
E
0.454
J
0.453
b5 0.452
0.451
o)
$, 0.450
.-
!= 0.449
2 0.448
$ 0.447
0.446
0.445
0.444
O 50 100 150 200 250 300 350 400 450 500
||| | |---
Temperature, O F
|||| | || ||| | || ||
| |||
|
| ||| | || | ||
--
c
m
a
I
C
m
f
500 550 600 650 700 750 800 850 900 950 1000
Temperature, F
FIG. 5.19-2 MEAN SPECIFIC HEAT OF WATER VAPOR VERSUS

T E M PE RATU RE
127
S T D O A S M E P T C 4-ENGL 1998 0759b70 ObL50bB b90
--
ASME Pn= 4-1998 FIRED STEAM GENERATORS

| ||| | || | ||
Water vapor (77'F reference)

|
| |||
0.499
|||| | || ||| | || ||
0.498
0.497
0.496
0.495
4 i:
||| | |---
5 0.492
0.491
p 0.490
c, 0,489
0.488
Q) 0.487
0.486
5 0.485
0.484
0.483
0.482
m 0.481
f 0.480
0.479 -
0.478 - /I
0.477
0.476 -
1000
y '
1050
'
1100
1
1150
1 1
1200 1250 1300
1 1
1350
1
1400
1
1450
1
1500
Temperature, "F
1 1 1 1 1 1 1 1
1500 1550 1600 1650 1700 1750 1800 1850 1900 1950 2000
Temperature, O F
FIG. 5.19-2 MEAN SPECIFIC HEAT OF WATER VAPOR VERSUS

TEM PERATURE (CONT'D)
128
~ - -
STD.ASME PTC Y-ENGL 1998 = 0759670 O615069 527 =

FIRED STEAM GENERATORS ASME F*TC 4-1998
Dry flue gas (77°F reference)

0.252
0.251
0.250
e 0.249
; 0.248
e 0.247
3
m
0.246
a 0.245
0.244
$ 0.243
0.242
O
0.241
0.240
0.239
5 0.238
5 0.237
0.236
0.235
0.234
O 100 200 300 400 500 600 700 800 900 1000
Temperature, OF
Dry flue gas (77°F reference)
||| | |---
|||| | || ||| | || ||
| |||
|
| ||| | || | ||
1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000
Temperature, O F
--
FIG. 5.19-3 MEAN SPECIFIC HEAT OF DRY FLUE GAS VERSUS

TEM PERATU RE
129
STDOASME PTC 4-ENGL 1998 = 0759b70 Ob15070 249
ASME I'TC 4-1998 FIRED STEAM GENERATORS
Dry residue (77°Freference)
0.218
0.214
F
. 0.210
sgE
3
0.206
0.202
0.198
c
m 0.194
al
I I I
I l I I I I l I
I
o 0.190
.-
.c
%: O. 186
a
v) 0.182
C
m
O. 178
I O. 174
0.170
1 l 1 l 1 l 1 1 1 l 1 1 l 1 1 1 1 1 1
O 50 100 150 200 250 300 350 400 450 500
Temperature, F
Dry residue (77'F reference)
||| | |---
|||| | || ||| | || ||
| |||
|
,
'
| ||| | || | ||
0.217 -
0.215 fl ' I I I I I I I I I
500 550 600 650 700 750 800 850 900 950 1000
--
Temperature, O F
FIG. 5.19-4 MEAN SPECIFIC HEAT OF DRY RESIDUE VERSUS

TEM PERATU RE
130
~ ~~
~
STDeASME PTC 4-ENGL 1998 W 0759670 Ob15071 185
FIRED STEAM GENERATORS ASME PT'C 4-1998
Dry residue (77OF reference)
0.269
0.267
".
U
0.265
.
E 0.263
0
3
g 0.261
0.259
$ 0.257
I
.-
o 0.255
r
0.253
5
lu
0.251
s 0.247
1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000
Temperature,"F
FIG. 5.19-4 MEAN SPECIFIC HEAT OF DRY RESIDUE VERSUS

TEMPERATURE (CONT'D)
131
-- | ||| | || | || | | ||| |||| | || ||| | || || ||| | |---
TC = 2T - 77, O F (5.19-30) T Temperature

Tdb Dry-bulb temperature
For example, to obtain the instantaneous specific Thf Hot face temperature
heat at 300"F, enter the mean specific heat curve with Twb Wet-bulb temperature
a temperature of 523°F. V Velocity
Vh Velocity head
Vp Percent Volume
5.20.1.2 Function Symbols
||| | |---
5.20 CALCULATION ACRONYMS
Ad Additional
5.20.1 Basis for Section 5 Acronyms. The acronyms
|||| | || ||| | || ||
Di Difference (Delta)
used throughout this Section (except for uncertainty) Fr Fractional
are built from symbols from the following groups and Mn Mean
arranged in the following sequence: Sm Sum
| |||
PROPERTY > FUNCTION > (EQUIPMENT,
|
5.20.1.3 Equipment, Stream, and Efficiency
| ||| | || | ||
STREAM, EFFICIENCY) > (LOCATION, COMPO- Symbols
NENT, CONSTITUENT) > CORRECTION A Air
5.20.1.1 Property Symbols Ac Air preheater coil
--
Af Flat projected surface area Ah Air heater
A id Area, inside dimension Al Air leakage
CP Mean specific heat at constant pressure AP Ash pit
D Dry A9 Air quality control equipment
Dn Density As Ash
H Enthalpy B Credit
Hca Convection heat transfer coefficient Bd Blowdown
HHV Higher heating value, mass basis c Carbon
HHVcv Higher heating value, constant volume basis Ca Calcium
"VV Higher heating value, volume basis Cb Carbon burned
Hra Radiation heat transfer coefficient Cbo Carbon burnout
Hrca Combined radiation and convection heat cc Calcium carbonate
transfer coefficient Cf Coefficient
Ut Height Ch Calcium hydroxide
Hw Insulation heat transfer coefficient Clh Calcination andor hydration
M Mass Cm Combustion
Mo Mole CO Carbon monoxide
MP Percent mass CO2 Carbon dioxide
MCl Mass per unit of energy Coal Coal
Mr Mass rate cw Cooling water
Mv Mass volume E Efficiency, percent
Mw Molecular weight Ec Economizer
P Pressure EL Electrical
Pa Atmospheric pressure Ev Evaporation
PP Partial pressure F Fuel
Ps Saturation pressure Fe Fixed carbon
Q Energy Fg Flue gas
ep Percent fuel input energy Fo Fuel oil
Qr Heat transfer rate G Gaseous fuel
R Universal gas constant Gr Gross
Ra Radiation Hc Hydrocarbons, dry basis
Rhm Relative humidity I Input
Rs Required In Inerts
Se Stack effect L Loss
sg Specific gravity Lg Leakage
132
~
- 0759b70 Ob15073 T58
ASME PTC 4-1998
MC Magnesium carbonate To Total

Mh Magnesium hydroxide Ub Unburned
*2 Nitrogen W Water
N2Q Atmospheric nitrogen Wv Water vapor
NO, Nitrous oxides X Auxiliary
O output Xp Percent excess
o
2 Oxygen Xr X-ratio
Pc Products of combustion
5.20.1.4 Location, Area, Component, Constituent
PCU Products of combustion uncorrected for sulfur
Symbols
capture
d Design
Pr Pulverizer rejects
En Inlet or entering
Rh Reheat
Rs Residue
f Fuel, specific or related
j Fuel, sorbent component
RY Recycle
k Fuel, sorbent constituent
S Sulfur
Lv Outlet, exit, or leaving
Sb Sorbent
Re Reference
SC Sulfur capture
Z Location (refer to Figs. 1.4-1 through 1.4-7
Sh Superheat
for specific locations)
s!f Sulfation
so2 Sulfur dioxide 5.20.1.5 Correction Symbol
Src Surface radiation and convection Cr Reading or computational correction
Ssb Spent sorbent
St Steam 5.20.2 List of Acronyms Used
Th Theoretical See Tables 5.20.2-1 and 5.20.2-2.
133
-- | ||| | || | || | | ||| |||| | || ||| | || || ||| | |---
STD-ASME PTC 4-ENGL 1998 0759670 06L5074 994 =
TABLE 5.20.2-1
ACRONYMS
~ ~ ~~ ~~ ~~ ~~
Acronyms Description Units

Afz Flat projected surface area for location z ft2 í m Z )
ApAf Flat projected area of ash pit hopper opening ftz (mZ
A PZ Density of oil Degrees API
DnA Density of wet air Ibm/ft3 ( kg/m31

DnA Fg Density of wet air or flue gas Ibm/ft3 íkg/m3)
DnFg Density of wet flue gas Ibm/ft3 íkg/m3)
DnGF Density of gaseous fuel Ibm/ft3 (kg/m3)
DnSt Density of steam/water Ibm/ft3 (kg/m3)
DVpCO Percent CO in flue gas, dry basis % volume
DW O , Percent CO, in flue gas, dry basis Yo volume
D VpHc Percent hydrocarbons in flue gas, dry basis Yo volume
D VpN2a Percent nitrogen (atmospheric) in flue gas, dry basis % volume
D VpNZf Percent nitrogen from fuel in flue gas, dry basis Yo volume
D VpNOx Percent NO, in flue gas, dry basis o/o volume
D Vp02 Percent O2 in flue gas, dry basis % volume
D VpSO2 Percent SO2 in flue gas, dry basis % volume
ECrn Combustion efficiency %

EF Fuel efficiency %O
EGr Gross efficiency %O
EX Combined efficiency of auxiliary drive, coupling, and gears %
HA Enthalpy of wet air Btullbm (Jlkg)

HAAqL v Enthalpy of wet air at gas temperature leaving AQC device Btullbm (Jlkg)
HA En Enthalpy of wet air entering, general Btu/lbm (Jlkg)
HALgEn Enthalpy of infiltrating wet air entering Btu/lbm íJ/kg)
HAL vCr Enthalpy of wet air at average gas temperature leaving Btu/lbrn (J/kg)
envelope
||| | |---
HA TFgLv Enthalpy of air at the gas outlet temperature Btu/lbm (J/kg)
Hcaz Convection heat transfer coefficient for location z B t ~ / f t z. h . F
|||| | || ||| | || ||
(J/m,. s . C)
Hcc Enthalpy of calcium carbonate (limestone) Btullbm (J/kg)
HCoal Enthalpy of coal Btullbm (J/kg)
HDA Enthalpy of dry air Btu/lbm íJ/kg)
HDAEn Enthalpy of dry air at the average entering air temperature Btu/lbm (J/kg)
| |||
HDFg Enthalpy of dry flue gas Btu/lbm (J/kg)
|
HDFgLvCr Enthalpy of dry flue gas leaving, excluding leakage Btu/lbm (J/kg)
| ||| | || | ||
HEn Enthalpy entering, general Btu/lbm (J/kg)
HFc Enthalpy of fixed carbon Btu/lbm (J/kg)
HFEn Enthalpy of the fuel at the temperature of fuel Btu/lbm (J/kg)
--
HF9 Enthalpy of wet flue gas Btullbm íJ/kg)
HFgEn Enthalpy of wet flue gas entering Btu/lbm (J/kg)
HFgL v Enthalpy of wet flue gas leaving Btullbm (Jlkg)
HFo Enthalpy of fuel oil Btullbm íJ/kg)
HGF Enthalpy of natural gas Btullbm (J/kg)

HH VC Higher heating value of carbon Btu/lbm (Jlkg)
HH VCO Higher heating value of carbon monoxide Btu/lbm (Jlkg)
HH VCRs Higher heating value of carbon in residue Btu/lbm (J/kg)
HH VF Higher heating value of fuel at constant pressure Btullbm (Jlkg)
HH VFcv Higher heating value of fuel at constant volume Btu/lbm (J/kg)
HH VGF Higher heating value of gaseous fuel, volume basis Btulft’ (J/m3)
HH VHZ Higher heating value of unburned hydrogen Btu/lbrn (J/kg)
HH VHc Higher heating value of unburned hydrocarbons Btu/lbm (J/kg)
HHVPr Higher heating value of pulverizer rejects Btu/lbm (J/kg)
Hk Enthalpy of constituent k Btdlbrn íJ/kg)

Hkz Enthalpy of constituent k a t location z Btu/lbm (Jlkg)
HL Y Enthalpy leaving, general Btu/lbm (Jlkg)
134
~~
STD-ASME PTC 4-ENGL 1998 = 0 7 5 î b 7 0 Ob15075 820

TABLE 5.20.2-1
ACRONYMS
HMnA Average enthalpy of wet air Btuilbm (Jlkg)

HMnFg Average enthalpy of wet gas Btullbm (J/kg)
HMnFgL vCr Average enthalpy of wet gas at TMnLvCr Btuilbm (Jlkg)
HPr Enthalpy of pulverizer rejects leaving pulverizer Btullbm (Jlkg)
Hraz Radiation heat transfer coefficient for location z Btuift2 h . F

(Jim,. s. C)
HRe Enthalpy at reference temperature Btullbm (Jlkg)
Hrk Heat of reaction for constituent k Btullbm (Jlkg)
HrNO, Heat of formation of NO (or N 2 0 ) Btullb mole (Jlkg)
HRs Enthalpy of residue Btullbm (Jlkg)
H RsEn Enthalpy of residue entering Btdlbm (Jlkg)
HrSlf Heat generated due to sulfation Btuilbm (J/kg)
HRsL v Enthalpy of residue leaving Btullbm (Jlkg)
HSb Enthalpy of sorbent Btullbm (Jlkg)

HSbEn Enthalpy of sorbent entering steam generator envelope Btullbm (Jlkg)
HStEnz Enthalpy of additional moisture (steam) entering flue gas Btuilbm (Jlkg)
HStL vCr Enthalpy of steam (based on ASME Steam Tables), at Btuilbrn (Jlkg)
corrected exit gas temperature
HStz Enthalpy of steam at location z Btullbm (Jlkg)
HStzd Enthalpy of steam at location I , design conditions Btullbm (Jlkg)
Ut Height, elevation difference between pressure measurements f t (m)
H Vk Heat of reaction for calcination or hydration of constituent k Btullbm (J/kg)

H Vrni Enthalpy of volatile matter, i, where i is 1or 2 Btullbm (Jlkg)
HW Enthalpy of water (based on ASME Steam Tables) Btullbm (Jlkg)

H WRe Enthalpy of water at reference temperature Btullbm (Jlkg)
H Wv Enthalpy of water vapor (JANAFlNASA reference) Btuilbrn (Jlkg)
H WvEn Enthalpy of water vapor at average entering air temperature Btullbm (Jlkg)
Hwz Heat transfer coefficient for insulation and lagging Btulft2. h . F
(J/m2. s . C)
H Wzd Enthalpy of water at location z, design conditions Btuilbm (Jlkg)
MFrAsF Mass fraction of ash in fuel masdmass fuel

MFrAz Mass fraction of air at location z t o total air masdmass
MFrClhk Mass fraction of calcination or hydration constituent k mass CO2/
mass const
MFrCOZSb Mass of gas (CO2) from sorbent per mass fuel masdmass fuel
MFrFc Mass fraction of fixed carbon masdmass fuel
MFrFgz Mass fraction of wet gas at location z masdmass fuel
MFrH, OSb Mass fraction of the water in sorbent masdmass
sorbent
MFrlnSb Mass of inerts in sorbent per mass fuel masdmass fuel
MFrRs Total mass of residue per mass fuel masdmass fuel
MFrSb Mass of sorbent per mass of fuel masdmass fuel
MFrSbk Mass of reactive constituent k in sorbent masdmass
sorbent
MFrSc Sulfur capture ratio Ibmllbm (kg/kg)
MFrS03 Mass fraction of SO, formed in the sulfation masdmass fuel
MFrSsb Mass of spent sorbent per mass fuel masdmass fuel
MFrStCr Ratio of design main steam flow divided by test main steam I b d l b m (kg/kgl
flow
MFr ThA Theoretical air, ideal masdmass fuel
MFrThACr Mass of theoretical air corrected per masdmass fuel
MFr Vrn Mass fraction of volatile matter masdmass fuel
MFr Vrnl Mass fraction of primary volatile matter rnasdmass fuel
MFr Vm2 Mass fraction of secondary volatile matter masdmass fuel
MFr VrnCr Mass fraction of volatile matter, dry-ash free madmass fuel
135
-- | ||| | || | || | | ||| |||| | || ||| | || || ||| | |---
STD-ASME PTC 4-ENGL L948 0759630 Obl1507b 7b7
TABLE 5.20.2-1
ACRONYMS
MFr WAdz Additional water at location z per mass fuel masdmass fuel
MFr WDA Mass fraction of moisture in dry air, mass H,O/mass dry air Ibm/lbm (kgíkg)
MFrWF Mass fraction of water in fuel masdmass fuel
MFr WRs Mass fraction of water in dry residue masdmass residue
MFr WSb Water from sorbent per mass fuel masdmass fuel
MnCpA Mean specific heat of wet air Btullbm "F

(Jlkg K )
MnCpDFg Mean specific heat of dry flue gas Btu/lbm O F
(Jlkg K)
MnCpFg Mean specific heat of wet flue gas Btullbm O F
(Jlkg K)
MnCpk Mean specific heat of constituent k Btullbm O F
(J/kg K)
--
Moco2Sb Moles of dry gas (COz) from sorbent per mass fuel moledmass fuel
MoDFg Moles dry gas per mass fuel masdmass fuel
| ||| | || | ||
MoDPc Moles dry products from fuel (CO,, N,F, and actual SO2 moledmass fuel
produced)
MoDPcu Moles dry products from fuel (CO2, N2F, and total conversion moledmass fuel
|
| |||
of SO2 in fuel)
MoFg Moles wet gas per mass fuel moledmass fuel
|||| | || ||| | || ||
MoFrCaS Calcium to sulfur molar ratio moledmole

MoFrClhCc Calcination fraction of calcium carbonate moles COJmole
CaCO,
MoFrClhk Calcination fraction of constituent k moles Codmole
||| | |---
const
Mokj Moles of fuel constituent k in gaseous component j moledmass fuel
Mo502 Maximum theoretical SO2 per mass fuel moledmass fuel
Mo ThACr Moles of theoretical air required (corrected) molesJmass fuel
Mo ThAPcu Theoretical air required for gasified fuel products molesJmass fuel
Mo WA Moles of moisture in air molesimass air
Mo WPc MoDPc plus moles H20 from tuel, sorbent and any additional moledmass fuel
moisture
Mo WPcu MoDPcu plus moles H20 from fuel, sorbent and any additional moles/mass fuel
moisture
Mo WSb Moles moisture in sorbent moledmass fuel
MpAhLg Air heater leakage, percent of entering flue gas weight Yomass
MpAsF Percent ash in fuel Vo mass
MpCak Percent of sorbent calcium in the form of constituent k (CO3 or % mass
OH)
MpCb Carbon burned Yomass
MpCbo Percent carbon burnout YOmass
MpCF Percent carbon in fuel % mass
MpCG Rs Percent carbon dioxide in residue YOmass
MpC4 Rs Percent carbon dioxide in residue Oí0 mass
MpCRs Percent free carbon in residue O%. mass
MpFk Percent fuel constituent k YO mass
MPHz~ Percent hydrogen burned YO mass
MPHZF Percent hydrogen in fuel YO mass
MPH2 OF Percent water in fuel % mass
MpInSb Percent of sorbent inert material O%. mass
MPNZf Nitrogen in fuel OX, mass
MpOZF Oxygen in fuel YOmass

MpRsFgz Solids in flue gas at location z, percent of wet gas Ya mass
MpRsz Mass of residue collected at location z YO mass
MpSbk Percent of constituent k in sorbent % mass .
MpSF Sulfur in fuel % mass
Mp ToCRs Total carbon content in residue sample, includes CO2 YO mass
136
HRED STEAM GENERATORS
STD-ASME PTC U-ENGL L998 - 0759b70 Ob15077 bT3
~
ASME PTC 4-1998
TABLE 5.20.2-1
ACRONYMS
MpUbC Percent unburned carbon % mass

MpUbH2 Percent unburned hydrogen % mass
--
Mp WFgz Moisture in flue gas at location z, percent of wet flue gas mass
| ||| | || | ||
MqA/ Mass rate of wet infiltration air Ibm/Btu (kg/J)

MqAz Mass wet air at location z on input from fuel basis IbmfBtu (kg/J)
MqC4 Sb Mass of dry gas ( C O z ) from sorbent, input from fuel basis IbrdBtu (kg/J)
|
MqDAz Mass dry air at location zon input from fuel basis IbmfBtu (kg/J)
| |||
MqDFgz Mass dry gas at location I on input from fuel basis Ibm/Btu (kg/J)
|||| | || ||| | || ||
MqFgfn Mass wet flue gas entering on input from fuel basis Ibm/Btu (Kg/J)
MqFgF Wet gas from fuel Ibm/Btu (kg/J)
MqFgz Mass of wet gas at location z, input from fuel basis IbmfBtu (kg/J)
Mqk Mass of constituent k on input from fuel basis I b d B t u (kg/J)
||| | |---
MqNOx Mass of NO, in flue gas expressed on input from fuel basis IbmfBtu (kg/J)
Mq Pr Mass of pulverizer rejects on input from fuel basis I b d B t u (kg/J)
MqRsz Mass of residue collected at location I IbmfBtu (kg/J)
MqSb Mass of sorbent on input from fuel basis IbmlBtu (kg/J)
MqSbk Mass of sorbent constituent k, input from fuel basis IbmfBtu (kg/J)
Mq JhA Theoretical air, ideal, on input from fuel basis Ibm/Btu (kg/J)
Mq ThACr Theoretical air corrected on input from fuel basis IbmfBtu (kg/J)
Mq ThAf Typical value of theoretical air for fuel f (ideal) IbmfBtu (kg/J)
Mq WA Water from moisture in air IbmlBtu (kg/J)
Mq WAdz Additional water at location z, input from fuel basis IbmfBtu (kg/J)
Mq WF Water from H,O in fuel Ibm/Btu (kg/J)
Mq WFgz Total moisture in flue gas at location z IbmfBtu (kg/J)
Mq WH, F Water from combustion of hydrogen in fuel IbmlBtu (kg/J)
Mq WSb Water from sorbent on input from fuel basis IbmfBtu (kg/Jl
Mq WvF Water from HzO vapor in fuel Ibm/Btu (kg/J)
MrAFg Mass flow rate of air or flue gas, general Ibmh (kg/s)
MrAFgCr Mass flow rate of air or flue gas, corrected for fuel and Ibm/h (kg/s)
efficiency
MrAz Mass flow rate of wet air at location z Ibmlh (kg/s)
MrCwz Mass flow rate of cooling water at location z Ibmfh (kg/s)
MrDA Mass flow rate of dry air Ibmk (kg/s)
MrF Mass flow rate of fuel Ibm/h (kg/s)
MrFgz Mass flow rate of wet gas at location z I b d h (kg/s)
MrPr Mass flow rate of pulverizer rejects Ibmh (kg/s)
MrRs W Mass flow rate of residue/water mixture Ibmk (kg/s)
MrRsz Mass flow rate of residue at location z I b d h (kg/s)
Mr RyFg Mass flow rate of recycled flue gas Ibmh (kg/s)
MrRyRs Mass flow rate of recycled residue Ibmk (kg/s)
MrSb Mass flow rate of sorbent Ibmk (kg/s)
MrStd Mass flow rate of steam, design value Ibm/h (kg/s)
MrStEnz Mass flow rate of additional moisture (steam) entering flue gas Ibmh (kg/s)
MrStX Mass flow rate of auxiliary equipment steam Ibm/h (kg/s)
MrStz Mass flow rate of steam at location z Ibmlh (kg/s)
MrStzd Mass flow rate of steam at location 6 design value Ibm/h (kg/s)
M r WSb Mass flow rate water in sorbent I b d h (kg/s)
Mr Wz Mass flow rate water at location z I b d h (kg/s)
Mr WzCr Mass flow rate of feedwater corrected Ibmh (kg/s)
MvFk Mass fuel constituent k per mole gaseous fuel rnass/mole

MvRs Mass per unit volume, used in dust loading g rains/f t 3 ( g/m3)
MwA Molecular weight of wet air massímole

MwCak Molecular weight of sorbent calcium compound k masdmole
MWCC Molecular weight of calcium carbonate massímole
MwCo Molecular weight of carbon monoxide, CO mass/mole
M wCO~ Molecular weight of carbon dioxide, CO2 masshole
137
~
STD.ASME PTC Ii-ENGL iI998 0759b70 Obi15078 53T
ASME FTC 4-1998 FIRED S T E A M GENERATORS
TABLE 5.20.2-1
ACRONYMS
MwDFg Molecular weight of dry flue gas massfmole

MwFg Molecular weight of wet flue gas massfmole
MwGF Molecular weight of gaseous fuel masdmole
MwHc Molecular weight of hydrocarbons masdmole
MWk Molecular weight of constituent k masdmole
MwNO, Molecular weight of NO masgrno Ie
MwS Molecular weight of sulfur masdmole
Pa Barometric pressure psia (Pa)

PAZ Static pressure of air at point I in. wg (Pa)
PDIAFg Pressure differential, air (air resistance) or flue gas (draft loss) in. wg (Pa)
PDiAFgCr Pressure differential, air or flue gas corrected to contract in. wg (Pa)
PFgk Static pressure of flue gas at point k in. wg (Pa)
Pp WvA Partial pressure of water vapor in air psia (Pa)
Ps W Tdb Saturation pressure of water vapor at dry-bulb temperature psia (Pa)
PsWTwb Saturation pressure of water vapor at wet-bulb temperature psia (Pa)
Ps Wv TZ Saturation pressure of water vapor at temperature T psia (Pa)
Qb Energy balance closure Btu/h (W)

QEn Energy entering the system Btu/h (W)
QLv Energy leaving the system Btdh (W)
QPB Credits calculated on a %O input from fuel basis, general % fuel input
QpBDA Credit due to energy in entering dry air % fuel input
QPBF Credit due to sensible heat in fuel Yo fuel input
QpBk Credit due to constituent k % fuel input
QpBSlf Credit due to sulfation % fuel input
QPBWA Credit due to moisture in entering air % fuel input
QPL Losses calculated on a % input from fuel basis, general Oh fuel input
QpLALg Loss due to air infiltration O/O fuel input
QpLAq Loss from hot air quality control equipment % fuel input
--
QPLCO Loss due to carbon monoxide ((Co) in flue gas % fuel input
QpLDFg Loss due to dry gas O+& fuel input
| ||| | || | ||
QPLHZF Loss due to water formed from combustion of H, in fuel % fuel input
QPLY Rs Loss due to unburned hydrogen in residue Y' fuel input
QpLk Loss due to constituent k % fuel input
|
QpLNOx Loss due to the formation of NO, % fuel input

| |||
QpLPr Loss due to pulverizer rejects %O fuel input

|||| | || ||| | || ||
QPLRs Loss due to sensible heat of residue %O fuel input
QpLSmUb Summation of losses due to unburned combustibles %O fuel input
QpL UbC Loss due to unburned carbon in residue %O fuel input
QpL UbHc Loss due to unburned hydrocarbons in flue gas Y' fuel input
||| | |---
QPLWA Loss due to moisture in air %O fuel input
QPLWF Loss due to water in fuel %O fuel input
QpL WvF Loss due t o water vapor in gaseous fuel Yo fuel input
QrAp Equivalent heat flux through furnace hopper Btu/h ( W )

QrApEv Loss due to evaporation of ash pit water Btu/h ( W )
QrAPW Energy increase in ash pit water B t d h (W)
QrAxSt Energy in auxiliary steam Btu/h ( W )
QrB Credits calculated on an energy basis,, general Btulh (W)
QrBd Energy increase in output for blowdown water Btuh ( W )
QrBk Credit due to constituent k Btuh (W)
Qr5Sb Credit due t o sensible heat in sorbent Btu/h ( W )
QrBWAd Credit due to energy supplied by additional moisture Btuh ( W )
QrBX Credit due to auxiliary equipment power Btu/h (W)
QrF Potential energy of combustion available from fuel B t u h (W)
QRh Reheat absorption Btu/h ( W )
QrI Energy input (QrFfor input from fuel) B t u h iW )
QrIGr Energy input gross, energy input from fuel plus credits Btulh ( W )
I38
~~
STD-ASME PTC 4-ENGL 1998 m 0759670 Ob15079 476 D
TABLE 5.20.2-1
ACRONYMS
QrL Losses calculated on an energy basis, general

QrLAc Loss due to air preheater coil supplied from the steam
generator
QrLAP Total wet ash pit losses when tested Btulh (W)
QrL C/h Loss due to calcination and dehydration of sorbent Btu/h (W)
QrLCw Loss from cooling water B t u k (W 1
QrLk Loss due to constituent k Btulh (W)
QrLRY Loss from recycled streams Btuh (W)
QrLRyFg Loss from recycled flue gas Btulh (W)
QrL RyRs Loss from recycled residue Btulh (W)
QrL Src Loss due t o surface radiation and convection Btu/h (W)
QrL WAd Loss due to additional moisture Btulh (W)
QrL WSb Loss due to water in sorbent B t u k (W)
QrO Total heat output Btuh (W)
QrRhCr Corrected reheat absorption for contract conditions Btuh (W)
QrRsWLY Sensible heat in residudwater leaving the ash pit .
Btu/ft2 i W/m2 )
--
QrShCr Superheater absorption corrected for design conditions Btu/h (W)

| ||| | || | ||
QSh Superheat absorption B t u k (W)

QX Energy input to auxiliary equipment drives kWh (J)
R Universal molar gas constant f t Ibf/mole . R

|
| |||
Rhmz Relative humidity at location z masslmass

|||| | || ||| | || ||
Rk Specific gas constant for gas k füR (J kg/K)

RqQrRhd Required reheater absorption, design Btu/h (W)
RqQrShd Required superheater absorption, design B t u k (W)
Se Stack effect in. wg (Pa)

||| | |---
Sg Specific gravity mass/mass

SrnQpB Total credits calculated on a % input from fuel basis % fuel input
SrnQpL Total losses calculated on a % input from fuel basis o/o fuel input
SrnQrB Total heat credits calculated on an energy basis Btu/h (W)
SrnQrL Total losses calculated on an energy basis Btulh (W)
TAEn Entering air temperature OF (OC)
TAEnd Design entering air temperature O F (OC)
TAfz Average surface temperature of area z O F (OC)
TAz Temperature of wet air at location z O F ("Cl

TC Temperature on X-axis of enthalpy figures O F (OC)
TDAz Temperature of dry air at location z O F("C)

Tdb Dry-bulb temperature "F ( O C )
TDi Temperature difference "F ( O C )
TDiFgEn Air heater temperature correction for entering gas temperature "F ("Cl
TDiMrFgEn Air heater temperature correction for entering gas mass flow O F ("Cl
TDi TAEn Air heater temperature correction for entering air temperature OF (OC)
TDiXr Air heater temperature correction for off design X-ratio OF (OC)
Tfg Temperature of flue gas O F ("C)

TFgEn Temperature of flue gas entering component "F (OC)
TFgEnCrd Gas temperature entering air heater corrected to design "F ("Cl
conditions
TFgLv Temperature of flue gas leaving "F (OC)
TFgLvCr Corrected gas outlet temperature (excluding leakage) OF (OC)
TFgL vCrd Exit gas temperature corrected to design conditions O F ("C)
Thfz Hot face (wall) temperature at location z "F (OC)
TK Temperature in K O F ("Cl
Tkz Temperature of constituent k a t location z OF (OC)
TLvk Temperature of constituent k leaving the steam O F (OC)

TMnAEn Average entering air temperature "F (OC)
139
__
STD-ASME PTC 9-ENGL 1998 W 0759670 ObL5080 198
TABLE 5.20.2-1
ACRONYMS
TMnAfCrz Average surface temperature corrected to design at location I "F (OC)
TMnAfz Average surface temperature at location z "F ( O C )

TMnARe Reference surrounding air temperature "F ( O C )
TMnAz Average surrounding air temperature "F ( O C )
TMnFgL vCr Average corrected gas outlet temperature "F ("Cl
TRe Reference temperature "F ("Cl
TStz Temperature of steam at location z O F ("Cl
Twb Wet-bulb temperature OF (OC)
VA2 Average velocity of air füsec ( d s )

VPCG Percent of COz in flue gas, wet basis YO volume
vpcoz Percent CO in flue gas at location I< wet basis YO volume
VPGj Gaseous fuel component j Btu/ftz (J/mz)
VpH20 Percent water in flue gas, wet basis Yo volume
VpHc Percent hydrocarbons in flue gas, wet basis % volume
VpNZa Percent N, (atmospheric) in flue gas, wet basis YOvolume
VpN2f Percent N, from fuel in flue gas, wet basis % volume
VpNOx Percent NO, in flue gas, wet basis YO volume
vp02 Percent of Oz in flue gas, wet basis YO volume
vpso2 Percent of SOz in flue gas, wet basis YO volume
XpAz Percent excess air at location z % mass
--
| ||| | || | ||
|
| |||
|||| | || ||| | || ||
||| | |---
~~ ~
STDDASME PTC 4-ENGL 1998 0759b70 Ob15081 024
TABLE 5.20.2-2
M EAS U REM EN T AND U NCERTAI NTY
ACRONYMS
Acronyms Description
ASENSCO Absolute sensitivity coefficient
BIAS Bias error
BIAS R Overall bias error
CHGPAR Incremental change in value of measured
parameter
DEGREE Number of degrees of freedom
DEGFREER Overall degrees of freedom for test
F Weighting factor
i Measured parameter
m Number of sets of data or grid points
n Number of times parameter is measured
PCHGPA R Percent change in value of measured parameter
PI Precision index
PIR Overall precision index
PSTDDEV Population standard deviation
Pv Velocity pressure measurement
RECAL EF Recalculated fuel efficiency
RSENSCO Relative sensitivity coefficient
SDI Spatial distribution index
S TODE V Standard deviation of the sample
S TDDEVMN Standard deviation of the mean
STDVAL Two-tailed Student's t-value
U Integrated average value of measured parameter
"P,, Arithmetic (or velocity weighted if applicable)
average value of each row, p, and column, 9,
measurement point
UNC Total uncertainty
uPC Precision component of uncertainty
XA VE Arithmetic average value
xi Value of a measured parameter at time i
Z Summation, integrated average value of z
z Time averaged value of the measured parameter
4 Pitch angle
9 Yaw angle
141
-- | ||| | || | || | | ||| |||| | || ||| | || || ||| | |---
~
STD-ASME PTC q-ENGL 1998 0757670 Ob15082 Tú0 M
FIRED STEAM GENERATORS ASME P E 4-1998
SECTION 6 - REPORT OF TEST RESULTS
6.1 INTRODUCTION - dates of the test

0 Summary. This Section briefly describes the objec-
The performance test report documents the data,
tives, results, and conclusions of the test.
calculations, and processes employed in conducting the
||| | |---
Introduction. The introduction states the purpose of
performance test. The report presents specific informa- the test and relevant background information such as
tion to demonstrate that all objectives of the test have
|||| | || ||| | || ||
age, unusual operating characteristics, problems, etc.,
been met and to describe the test procedures and on the unit to be tested.
pertinent results. This Section presents guidance on both 0 Objectives and Agreements. This section addresses
content and format of information typically included in the objectives of the test, required test uncertainty,
| |||
this report guarantees, operating conditions, and any other stipu-
|
| ||| | || | ||
lations.
0 Test Descriptions and Procedures. This section in-
6.2 REPORT CONTENTS cludes the following:

- a schematic of the steam generator system bound-
--
Although the materials prepared for the performance ary showing the locations of all measured param-
test reports may vary somewhat, the contents will eters
typically be organized and include the information as - a list of the equipment and auxiliaries being tested,
described below: including nameplate data
- a list and description of the test instruments identi-
Title Page. The title page contains the title of the fied in the system diagram
test, the name of the plant on which the test is being - a summary of key observations
conducted and its location, the unit designation; the - the magnitude of primary uncertaintiesin measure-
names of those who conducted the test and .ipproved ment and sampling, and the methods of calculation
it, and the date the report was prepared. and correction factors. Sample calculationsare also
0 Table of Contents. The table of contents lists major presented.
subdivisions of the reports to the third level, as well Results. Test results are presented on the basis of op-
as titles of tables, figures, and appendices. erating conditions and as corrected to specified condi-
General Information. This portion of the report gives tions. Test uncertainty is also stated in the results.
the reader information needed to understand the basis 0 Uncertainty Analysis. This section provides sufficient
of the test and must include the following: detail to document the target uncertainty and demon-
- title of test strate that the test has met this target.
- owner 0 Conclusions and Recommendations. This section in-
- steam generator manufacturer cludes conclusions directly relevant to the test objec-
- steam generator size tives as well as other conclusions or recommendations
- date of first commercial operation drawn from the test.
- elevation of steam generator above mean sea level Appendices. Test logs, test charts, data sheets, instru-
- manufacturer’s predicted performance data sheets ment calibration sheets and corrections curves, records
- guaranteed performance data of major fluctuations and observations, laboratory
- name of chief-of-test analyses, computations, computer printouts, and un-
- test personnel, their affiliations and test responsi- certainty analyses are among the kinds of materials
bilities which are included in the appendices.
143
Previous Page
08/29/2002 18:04:05 MDT Questions or comments about this message: please call is Blank
~
STD-ASME PTC Li-ENGL 1998 0 7 5 î b 7 0 Ob15083 î T 7 =

SECTION 7 - UNCERTAINTY ANALYSIS
7.1 INTRODUCTION T temperature

f Student’s t-statistic
Uncertainty analysis is a procedure by which the
U uncertainty
accuracy of test results can be quantified. Because it
U any parameter
is required that the parties to the test agree to the
V velocity
quality of the test (measured by test uncertainty), pretest
V any parameter
and post-test uncertainty analyses are an indispensable
W any parameter
part of a meaningful performance test.
X any parameter
PTC 19.1, Measurement Uncertainty, is the primary
Y any parameter
reference for uncertainty calculations and any uncer-
Z any parameter
tainty analysis method that conforms to PTC 19.1 is
acceptable. This Section provides specific methods 8) small change of ()
R @x sensitivity coefficient for parameter x on result
which are tailored for use in conducting uncertainty
analysis specific to this Code. This Section addresses
R ( R ~ x= max)
V degrees of freedom
the following:
population standard deviation (c? is the popula-
0 determining precision uncertainties tion variance)
0 estimating bias uncertainties b
sum of ()¡ from i = a to i = b
||| | |---
o propagating the precision and bias uncertainties ()i
a
0 obtaining the test uncertainty 7 time
|||| | || ||| | || ||
Additional information on uncertainty is available in 7.1.1.1 Subscripts
PTC 19.1, Measurement Uncertainty. B bias
7.1.1 General List of Symbols for Section 7. The I instrument, instrumentation
| |||
following symbols are generally used throughout Section 1 index of summation, a specific point
|
| ||| | || | ||
7. Some symbols are used only in a specific paragraph j index of summation, a specific point
and are defined or redefined locallv: k index of summation, a specific point
A (cross-sectional) area n pertaining to numerical integration
P precision
--
ao. al polynomial coefficients
B bias limit R pertaining to result R
C a constant r real
F statistical parameter X pertaining to parameter x
(mathematical) function W weighted (average)
f0
N number of measurements or number of points
7.1.1.2 Superscript
n number of data points used in calculating stan-
- average
dard deviation
m number of grid points or number of different
measurement locations
o2 oxygen concentration
PI precision index 7.2 FUNDAMENTAL CONCEPTS
R a result (such as efficiency, output) 7.2.1 Benefits of Uncertainty Analysis. The benefits
r number of readings or observations of performing an uncertainty analysis are based on the
S precision index, standard deviation of the mean following facts about uncertainty:
S sample standard deviation (s2 is the sample
variance) Uncertainty analysis is the best procedure to estimate
SDI spatial distribution index the error limit in a set of measurements or test results.
145
Previous Page
is Blank
STDmASHE PTC 4-ENGL 1998 = 0759670 OhL5084 833 m
O There is a high probability (usually 95%) that a band way, a typical value, say 95% coverage, means that
defined by the measured value plus or minus the uncer- the true value will be bounded by the measured value
tainty includes the true value. plus or minus the uncertainty for 95% of the measure-
O The uncertainty of a test result is a measure of the ments. The concept of coverage is necessary in uncer-
quality of the test. tainty analysis since the uncertainty is only an esti-
0 Uncertainty analysis performed after a test is run mated error limit.
allows the test engineer to determine those parameters
and measurements that were the greatest contributors The calculated average value of a parameter plus or
to testing error. minus the uncertainty thus defines a band in which
0 Uncertainty analysis performed while a test is being the true value of the parameter is expected to lie, with
planned (using nominal or estimated values for pri- a certain coverage.
mary measurement uncertainties) identifies potential Error and uncertainty are similar in many respects.
measurement problems and permits designing a cost- There are many types and sources of error, but when
effective test. a number is assigned to error, it becomes an uncertainty.
||| | |---
O A performance test code based on a specified uncer- Accuracy is used interchangeably with uncertainty; how-
tainty level is much easier to adapt to new measure- ever, the two are not synonymous since high accuracy
|||| | || ||| | || ||
ment technology than a code tied to certain types of implies low uncertainty.
instruments [ 11. Measurements contain two types of error, which are
illustrated on Fig. 7.2-1. The total error of any specific
This Code allows the parties to a steam generator measurement is the sum of a fixed bias error and a
| |||
test to choose among many options for test instruments random precision error. Other names for bias and
|
| ||| | || | ||
and procedures and even to choose between two differ- precision error are systematic error and random error,
ent methods (energy balance or input/output) for evaluat- respectively. The characteristics of these two types of
ing steam generator efficiency. Uncertainty analysis error are quite different.
helps the parties to the test make these choices.
--
Precision is manifested by the fact that repeated
7.2.2 Uncertainty Analysis Principles. This Section measurements of the same quantity by the same measur-
reviews fundamental concepts of uncertainty analysis. ing system operated by the same personnel do not
It is an accepted principle that all measurements yield identical values. Precision is a random quantity
have errors. Any results calculated from measured data, and is expected to be described by a normal (Gaussian)
such as the efficiency of a steam generator, also contain probability distribution.
errors, resulting not only from the errors in the data Bias is a characteristic of the measurement system.
but also from approximations or errors in the calculation Bias is not random; it is an essentially fixed (although
procedure. The methods of uncertainty analysis require unknown) quantity in any experiment or test2 that uses
the engineer to first determine the errorhncertainty of a specific instrument system and data reduction and
the basic measurements and data reduction procedures calculation procedures.
and then to propagate those uncertainties into the uncer- When the magnitude and sign of a bias is known,
tainty of the result. it must be handled as a correction to the measured
Note the following definitions: value with the corrected value used to calculate test
result. Bias estimates considered in uncertainty analysis
Error is the difference between the true value of a attempt to' cover those biases whose magnitudes are
parameter and the measured or calculated value of the unknown. Examples of biases that are intended to be
parameter. Error is unknown because the true value included in uncertainty analysis are drift in calibration
is unknown. Obviously, if the error were known, the of a flue gas analyzer, the bias resulting from using
test results could be based on the true value, not the an uncalibrated flow meter, the bias arising from the
measured or calculated value. deteriorated condition of a previously calibrated flow
0 Uncertainty is the estimated error limit of a measure- meter, errors resulting from calculation procedure ap-
ment or result.' proximations, and the potential errors made in estimating
0 Coverage is the percentage of observations (measure- values for unmeasured parameters.
ments) that can be expected to differ from the true It is not always easy to classify a specific uncertainty
value by no more than the uncertainty. Stated another as bias or precision. Usually precision uncertainties
'Note that measurement uncertainty is nor a tolerance on equipment 'Note that bias may change slowly over the course of a test. such
performance. as calibration drift of an instrument.
146
~
STDmASME PTC 4-ENGL 1998 m 0759670 Ub15085 77T m
True population
average ( p )
Parameter x
Measured
value (X&
FIG. 7.2-1 TYPES OF ERRORS I N MEASUREMENTS
are associated with variability in time, whereas bias (unsteadiness). It should be realized that this variation
uncertainties are considered fixed in time as shown on is primarily due to physical processes rather than experi-
Fig. 7.2-2. Variability in space (such as temperature mental error. For example, the laws of physics dictate
stratification or non-uniform gas velocity in a flue gas that the velocity of a flowing fluid must be. zero at
duct) has been treated as precision [2] or bias [3] in the walls of a duct while the velocity nearer the center
different works. This Code treats spatial variability as of the duct is usually not zero.
a potential source of bias. In a performance test, engineers sample several points
A complete uncertainty analysis requires determining in space and time and then use averages of the data
values for both precision and bias in the basic measure- to calculate test results. The averages are the best
ments, their propagation into the calculated results, and available estimates, and the differences between the
their combination into the overall uncertainty of the average value of a parameter and its instantaneous and/
results. Uncertainty analysis can be performed before or local values are used to estimate the error in the
measurements and in any results calculated from them.
--
a test is run (pretest analysis) and/or after a test is

run (post-test analysis). The method of calculating the average and the method
| ||| | || | ||
of calculating the uncertainty in the average depend

7.23 Averaging and Models for Variability. Instru- on the model selected for the variability of the parame-
ments used in performance testing measure parameters ter. The choice is between a “constant value” model,
|
| |||
such as temperature and concentration of certain constit- in which the parameter is assumed to be constant in
|||| | || ||| | || ||
uents in a gas stream. Most instruments are capable time and/or space, and a “continuous variable” model,
of sensing the value of a parameter only at a single in which it is assumed that the parameter has some
point or within a limited region of space and at discrete continuous variation in time and/or space (refer to
instants or over limited “windows” of time. It is well Subsection 5.2.3.1).
||| | |---
known that parameters such as gas temperature and Consider the velocity of gas in a duct. The proper
composition vary in space (stratification) and time model for the variation over time of gas velocity at a
147
~
STD=ASME PTC 4-ENGL 1798 W 0757b70 ObL508b b o b
ASME pIy3 4-1998 FiRED STEAM GENERATORS
Mean measured Total error 6 = ß + E

value of
parameter
Obvious error - outlier
L
A
Precision
||| | |---
A A A
|||| | || ||| | || ||
Frequency
Bias error distribution of
measurement
| |||
I True value of
|
parameter
| ||| | || | ||
-
I Time during which the parameter
I Time
--
is assumed to be constant
t b
FIG. 7.2-2 TIME DEPENDENCE OF ERRORS
fixed point in the center of the duct may be a constant

value; however, it is improper to adopt a constant value
-
y =-I l
T O
r
ydt
model for the variability of gas velocity over the duct
cross section because the laws of physics dictate that and for area variation it is
it must be otherwise. Figure 7.2-3 illustrates these
concepts. All of the variability in the actual data for
a constant value model parameter is taken as error;
however, only the scatter about the continuous variation
should be considered error for a continuous-variable
model. Because data are obtained only at discrete points in
The proper average value for a constant vaiue model space and/or instants of time, numerical integration
is the familiar arithmetic average schemes are typically used to approximate the integrated
average. If the data are sampled at the midpoints of
equal time or area increments, the integrated average
- l N
x = - xi (7.2-1) may be calculated with Eq. (7.2-1); however, the preci-
N i = L
sion index is not calculated by Eq. (7.2-2) because a
constant vaiue model is inappropriate. It must ais0 be
and the population deviation Of the mean Or emphasized that alternative, more accurate, numerical
its estimate, the sample standard deviation of the mean integration schemes can be developed that do not use
Eq. (7.2-1) to calculate the average.
The experimental error in an integrated average is
(xi - Y’)] (7.2-2)
due to two sources: error in the point values of the
data, and error due to the numerical integration. The
is the proper index of the precision error. first type is the “ordinary” experimental error due to
The proper average for a continuous-variable model process variations, instrument errors, etc. The second
parameter is an integrated average. For time variation, type results from the imperfect representation of the
the proper average is continuous variable by a set of discrete points and the
148
STDOASME PTC 4-ENGL 3778 m O757670 Ob35087 542
FRED STEAM GENERATORS ASME PTC 4-1998
constant value and continuous variable parameters, was

discussed in Subsection 7.2.3.
Precision errors are the result of random variations
during the test. Precision errors can be estimated by
taking numerous readings and applying the methods of
statistics to the results. The following discussion of
these methods is based on the assumption that the
reader has an understanding of elementary statistics.
Statistical concepts for performance test code work are
discussed in PTC 19.1 and Benedict and Wyler [4].
Not ail methods advocated in these references have
been adopted in this Code.
- Analysis of precision errors is based on the assump
t tion that they follow a Gaussian (normal) probability
Constant Value Model distribution. One important result of this assumption is
the root-sum-square method for combining errors due
to individual sources.
Two important concepts concerning precision error
are independence and degrees of freedom.
Parameters are independent if a change in one does
not imply a change in another. If this is not true, the
parameters are dependent. As an example, the dry gas
--
Integrated loss depends on both the gas temperature and the

| ||| | || | ||
oxygen content of the gas. Any error in temperature

is unconnected with oxygen content; the two are inde-
Improper
pendent. On the other hand, the results of a fuel analysis
|
error Continuous
| |||
variation are given as percentages of various constituents. Since

|||| | || ||| | || ||
all of the percentages must add to 100, the constituent

percentages are dependent. Physically, if the percentage
- of one component, (e.g., carbon), is lower than the
percentage of another component (e.g.. ash), the percent-
||| | |---
t
age of another component(s) must be higher.
Continuous Variable Model
Measurement errors can also be independent or
dependent. The independence or dependence of errors
can be different from the independence or dependence
FIG. 7.2-3 CONSTANT VALUE AND of the measured parameters. If all constituents of a
CONTINUOUS VARIABLE MODELS fuel sample are determined independently from different
procedures applied to different subsamples, then the
errors are independent, even though the constituents
themselves are dependent. If, however, one constituent
is determined by difference rather than by direct analy-
approximations in the integration scheme. The first sis, then the error of that constituent is obviously
error is precision. Special equations must be used to
dependent on the errors of the remaining constituents.
propagate the point precision error into the error of the
Special care must be taken in dealing with dependent
integrated average. In this Code, the second (numerical
parameters or dependent errors. When parameters are
integration) error is taken as bias.
dependent, this dependence must be accounted for in
7.2.4 Overview of Procedures for Determining Pre- the sensitivity coefficients. When errors are dependent,
cision and Bias and Their Propagation. The working the cross-correlation between them must be considered.
equations and procedures for calculating uncertainties Problems with parameter and error dependence can
for steam generator test results are given in Sections be minimized by reducing measurements and result
7.4 through 7.6. This section gives an overview of the calculations to sets involving only independent parame-
procedures and emphasizes certain critical concepts. ters and measurements. For example, the closure rela-
An especially critical concept, the distinction between tionship between fuel constituent percentages should
149
STD-ASME PTC rl-ENGL 2998 O759670 0625088 489 M
be used to eliminate one measurement and its error. values for bias. The problem of estimating uncertainty
This Code generally follows this approach; therefore was discussed by Kline and McClintock [5]. Note that,
it is usually not necessary to include consideration of although the actual biases are not random variables,
dependent parameters and dependent errors. estimares of bias are random variables.
The degrees of freedom of a set of data is a measure Bias estimates must be based on experience and
of the amount of independent information in the data. good judgment. FTC 19.1 provides a few general
A set of 10 temperature readings begins with 10 degrees guidelines for estimating bias. Obviously, the person
of freedom. The number of degrees of freedom of a in the best position to estimate bias is the person
particular statistic calculated from the data is reduced who conducted the test. The recommended practice in
by the number of other statistics used to calculate the estimating bias is to estimate the value that is expected
particular statistic. The mean temperature calculated to provide 95% coverage. This estimated value is called
from 10 readings has 10 degrees of freedom. To the bias limit.
calculate the sample standard deviation of the temper- There are also times when it is necessary to estimate
ature. precision indexes. Obviously, a pretest uncertainty anal-
ysis must use estimated values of the precision indexes,
s = [- l 2
N ( T - T)z] ‘/z
(7.2-3)
since the test data from which to calculate them do
not yet exist. In some cases, it is not feasible to obtain
N - 1 i=i multiple observations of the data during a test. If only
one observation of each measurement is available, the
requires use of the calculated mean, y, so the standard precision uncertainty of the data must also be estimated.
deviation has only 9 degrees of freedom. (This is why It is sometimes necessary to use “data” in a perform-
the division is N - 1 rather than N.) ance test that are based on estimates rather than on
A somewhat cumbersome formula is needed to deter- measurements. Likewise, it is sometimes more cost-
mine the resulting degrees of freedom when a result effective to assign reasonable values to certain parame-
depends on several parameters, each with a different ters rather than measure them. Examples include the
number of degrees of freedom. Fortunately, if all param- distribution fractions (“splits”) of combustion residue
eters have a large number of degrees of freedom, between various hoppers or the amount of heat radiated
the effects of degrees of freedom disappear from the to an ash pit. It is also necessary to assign uncertainties
calculations. (A “large sample” has more than about to such data. It is perhaps an academic question whether
25 degrees of freedom.) It is important to note that if such assigned values of uncertainty are labeled as bias
a few parameters have small degrees of freedom, these or precision. In this Code, uncertainties in estimated
can dominate the degrees of freedom of the result. parameters are generally treated as bias.
The precision uncertainty of a result is the product After values for both precision and bias uncertainties
of the precision index of the result and the appropriate have been determined, it is necessary to determine the
Student’s t-statistic. The Student’s t-statistic is based uncertainty in any results calculated from the data. This
on the degrees of freedom of the precision index of process is called propagation of uncertainties. Because
the result and the probability level selected (95% in precision and bias uncertainties are different types of
this Code). The precision index of a single set of data quantities, it is customary to propagate them separately
--
is the standard deviation of the mean of the single set and combine them as the final step in an uncertainty
| ||| | || | ||
of data. The precision index of a result is obtained by calculation. The calculation procedure is straightfor-
combining the values of the precision indexes of all ward, if somewhat tedious. Assume that a result (R)
|
the parameters that affect the result according to the is calculated by

| |||
equations given in Section 7.4.

|||| | || ||| | || ||
Bias is “frozen” in the measurement system and/or

the data reduction and result calculation process and
cannot be revealed by analysis of the data. For a given
||| | |---
set of measurements using a given measurement system,

the bias is fixed and is not a random variable. Bias
errors are those fixed errors that remain even after where
instrument calibration (bias e m r can be no smaller xI through x, =independent measured quantities
than the precision error of the calibration experiment). Each x has both precision and bias uncertainty.
It is sometimes possible to conduct experimental tests For either type of uncertainty, the basic propagation
for bias. Most often, however, it is necessary to estimate equation is
150
STD-ASME PTC 4-ENGL 1998 = 0759b70 Ob15089 315
where u is the degrees of freedom of the result, and

+. the bias uncertainty is
where u, = u, (7.2-8)
e = the precision index (Pl)for precision
or The final step in uncertainty analysis combines the
e = the bias limit (B) for bias bias uncertainty (or bias limit) and precision uncertainty
M= the number of independent measured quantities (Student’s t-times precision index) into the total uncer-
The root-sum-square addition of errors is theoretically tainty. This Code adopts the root-sum-square combina-
correct for random quantities (precision uncertainty) tion, in order to obtain 95% coverage
and is assumed to be . proper
. for bias as well [2,5].
The propagation equation can be written in the u = cup + vg,‘/2 (7.2-9)
following dimensionless form:
‘12
2
R = [il[(52)[2)J2]
ax,R
(7.2-5)
7.3 PRETEST UNCERTAINTY ANALYSIS
AND TEST PLANNING
--
A pretest uncertainty analysis is an excellent aid in

| ||| | || | ||
test planning. The parties to a test can use a pretest

where e,¡ is the uncertainty (precision or bias) in xi. uncertainty analysis to assist in reaching many of the
The coefficients agreements required in Section 3. Decisions regarding
|
| |||
number and types of instruments, number of readings,

|||| | || ||| | || ||
number of sampling points in a grid, and number of

fuel andor sorbent samples can be made based on
their predicted influence on the uncertainty of the test
results.
||| | |---
are called relative sensitivity coeflcients. A careful pretest uncertainty analysis can help control
Since the calculation procedure is often complicated, the costs of testing by keeping the number of readings
it is often impossible to analytically evaluate the required or samples at the minimum necessary to achieve the
partial derivatives. These derivatives are usually esti- target uncertainty and by revealing when it is not
mated by a numerical perturbation technique necessary or cost-effective to make certain measure-
ments. For example, it may be possible to achieve the
agreed upon target test uncertainty by using a nine
_
af - I
(7.2- 6) point flue gas sampling grid rather than a 16 point
axi
grid or by using historical data rather than multiple
f(X1. . . ., x; + 6 x;. . . ., XM) -Ax¡, . . .. x;. . . ., XM) laboratory analyses for fuel and sorbent properties.
6X; The methodology of a pretest uncertainty analysis
is formally identical to that for a post-test analysis
One at a time, each parameter (xi)is changed by a with one exception. Since the actual test data are not
small amount ( a ,typically 0.1 to 1%) and the result yet available, elementary precision indexes must be
is recalculated with the perturbed parameter replacing estimated rather than calculated from test statistics.
the nominal value. All other parameters are held constant This makes it possible to “decompose” the precision
for the recalculation. The difference between the result error into its various components (process variations,
with the perturbed value and the nominal result, divided primary sensor, data acquisition, etc.). Precision esti-
by the perturbation, estimates the partial derivative. mates, like estimates of bias in both pretest and post-
Since this procedure requires recalculation of the result test analyses, should be the best estimates of experienced
many times (one recalculation for each independent persons. Values obtained from similar tests are often
parameter), an automated calculation procedure is highly a good starting point.
desirable. A complete pretest uncertainty analysis may require
The precision uncertainty is then several repetitions of the calculations as basic instrument
151
uncertainties, numbers of readings, and numbers of one-fifth of the real variance of a measured parameter,
samples are all varied in an effort to obtain the target the instrumentation precision error can be ignored.
uncertainty in the most cost-effective manner. Computer
support is essential to do this effectively. 7.4.1 Precision Index of Individual Parameters. The
Sotelo provides an excellent discussion of pretest precision index of an individual parameter depends on
uncertainty analysis and test planning [6]. the type of parameter, integrated-average or constant-
value, and the method used to measure the parameter.
Some of the methods are as follows:
7.4 EQUATIONS AND PROCEDURES FOR multiple measurements made over time at a single
DETERMINING PRECISION INDEX location, e.g., main steam pressure and power input
||| | |---
This Section contains equations and procedures for to a motor driver
calculating the precision index. The required post- multiple measurements made at several locations in a
|||| | || ||| | || ||
test uncertainty analysis uses actual data from the given plane, e.g., flue gas temperature, flue gas constit-
performance test. The recommended pretest uncertainty uents, and air temperature at air heater inlet
analysis uses predicted values for the parameter averages the sum of averaged measurements, e.g., total coal
| |||
and precision indexes. The equations and procedures flow rate when multiple weigh feeders are used
|
of this Section are aimed at a post-test uncertainty measurements on samples taken in multiple incre-
| ||| | || | ||
analysis, for which actual test data are available. ments, e.g., fuel and sorbent characteristics
Process parameters (such as exit gas temperature or multiple sets of measurements at weigh bins or tanks
steam pressure) naturally exhibit perturbations about to determine the average flow rates, e.g., solid residue
--
their true (or average) values. These perturbations are flow rates
the real variations of the parameters. For a set of a single measurement
measurements of the process parameters, the instrumen- the sum of single measurements
tation system superimposes further perturbations on the
7.4.1.1 Multiple Measurements at a Single Point.
average values of the parameters. These instrumentation
For multiple measurements of a constant value parame-
based perturbations are assumed to be independent
ter made over time at a single location, the precision
random variables with a normal distribution. The vari-
index is
ance of the measured value-of a parameter is
1,2
a;l=d,+o-j (7.4-1) PI = s, = J$ (7.4-2)
where
4= the (population) variance of the measured value
of parameter x where
o$= the real (population) variance of parameter x
o$= the (population) variance of the instrumenta-
tion system
The precision of an instrument is sometimes called
the reproducibility of the instrument. Reproducibility
includes hysteresis, deadband, and repeatability [7]. The number of degrees of freedom is
The instrumentation variance is often estimated from
published data because testing of a specific instrument
for its precision can rarely be justified. U, =N- 1 (7.4-4)
For a post-test uncertainty analysis, the instrumenta-
tion variances are not specijìcally required, because
they are already imbedded in the data. Knowledge of 7.4.1.2 Integrated Average Parameters (Un-
instrumentation variances may be needed when instru- weighted Averages). Examples of integrated average
mentation alternatives are compared in a pretest uncer- parameters are flue gas temperature and oxygen content.
tainty analysis. In most instances, an instrument's vari- Multiple measurements are made over time at each of
ance is small enough relative to the real variance of several points in a grid. The measurements over time
the parameter that the instrumentation variance may be at each point are averaged to determine the value of
ignored. If the instrumentation variance is less than the parameter at the point:
152
RRED STEAM GENERATORS ASME FTC 4-1998
p = the number of points in the x-direction

(7.4-5) q= the number of points in the y-direction
The associated degrees of freedom is also determined
where N is the number of readings over time and i in two steps:
identifies the point in the grid. For unweighred averages
x is the measured parameter, such as temperature or %k =
%k
(7.4-10)
oxygen. --I
--
The sample standard deviations, sample standard k: : ' [ l6q3j+I,k

+I- g1g3j+2.k
| ||| | || | ||
deviations of the mean, and degrees of freedom are j=O R3j+l.k R3j+2.k
calculated ar each grid point as if the parameter exhib-
ited a constant value; that is by Eqs. (7.4-3), (7.4-2), where
|
| |||
and (7.4-4).
|||| | || ||| | || ||
The precision index of the integrated average parame- S,4 (64 ~ 4 ) ~

ter depends on the averaging rule used. u, = (7.4-1I )
4
--I
For multiple midpoint rule averages, the precision
index is:
||| | |---
(7.4-6)
For the composite midpoint rule average, the precision
The associated degrees of freedom is index is
'12
PI4
u= (7.4-7)
5 [A]
(7.4-12)
i= I
The associated degrees of freedom is

where
Sxi= the precision index of the parameter at point
i [from Eq. (7.4-2)] (7.4-13)
m = the number of grid points - - I
3
y = the degrees of freedom of Sxi which is the 81 E Ai
number of readings at point i minus one j=O
For triple midpoint rule averages, the precision index where

is determined in two steps:
8 s%j,k 6$3j+i .k 8 1 $3ji,2,k
AJ. = -+-+-
1- (7.4-14)
P_ -
[
I
3 R3j.k R3j+2,k
swk= k: :9 ~ 4sx3j+i.k + 9%j+Z.k (7.4-8)
R3j+i.k
j=O '3j+ I .k r3j+2.k

7.4.1.3 Integrated Average Parameters
(Weighted Averages). Parameters such as flue gas
temperature or oxygen are sometimes calculated as
weighted averages. The weighting factor is the fluid
velocity fraction evaluated at the same point as the
parameter measurement. Calculation (or estimation) of
the precision index for a flow-weighted integrated aver-
where age depends on the available data for the velocity
Swk= the sample standard deviation of the kth set distribution.
of measurements Velocity measured simultaneously with the parameter,
the sample standard deviation with respect to with several complete traverses. The number of readings
time at point j , k [from Eq. (7.4-3)l at each point in the grid must be large enough to
rj,k= the number of readings at j , k assure statistical significance. Generally six or more
153
STD-ASME PTC 4-ENGL 1998 M 0759b70 ObL5092 90T D
readings are required. In this case, the precision index 7.4.1.4 Measurements on Samples Taken in Mul-
and degrees of freedom are calculated using Eqs. (7.4- tiple Increments. Samples of material streams .are
2) through (7.4-14), as appropriate, with the parameter obtained and analyzed to determine the chemical compo-
xi.¡ being the weighted value. For temperature, for sition of the streams. These streams may be gaseous
example, (such as flue gas) or solid (such as coal, sorbent,
and residue). Usually, these samples are obtained in
v. increments; that is a finite sample is taken at periodic
Xj,¡ = (+) lji
’
(7.4- intervals. The sample locations may be separated in

space, as in sampling multiple coal feeders or multiple
points in a flue gas duct cross section, as well as in
where 7 is the space- and time-averaged velocity.
time. It should be noted that in this Code, solids
Velocity Measured Simultaneously With the Parame-
composition is treated as a constant value parameter
ter with a Small Number of Complete Traverses. In
and flue gas composition is treated as a spatially
this case, the precision index is estimated from a large
nonuniform parameter. A second major difference be-
number of readings taken at a single point. Instruments
tween solid streams and gaseous streams is that the
must be provided to simultaneously measure the velocity
gaseous samples are usually analyzed “online” during
and the parameter at a single fixed point. The point
should be selected so that the expected values of velocity the test while solid samples are usually analyzed in a
and the parameter are approximately the average values. laboratory at a later time.
Data should be recorded with a frequency comparable There are two alternative means for determining
to that for other data. the average properties of material samples taken in
The instantaneous values from the point are multiplied increments; therefore, there are two means for determin-
to give a variable xj: ing the precision index. The first method for determining
the average properties uses a separate analysis of each
individual sample. The average value for all samples
xj = p) Tj (7.4- 16) (the value to be used in the performance calculations)
is then determined as the mean of all of the individual
sample results. In the second method, the individual
The sample standard deviation for x is calculated samples are mixed together into a composite sample
from Eq. (7.4-3). This sample standard deviation is used and an analysis is made of the composite sample. While
together with the statistical F distribution to estimate the there may be replicated analyses of the composite
standard deviation for the integrated average parameter sample, there is still only one sample for analysis.
following the method described in Subsection 7.4.1.4 Often, a combination of both methods is the most
using Eq. (7.4-18) and Table 4.8-1. cost-effective approach. Some constituents can be deter-
Velocity Measured Separately from the Parameter. mined from a single analysis of a gross sample while
The precision index of the weighted average parame- other constituents are determined from analysis of indi-
ter is: vidual samples. For example, when the steam generator
fires coal from a single seam, the moisture and ash
can be highly variable while the other constituents,
expressed on a moisture-and-ash-free basis, are rela-
tively constant. In this case, as-fired moisture and ash,
where and their precisioii indexes, should be determined from
FW= the weighted average analysis of several individual samples, while the average
üW= the unweighted average values for the other constituents (on a moisture-and-
P = the parameter (temperature or oxygen) ash-free basis) can be determined from a single analysis
PIw is calculated as described in Subsection 7.4.1.2. of a mixed gross sample. The following paragraphs
Ideally, the precision index of velocity is evaluated describe determination of precision in these two cases.
from multiple readings over time at each point in the Increments Individually Analyzed. If each incremental
velocity measuring grid. If such readings are not avail- sample is properly mixed, reduced, and divided sepa-
able, the precision index of velocity is estimated from rately, the average value of a constituent is the mean
multiple readings at a single point, together with the of the analysis measurements. The precision index and
statistical F distribution, as described in the previous degrees of freedom are determined from Eqs. (7.4-2)
paragraph. and (7.4-4).
154
-- | ||| | || | || | | ||| |||| | || ||| | || || ||| | |---
STD-ASME PTC 4-ENGL 1998 0759670 Ob15093 8 4 b
FIRED STEAM GENERATORS ASME FIT 4-1998
Increments Mixed Prior to Analysis. If the sample popularion standard deviation (dby assuming that sH
increments are mixed prior to analysis, the various is the smaller of (sH,cr).The precision index can be
increments are mechanically averaged (an example is conservatively estimated by:
the “ganging” of several flue gas sampling lines into
a mixing chamber or bubbler prior to analysis). If
proper procedures have been followed in mixing and (7.4- 18)
reducing the gross sample, the results of the analysis
of the mixed sample may be considered a proper
average. As there is only one set of results, the precision where N is the number of individual samples that were
index cannot be calculated from statistics and must mixed. The degrees of freedom for this estimate can
therefore be e~timated.~ It is often possible to obtain be taken as infinite. Refer to Subsection 4.8.2 for
accurate estimates using historical data or, sometimes, additional requirements when using this method to
limited measurements, for determining precision. estimate coal-constituent precision.
Estimates from Historical Data. Cases where this Estimates from Limited Measurements. To illustrate
method can be used include those where past test data this approach, consider the precision of flue gas oxygen
are available or when fuel or sorbent used during the concentration, Oz. While samples are typically taken
test has been obtained from a source whose characteris- from several grid points in a duct cross section, seldom
tics have been previously established. One criterion for are the individual point samples analyzed; instead,
a proper estimate is that the historical data and the test samples are mixed and passed to a single analyzer. As
data are taken from the same measurement population. If flue gas oxygen concentration is a spatially nonuniform
this is the case, the data have the same population parameter, the mixing simulates the integrated-averaging
mean p and the same population standard deviation process. If equal extraction rates are taken from each
0: Moisture-and-ash-free constituents for coal mined
grid point, the process most closely matches multiple
from a single seam should satisfy this condition so midpoint averaging. The point-to-point variation in Oz,
that historical data from the same seam can be used although not revealed by the composite sample, is
to estimate the precision for the test data. considered a bias due to numerical integration by
If a number of measurements are made from the this Code.
same population, it is unlikely that the sample standard Even though the point-to-point variation is not consid-
deviations will be the same. Suppose that historical ered as precision error, the variation over time at each
data on a particular parameter (e.g., carbon content) point does contribute to precision error. Information
are available. The historical data are based on nH on this variation is revealed only in the composite
observations and have sample standard deviation sw sample. It is assumed that several composite samples
Now imagine that a different set of data is available, are taken and analyzed over time. The precision index
consisting of n observations with sample standard devia- and degrees of freedom should be calculated from Eqs.
tion s. According to statistical theory, (7.4-2) and (7.4-4) and the results for the mixed samples
as if the parameter (e.g., spatially averaged oxygen
concentration) were a constant value parameter:
7.4.1.5 A Single Measurement or the Sum of
Single Measurements. For parameters determined by
where s, and sminare the larger and smaller values a single measurement or the sum of single measure-
of (sH,s)and Fnmax-i,nmin-i,5a is the upper 5% point ments, the precision index is the square root of the
of the F distribution for nmax and nmin degrees of estimate of the instrumentation variance. The magnitude
freedom (note that F > 1). Values for F are given in of the precision index is likely to be small enough so
Table 4.8-1. that it can be neglected. The spatial and time variations
Now suppose that the number of readings in the of such parameters should be considered as biases,
second set is very large ( n + m). We can generate with appropriate estimates made for their magnitude.
an estimate of the probable maximum value of the The problem of uncertainty of single measurements was
considered extensively by Kline and McClintock [5 J.
)It should be noted that mulriple analyses of the same gross sample
can give the precision index of the analytical instruments and
procedures but give no information about the real variation in the 4While it may be argued that the precision index and degrees of
material properties or the sampling variation. In most cases, these freedom are better than those calculated by Eqs. (7.4-2) and (7.4-
latter two sources of variability dominate the precision of material 4) because several points are sampled, it is impossible to determine
properties. these “better” values after the samples are mixed.
155
-- | ||| | || | || | | ||| |||| | || ||| | || || ||| | |---
~ _ _ _ _ _ ~~ ~~
STDmASME PTC 4-ENGL 3998 W 0759670 Ob35094 782
7.4.2 Precision Index and Degrees of Freedom for z = cüv

Intermeàiate Results. Frequently, a parameter used as
if it were measured data is actually calculated from and uses the “propagation of error” formula. The sensi
more primary measurements. Two examples are fluid tivity coefficients are
flow rate, which is often determined from differential
pressure measurements, and enthalpy, which is deter- = C v and ( z @ v ) =
(,Su) CU (7.4-21
mined from temperature (and sometimes, pressure) mea-
surements. There are two possibilities for calculating
The precision index is
the precision index of these intermediate results. One
is to use the “propagation of error” formula, Eq. (7.2-
4j, together with the equation(sj relating the intermediate Pi = [(CV Su)’ + (CUS,)2]1’2 (7.4-22)
result to the primary measurements. This is not as
difficult as it appears because the equations connecting The degrees of freedom is
the intermediate results to the data are usually simple.
The second option is to transform the data into the
intermediate result prior to averaging and then calculate \ L I
v = (7.4-23)
the precision index of the result. The following describes - sy + u4 s-
;
v4 -
specific cases. vu V”
7.4.2.1 Parameters of the Form z = C 4.
The
measurements, xi, should first be converted to zi.Then
7.4.2.4 Fìow Rates Using Weigh Bins or Tanks.
the average and the sample variance of z can be
Weigh bins or tanks are used as integrating devices
calculated from the z;. Differential pressure flow meters
to smooth out variances in the flow rate. The desired
exhibit this type of parameter relationship.
flow rate generally is one occurring upstream of a
||| | |---
7.4.2.2 Parameters of the Form z = ao + alF + component with storage capacity. For example, the
ug2+ . . . + u p n . Equation (7.2-4) is applicable to catch of a baghouse can be determined by a weigh
|||| | || ||| | || ||
functions of one variable; in this case the variable is bin on the disposal line from the baghouse hoppers.
T. The sensitivity coefficient for j s is
If weight and time readings are taken at the beginning
and the end of the test period, the average flow rate,
| |||
w, is:
|
a = a l + 2azF + . . . + n a z - I
,o, = 2
| ||| | || | ||
(7.4-19)
ax w = - u2 - u1 (7.4-24)
72 - 72
--
The precision index is where
u ] , u2= the initial and final weight readings, respec-
tively
T], = the initial and final time readings, respectively
As multiple measurements are not typically made of
the weights and times, the precision of w depends on
The degrees of freedom for z is the same as for x. the instrumentation precision. The precision index is:
The most common occurrence of this form of equation
in steam generator performance testing is an enthalpy-
temperature relationship.
7.433 Parameters of the Form z = C ü F.

Generally, the magnitude of the instrumentation vari-
For this type of parameter, two choices are available.
ances is small and the precision index can be neglected.
The first is to transform the primary data values (u,vi)
The instrumentation biases are likely to be significant.
into the intermediate result (2;) and then average the
values of the intermediate result and calculate their 7.43 Precision Index and Degrees of Freedom of
precision index and degrees of freedom. Test Resdts. If the test result is a measured parameter,
The second alternative calculates z from the averages such as the temperature of the flue gas exiting the
of u and v steam generator, then the precision index and degrees
156
~
STD-ASME PTC 4-ENGL 1998 0759b70 Ob15095 b 1 9
of freedom of the result are just the values for the methods using a computer. If a computer program is
parameter itself. If the test result must be computed available to calculate the test resultant, R, from the
from the measured data, such as steam generator effi- parameters xI,. . ., xk. then the sensitivity coefficients
ciency, then the precision index and degrees of freedom can be approximated by perturbing each parameter, one
of the result must be calculated from their values for at a time, by a small amount (hi), keeping the value
the individual parameters. of the other parameters constant and evaluating the
change in the calculated value of the test resultant, 6R.
7.43.1 Combining Precision Indexes. The preci-
The sensitivity coefficient is then
sion index of a calculated result is obtained by combin-
ing the precision indexes of all of the parameters that
affect the result according to the root-sum-square rule (7.4-30)
] ”’ (7.4-26) hi is a small value such as xi/lûû or xi/l,ûûû.

For a pretest uncertainty analysis, predicted perform-
ance data are used for the average values. The actual
where
average values of the measured parameters are used
=(dR/dxi)
Rexi =the sensitivity coefficient of parame-
ter xi on result R and k is the total for a post-test analysis.
number of parameters that are used
to calculate R
7.5 EQUATIONS AND GUIDANCE FOR
7.43.2 Combining Degrees of Freedom. The de- DETERMINING BIAS LIMIT
grees of freedom of the precision index of R is com-
puted by: Bias is a systematic or “built-in” component of the
error. The bias error is what remains after ail reasonable
attempts to eliminate it (such as calibrating instruments)
YR =
i (Rex;
(7.4-27) have been made. An essential characteristic of bias is
that it cannot be determined directly from the test data.
i = I Yxi It is always necessary to estimate bias. Sometimes,
models based on the test data or observations of condi-
tions during the test can be used in making estimates,
7.43.3 Sensitivity Coefficients. The sensitivity co- but they remain estimates nevertheless. A second essen-
efficients are the partial derivatives of the result with tial fact concerning bias is that its value(s) is unique
respect to the parameter: to the measurement system employed in a specific
test and to the process and ambient conditions during
the test.
(7.4-28)
This Section gives certain mandatory rules for making
bias estimates and for mathematical manipulation of
in accordance with Eq. (7.2-4). them. It also provides guidance and some models for
Sometimes, it may be more convenient to work with estimating values of bias limits. Users of this Code
a relative sensitivity coeficient, which is calculated by: are free to adopt, modify, or reject any models for
bias set forth in this Section, provided that the parties
to the test agree to do so and that they agree on an
(7.4-29) appropriate substitute.
7.5.1 General Rules
The relative sensitivity coefficient is useful in a Bias limits used in this Code have the following
pretest analysis when judging the relative influence of characteristics:
the error in a particular parameter on the uncertainty
0 bias limits shall be agreed upon by the parties to the test
of the test result.
0 bias limits should be estimated at a 95% confidence
7.43.4 Calculation of Sensitivity Coefficients. For level; the maximum conceivable values of bias should
test results such as steam generator efficiency, calculat- not be used
ing the sensitivity coefficients analytically is cumber- 0 bias estimates may be one-sided or nonsymmetrical if
some. An alternative is to calculate them by numerical the physical process so suggests and the parties to the
157
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~
STDsASIE PTC 4-ENGL 1998 0759670 0615096 555
test agree that such estimates are the best available. The maximum positive or negative deviation from
If nonsymmetcical or one-sided bias limits are used, the zero deviation line, C, is sometimes called the
then it is necessary to propagate positive and negative “reference accuracy.” The reference accuracy of a typi-
values separately into the result. cal device can be used as an estimate of the correspond-
ing “‘biases of similar devices. Bias limits estimated
Although the actual bias in any measurement or from reference accuracy do not include the effects of
result is a fixed value, an estimare of the bias is a drift, installation, etc.
random variable. This Code specifies that bias estimates If the curve is for a spec& device, then the values
(bias limits) shall be combined by using the root-sum- to the midpoints, B, of the envelope at various inputs
square principle. are to be used as calibration corrections in the data
Generally, the same bias limits will be used for both reduction. In this case, the bias limit is estimated as
pretest and post-test uncertainty analyses. Observations (A/2). Note that such estimates may not include biases
of conditions during the test may indicate that it is arising from drift, ambient effects, etc.
allowable to decrease one or more bias limits or that If an instrument or an entire instrumentation loop
it is advisable to increase one or more bias limits. This has been calibrated for a test, the bias limit is estimated
shall be permitted if both parties to the test agree. as the root-sum-square of the precision index of the
calibration curve (the Standard Error of Estimate of
7.5.2 Biases in Measured Parameters Due to Instru- the fitted curve) and the bias limit of the reference
mentation instrument. Refer to PTC 19.1, Measurement Uncer-
There are a number of sources of instrumentation tainty, for further information.
bias in any measurement; among those are: primary
7.5.2.2 Combining Biases From Several Compo-
element, primary sensor, transducer, amplifier, analog/
digital converter, recording device, and environmental nents. If an instrument system has several components
and each has a separate bias limit, the combined bias
effects. ISA Standard ANSVISA S5 1.1 may be consulted
limit of the measurement is
for general information about instrumentation bias [7].
Section 4 gives guidance for estimating bias limits
due to specific instrumentation systems. This section B = (B: + B: + . . . . + B;)”’ (7.5- I )
provides general guidelines and rules for combining
these elemental biases. where subscripts 1, 2 . . . m represent the various
If separate components of an instrumentation loop components of the system. Because this root-sum-square
or the entire loop has been calibrated and the calibration rule is used, biases whose estimated magnitude is less
data (biases) are incorporated into the test data, the than one-fifth of the largest in a specific loop may be
biases shall be excluded from the uncertainty analysis. ignored in calculating the bias of the parameter.
Estimated biases resulting from drift in calibration,
ambient effects, etc., are included in the uncertainty 7.5.2.3 Multiple Measurements With a Single In-
analysis. strument. For multiple measurements at a single loca-
tion with a single instrument (such as measuring the
7.5.2.1 Bias Due to a Single Component. If a temperature at several points in a flue gas duct cross
typical calibration curve for an instrumentation compo- section with the same thermocouple system) the instru-
nent is available, the magnitude of the component’s mentation bias of the average value of the parameter
bias can be estimated. Figure 7.5-1 is a generic calibra- is equal to the instrumentation bias of a single mea-
tion curve. The deviation is the difference between the surement:
input, as measured by a standard, and the output of
the device under steady-state conditions. B, = BXi (7.5-2)
The deviation is expressed in a number of ways:
||| | |---
units of the measured variable, percent of span, percent

of output reading, etc. Figure 7.5-1 shows an envelope 7.5.2.4 Multiple Measurements With Multiple In-
|||| | || ||| | || ||
within which repeated readings at the same input have struments at Several Locations. The most common
been made. The width of the envelope, A, is a measure example is the use of a fixed grid of thermocouples
of the precision of the device and is sometimes called the to measure (average) flue gas temperature. Two different
| |||
reproducibility of the device. Reproducibility includes situations may be present.

|
hysteresis error, deadband, repeatability, and, occasion- The first situation is when all instrument loops (each
| ||| | || | ||
ally, limited time drift. thermocouple plus lead wire, data logger, etc., consti-
158
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STD-ASME PTC 4-ENGL 1998 m O759’b7O Ob35097 491
FIRED STEAM GENERATORS ASME 4-1998
||| | |---
|||| | || ||| | || ||
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---r--r v
|
10 30
| ||| | || | ||
Percent input
--
FIG. 7.5-1 GENERIC CALIBRATION C U R V E
tutes one loop) are judged to have the same bias. This 7.53 Bias in Spatially Nonuniform Parameters.
would typically occur when all thermocouples are of Certain parameters in a steam generator performance
the same type and quality and all other components test, namely flue gas and air temperatures at the steam
of each loop are identical. In this case, the instrument generator envelope boundaries and flue gas composition,
bias in the average parameter (temperature) is equal should be evaluated as flow weighted integrated average
to the instrument bias for any one of the loops: values [8] (refer to Subsections 4.3.4 and 7.2.3).
In practice, integrated averages are approximated by
Bx = BXi(any i ) (7.5-3A) sampling at a finite number of points and using a
numerical approximation to the necessary integral. In
The second situation is when different loops are addition to this approximation, the parties to the test
judged to have different biases. This would occur if may agree to forego measurement of the velocity and
the thermocouples were of different types, or for a omit the flow weighting. In certain cases, e.g., flue gas
variety of other reasons. In this case, the instrument composition, the samples may be mixed and mechani-
bias for the average parameter is the average of the cally averaged prior to analysis. Each of these approxi-
biases for each loop: mations introduces an error which this Code treats as
bias. These biases are in addition to instrumentation
l N biases discussed in Subsection 7.5.2.
BI = - BXi (7.5-3B)
If measurements are made at only a few points
Nx=i
(sometimes as few as one or two), then the methods
where suggested below for estimating these biases cannot be
N = the number of different instrument loops used. Likewise, these methods cannot be used for
B,,= the bias of a single instrument loop i multipoint samples which are mixed prior to analysis.
159
In both cases, the bias in integrated averages must be

estimated and assigned by agreement between parties
to the test. Experience and data from previous tests
Bn = [ml OS SDI (7.5-5)
on similar units can serve as the basis for a model. Multiple Midpoint Rule
Bias estimates must be large enough to account for
the indeterminate errors present in small samples.
(7.5- 6)
7.53.1 Spatial Distribution Index. It is possible
to make mathematically elegant estimates of numerical
integration error; however, these estimates require where m is the number of points in the measurement
knowledge of the exact distribution. Since this informa- grid. The coefficients in Eqs. (7.5-5) and (7.5-6) were
tion is usually not available, a heuristic model is selected by the Code committee to reflect the relative
proposed for numerical integration bias. The model magnitude of the biases and the dependence of the
assumes that numerical integration errors are propor- bias on the number of grid points but have no other
tional to the following spatial distribution index: theoretical basis. In the case of a single stream (e.g.,
flue gas) divided between two or more separate ducts,
the model is applied to each duct. If historical or
1 preliminary traverse data are used to estimate SDI,
these bias estimates should be increased as appropriate
to the applicability of the preliminary data to the
where z is the time averaged value of the continuously actual test.
distributed parameter (temperature, oxygen content, etc.)
and is the integrated average value of 2. Since SDI 7.53.3 Bias Associated with Flow Weighting. Al-
is itself an integral, it must be calculated by a numerical though the theoretically proper averages for some pa-
integration method. While it is probably advantageous rameters such as flue gas temperature and oxygen
to use the same integration nile that is used to calculate content are flow-weighted, it is often not advisable to
z for the performance calculations, the value calculated use flow weighting in a performance test because the
by the multiple midpoint rule is satisfactory: errors associated with velocity determination may be
greater than the error made by not flow weighting.
There are, therefore, two different types of bias error
associated with flow weighting:
If flow weighting is used in the performance calcula-
where rn is the number of points in the measurement tions, then there is a bias error due to the bias in the
grid. In the case of a single stream (e.g.. flue gas) velocity data used for weighting.
divided between two or more separate ducts, SDI is If flow weighting is not used in the performance calcu-
calculated for each duct. It should be noted that although lations, then there is a (bias) error of method. This
SDI as calculated by Eq. (7.5-4) appears to be identical error is equal to the difference between the (true)
to the “standard deviation,” it does not have the same weighted average and the unweighted average actually
statistical significance. used in the calculations.
If reliable historical data or data from a preliminary It is clear that only one of these two types of errors
traverse are available, the parties to the test may agree can be present in any one data set (either the average
to estimate the SDI for one or more parameters from is weighted or it is not). This Code treats either type
this data. as flow weighting bias.
7.53.2 Bias Due to Numerical Integration. Sub- Flow Weighting Bias When Flow Weighting Is Used.
section 5.2.3.3 describes three numerical integration There are two options in this case: (1) the velocity
used for flow weighting. is measured simultaneously
||| | |---
schemes (averaging rules). The recommended bias limits

for each method are: with the parameter being weighted (temperature or
oxygen content); and (2) the velocity used for flow
|||| | || ||| | || ||
Triple Midpoint Rule

weighting is measured in one or more preliminary
traverses. In either case, it is assumed that the velocity
B, = O data are deemed sufficiently accurate and statistically
| |||
valid (see Subsection 4.3.4 for rules regarding use of

|
Composite Midpoint Rule velocity data for flow weighting),

| ||| | || | ||
160
--
STD*ASME PTC 4-ENGL 1998 0759670 Ob15099 2b4
--
| ||| | || | ||
For the firsr option, where the velocity is measured

|
| |||
simultaneously with the parameter being averaged, the (7.5- 11)

|||| | || ||| | || ||
flow weighting bias estimate is:

For the second oprion, where preliminary velocity
data are available, but not used to calculate a weighted
||| | |---
(7.5-7)
average, the recommended bias model is:
where
- BFW = pUW - PFW (7.5-12)
P = the (integrated) average parameter (either tem-
perature or oxygen concentration) where the velocity data are used to calculate an estimate
U W = unweighted averages of the weighted average, Pw
FW= weighted averages
7.53.4 Combined Bias for Integrated Averages.
- bias limit for velocity
Bv=
The combined bias for integrated average values is
V = average velocity
For the second option, where the velocity is deter-
mined by preliminary uaverse(s), the following is rec- BIA = ( B i + Bi + B;W)“~ (7.5-13)
ommended:
where BI is the instrumentation bias discussed in Subsec-
tion 7.5.2.
(7.5-8)
7.5.4 Bias Due to Assumed Values for Unmeasured
Parameters. The midpoint between reasonable “lim-
iting’’ values of an assumed parameter normally should
The terms in this equation have the same meaning
be used as the value of the parameter in performance
as above.
calculations. Half the difference between the “limiting”
Flow Weighting Bias When Flow Weighting Is Not
values is normally used as a bias in uncertainty analyses.
Used. In this case, the bias estimate is an estimate of
If, for example, the bottom ash fiow rate was taken
the difference between the weighted and unweighted
as a percentage of the total ash produced in a pulverized
averages. Again, there are two options: (1) there are
coal fired boiler, the percentage would be an assumed
no reliable velocity data, or (2) preliminary velocity
parameter. It would be the midpoint between the “lim-
traverse data exist, but the parameters are nevertheless
iting” values set, of course, by judgment and agreed
not flow weighted.
to by the parties to the test.
For the first option, where there are no reliable
In some cases, unsymmetrical bias limits may be
velocity data available, the bias limit for temperature
used if physical considerations imply it. For example,
is estimated as follows. First, a weighted average is
an ash split cannot be 10% +15%, as a negative 5%
estimated by:
is unrealistic. Likewise, bias due to air infiltration into
an oxygen sampling system cannot be positive (the
true value can be lower than the measurement but not
(7.5-9) higher).
7.5.5 Bias Limit for Test Results. The total bias
where limit for a result calculated from the measured and
m = number of points in the traverse plane assumed parameters is
û= absolute temperature (û = T OF + 459.7)
The bias estimate is:
BR = [ k
i= I
BxJ2]
‘12
(7.5-14)
Bias limits are independent parameters. If unsymmet-

rical bias limits are used, they must be carried separately
The bias limit for oxygen concentration is taken to the final result. The sign of the product
as the same percentage of the average value as the ( R @>(BXJ determines the classification as positive or
temperature bias: negative.
161
STDOASME PTC 4-ENGL 1778 D 0757670 0 6 1 5 1 0 0 806
ASME F K 4-1998 FIRED STEAM GENERATORS
7.6 UNCERTAINTY OF TEST RESULTS for u = % degrees of freedom and a 95%

The precision index and the bias limit of a test result confidence limit and is taken from Table 5.16-
are combined into the test uncertainty according to: 1 or Eq. (5.16-7). In addition to the value for
UR, the test report shall also state the values
of PI,, 3,and B,y
where
fuo.025 = the percentile point of Student’s t-distribution
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i 62
STD-ASME PTC 4-ENGL 1998 0759b70 O b L 5 L O L 742
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| ||| ASME PTC 4-1998
NONMANDATORY APPENDIX A
|||| | || ||| | || ||
CALCULATION FORMS
||| | |---
A.l INTRODUCTION water flow by energy balance. For units with reheat,
calculation of feedwater heater steam extraction flow,
Calculation forms are provided at the end of this cold reheat flow, and reheat absorption are provided
Appendix to aid the user in performing calculations in
for.
a logical sequence. The forms also are an instructional PREC - PRECISION DATA REDUCTION WORK
aid. Even when a computer program is used, it is SHEET. Used to average each data point with respect
suggested that the first-time user perform a set of to time and to calculate the standard deviation. Con-
calculations by hand. Brief instructions have been pre- version from digital (mv, ma, etc.) to English units
pared for each calculation form; these should be supple- and calibration correction factors are also performed
mented by the main text, Sections 4, 5, and 7. on this form.
Due to the wide variety of the types of units and BIAS -BIAS DATA REDUCTION WORK SHEET.
fuels addressed by this Code, several calculation forms Used to account for and calculate the bias limit for
have been developed for specific requirements. The each measurement device, including all the compo-
purpose of each form is described briefly below: nents of the measurement.
O EFF - EFFICIENCY CALCULATIONS. Used to o UNCERTa - UNCERTAINTY WORK SHEET NO.
calculate efficiency by the energy balance method. It 1. Contains the input information for data reduction
is necessary that the combustion calculation forms be and information required for determination of the pre-
completed first. cision componentof uncertainty. This work sheet is set
O CMBSTN - COMBUSTION CALCULATIONS.
up for spatially uniform parameters, Le., parameters
Used for the general combustion calculations such as which vary with respect to time only. Form INTAVG
excess air, dry gas weight, etc. should be used for spatially nonuniform parameters
O GAS -GASEOUS FUELS. Used to convert the ulti-
first. Separate forms are included for output and effi-
ciency.
mate analysis of gaseous fuels from a percent volume
UNCERTb -UNCERTAINTY WORK SHEET NO.
basis to a percent mass basis. All calculationsrequiring
2. Contains the information required to calculate total
a fuel analysis are on a percent mass basis.
uncertainty. Separate forms are provided for output
O RES - UNBURNED CARBON AND RESIDUE
and efficiency. The work sheet is set up for calculating
CALCULATIONS. Used to calculate the weighted the uncertainty effect on output and efficiency; how-
average of carbon in the residue, unburned carbon, ever, this sheet can be used for any calculated item
and sensible heat of residue loss. When sorbent is used, such as fuel flow, calciudsulfur ratio, etc.
this form is used to calculate the weighted average of INTAVG -UNCERTAINTYWORK SHEET INTE-
carbon and carbon dioxide in the residue. These results GRATED AVERAGE VALUE PARAMETERS.
are used in conjunction with the sorbent calculation Contains the input information for data réduction and
forms to calculate unburned carbon and calcination information required for determination of the preci-
fraction of calcium carbonate. sion component of uncertainty for spatially nonuni-
SRB -SORBENT CALCULATION SHEET, MEA- form parameters; i.e., any parameter which varies with
SURED C AND CO2IN RESIDUE. Used in conjunc- both space and time, such as flue gas temperature in
tion with the unburned carbon and residue calculation a large duct cross section.
form to calculate unburned carbon in the residue and
calcination. Percent sulfur capture, calcium to sulfur
molar ratio, and losses and credits associated with A.2 SYSTEM OF UNITS
sorbent and sulfur capture are also calculated.
O OUTPUT -OUTPUT. Used to calculate unit output. Fuel efficiency is a function of the percent input
Provision is made for calculating superheater spray from fuel. Therefore, calculations that are related to
163
STD=ASVE PTC 4-ENGL
ASME F"C 4-1998 NONMANDATORY APPENDIX A
the fuel, such as airflow, use units of IbmAbm of fuel age exit gas temperature is required. Refer to Subsec-
or lbm/Btu input from fuel. The latter is a convenient tion 5.13 and the input instructions for Form EFF.
system of units because, in effect, it is a normalized This item requires that the combustion calculations
result. For example, 10% ash in the fuel has a meaning be completed first and is mentioned here only because
only when fuels with similar higher heating values it might require reiteration.
(HHV)are compared. If the HHV of a fuel is 10,OOO gaseous fuels - calculate the ultimate analysis and
Btdlbm fuel, 10% ash would be 10 Ibdmillion Btu. HHV on a percent mass basis
For a 5,000 BtuAbm fuel, 10% ash would be 20 lbml estimate the total input from fuel - the following
million Btu, or twice as much actual ash as the higher calculations require an estimated fuel input. Refer to
Btu fuel. the input instructions for Form CMBSTN regarding
In the interest of space on the forms and convenient estimating input. The estimated total input must be
numbers to work with, the units used on the forms compared to the calculated result when the efficiency
are abbreviated and are some multiple of the basic results are completed and the calculations reiterated
mass/mass or masdunit of heat input. Some of the if the difference is greater than 1%. Refer to Subsec-
more frequently used abbreviations are described below: tion 5.7.3.
multiple fuels - calculate a composite fuel analysis
1bmAbm - pound mass of one constituent per pound
and weighted average HHV based on the percent mass
mass of another constituent or total. For example, lbm
flow rate of each fuel. Use the measured fuel flow for
asMbm fuel is the mass fraction of ash in the fuel.
the fuel(s) with the lesser input and calculate the fuel
0 lb/100 lb - pound mass of one constituent per 100
flow for the fuel with the major input by the difference
pound mass of another constituent or total. For exam-
between the total input and the input from the mea-
ple, Ibm ashl100 lbm fuel is the same as percent ash
sured fuel flow.
in fuel.
0 lb/lOKBtu - pound mass per 10,Ooo Btu input from
A3.1 Order of Calculations for Low Ash Fuels
fuel. These are convenient units to use for the combus-
(Oil and Gas)
tion calculations.
0 1bAOKB - abbreviation for lb/lOKBtu
Step I. Complete the combustion calculation forms,
0 Klwh - 1,OOO pound mass per hour
CMBSTN.
MKBtu/h - million Btuh
Step 2. Complete the efficiency calculation forms,
MKB - abbreviation for million Btu/h
EFF.
Step 3. If the unit configuration or fuel required
estimating total input as described in Section A.3 above,
A.3 ORDER OF CALCULATIONS
repeat the calculations until convergence is obtained.
The calculation sequence is described below for three
A.3.2 Order of Calculations for Fuels with Ash
levels of complexity, depending upon fuel type. Prior
to these calculations, the user will have to complete
(Coal) -
No Sorbent
the following preliminary calculations:
Step I. Complete the residue calculation form, RES.
average the data with respect to time, Form PREC Step 2. Complete the combustion calculation forms,
output -calculate the boiler output for the test condi- CMBSTN.
tions, Form OUTPUT Step 3. Complete the efficiency calculation forms,
temperature grids -calculate the average gas and air EFF.
temperatures for each of the air and gas temperature Srep 4. If the unit configuration or fuel required
grids as described in Section 5.17, Form INTAVG estimating total input as described in Section A.3 above,
average entering air temperature - if air enters the or the residue split was measured at some but not all
steam generator envelope at different temperatures, locations as described for RES, repeat the calculations
for example, primary and secondary air, calculate the until convergence is obtained.
weighted average entering the air temperature. Refer
to Section 5.13. A.3.3 Order of Calculations When Sorbent Is Used.
average exit gas temperature (excluding leakage) - These instructions assume that the residue mass flow
if the gas temperature leaves the steam generator enve- rate leaving the steam generator envelope is measured
lope at different temperatures, for example, units with at some locations and calculated by difference for the
primary and secondary air heaters, the weighted aver- unmeasured location. (Refer to instructions for RES.)
164
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STD=ASME PTC Y-ENGL 1998 0759b70 Ob15103 515
NONMANDATORY APPENDIX A ASME PTC 4-1998
Srep 1. Complete Items [ i ] through [lo], Form RES. than one source of air, such as primary
Srep 2. Complete the calculations on Forms SRBa and secondary air, enters at different tem-
and SRBb. The calculations are iterative until conver- peratures, the average entering air tem-
gence on unburned carbon and calcination is obtained. perature is the weighted average of the
Step 3. Repeat Steps 1 and 2 until convergence is different sources. Refer to Items [35]
obtained for the mass rate of residue. through [ U ] below.
Srep 4. Complete the remaining items on Form RES. Item 3 Average Exit Gas Temperature (Exclud-
Srep 5. Complete the calculations on the combustion ing Leakage). Enter the average gas tem-
calculation forms, CMBSTN. perature leaving the steam generator en-
Srep 6. Complete the efficiency calculations on Forms velope. When an air to gas heat exchanger
EFF and SRBc. is used and there is air leakage from the
Srep 7. Compare the estimated fuel flow (input) to air to gas side of the air heater, this is
I
that calculated on E m , and repeat calculations in the gas temperature corrected for leakage
Section A.3 (if applicable) and Steps 1 through 6 until (gas temperature excluding leakage).
convergence is obtained. When gas leaves the steam generator en-
velope at different temperatures, such as
on a unit with primary and secondary air
heaters, this is the weighted average of
the gas temperature leaving each location
A.4 EFFICIENCY CALCULATIONS - (excluding leakage if leaving air heater).
Refer to Items [45] through [51] below.
INSTRUCTIONS FOR EFF FORMS
Item 4 Fuel Temperature. Enter the temperature
The efficiency calculation forms are used to calculate of the fuel entering the steam generator
efficiency as tested as well as efficiency corrected envelope. This item is required to calcu-
to standard or contract conditions. The combustion late the enthalpy of fuel. For multiple
calculation forms, CMBSTN, must be completed prior fuel firing, calculate an average enthalpy
to performing the efficiency calculations. These instruc- based on the percent input of each fuel.
tions are intended as an aid to completing the calculation Items 5, 6 Hot Air Quality Control Equipment.
form. The user should refer to Section 5 for details These items refer to equipment such as
regarding the definition and calculation of individual hot precipitators where there is a com-
losses and credits. bined efficiency loss due to surface radia-
tion and convection, and air infiltration.
A.4.1 Form EFFa. This form contains the input data If applicable, enter the gas temperature
required for the efficiency calculations. Some efficiency entering and leaving the equipment.
calculations are performed on other calculation forms, Items 10-25 Results From Combustion Calculation
if applicable, and so noted under the specific efficiency Form CMBSTN. These items are calcu-
loss or credit items. lated on the combustion calculation forms
and the item number from those forms is
Items 1 4 Temperatures, OF. These items require indicated in brackets.
that the user enter the temperature and Item 10 Dry Gas Weight [77]. Enter the dry gas
determine an enthalpy for certain constit- weight leaving the boiler, economizer, or
uents. Calculation of enthalpy for wet air entering the air heater (no hot AQC
and wet flue gas requires data from the equipment). This is normally the boiler
combustion calculation form (Items [ 101 operating control point for excess air.
through [25] below). Refer to Section 5 This item is used to calculate the dry
for calculation of enthalpies. gas loss. The loss due to air infiltration
Item 1 Reference Temperature. The standard beyond this point will be accounted for
reference temperature for efficiency cal- by either the air heater gas outlet tempera-
culations in accordance with this Code is ture corrected for leakage, hot AQC
77°F (25°C). equipment loss, or separately as an addi-
Item 2 Average Entering Air Temperature.Enter tional air infiltration loss. This should be
the average air temperature entering the a mass weighted value for units with sep-
steam generator envelope. Where more arate air heaters.
165
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STD.ASME PTC 4-ENGL 1998 O759670 Ob15104 4 5 1
ASME PTC 4-1998 NONMANDATORY APPENDIX A
Item i 1 Dry Air Weight [69]. Enter the dry air Item 35A Primary Air Temperature Entering, O F .
weight corresponding to the same loca- This is the temperature of the primary air
tion as Item [lo] above. This should be as it enters the boundary and normally the
a mass weighted value for units with sep- same as Item [16B] on Form CMBSTNa.
arate air heaters. Item 35B Calculate the enthalpy of wet air based
Items 12-14 Water from Fuel. Enter results from com- on the moisture in air content indicated
bustion calculation form as indicated. for Item [7], CMBSTNa.
||| | |---
Item 15 Moisture in Air, 1bAb DA [7]. This item Item 36A Primary Air Temperature Leaving Air
is required to calculate the enthalpy of Heater, O F . This item is required only
|||| | || ||| | || ||
wet air. when pulverizer tempering air calcula-
Item 16 Moisture in Air, lb/lOKB [72]. Enter the tions are required for pulverized coal fired
moisture in air on an input from fuel basis units. Refer to Item [38A].
Calculate the enthalpy of wet air. Refer
| |||
corresponding to the same location as Item 36B
Item [lo] above. to Item [35B].
|
| ||| | || | ||
Item 17 Fuel Rate Estimated, Klbh [3]. Enter the Item 37A Average Air Temperature Entering Pul-
estimated mass flow rate of fuel. Refer verizers, O F . This item is required only
to Item [3] on Combustion Form a. when Pulverizer tempering air calcula-
--
Items 18, 19 Enter values as described. tions are required for pulverized coal fired
Items 20-23 Hot AQC Equipment. Refer to Items [5] units. Refer to Item [38A].
and [6] for applicability. The item " E Item 37B Calculate the enthalpy of wet air. Refer
refers to entering the equipment, and "L" to Item [35B].
refers to leaving the equipment. Item 38A Average Pulverizer Tempering Air Tem-
Item 25 Excess Air Leaving Steam Generator, %. perature, "F. This item is required to cal-
Enter the calculated excess air leaving culate pulverizer tempering airflow for
the steam generator and entering the air pulverized coal fired units. When the pul-
heater(s). This should be a mass weighted verizer tempering air temperature is dif-
value for units with separate air heaters. ferent from the entering primary air tem-
Item 30 Unit Output, MKBtuh. Enter the unit perature, Item [35A], it is necessary to
output in units of million Btu per hour; calcufatethe pulverizer tempering airflow
Item 31 Auxiliary Equipment Power, MKBtuh. to obtain the average entering air temper-
Enter the input to the steam generator ature. The temperature of pulverizer tem-
envelope from auxiliary equipment in pering airflow may also be helpful in
units of million Btu per hour. This item is evaluating air heater performance.
the credit for energy supplied by auxiliary Item 38B Calculate the enthalpy of wet air. Refer
equipment power. If applicable, this item to Item [35B].
must be calculated and the result entered Item 39 Secondary Air Temperature Entering, O F .
here. Refer to Section 5. Note that energy Enter value from Form CMBSTNa, Item
added to the envelope is credited; the [16A].
power to the driving equipment must be Item 40 Primary Airflow (Entering Pulverizer),
reduced by the overall drive efficiency Klwh. Enter the measured primary air-
which includes the motor, coupling, and flow. For pulverized coal fired units, this
gear drive efficiency. is the total airflow to the pulverizers, in-
Items 32-33 Loss Due to Surface Radiation and Con- cluding tempering airflow.
vection, %. Items [33A] through [33D] Item 41 Pulverizer Tempering Airflow, Klbh.
can be used if this loss is calculated. Calculate the pulverizer tempering air-
flow by energy balance as indicated. Note
that the calculations assume that the mea-
The calculations of Items [351 through [44] are sured primary airflow includes the tem-
required only when two or more air streams enter the pering airflow.
unit at different temperatures. Units with separate pri- Item 42 Total Airflow, Kibh. Enter the calculated
mary and secondary air streams and pulverized coal value from Form CMBSTNc, Item [96],
fired units with atmospheric tempering air are examples based on the excess air leaving the pres-
of units that require these calculations. sure part boundary.
166
STDeASME PTC 4-ENGL 1998 0759670 Ob15105 398 -
ASME PTC 4-1998
Item 43 Secondary Airflow, Klbh. Calculate the result in Column B, %. For losses or credits calculated
secondary airflow by difference. on input basis, enter the results in Column A, MKB
Item 44 Average Entering Air Temperature, O F . (million BtUn). Upon completion of the input from
Calculate the weighted average entering fuel calculation, Item [loll, those items calculated on
air temperature. an input basis can be converted to a percent fuel
efficiency basis by dividing the result by the input
The calculations of Items [45] through [51] are
from fuel and multiplying by 100. Each section of
required only for units with separate primary and sec-
losses and credits contains an item titled "Other," which
ondary air heaters.
refers to the results from Form EFFc.
Item 45A Flue Gas Temperature Entering Primary The calculation of losses and credits is generally
Air Heater, OF. Enter measured flue gas self-explanatory with the aid of the instructions for the
temperature from CMBSTNb Item [50]. input form, EF'Fa. Refer to Section 5 for definitions
Item 45B Calculate the enthalpy of wet flue gas and explanations.
based on the flue gas moisture and solids
content determined on Form CMBSTNc, Item 75 Surface Radiation and Convection Loss.
Items [78] and [81]. This is the one item on this form for
Item 46A Flue Gas Temperature Leaving Primary which a complete calculation form has
Air Heater. Enter calculated value ex- not been provided. Refer to Items [33A]
cluding air heater leakage from Form through [33D] from EFFa for required
CMBSTNc, Item [88]. measured parameters. If a test has been
Item 46B Calculate the enthalpy of wet flue gas. performed, enter the test result. Refer to
Refer to Item [4SB]. Section 5 for estimating a value to use
Item 47 Flue Gas Temperature Leaving Second- for contract or reference conditions.
ary Air Heater. Enter calculated value Item 100 Fuel Efficiency, %. Calculate fuel effi-
excluding air heater leakage from Form ciency in accordance with the equation.
CMBSTNc, Item [88]. This equation allows the direct computa-
Item 48 Total Gas Entering Air Heaters, Klbh. tion of efficiency using losses and credits
Enter calculated value from Form calculated in mixed units.
CMBSTNc, Item [93]. Item 101 Input from Fuel, MKB. Calculate the in-
Item 49 Flue Gas Flow Entering Primary Air put from fuel in million Btu per hour in
Heater, Klbh. Calculate by energy bal- accordance with the equation.
ance as indicated. Item 102 Fuel Rate, Klbm/h. Calculate the mass
Item 50 Gas Flow Entering SecondaryAir Heater. flow rate of fuel based on the measured
Calculate by difference as indicated. efficiency and measured output. For some
Item 51 Average Exit Gas Temperature, OF. Cal- units, an estimated mass flow rate of fuel
culate the weighted average exit gas tem- (input) is required for the calculations.
perature. This item should be compared to Form
EEFa Item [17],and if the result is not
The above calculations or Item [51] must be iterated within 1% (refer to Section A.3 or Sub-
to determine the primary/secondary air split. An air section 5.7.3 for convergence tolerance
split must initially be assumed and then recalculated based on application), the CMBSTN (and
until convergence occurs. applicable accompanying calculations)
A.4.2 Form EFFb should be repeated until convergence is
obtained. Examples of where fuel rate
Calculation of the major and most universally applica- is required (but not necessarily limited
ble losses and credits are provided for on this form. to) are:
The losses and credits are separated into those that
can be conveniently calculated on a percent input from e more than one source of entering air temperature, not
fuel basis and those that can be calculated on a Btu/ all sources measured (use calculated total airflow to
h basis (units of million Btu per hour are used). The calculate weighted average)
efficiency is then calculated directly in accordance with e more than one source of exiting gas temperature, not
the equation for Item [100]. For losses or credits all sources measured (use calculated total gas flow to
calculated on a percent input from fuel basis, enter the calculate weighted average)
167
-- | ||| | || | || | | ||| |||| | || ||| | || || ||| | |---
STDmASHE PTC 4-ENGL 1778 0757670 ObL510b 224
ASME FTC 4-1998 NONMANDATORY APPENDIX A
residue mass flow rate measured at some locations and A.5.1 Form CMBSTNa. This form contains most of
calculated result used to determine total the input required to complete the three combustion
sorbent used calculation forms. Some of the general input and im-
multiple fuel firing pacting combustioníefficiency calculations required for
other calculation forms are also contained here. Below
A.4.3 Form EFFc. This form provides for entering are supplementary comments to assist the user. Refer
the results of losses and credits that are not universally to Section 5 of the Code if more in-depth explanation
applicable to all fossil fired steam generators and are
is required.
usually minor. Refer to Section 5 for the definition of
the losses. For any unit to be tested, if the losses/
credits are applicable, it should be indicated whether
they were tested or estimated. The calculated or esti- Item 1 HHV - Higher Heating Value of Fuel,
mated result should be entered' where appropriate. It Btu/lbm As Fired. This item must be con-
is noted that it is not possible to identify all potential sistent with the fuel analysis in Item [30].
lossedcredits in a changing technology. This form When multiple fuels are fired simultane-
should also be used to record the results of losses and ously, this is the weighted average HHV
credits that are not currently identified. based on percent mass flow rate from
each fuel. (Refer to Section 5 . )
Item 2 UBC -Unburned Carbon, lbm/iûû Ibm
fuel from RES or SRBb Form. Also enter
A S COMBUSTION CALCULATIONS - in Item [30B].
INSTRUCTIONS FOR CMBSTN FORMS For gaseous and liquid fuels, this item
is normally zero. For solid fuels with ash
The combustion calculation forms are used to perform and/or when sorbent is used, completion
all combustion calculations. They are useful for normal of the residue calculation form, RES, is
--
power plant performance monitoring calculations and required if UBC is tested.

| ||| | || | ||
for efficiency calculations. Users will find this calcula- For general combustion and excess air
tion form readily adaptable to a spreadsheet program calculations, use a typical value for the
as well as a subroutine(s) for a larger program. type unit.
|
| |||
The calculations on this form include the following: Item 3 Fuel Flow, Klbm/h [4a] or [4b]. For some
|||| | || ||| | || ||
intermediate calculations (in particular

excess air for Oz. wet or dry basis when residue mass flow rates are mea-
O*, CO2,and SO2 on a wet or dry basis for excess air sured and/or when sorbent is used), the
(commonly used for a stoichiometric check on orsat calculations require a fuel flow. For the
||| | |---
and/or analyzer results) first interaction, the fuel flow is estimated.

a conversion of O*, CO2, and SO2 from a wet to dry or The calculations are reiterated using the
dry to wet basis calculated fuel flow until convergence is
a dry gas weight, used for efficiency calculations obtained.
a wet gas weight, used for energy balance calculations For the first estimate, the user may use
O dry and/or wet air weight measured fuel flow, Item [4a], or calcu-
a determination of air infiltration lated fuel flow, Item [4b], from measured
a calculation of corrected air heater exit gas temperature output and estimated efficiency. If the
(temperature excluding air heater leakage) operating characteristics of a unit are
O percent moisture in flue gas, used for determining en- known, the calculated fuel flow based on
thalpy of flue gas an estimated fuel efficiency is usually bet-
a percent residue in flue gas, used for determining of ter than the measured fuel flow.
enthalpy of flue gas (high ash fuels or when sorbent Item 4a Measured Fuel Flow, Klbm/h. Refer to
used) Item [3].
a fuel, residue, flue gas, and air mass flow rate when Item 4b Calculated Fuel Flow, Kib&. Refer to
input is known Item [3]. Calculated result, Option 4b,
a fuel analysis check based on theoretical air. This is a and used for subsequent efficiency calcu-
check on whether the fuel analysis is reasonable. Refer lation iterations when fuel flow is re-
to Section 5. quired.
168
~
STD=ASME P T C 4-ENGL 1998
Item 5 Output, MKBtu/h. Required to calculate type are usually averaged for efficiency
fuel flow, Option 4b, and used for subse- calculations but may be calculated indi-
quent efficiency calculation iterations vidually for more detailed analysis of in-
when fuel flow is required. dividual air heater performance and leak-
Item 6 Fuel Efficiency, % (estimate initially). age and the results averaged later. Refer
Required to calculate fuel flow, Option to Items [45] through [51] on EFFa for
4b, and used for subsequent efficiency separate air heaters with different flow
calculation iterations when fuel flow is rates.
required. Item 16 Air Temperature Entering Air Heater, OF,
Item 7 Moisture in Air, lbrdlbm Dry Air. This Primary/Secondary or Main. Refer above
item is required for the general gas and for multiple air heaters. Enter air temper-
air mass flow calculations and is required ature entering each air heater compatible
for excess air/02 calculations on a wet with format above. This temperature is
basis. Refer to Items [8] through [i i]. If used to calculate the corrected gas tem-
moisture in air is not measured, a standard perature leaving the air heater (excluding
value may be used. The standard US in- leakage). For a trisector air heater (two
dustry value is 0.013 Ibm H20/lbm dry air streams entering air heater with one
air (80°F ambient and 60% relative hu- gas stream leaving), enter the weighted
midity). average air temperature of the infiltrating
Items 8-1 1 These items are required to calculate air based on the expected air to gas leak-
moisture in air. Moisture in air may be age splits for each entering air stream
determined from relative humidity and supplied by the manufacturer (refer to
dry-bulb temperature and/or wet- and Item [ 18C] below).
||| | |---
dry-bulb temperature. Refer to Section 5 Item 17 O2Entering Air Heater, Primary/Second-
for calculation procedure. ary or Main. Enter the measured oxygen
|||| | || ||| | || ||
Item 12 Summation Additional Moisture Mea- content entering each air heater.
sure, Klbm/h. Enter any moisture intro- Item 18 O2Leaving Air Heater, Pnmary/Second-
duced into the aidflue gas in the spaces ary or Main. Enter the measured oxygen
| |||
above. When steam soot blowers are content leaving each air heater.
|
used, enter the average value for the test Item 18C Enter the weighted average air to flue
| ||| | || | ||
period. gas leakage split. This would normally
Item 13 Additional Moisture, lbd100 Ibm Fuel. be based on the manufacturer’s data.
Convert the additional moisture to an Ibm Fuel Analysis, % Mass as Fired. Enter
--
moisture per 100 lbm fuel basis. When in Column [30]. This analysis must corre-
atomizing steam is the only source of spond to the HHV in Item [ i]. For multi-
additional moisture, this value is fre- ple fuel firing, this is the composite analy-
quently measured and/or agreed upon sis. Refer to Item [i].
prior to a test on a lbm H20/100Ibm Item 19 Mass Ash, IbnúlOKbtu. The mass frac-
fuel basis, in which case this agreed upon tion of total residue is required at specific
value would be entered here. locationsto determine the enthalpy of flue
Item 14 Additional Moisture, IbnúlOKEitu. Con- gas. For low ash fuels when sorbent is
vert additional moisture above to I b d not used, the sensible heat of ash in flue
10KBtu basis. gas can be ignored when the enthalpy of
Item 15 Gas Temperature Leaving Air Heater, OF; flue gas is determined.
Primary/Secondaryor Main. This item is If sorbent is not used and the result of
used for the calculation of gas tempera- the calculation for Item [19] is less than
ture leaving the air heater(s) corrected for 0.15 Ibm/lOKBtu,enterzeroforItem[79]
no leakage (excluding leakage). If there for each column where O2 is entered.
is no air heater, this item may be ignored. If the result of Item [ 191 is greater than
If applicable, enter the measured gas tem- O. 15 IbnúlOKBtu or sorbent is used, enter
perature (including leakage). Space is the mass fraction of residue in the flue
provided for two types of air heaters. Val- gas with respect to the total residue leav-
ues for multiple air heaters of the same ing the steam generator envelope under
169
STD-ASME PTC 4-ENGL 1998 m 0759b70 ObLSLO8 OT7 m
Item [79] for each column where O2 is weight for efficiency corrected to contract conditions. If
entered. This iiormally can be calculated excess air is known, proceed to Item [6û] on CMBSTNc.
from Item [8] on the residue form (RES)
depending upon whether sorbent is used. LOCATION Enter description such as “AH IN,” “AH
For example, if there is 75% residue leav- OUT,”“SAH IN,” etc., in accordance
ing the air heater, enter 0.75 under Item with input from Item [16].
[79] for entering and leaving the air Item 50 Enter the measured flue gas temperature
heater. entering the air heater(s).
Items 20-25 These items are applicable only if sorbent Item 51 Enter the measured combustion air tem-
is used. Enter zero if not applicable. It is perature leaving the air heater@).
noted that any addition of solids other Item 52 Enter the flue gas O2entering and leaving
than fuel qualifies as sorbent for calcula- the air heater(s). This should be the sum
tion purposes. If applicable, the residue values entered on EFFa, Items [17A],
(RES) and sorbent (SRB) calculation [17B], [i8A], and [18B].
sheets must be completed and the results Item 53 Moisture in air. If O2 at location is on a
entered for these items. dry basis, enter zero. If O2 at location is
on a wet basis, enter the result of the
A.5.2 Form CMBSTNb calculation.
Item 54 Enter the appropriate value depending
Items 30-34 Complete calculations as indicated. The upon whether the O2 for the location is
term K refers to the constant in the col- on a wet or dry basis.
umn under the Item number. Refer to Item 55 If O2 at location is on a dry basis, enter
Section 5 for the significance of the indi- zero. If on a wet basis and there is addi-
vidual columns. If the sorbent calculation tional moisture (refer to Item [13]), per-
forms (SRB) were used, Items [31], [32], form calculation.
and [33] are the same as SRBa Items Items 5 6 5 8 These calculations are reduced to several
[16], [17], and [18], and the previously steps to simplify the calculation of excess
calculated results may be copied. air by using a calculator.
Item 35 Total Theoretical Air Fuel Check, Ib/ Item 60 The calculation process yields excess
IOKB. All fossil fuels have a statistical air, %.
theoretical air range that should be
checked to ensure that the fuel analysis A.5.3 Form CMBSTNc
is reasonable. Refer to Section 5. Item 60 Enter excess air calculated on CMBSTNb
A.5.2.1 Corrections for Sorbent Reactions and or, if combustion calculations are desired
Sulfur Capture for a specific excess air, such as correc-
tions to contract conditions, enter the
Items 40-44 The calculations are descriptive and self- known excess air.
explanatory. Enter zero for Items [40] Items 6 1 4 8 These items are used to calculate CO2
through [42] if sorbent is not used. and SO2 stoichiometrically, such as to
Items 46-48 Theoretical air expressed in different check orsat or analyzer readings and to
units. Calculations are in a logical pro- calculate O2 when excess air is known.
gression, and different units are required These items are not required for the re-
for convenience of other calculations. maining combustion calculations and
Item 49 Wet Gas from Fuel, IbdlOKB. This is may be skipped.
the mass of gaseous combustion products If the stoichiometric O,, CO2, and SO2
from fuel on an input from fuel basis. results are desired, complete items [62]
and [64] to obtain 9,CO2, and SO2 on
A.5.2.2 Calculation of Excess Air Based on Mea- a dry basis and items [63] and [65] to
sured O,. Items [50] through [60] on CMBSTNb are obtain Oz, CO2, and SO2 on a wet basis.
used to calculate excess air when O2 is measured. When orsat CO2 results are checked, the
The CMBSTN calculation forms may also be used to orsat CO2reading is actually CO2 + SO2
calculate 4, CO2, SO2, air, and gas weights when since the orsat CO2 sorbent also ab-
excess air is known, such as when calculating dry gas sorbs SOz.
i 70
-- | ||| | || | || | | ||| |||| | || ||| | || || ||| | |---
~
STD-ASME PTC ri-ENGL 1978 0759b70 Ob15109 T 3 3 W
A.5.3.1 Flue Gas Products, IbdlOKBtu Item 85 Enter the enthalpy of wet air based on
the temperature of the gas leaving the air
heater (in Item [83]) and the moisture in
Items 69-74 The mass of the products that make up air (in Item [7]).
wet flue gas on an IbdlOKBtu input Item 87 Enter the specific heat of wet flue gas
from fuel basis. based on the temperature of the gas leav-
Item 75 The mass of wet flue gas is the sum of ing the air heater (in Item [83]), moisture
the products in the wet flue gas on an in flue gas entering the air heater (in Item
l b d l OKBtu basis. [78E]), and residue in wet flue gas enter-
Item 76 The sum of water in the flue gas on an ing the air heater (in Item [81E]). If the
1bdlOKBtu basis. corrected temperature of the gas leaving
Item 77 The mass of dry flue gas is the difference the air heater is significantly higher than
between the mass of wet flue gas less the the measured gas temperature, use the
total mass of water in wet flue gas. average between the measured and cor-
Item 78 The moisture in wet flue gas expressed rected gas temperature to determine the
||| | |---
on a percent mass basis. This item is used mean specific heat of flue gas.
to determine the enthalpy or specific heat Item 88 Calculate the corrected air heater gas out-
|||| | || ||| | || ||
of wet flue gas. let temperature or gas temperature ex-
Items 79-81 Required to determine the enthalpy of cluding leakage. This is the temperature
wet flue gas. For gas, oil, and other low of the gas leaving the steam generator
| |||
ash fuels, these calculations may be omit- envelope. that is used for the energy bal-
|
ted. Refer to Item [19]. ance efficiency calculations.
| ||| | || | ||
Item 79 The mass fraction of residue in flue gas
at location with respect to the total residue
A.5.3.2 Air, Gas,Fuel Mass Flow Rates, Kìbm/h.
leaving the steam generator envelope.
--
These items are calculated after the efficiency calcula-
Refer to Item [19].
tions have been completed but are included on this form
Item 80 The mass of residue leaving the steam
since the calculations fall under the general category of
generator envelope on an 1bdlOKBtu
combustion calculations.
basis. It is the sum of the ash in fuel,
unburned carbon, and spent sorbent prod-
ucts. If residue is recycled from a point Item 90 Enter the input from fuel from the effi-
downstream of the location, the mass of ciency calculation form in million Btu/h.
recycled residue must be added. Items 91-93 Calculate the fuel rate, residue rate, and
Item 81 The mass fraction of residue in wet flue wet flue gas rate in Klbh.
gas, lbm/lbm wet gas. Item 95 Enter the percent excess air if calculating
Item 82 Leakage, % Gas Entering. This item is the total air weight to the boiler is desired.
used to calculate the air infiltration be- This item is commonly required to calcu-
tween two locations, for example, when late the weighted average air inlet temper-
the O2 entering and leaving the air heat- ature for determining efficiency when air
er(s) has been entered. Item [75E] is the is supplied from two sources such as pri-
wet gas weight entering and Item [75L] mary and secondary air fan. It may also
is the wet gas weight leaving as calculated be required to correct air resistance to
above. contract conditions. O2 (excess air) is
Items 83-88 Used to calculate the gas temperature usually measured at the boiler exit; most
leaving an air heater corrected for no units have some setting infiltration and/
leakage, or gas temperature excluding or seal air, and thus the calculated value
leakage. These items may be skipped if using the excess air leaving the boiler will
there is no air heater or temperature is be higher than the actual flow through the
not measured. forced draft fan(s). For air resistance and/
Item 83 Enter (from Item [ 151) the measured tem- or fan power corrections, an allowance
perature of the gas leaving the air heater. for setting infiltration may be desired.
Item 84 Enter (from Item [16]) the temperature Item 96 Calculate the total wet airflow based on
of the air entering the air heater. the excess air in Item [95].
171
ASME €‘TC 4-1998 NONMANDATORY APPENDIX A
A.6 GASEOUS FUELS - INSTRUCTIONS and enter the result on this line. The cal-
FOR GAS FORM culated result of the largest constituent
should be rounded so that the summation
The gaseous fuel calculation form is used to convert
of the constituents equals 100.00%.
a gaseous fuel analysis from a percent volume basis
Item 18 Density at 60°F and 30 in. Hg, lbdft’.
to a percent mass basis. The ultimate analysis of a
Calculation of the density is based on the
gaseous fuel is reported in terms of the as-fired fuel
sum of Column 4.
components (such as CH4, C2H6) on a percent volume Higher Heating Value, Btdft3. Calculate
Item 19
basis. The higher heating value of a gaseous fuel is
the higher heating value on a volume ba-
reported on a volume or Btu/ft3 basis. The calculations
sis. This is the total of Column 6 divided
in this Code require an elemental fuel analysis on a
by 100.
percent mass basis and a higher heating value on a
Item 20 Higher Heating Value, Btdlbm. The
mass or Btullbm basis. The components of the elemental
higher heating value is calculated as indi-
analysis are C, Ha, 02,N,, S, and H,Ov.
cated.
Item 1 Fuel Type. This item is provided to allow
the user to identify the fuel source.
Item 2 Ultimate Analysis, % by Volume. Enter A.7 UNBURNED CARBON AND RESIDUE
the percent by volume of each gaseous CALCULATIONS - INSTRUCTIONS FOR
component in Column 5. Space is pro- RES FORM
vided for additional components.
This form is used to calculate the weighted average
Item 3 Density of Constituent, Ibdft3. The ref-
of carbon in the residue, unburned carbon, and sensible
erence conditions for density are 60°F
heat of residue loss. When sorbent is used, this form
(15.6OC) and 30 in. Hg (762 mrn) in ac-
is used to calculate the weighted average of carbon
cordance with the standard referencetem-
and carbon dioxide in the residue. These results are
perature for reporting the higher heating
used in conjunction with the sorbent calculation forms
value of gaseous fuels.
to calculate unburned carbon and calcination fraction
Item 4 Density of Gas. Multiply Columns 2 and
of calcium carbonate.
3 to obtain the gas density of each con-
Determine where ash is removed from the unit, and
stituent.
enter the description under “Location.” Typical locations
Item 5 The higher heating value of each constit-
are furnace bottom ash (bed drains), economizer or
uent is provided. Refer to Item [3].
boiler hoppers, and multiclone rejects and fly ash leaving
Item 6 Higher Heating Value of Gas. Multiply
the unit.
Columns 2 and 5 to obtain the HHV of
It is necessary to know the quantities of ash leaving
each constituent.
the unit at each location in order to determine the
Items 7-12 Elemental Constituents,moled100 moles
weighted average of carbon (and carbon dioxide for
gas. Calculate the molar percentage of
units with sorbent) in the residue and sensible heat
the elemental constituents and enter the
loss for each location. There are several methods for
sum for each constituent on Line 14. The
determining the quantities of residue leaving each lo-
constant K refers to the constant in each
cation.
column and is the number of moles of
each elemental constituent in the fuel The mass of residue leaving each location may be
component. Note that water, HZOv, is measured, in which case the measured values for each
considered to be in the vapor state. location would be entered in Column 5.
Item 14 M W , Ibdmole. The molecular weight of 0 The residue at one or more locations may be measured
each elemental constituent is given on and the quantity at the other locations calculated by
this line. difference. For example, the quantity of residue leav-
Item 15 Mass,lbd100 moles. Calculate the mass ing the boiler may be measured by dust loading and
of each elemental constituent and enter the split of the remaining residue estimated for the
the result for each column of Line 16. other locations.
Item 16 Summation of Line 16. Enter the summa- The percent residue leaving each location may be esti-
tion Line 16. mated on the basis of typical results for the type of
Item 17 Analysis, % mass. Calculate the ultimate fuel being used and the method of firing. For example,
analysis of each elemental constituent for a stoker fired unit, 90% furnace bottom ash and
172
-- | ||| | || | || | | ||| |||| | || ||| | || || ||| | |---
STD-ASME PTC 4-ENGL 1998 9 0759b70 Ob15L1L b 9 1
10% fly ash leaving the boiler may be assumed. In percent residue split for each location. If
this case, the assumed residue split would be entered the residue split is estimated, enter the
in Column 8. The larger the total residue mass rate assigned value in this column. Refer to
andor the difference in carbon in the residue at each Item [ 5 ] .
location, the greater the uncertainty of both unburned Item 9 C Weighted Average, %. Calculate the
carbon and sensible heat loss, and thus the test. unburned carbon in residue for each loca-
tion and enter the sum under Item [9F].
Item 10 COz Weighted Average, %. Calculate the
Item 1 Ash in Fuel, %. Enter percent ash in fuel. carbon dioxide in refuse for each location
Item 2 HHV Fuel, Btu/lb as-fired. Enter the and enter the sum under Item [lOF].
higher heating value of the fuel as-fired.
Item 3 Fuel Mass Flow Rate, Kib&. Not re- A.7.1 Units Without Sorbent
quired if residue split is measured or mea-
Item 11 Unburned Carbon, lbd100 Ibm Fuel.
sured at all locations. When residue is
Calculate the average unburned carbon.
measured at some locations, the total resi-
This item is used on the combustion cal-
due rate is dependent upon fuel rate. Use
culation and efficiency forms.
measured or estimated fuel rate initially.
Item 20 Total Residue, lbd100 Ibm Fuel. The
Refer to Form CMBSTNa. It will be nec-
total residue is the sum of the ash in fuel
essary to recalculate the residue (RES)
and unburned carbon.
and sorbent (SRB) forms after comple-
tion of the efficiency calculations until A.7.2 Units With Sorbent
the efficiency result converges. For effi- Enter the average carbon, C, and carbon dioxide,
ciency calculations this is generally COz, in residue, Items [9F] and [lOF], on Form SRBa
within 1% of the fuel rate used for the (Items [4] and I[ 5 ] ) and complete the sorbent calculation
calculations. Refer to Subsection 5.7.3. forms.
Item 5 Residue Mass Flow, Kib&. If residue
split is estimated or measured at all loca- Item 11 Unburned Carbon, lbd100 lbm Fuel. En-
tions, enter the split in Item [8]. When ter the calculated value from Form SRBb,
residue is measured at some locations, Item [49].
enter the measured residue mass flow rate Item 20 Total Residue, lbd100 Ibm Fuel. Enter
for the applicable locations. Enter the to- the total residue calculated on Form
tal residue (from Item [21]) under Item SRBb, Item [50].
[5F]. Estimate the total residue, Item
[5F], initially from the sum of the sorbent A.73 Total Residue
flow rate plus Item [i] x Item [3]/100.
Item 21 Total Residue, Kib&. Calculate the to-
For locations where residue mass flow
tal residue in Kibmni. Compare Item [21]
rate was not measured, enter the esti-
to Item [5F]. Repeat Items [ 5 ] through
mated mass flow rate. This is calculated
[21] (including sorbent forms if applica-
from the differencebetween the total resi-
ble) until Item [5F] and Item [21] are
due mass flow rate, Item [5F], and the
within 2%.
sum of the measured mass flow rates
Item 22 Total Residue, IbdlOKBtu. Convert res-
times the estimated split for the remaining
idue to IbdlOKBtu input from fuel basis.
residue locations. The column for calcu-
lated residue mass flow rate is used if the A.7.4 Sensible Heat Residue Loss, %
residue splits are entered in Item [8].
Item 6 C in Residue, %. Enter the free carbon Item 24 Enter the temperature of the residue leav-
(carbon corrected for COz) in the residue ing the unit for each location and calcu-
for each location. late the enthalpy of residue for each tem-
Item 7 CO2 in Residue, %. Required only for perature. Using the residue splits in
units using sorbent. Enter the carbon di- Column 8, calculate the sensible heat of
oxide for each location. residue loss for each location.
Item 8 Residue Split, %. If the residue quantity Item 25 Sensible Heat Residue Loss, %. Enter the
is measured at all locations, calculate the summation of the loss for each location.
173
-- | ||| | || | || | | ||| |||| | || ||| | || || ||| | |---
~ -~~
STD.ASME PTC U-ENGL 1998 9 0759b70 ObLSll2 528 9
ASME ITC 4-1998 NONMANDATORY APPENDIX A
A.8 SORBENT CALCULATION SHEET - results. Refer to Section A.3 or Subsec-

MEASURED C AND CO, IN RESIDUE tion 5.7.3 for convergence tolerance for
different applications.
The sorbent calculation forms SRBa and SRBb are
Item 2 Sorbent Rate, Klbh. Enter the measured
used to calculate sulfur capture, calcination of calcium
sorbent mass flow rate.
carbonate (Caco,), unburned carbon (C), mass flow
+Item 3 Sorbenfluel Ratio. The sorbent-to-fuel
rate of spent sorbent and residue, and the calcium-to-
ratio (Ibm sorbentnbm fuel) is used to
sulfur molar ratio. These two forms are used in conjunc-
convert the sorbent mass flow rate to a
tion with the unburned carbon and residue calculation
fuel rate or input from fuel basis which
form for units with sorbent, RES. Sorbent Form SRBc
is used for all calculations related to input
is used to calculate the efficiency losses and credits
from fuel. It is calculated by dividing
related to sorbent, including losses and credits due to
Item [2] by Item [i].
sorbent chemical reactions and sulfur capture. The
Item 4 Carbon in Residue, %. This is the
sensible heat loss from residue, which includes spent
weighted average of carbon in all the resi-
sorbent, is calculated on Form RES.
due streams leaving the steam generator
The calculations are based upon measuring C in
envelope. Enter the result calculated for
the residue to determine unburned carbon, and carbon
Item [9F] on Form RES. For general per-
dioxide (COz) in the residue to determine percent
formance calculations when the C and
calcination of the Caco3 in the sorbent. As a result,
CO2in the residue are not measured, enter
the calculations on Forms SRBa and SRBb are iterative.
zero to indicate not measured.
It is necessary to estimate unburned carbon, Item [ 15B1,
Item 5 CO2 in Residue, %. This is the weighted
and percent calcination, Item [23A], initially and reiter-
average of carbon dioxide in all the resi-
ate until the estimated values agree within 2% of the
due streams leaving the steam generator
calculated values. It will be found that these items
envelope. Enter the result calculated for
converge readily.
Item [lOF] on Form RES. For general
Items marked with an asterisk (*) are the items that
performance calculations when the C and
are estimated initially and results are reiterated using
CO2in the residue are not measured,enter
the last calculated values.
--
zero to indicate not measured.

Items marked with a plus sign (+) are the calculatioh
Item 6 Moisture in Air, l b d b m Dry Air. Enter
| ||| | || | ||
results that must be recalculated after each iteration.

the moisture in air from CMBSTNa, Item
The results of this form are also required for general
[7]. This item is not required if the O2 and
combustiodefficiency calculations, such as for correc-
|
SO2analyses are measured on a dry basis.

| |||
tions to contract conditions or performance monitoring.

Items 7, 8 Sulfur capture is calculated from O2 and
|||| | || ||| | || ||
For general combustion/efficiency calculations when the

SO2 measured at the same location. The
C and CO2 in residue are not measured, enter typical
method of measurement should be on the
values for unburned carbon, Item [lSB], and calcination,
same basis, Le., wet or dry. Although this
Item [23A]. Typical values for sulfur capture may be
||| | |---
is not described, if they are not on the

used, or calculations of sulfur capture may be based
same basis, the conversion ratio from wet
on measured SO2 and 0 2 and a typical fuel analysis.
to dry may be assumed to convert the
For corrections to contract conditions, refer to Section 5.
constituent measured on a wet basis to a
dry basis and the calculations reiterated
A.8.1 Form SRBa
until the assumed wet-to-dry conversion
A.8.1.1 Data Required ratio agrees with the calculated ratio.
Item 7 SO2 Hue Gas. Enter the measured value
*Item i Fuel Rate, Wbh. Initially enter the mea- of SO2 in ppm in Item [7A] and convert
sured or estimated fuel mass flow rate. to percent and enter in Item [7B].
Refer to Form CMBSTNa. It will be nec- Item 8 O2 Flue Gas at Loc S02, %. Enter the
essary to recalculate the residue and sor- measured value of 0, measured at the
bent using the RES and SRB forms after same location as the SO2 above.
completion of the efficiency calculations Item 9 SO2 and O2 Basis Wet or Dry. Enter
until the estimated fuel flow used for “wet” or “dry,” depending upon the
these calculationsagrees within 1% of the method of measurement for Items [7]
fuel flow calculated from the efficiency and [8].
174
STD-ASME PTC 4-ENGL 1998 0759670 Ob15113 4b4
Item 10 Additional Moisture, lb/100 lb Fuel. En- A.8.2 Form SRBb

ter the total additional moisture from
A.8.2.1 Sulfur Capture Based on Gas Analysis
CMBSTNa, Item [13]. This item is not
required if Items [7] and [8] are measured
on a dry basis. Items 30-45 Calculate sulfur capture based on SO2
and 0, in the flue gas. These calculations
have been divided into several steps to
A.8.1.2 Combustion Products simplify the calculation of sulfur capture
when a calculator is used. For general
Item 15 Ultimate Analysis, % Mass. Enter the ul- combustion calculations, if sulfur capture
timate fuel analysis. Enter the estimated is estimated or assigned a value for cor-
value for unburned carbon, Item [15B]. rections to contract conditions, enter the
Item [15C] is the carbon burned, [15A] assigned value under Item [45] and skip
minus [ 15Bl. When carbon in the residue Items 1301 through 1401.
is measured, it will be necessary to repeat Items 3&33 If O2 and SO2 are measured on a dry
the calculations until the assumed un- basis, enter the values indicated in the
burned carbon is within 2% of the esti- ‘‘Dry’’ column. If measured on a wet ba-
mated value. sis, perform the calculations in the “Wet”
Items 1 6 1 8 Complete calculations as indicated. The column.
term K refers to the constant in the col-
umn under the item number. These items A.8.2.2 Unburned Carbon, Calcination, and
are the same as Items 1311 through [33] Other SorbentíResidue Calculations
from Form CMBSTNb. Refer to instruc-
tions for CMBSTNb for more details. +Item 47 SO3Formed, lb/l00 lb Fuel. Calculate the
SO3 formed in the calcium oxide (Ca0 +
A.8.1.3 Sorbent Products SO3) reaction to form Caso4 on a 100
Ibm fuel basis.
Item 20 % Mass. Enter the sorbent analysis on a +Item 48 Spent Sorbent, lb/100 lb Fuel. Calculate
percent mass basis. the mass of spent sorbent added less the
Item 21 M W . Molecular weight of the sorbent CO2 and H 2 0 released plus the SO3 in
products; used for calculation of Item the C a 0 + SO3 sulfur capture reaction to
1221. form Caso4
Item 22 Ca Mol/100 Ib. Calculate the moles of +Item 49 Unburned Carbon, lb/100 lb Fuel. Calcu-
calcium per 100 lbm sorbent (unshaded late the unburned carbon in fuel. If carbon
items) and enter the sum under Item [22I]. in residue is not measured, enter the esti-
This item is used to calculate the calcium- mated value from Item [ 15Bl.
to-sulfur molar ratio, Item [52]. +Item 50 Residue Rate, lb/100 lb Fuel. Calculate
*Item 23 Calcination Fraction. Enter the estimated the total mass of residue on a 100 lbm
calcination fraction for Caco3, Item fuel basis. Residue is the sum of the ash
[23A]. When CO2in residue is measured, in the fuel, unburned carbon, and spent
it is necessary to repeat the calculations sorbent.
until the assumed calcination fraction is +Item 51 Calcination, lb/lb CACO3. Calculate the
within 2% of the calculated value. mass fraction of Caco3 converted to
+Item 25 COz, lb/100 lb Sorbent. This item is the Cao. If CO2 in residue is not measured,
CO2 added to the flue gas from the sor- enter the estimated value from Item
bent. Complete the calculation for the un- [23A].
shaded items and enter the sum under Item 52 C d S Molar Ratio, Mols Ca/Mol S. Calcu-
Item [25I]. late the calcium-tesulfur molar ratio.
Item 26 H20, lb/100 lb Sorbent. This item is the This is an important operating parameter
H 2 0 added to the flue gas from the sor- when sorbent is used for sulfur capture.
bent. Complete the calculation for the un-
shaded items and enter the sum under Compare the calculated unburned carbon and calcina-
Item [26I]. tion fraction to the values estimated. Repeat the calcula-
175
-- | ||| | || | || | | ||| |||| | || ||| | || || ||| | |---
ASME pM3 4-1998
S T D O A S M E PTC 4-ENGL 3978 0759b70 ObL5LL4 3TO
-
tions of Items [15] through [51] marked with a plus Item 80 Credit Due to Sulfation, % fuel input.
sign (+) until estimate is within 2% of the calculated Calculate credit due to sulfation and enter
result. result on Form E m , Item [66], in Col-
Refer to the instructions for Form RES. Enter the umn B (%).
results of Item [50] above under Item [20] on Form Item 85 Credit Due to Sensible Heat from Sor-
RES and complete the calculations on Form RES. If the bent, MKBtuh. Calculate credit due to
residue mass flow rate was measured for some locations sensible heat from sorbent and enter re-
and calculated by difference for the remaining locations, sult on Form EFFb, Item [73], in Column
Item [21] on RES must be within 2% of Item [5F]. A (MKB).
If not, repeat the residue calculations, RES Items [5]
through [lo], revise Items [4] and [5] on SRBa, and
||| | |---
repeat the sorbent form calculations for the items marked
with a plus sign (+) until convergence is obtained.
A.9 OUTPUT - INSTRUCTIONS FOR FORM
|||| | || ||| | || ||
OUTPUT
A.8.3 Sorbent Calculation Form SRBc -Efficiency This form is used to calculate unit output. The form
Calculations consists of two parts. The first portion deals with the
| |||
calculation of output from the main steam or high-
|
Calculation of efficiency losses and credits related pressure side of the boiler. Provision is made for
| ||| | || | ||
to sorbent, including losses and credits due to sorbent calculation of superheater spray flow by energy balance
chemical reactions and sulfur capture, are provided for if the flow is not measured. For units with reheat, the
on this form. The sensible heat loss from residue, second portion of the form deals with the calculation
--
which includes spent sorbent, is calculated on Form of reheat steam flow and reheat output. For units with
RES. The calculation of average exit gas temperature two stages of reheat, the calculations for the second
requires that the combustion calculation forms, stage are similar to the first reheat stage except reheat-
CMBSTNa through CMBSTNc, be completed first. It 2 flow is calculated by subtracting the reheat-2 extraction
is suggested that this form be completed after completing and turbine seal flow and shaft leakage from the sum
the input for the efficiency calculation forms. of the cold reheat-1 flow plus reheat-1 spray water flow.
Enter all applicable measured flows, temperatures
Item 61 Sorbent Temperature, O F . Enter the tem- and pressures in the lightly shaded blocks. Determine
perature of the sorbent. Calculate h e en- the enthalpy for each applicable parameter and enter in
thalpy of sorbent (77'F reference temper- Column H. For the applicable high-pressure parameters,
ature) based on the constituents in the calculate the absorption, Q, with respect to the entering
sorbent in accordance with Section 5. For feedwater.
limestone, refer to calculations at bottom
A.9.1 High-Pressure Steam Output
of SRBC.
Item 62 Average Exit Gas Temperature (Exclud- Item 1 Feedwater. The steam mass flow
ing Leakage). Refer to Item [3] on effi- throughput is determined from either
ciency calculation Form EFFa. Enter en- measured feedwater flow or measured
thalpy of steam @ 1 psia (32°F reference steam flow with feedwater flow usually
temperature) under Item [62A], which is having the lowest uncertainty. When SH
the same as Item [3b] on Form EFFa. spray water is supplied from the feed-
Item 63 HHV Fuel, Btdlbm as fired. Enter the water, for purposes of accounting in these
higher heating value of fuel as fired. instructions, the feedwater flow in Item
Item 65 Water from Sorbent Loss, MKBtuh. Cal- [i] should not include SH spray water
culate water from sorbent loss and enter flow.
result on Form EFFb, Item [59], in Col- Item 2 SH Spray Water. When SH spray water is
umn A (MKB). supplied from feedwater, enter the flow,
Items 71-77 Losses from CalcinatiodDehydration, pressure, and temperature. The flow may
MKBtu/h. Calculate the losses for the in- be calculated by energy balance. Refer
dividual constituents in the sorbent and to Items 131 through [81. Note that when
enter the sum under Item [77] and on the spray water temperature is lower than
Form E m , Item [58], in Column A the feedwater temperature, the energy
(m). with respect to the feedwater, Q,is nega-
176
STD=ASME PTC 4-ENGL 1998 D 0757670 Ob15115 237 M
tive. This item is not applicable to units flow, temperature, and pressure, and cal-
where the spray water is from a sweet culate the enthalpy. It is recommended
water condenser internal to the steam the flow be measured rather than cai-
generator envelope. culated by energy balance due to the dif-
Items 3-8 These items are used to calculate SH ficulty of obtaining a representative
spray water by energy balance. If SH temperature downstream of the desuper-
spray is not measured, enter the applica- heater.
ble data and perform the calculations. Item 23 Cold Reheat Extraction Flow. Enter any
Items 9-14 Internal Extraction Flows. These are extraction flows between the point where
steadwater extraction flows internal to main steam flow (Item [ 181, Column W)
the steam generator and are considered was determined and the reheat desuper-
as part of the boiler output. These items heater inlet in addition to feedwater
are provided to calculate main steam flow heater extraction flow(s) and turbine seal
from feedwater flow (or feedwater flow flow and shaft leakages. This flow would
||| | |---
from main steam flow); therefore, only normally be an additional measured flow.
|||| | || ||| | || ||
the flows are required to calculate output. Item 24 Turbine Seal Flow and Shaft Leakage.
Provision for entering temperature and This item is normally estimated from the
pressure is provided should the user de- manufacturer’s turbine heat balances or
sire to calculate the absorption related to turbine test data.
| |||
these items. Items 25-29 FW Heater No. 1. The highest pressure
|
| ||| | || | ||
Items 15-17 Auxiliary Extraction Flows. These are feedwater heater is considered to be the
steam extraction flows that are considered No. 1 FW heater. Enter the feedwater
as part of the boiler output and are in flow, temperatures, and pressures indi-
addition to the output from main steam cated, and calculate enthalpy. The steam
--
calculated in Item [18]. extraction flow is calculated by energy
Item 18 Main Steam. When feedwater flow is balance in Item [29].
measured, main steam flow is the sum of Items 30-34 FW Heater No. 2. Applicable for units
the feedwater flow and SH spray water where the second point heater extraction
flow less the blowdown flow, internal exis from the cold reheat (usually first point
traction flows, and miscellaneous auxil- heater supplied from intermediate high-
iary extraction flows. pressure turbine extraction point). Enter
Item 19 High-pressure Steam Output. The high- the feedwater flow and temperatures and
pressure steam output is the sum of the pressures indicated, and calculate en-
energy in the main steam, internal extrac- thalpy. The steam extraction flow is cal-
tion flows, miscellaneous auxiliary ex- culated by energy balance in Item [34].
tractions, and energy added to the super- Item 35 Cold Reheat Flow. The cold reheat flow
heater spray water. Note that the term is calculated from the main steam flow
for the latter, Q2, is negative due to the less the feedwater heater extraction
method of accounting in Item [2]. flow(s), turbine seal flow and shaft leak-
ages, and any other miscellaneous extrac-
tion flows.
Item 36 Reheat Output. The reheat output is the
A.9.2 Units with Reheat
sum of the energy added to the cold reheat
flow and the energy added to the reheater
spray water flow
Item 20 Reheat Outlet. Enter the reheat outlet Item 37 Total Output. Total output is the sum of
temperature and pressure and calculate the high-pressure steam output plus the
the enthalpy. reheat steam output. Note that if there is
Item 21 Cold Reheat Entering Desuperheater.En- a second stage of reheat, the output for
ter the temperature and pressure upstream the second stage must be calculated by
of the reheat desuperheater and calculate following the same principles as for the
the enthalpy. first stage reheater and added to the total
Item 22 RH Spray Water. Enter the spray water output above.
177
~~ ~
STD-ASME PTC Li-ENGL 1778 0757b70 ObIISIIIIb II73
A.10 DATA REDUCTION WORK SHEETS - a percent of the reading or in the same
INSTRUCTIONS FOR DATA FORMS units as the measured parameter. Note
that the units must be the same as the
A.lO.l Form PREC, Precision Data Reduction
units for the average value of the mea-
Work Sheet
sured parameter. For spatially nonuni-
This form is used to average each data point with form parameters, enter the result of the
respect to time and calculate the standard deviation spatial distribution index, Item [43], on
for use in determining the precision component of Form INTAVG.
uncertainty. This form is also used to average each Items 2A,2B, Calculate the total positive and nega-
data point within a sampling grid before the average 3A,3B tive bias limit and enter the result.
for the grid is determined. One of these forms needs
to be completed for each measured parameter.
Item 1 Enter each data reading for a single data
point in the first column. This may be an
A.11 UNCERTAINTY CALCULATIONS -
INSTRUCTIONS FOR UNCERTAINTY
analog value or a digital value, such as
WORK SHEET FORMS
millivolts. If the value in Column 1 is a
digital value, convert it to an analog value The uncertainty work sheet forms are used to calculate
in Column 2. If the instrument has a cali- overall test uncertainty. These forms can be used to
bration factor, enter this in Column 3 and estimate pretest uncertainty or to calculate the as-
calculate the calibrated value and enter tested uncertainty. All other calculation forms should
in Column 4. be completed before the uncertainty calculations are
Item 2 Calculate the average value for the test performed. The user should refer to Section 5 of
period. the Code for details on the uncertainty calculation
Item 3 Calculate the standard deviation for this procedures. The user should refer to Sections 4 and 7
data point as indicated. Refer to Subsec- of the Code for details on uncertainty analysis as well
tion 5.2.4.1 for information on standard as guidance on determining precision and bias errors
deviation. for measured parameters.
A.ll.l Form UNCERTa - Uncertainty Work

A.10.2 Form BIAS - Bias Data Reduction Sheet No. 1
Work Sheet Two similar work sheets have been provided, one
This data sheet is used to account for and calculate for output and one for efficiency. Each work sheet
the bias limit for each measurement device, which form contains the input information for data reduction
includes ail the instrument components required for the and information required for determination of the preci-
sion component of uncertainty. As noted on the form,
--
measurement. Therefore, if pressures are read by two

different qualities of pressure transducers or some ther- this work sheet is set up for spatially uniform parame-
| ||| | || | ||
mocouples are read with an automated voltmeter and ters, i.e., parameters which vary with time only. Form
others read with a hand-held potentiometer, more than INTAVG should be completed first for spatially nonuni-
form parameters to obtain input for this form.
|
one data sheet would be required for both pressure

| |||
and temperature. Refer to Section 4 for suggestions on

|||| | || ||| | || ||
what should be considered and typical values. Items a-z Measured Parameters. These items
should include all parameters which are
Item 1 List all of the potential sources of bias measured and/or estimated for use in cal-
error. For spatially nonuniform param- culating output or efficiency (or any other
||| | |---
eters, such as temperaturegrids in large calculated result such as fuel flow).

ducts, include the spatial distribution Item 1 Average Value. Enter the average value
index to account for the finite coverage of each measured parameter from Form
of the grid. PREC, Item [2], or Form INTAVG,
Items 2, 3 Enter agreed upon values for both posi- Item [40].
tive and negative bias. Two columns Item 2 Standard Deviation. Enter the standard
are provided for each positive and neg- deviation of each measured parameter
ative bias. The bias may be entered as from Form PREC, Item [3].
178
S T D - A S M E PTC ‘4-ENGL 1998 0759b70 Ob15117 OOT
BIAS Sheet Enter the BIAS Sheet Number. The same Item i0 Recalculated Efficiency. Enter the recal-
Number BIAS data can often be used for measured culated efficiency (or other calculated
parameters using similar instrumentation. item such as output) based on the incre-
Item 3 Total Positive BIAS Limit. Enter the ap- mental change in the measured parameter
plicable positive bias information from from Item [7]. The average value of all
the BIAS work sheet. other measured parameters should not
Item 4 Total Negative BIAS Limit. Enter the a p change during the recalculation for each
plicable negative bias information from measured parameter.
the BIAS work sheet. Item 11 Absolute Sensitivity Coefficient. Calcu-
Item 5 Number of Readings. Enter the number late the absolute sensitivity coefficient in
of times each parameter was measured accordance with the equation.
during the test period. Item 12 Relative Sensitivity Coefficient. Calcu-
Item 6 Calculate the precision index for each late the relative sensitivity coefficient in
measured parameter in accordance with accordance with the equation.
the equation. If Form INTAVG was used, Item i 3 Precision Index of Result Calculation.
enter the result from Item [41]. Enter the product of Items [ 1i] and [6].
Item 7 Degrees of Freedom. The degrees of free- Item 14 Overall Degrees of Freedom Contribu-
dom for each measured parameter is one tion. Calculate the numerator of Eq.
less than the number of readings. If Form (5.16-5) in accordance with the equation.
INTAVG was used, enter the result from Item 15 Positive Bias Limit of Result. Calculate
Item [42]. the positive bias limit of result using the
Item 8 Percent Change. Enter the percent change equation shown. This converts the per-
in the average value of each measured centage bias numbers to the measured
parameter. The recommended percent units for each measured parameter.
change is 1.0% (1.01). Item 16 Negative Bias Limit of Result. Calculate
Item 9 Incremental Change. Calculate the incre- the negative bias limit of result using the
mental change for each measured param- equation shown. This converts the per-
eter in accordance with the equation. If centage bias numbers to the measured
the average value of the measured param- units for each measured parameter.
eter is zero, enter any small incremental Item 20 Base Output or Efficiency. Enter Item
change. It is important that the incremen- [37] from Form OUTPUT or Item [80]
tal change be in the same units as the from Form EFFb, calculated with the
average value. average value of all measured param-
eters.
A.11.2 Form UNCERTb - Uncertainty Work Item 21 Precision Index of Result. Calculate the
Sheet No. 2 precision index of the result in accord-
ance with the equation.
||| | |---
Item 22 Overall Degrees of Freedom. Calculate
Two similar work sheets are provided, one for output
|||| | || ||| | || ||
the overall degrees of freedom in accord-
and one for efficiency. Each work sheet form contains ance with the equation.
the information required to calculate total uncertainty. Item 23 Student’s ?-Value. Enter the Student’s r-
The nomenclature used on these work sheets refers to value determined from Table 5.16-1 in
| |||
output and efficiency; however, the sheet can be used the Code.
|
for any calculated item such as fuel flow, calcium/ Item 24 Precision Component of Uncertainty.
| ||| | || | ||
sulfur ratio, etc. Calculate the precision component of un-

certainty in accordance with the equation.
Items a-z Measured Parameters. These items Items 25, 26 Positive and Negative Bias Limit of Re-
--
should include all parameters which are sult. Calculate in accordance with the
measured and/or estimated for use in cal- equation for each item.
culating efficiency (or any other calcu- Items 27, 28 Total Positive and Negative Uncertainty.
lated result such as output). These param- Calculate the final positive and negative
eters should correspond to the items on uncertainty result in accordance with the
Form UNCERTa. equation for each item.
179
STDmASME PTC 4-ENGL 3998 0759b70 Obi15118 Tlib =
ASME PM3 4-1998 NONMANDATORY APPENDIX A
A.113 Form INTAVG, Uncertainty Work Sheet dom equation for each grid point in ac-
No. 3 -
Spatially Nonuniform Parameters cordance with the equation.
Item 39 Spatial Distribution Index Calculation.
This work sheet form contains the input information calculate a component of the spatial dis-
required for the data reduction of each grid point as tribution index in accordance with the
well as the information required for determination of equation.
the precision component of uncertainty and the spatial Item 40 Average Value of Grid. Calculate the av-
distribution index for spatially nonuniform parameters. erage value of the grid measurement in
This includes any parameter which varies with both accordance with the equation.
space and time such as the temperature in a large duct. Item 41 Precision Index of Grid. Calculate the
On large units, there may be more than one flue or precision index of the grid in accordance
duct, such as two or more air heater gas outlets. This with the calculation.
sheet should be filled out for each flue or duct and Item 42 Degrees of Freedom for Grid. Calculate
the average result of each flue or duct then averaged the degrees of freedom for the grid in
together. Refer to Section 5.13 for considerationsregard- accordance with the equation.
ing averaging multiple ducts. This form is set up for Item 43 Spatial Distribution Index for Grid. Cal-
averaging using the multiple midpoint rule for the culate the spatial distribution index for
integrated average. Refer to Section 5 for other types the grid in accordance with the equation.
of integrated averaging. Include the result with the biases on Form
BIAS.
Item 30 Number of Points Wide. Enter the num- Item 44 Bias for Integrated Average. Enter the
ber of grid points in the horizontal (X) bias based on the method used for de-
direction. termining the integrated average. Refer
Item 31 Number of Points High. Enter the number to Sections 5 and 7 of the Code.
of grid points in the vertical (Y)direction. Item 45 Bias for No Flow Weighting. Enter the
Item 32 Number of Points Total. Enter the total agreed upon bias if no flow weighting
number of grid points. is used.
Item 33 Number of Readings per Point. Enter the Item 46 Bias for Thermocouple Type. Enter the
number of measurement readings rec- appropriate bias based on the type of in-
orded at each grid point from Form strumentation used to measure the tem-
PREC. perature.
||| | |---
Item 34 Degrees of Freedom per Point. The de- Item 47 Estimated System Bias. Enter the esti-
grees of freedom per point is one less mated system bias. A value of 0.1% of
|||| | || ||| | || ||
than the number of readings. the average is recommended.
Grid Point Identify each grid point location. Item 48 Estimated Total Bias of Grid. Calculate
Item 35 Average Value. Enter the average value, the total bias of the grid from Items [U]
| |||
with respect to time for each grid point through [47].
|
from Form PREC. After this form is completed, Items [40] through
| ||| | || | ||
Item 36 Standard Deviation. Enter the standard [42] and [48] should be entered on Form UNCERTa,
deviation with respect to time for each Items [i], [6], [7], and [3] and [4], respectively, and
grid point from Form PREC. treated the same as spatially uniform parameters starting
--
Item 37 Precision Index. calculate the precision with Item [8]. For units with more than one duct per
index for each grid point in accordance measured parameter, the parameter, precision index,
with the equation. and spatial distribution must be averaged and that result
Item 38 Degrees of Freedom Calculation. Calcu- entered on Form UNCERTa. Refer to Section 5.13
late a component of the degrees of free- regarding air and gas temperatures.
180
~
STDmASME PTC 4-ENGL 1998 m 0759b70 ObL5119 982 m
NONMANDATORY APPENDIX A ASh4E pM3 4-1998
FORM EFFa EFFICIENCY CALCULATIONS

Data Required
Average Entering Air Temp
||| | |---
|||| | || ||| | || ||
| |||
|
| ||| | || | ||
--
47 Flue Gas Temp Lvg Sec AH, F CMBSTNc C8811 I 48 I Total Gas Ent Air Htrs, Klb/hr CMBSTNc C931 I
49 Flue Gas Flow Ent Pri Air Htr, Klb/hr C401 x (C37Bl - C35Bl)/(C45Bl - C46B1)
50 Flue Gas Flow Ent Sec Air Htr. Klb/hr C481 - C491 I
I 51 I Averaqe Exit Gas Temoerature. F (C46Al x C491 + C471 x C501)/[481 I
I
Iteration of flue gas split, % primary AH flow Initial Estimate I I Calculated I I
NAME OF PLANT ASME PTC 4 MASTER FORM IUNIT NO.
TEST NO. DATE I LOAD
(TIME START: END: JCALC BY I
IDATE
ISHEET OF I
181
~~ ~ ~
STD-ASME PTC 4-ENGL 1798 0757670 Ob35L20 bT4
LOSSES, YO Enter Calculated Result in YOColumn [BI A( MK8 BI Oh
60 Dry Gas C101 x C3Al 1100

X I100
Water from H2 Fuel C121 x (E361 - ClAl) I 100
x ( - 45) 1 1 0 0
Water from H20 Fuel C131 x (C3Bl - ClAl) I100
x ( - 45) 1100
Water from H20v Fuel C141 x C3C1 1100
X I100
65 Unburned Carbon in Ref C181 x 14500 I C191 = x 14500 I

66 Sensible Heat of Refuse - from Form RES
67
- Hot AQC Equip (C201 x (CSAI - C6AI) - (C221- C201) x (C6B1 - C6C1)) 1 1 0 0
I 68 IOther Losses. % Basis - from Form EFFc Item C1101 I I I

I 69 ISummation of Losses. % Basis I I I
I LOSSES. MKBtu/hr Enter in MKB Column CAI I ~.
r- ~~
75 Surface Radiation and Convection - from Form EFFa Item C321

76 Sorbent Calcination/Dehydration - from Form SR8c Item C771
77 Water from Sorbent - from Form SRBc Item C651
78
79
80 Other Losses, MKBtu/hr Basis - from Form EFFc Item Ci111
81 Summation of Losses, MKBtu/hr Basis
c-] Moisture in Air C161 x C2Bl I 1 0 0

x I100 I I
% (100 - C691+ C901 1 x C301 I( C301+ C811 - C981 )

+ +
NAME OF PLANT ASME PTC 4 MASTER FORM UNIT NO.

TEST NO. DATE LOAD
TIME START: END: CALC BY
DATE
SHEET OF
-- | ||| | || | || | | ||| |||| | || ||| | || || ||| | |---
~
~~
STD.ASME PTC 4-ENGL 1798 m 0759b70 Ob15LZL 530 m
NONMANDATORY APPENDIX A ASME I'TC 4-1998
FORM EFFc EFFICIENCY CALCULATIONS

Other Losses and Credits
The losses and credits listed on this sheet are not universally applicable to all
fossil fired steam generators and are usually minor. Losseskredits that have
not been specifically identified by this Code but are applicable in accordance
with the intent of the Code should also be recorded on this sheet.
Parties to the test may agree to estimate the losses or credits in lieu of
testing. Enter a 'T' for tested or 'E' for estimated in the second column, and
result in appropriate column. Enter the sum of each group on Form EFFb.
Refer to the text of PTC 4 for the calculation method.
Itm I T or E ILOSSES, % Enter Calculated Result in % Column [ B I 1Al MKB IBI YO

10A CO in Flue Gas
10B Formation of NOx
.1oc Pulverizer Rejects
.10D Air Infiltration
.10E I Unburned Hydrocarbons in Flue Gas I
.1OF 1 I l
.1OG I I I
110 1 (Summation of Other Losses, Yo Basis
LOSSES, MKBtulhr Enter in MKB Column CAI

1llA I IWet Ash Pit I
Sensible Heat in Recycle Streams - Solid
CREDITS, % Enter Calculation Result in YOColumn Ci31

112A I
!Summation of Credits. YO Basis I I
CREDITS. MKBtuhr Enter Result in MKB Column CAI
113A I I Heat in Additional Moisture (external to envelooe) I l I
1138
113 Summation of Credits, MKBtuhr Basis
~~~~

DATE
SHEET OF
183
-- | ||| | || | || | | ||| |||| | || ||| | || || ||| | |---
STD-ASME PTC 4-ENGL 1998 0757b70 Ob15122 i177
ASME FTC 4-1998 NONMANDATORY APPENDD( A
FORM CMBSTNa COMBUSTION CALCULATIONS
||| | |---
|||| | || ||| | || ||
| |||
|
| ||| | || | ||
--
13 IAdditional Moisture, lbm/100 Ibm Fuel 100 x C121 / C31
14 IAdditional Moisture. Ibm/lO KBtu C131 / (C11 / l o o )
I I I f Air Heater (Excl StmNVtr Coil) Enter followinq I
I 15 IGas Temp Lvg AH, F Primary / Secondary or Main 11581 I15AI
I
16 Air Temp Ent AH, F Primary / Secondary or Main 168 16A
17 02 Entering Air Heater Primary / Secondary or Main 178 17A
18 02 Leaving Air Heater Primary / Secondary or Main 188 18A
18C Pri air to gas/Sec air to gas leakage split for Trisector Type AH I 18C I
Fuel Analysis, % Mass as fired - Enter in C d C301
19 Mass Ash, IbWlOKBtu 100 x C3OJl/ C11

I IIf mass of ash (Item C191) exceeds 0.15 IbWlOKBtu or Sorbent I
(utilized, Enter Mass Fraction of Refuse in Col C791 for each location
1
SORBENT DATA (Enter O if Sorbent not Used)
20 Sorbent Rate, Klbm/hr
21 CO2 from Sorbent, lbm1100 Ibm Sorb from SRBa Item C2511
22 H20 from Sorbent, lbrd100 Ibm Sorb from SRBa Item C26Il
23 Sulfur CaDture, Ibrdlbrn Sulfur from SRBb Item C451
24 (Spent Sorbent, lbW100 Ibm fuel Ifrom SRBb Item C481
25 ISorWFuel Ratio, Ibm SorWlbm Fuel IC201 / C31
NAME OF PLANT ASME PTC 4 MASTER FORM UNIT NÖ.

TEST NO. DATE LOAD
DATE
SHEET OF
184
FORM C M BSTNb COM BUSTION CALC U LATIONS

COMBUSTION PRODUCTS
o] Ultimate 9 Theo Air F 4 Dry Prod F 4 Wet Prod F 3 H 2 0 Fuel
Analysis lbm/100 Ibm Fuel Mo11100 Ibm Fuel Mo1/100 Ibm Fuel Ib d l OK B
Yo Mass C301 x K C301 / K C301 / K C301 x WíC11/1001
35 /Total The0 Air Fuel Check, Ib/lOKB (C31M1 + C30Bl x 11.51) / (C11 / l o o )
I I
CORRECTIONS FOR SORBENT REACTIONS AND SULFUR CAPTURE
40 CO2 from Sor lb/100 Ib fuel C211 x C251
41 H 2 0 from Sor lb/lOO Ib fuel C221 x C251
42 SO2 Reductio Mo11100 Ib fuel C32Dl x C231
43 Drv Prod Com Mo1/100 Ib fuel C32Ml + C401/ 44.01 - C421
1
54 Drymet Products Comb C431 C441
55 ]Additional Moisture O C131/18.015
56 C471 x (0.7905 + C531)
57 Summation C541+ C551 + C561
58 20.95 - C501 x (1 + C531)
~~
TEST NO. D A IE LOAD

DATE
SHEET OF
185
-- | ||| | || | || | | ||| |||| | || ||| | || || ||| | |---
ASME PTC 4-1998 NONMANDATORY APPENDX A
FORM C M BSTNc GENERAL COMBUSTION CALCU LATIONS
||| | |---
|||| | || ||| | || ||
| |||
|
| ||| | || | ||
--
91 Fuel Rate, Klbkr 1000 x C901/~11
92 Residue Rate, Klbkr C801 x C901/10 I I I
93 Wet Flue Gas, Klb/hr C751 x C901/10
I
95 Excess Air Lvg Blr, % I As Applicable from C601
96 ITotal Air to Blr, Klbmkr I (1 + C951/100) x (1 + C71) x E481 x C901/10
TEST NO. DATE LOAD
T I M E START: END: CALC BY
I DATE ~ ~
I I SHEET OF
186
STD-ASME PTC 4-ENGL 1998 0759b70 ObLSL25 L B b
FORM GAS GASEOUS FUELS

1 I Fuel Type
I
14 MW, Ibdrnole 12.01 2.0161 32.00) 28.021 32.061 18.02
I
15 Mass, l b d 1 0 0 moles C131 x C141 I I
1
16 Summation Line C161
17 IAnalysis, Oí0 Mass 100 xC151/Cl61 I I
18 I Density at 60°F and 30 in. Hs Ibm/cu ft C41/100 I
1
19 Higher Heating Value, Btu/cu f t C61/100
I
20 Higher Heating Value, Btu/lbm C181/C191
I NAME OF PLANT ASME PTC 4 MASTER FORM 1 UNIT NO. I

TEST NO. DATE 1 LOAD
TIME START: END: ICALC BY
1 I SHEET OF I
187
-- | ||| | || | || | | ||| |||| | || ||| | || || ||| | |---
FORM RES UNBURNED CARBON & RESIDUE CALCULATIONS
1 IAsh in Fuel, Yo from Form CMBSTNb C3OJ1 I 12 HHV Fuel, Btu/lb as fired
3 IFuel Mass Flow Rate. Klbm/hr from Form CMBSTNa C4bl from Form CMBSTNa C11
3 Residue Mass Flow 4 1J CO2 8J Residue Split % 24 CO2
IAIFurnace
Location
I
Input
Klbmlhr
I
Calculated
Klbmkr
I
in Residue
%
I
in Residue
O/,
l
Inwt I
I
Calculated
100 x C511C5F1
I
Wtd Ave O h
C61 x C811100
I
Wtd Ave Yo
C71 x C811000
I
B Econ 1 I I I 1
UNITS WITHOUT SORBENT

I
11 Unburned Carbon, l b d 1 0 0 Ibm Fuel IC11 x C9F1/(100 - C9Fl) I 0.001
I
20 Total Residue, l b d 1 0 0 Ibm Fuel IC11 + C111 I 0.00
UNITS WITH SORBENT

d Enter average C and CO2 in residue, C9Fl 8, C1OF1 above or SRBa (Items C41 & 151) and complete Sorbent Calculation Forms.
1
11 Unburned Carbon, l b d 1 0 0 Ibm Fuel Ifrom Form SRBb Item C491 I
I
20 Total Residue, l b d 1 0 0 Ibm Fuel Ifrom Form SRBb Item C501
TOTAL RESIDUE
21 ITotal Residue, Klbdhr C201 x C31/100
22 /Total Residue, IbdlOKBtu 100 x C20l/C21
23 I SENSIBLE HEAT RESIDUE LOSS, %

C81, x C221, x H Residue, 11000 Loss
Location YO Ibm1lOKBtu Btu/lbm YO
\A\Furnace I I X X 110000 I
IBIEcon I I X X /10000 I ~
C Precipitator X X 110000
D X X /10000
E X X /10000
I H residue = 0.16 x T + 1.09E - 4 x TA2 - 2.843E - 8 x T*3 - 12.95

~~

TEST NO. DATE LOAD
IDATE
t /SHEET OF
i 88
-- | ||| | || | || | | ||| |||| | || ||| | || || ||| | |---
STD-ASME PTC 4-ENGL 1996 0759b70 Ob15L27 T59
FORM SRBa SORBENT CALCULATION SHEET

Measured C'and CO2 in Residue
DATA REQUIRED
1 \Fuel Rate, Klbm/hr frm CMBSTNa C4bl I * 141Carbon in Residue. YO from Form RES C9Fl 1
2 Sorbent Rate, Klbmhr frm CMBSTNa C201 51C02 in Residue, % from Form RES ClOFI
3 SorblFuel Ratio c21/c11 + 6 I Moisture in Air, IWlb Dry Air frm CMBSTNaC71
7 SO2 Flue Gas, ppm 7~ 1 C7Al/ï0.000 Oh 178
8 ( 0 2 Flue Gas O LOCS02, % I 191SO2 & 02 Basis Wet(1) or Dry(0) 1
10 IAdditional Moisture, lb1100 Ib Fuel (CMBSTNa, Item C131)
item C11 - Use measured or estimated value initially. Recalculate after
boiler efficiency has been calculated until estimated value is within 1%of calc.
Enter fuel analysis in Col C151.
Enter sorbent analysis in Col C201.
* Estimate Unburned Carbon C15B1, and Calcination C23Al initially.
Reiterate until estimated value is within 2 % of calculated value.
+ Items that must be recalculated for each iteration.
COMBUSTION PRODUCTS
from CMBSTNb C301

--
| ||| | || | ||
|
| |||
|||| | || ||| | || ||
IMITOTAL
I 1171 + li81 I
||| | |---
2
o
J 4 4 Ca 231 J
4
2 251 CO2 26) H20
MoV100 Ib Calcination lb/lOO Ib Sorb lb/lOO Ib Sorb
Y' Mass MW C20l/C211 Fraction MW C221 x C231 x C241 C221 x C231 x C241
NAME OF PLANT ACME PTC 4 MASTER FORM UNIT NO.

TEST NO. DATE LOAD
I I DATE I
I SHEET
~ _______~
I OF I
189
ASME ITC 4- 1998 NONMANDATORY APPENDIX A
FORM SRBb SORBENT CALCULATION SHEET

Measured C and CO2 in Residue
30 Moisture in Air MO
S
M
IIOI DA 0.0 C61 x 1.608
31 Additional Moisture 0.0 [101/18.015
32 Products Combustion Fuel C17Ml C17Ml + C18M1 +
I I
||| | |---
I
33 H20 Sorb C31 x C2611/18.016 0.0 Calc
|||| | || ||| | || ||
135 I (0.7905 + C301) x Cl6M1/28.963 I+ I
I
36 Summation E311 thru C351 +
- 37 . 1.0 - (1.0 + C301) x C81120.95
I 1l
| |||
138 I (0.7905 + C301) x 2.387 - 1.0 I
I +
|
39 C7Bl x C361/C17DI/C371
| ||| | || | ||
--
UNBURNED CARBON, CALCINATION AND OTHER SORBENT/RESIDUE CALCULATIONS
1
47 SO3 Formed, IW100 Ib Fuel C451 x C17D1 x 80.064 +
48 ISwnt Sorbent. IW100 Ib Fuel C471 + (100- C2511 - C26Il) X C31 I+
49 Unburned Carbon, lb/100 Ib Fuel (C481 + C15J1) x C41/(100 - C41) +
50 Residue Rate, lb/100 Ib Fuel C491 + C481 + C15J1 +
51 Calcination, Ib/lb CaC03 1- C501 x C51 x 0.0227/C2OAI/C31 +
I52 1 CdS Molar Ratio. Mols CalMol S C31 x L2211 x 32.0646/C15Dl I I
Initial Est Calculated
I C23Al
Calcination, Mol C02/Mol CaC03 IC511
I
I
Enter result of Item C501 on Form RES, Item C201.
I f residue mass flow rate not measured at all locations, recalculate
II
I RES and SRBa and SRBb until converaence on refuse rate of 2%. I
~ _ _ _ ~
NAME OF PLANT ASME PTC 4 MASTER FORM I UNIT NO.

TEST NO. DATE LOAD
DATE
I ISHEET OF I
190
NONMANDATORY APPENDK A ASME PTC 4-1998
FORM SRBc SORBENT CALCULATION S H E E T

Efficiency
1 I Reference Temperature, F I
77 I60A EnthalDy Water (32 F Ref) 45
. Sorbent Temperature, F I I
I61A Enthalpy Sorbent (77 F Ref)
! Ave Exit Gas Temp (Excl Lkg) I
I62A Enthalpy Steam O 1 PSIA
I HHV Fuel, Btu/lbm as fired
LOSSES MKBtunir
Water from Sorbent C21 x C2611 x (C62Al - C60A1)/100000
X x ( - )/100000
CalcinatiodDehydration
1 ICaC03 ICZOAI x C23Al x C21 x 0.00766 = 0.00 x 0.00 x 0.00 x 0.00766
2 Ca(OH12 C2OBl x 1.0 x C21 x 0.00636 = 0.00 x 1.0 x 0.00 x 0.00636
3 MgC03 C2OC1 x 1.0 x C21 x 0.00652 = 0.00 x 1.0 x 0.00 x 0.00652
4 Mq(OH)2 C20Dl x 1.0 x C21 x 0.00625 = 0.00 x 1.0 x 0.00 x 0.00625
51 I I
I
7 Summation of Losses Due to CalcinatiodDehydration SUM C711 - C761
CREDITS, %
4 Suifation 6733 x C451 x Cl5DI I C631
CREDITS, MKBtuhr
5
J Sensible Heat from Sorbent C21 x C6lAl / 1000
X / 1000
- See text for other sorbents

Enthalpy of Limestone
HCAC03 = C611 x (0.179 + 0.1128E - 3 x C611) - 14.45
x (0.179 + 0.1128E - 3 x ) - 14.45
C61A1 = (1 - C20El/ 100) x HCAC03 + C20E1 x (C611- 77) / 100

= (1 - /loo) x + x ( -77) / l o o
JAME OF PLANT ASME PTC 4 MASTER FORM UNIT NO.

-EST NO. DATE LOAD
YME START: END: CALC BY
DATE
SHEET OF
191
-- | ||| | || | || | | ||| |||| | || ||| | || || ||| | |---
~
STDmASME PTC 4-ENGL 3998 0759b70 Ob35330 543
FORM OUTPUT
Q
W T P H ABSORPTION
FLOW TEMPERATURE PRESSURE ENTHALPY MKBtuIhr
--
| ||| | || | ||
|
| |||
15 Aux Steam 1
|||| | || ||| | || ||
16 Aux Steam 2
17
18 MAIN STEAM
1 1 9 1 ~PRESS
1 ~ ~ STEAM OUTPUT I O18 + O 2 + O9 throuah 017 I
||| | |---
29 I F W HEATER NO. 1 FLOW IW25 x (H26 - H25)/íH27 - H28) ~~.

FW HEATER NO 2
34 FW HEATER NO. 2 FLOW IW30 x C(H31 - H30)- W29 x (H28 - H33)l/(H32 - H33)
35 COLD REHEAT FLOW I W l 8 - W23
- W24 - W29 - W34
36 REHEAT OUTPUT W35 x (H20 - H21) + W22 x (H20 - H22)
37 TOTAL OUTPUT Pl9 + Q36
TEST NO. DATE LOAD
I DATE
SHEET OF
192
STD-ASME PTC 4-ENGL 1998 W 0759b70 Ob15131 4 8 T D
NONMANDATORY APPENDIX A ASME 4-1998
FORM PREC PRECISION DATA REDUCTION WORKSHEET
I Measured Parameter:
I
--
| ||| | || | ||
|
| |||
|||| | || ||| | || ||
||| | |---
I
2 Average Value (Clal + Clbl + Clcl + . . . Clz1)lz
3 Standard Deviation
( ( l / ( z - 1)) x ((Clal - C21)"2 + (Clbl - C 2 P 2 + . . . + (Cl21 - C21)*2))41/2)
N A M E OF PLANT ASME PTC 4 MASTER FORM U N I T NO.

TEST NO. DATE LOAD
DATE
SHFFT OF
193
STD.ASME PTC 4-ENGL 1’3’38 M 075’3670 ffbit5it32 3Lb M
FORM BIAS BIAS DATA REDUCTION WORKSHEET
* This is a percent of reading

TEST NO. DATE LOAD
DATE
SHEET OF
194
-- | ||| | || | || | | ||| |||| | || ||| | || || ||| | |---
--
| ||| | || | ||
|
| |||
|||| | || ||| | || ||
||| | |---
STDmASME PTC 4-ENGL 1998
0759670 0615133 252 -
ASME VIY: 4-1998
195
STDOASME PTC Y-ENGL L998 0759b70 ObL5L311 399
196
-- | ||| | || | || | | ||| |||| | || ||| | || || ||| | |---
STD-ASME PTC U-ENGL 1998 W 075qb70 Ob15135 0 2 5
NONMANDATORY APPENDIX A ASME PTC 4- i N a
LL
O
I-
J U
-Lu
C I
i
æ
Lu
+
ct
6
I-
V)
Lu
z
-
I-
197
-- | ||| | || | || | | ||| |||| | || ||| | || || ||| | |---
0759bïO Ob15L3b TbL 9
ASME F"C 4-1998

NONMANDATORY APPENT3IX A
-,
i u
V
L
U
W
F4
:
O
.-
r
O
.-VI
.-
u
EP
a.!
E
u-
O
'c
a.!
VI
E
m
a.!
m
07
9
e
E
--
2
| ||| | || | ||
n
-
W
m
*
|
m
| |||
y
O
C
|||| | || ||| | || ||
u
O
L 'I
L
0
c
3
v:
1
||| | |---
*ui
." Y
:o n u t
L
b
198
STD-ASME PTC 4-ENGL 1998 = 0759b70 Ob15137 îTô
ASME PTr: 4-1998

--
| ||| | || | ||
|
| |||
|||| | || ||| | || ||
E
B1
||| | |---
C
O
a
5
- I
C
199
STDmASME PTC Y-ENGL 1998 D 0759b70 Ob15138 834
FORM INTAVG UNCERTAINTY WORK SHEET

integrated Average Value Parameters
--
Grid Location:
| ||| | || | ||
30 [No. of Points Wide

No. of Points High
No. of Points Total C301 x C311
|
133 I No. of Readinss Per Point

| |||
|||| | || ||| | || ||
||| | |---
Y
2
40 Average Value of Grid (C35al + C35bl + ....)/C321

Precision Index of Grid UC37aIA2 + C37bIW + ....)A1/2)/C321
Degrees of Freedom of Grid C41lA4/(C38al + C38bl + ....
Soatial Distribution Index
~~ ~~
I ~~
I
Bias for Integrated Average
Bias for N o Flow Weighting
Bias for Thermocouole Tvoe I ~
I
Estimated System Bias (0.1% of average) I
Estimated Total Bias for Grid (C44IA2 + C45IA2 + C46IA2 + C47IA2.)A1/2

TEST NO. DATE LOAD
DATE
SHEET OF
~ ~
STDmASFlE PTC 4-ENGL 1998 0759670 ObL5L39 770
ASME PTC 4-1998
NONMANDATORY APPENDIX B
SAMPLE CALCULATIONS
This Appendix presents examples which demonstrate The bias error for this measurement is determined
the calculation methods outlined or recommended in by evaluating the measurement system shown on Figure
this Code. The calculations in this Appendix focus B.l-l. Subsection 4.4.2 of the Code was reviewed to
primarily on uncertainty calculations. The efficiency determine possible bias errors. The following individual
and output calculations are discussed in Section 5 and bias errors were evaluated for this example:
Appendix A - Calculation Forms. This Appendix
includes the following example problems: 0 thermocouple type
0 calibration
0 B. 1 Temperature Measurement 0 lead wires
0 B.2 Pressure Measurement 0 ice bath
0 B.3 Flow Measurement o thermowell location
0 B.4 Output Calculation 0 stratification of fluid flow
B.5 Coal Fired Steam Generator 0 ambient conditions at junctions
0 B.6 Oil Fired Steam Generator 0 intermediate junctions
0 electrical noise
The sample calculations presented in Sections B.l
0 conductivity
through B.4 are building blocks for the coal fired steam
o drift
generator example in Section B.5. The first three sections
illustrate temperature, pressure, and flow measurements
Section 4 of this Code provides additional bias
for feedwater to the steam generator.
errors which could be applicable for a temperature
In order to emphasize that bias limits must be assigned
measurement. Several of the above bias errors may not
by knowledgeable parties to a test, bias limits used in
be applicable for a particular temperature measurement.
the following examples do not always agree with the
As this example illusuates, most of the above bias
potential values listed in Section 4.
errors are very small and can be ignored.
The Bias Data Reduction Work Sheet provided with
this Code can be used to summarize the bias errors
and calculate the overall bias error for this measurement.
B.l TEMPERATURE MEASUREMENT
A completed Bias Data Reduction Work Sheet for
This example illustrates how feedwater temperature water temperature is shown in Table B.l-2.
can be measured and the uncertainty determined. Figure The feedwater temperature was measured with a
B.l-1 shows the temperature measuring system. The standard grade Type E thermocouple. This thermocouple
following temperatures were recorded during the test: has a bias error of 23°F. This value is determined
440"F, 440"F, 439"F, 439"F, 440"F, and 439°F. from published manufacturers' accuracy data. The bias
The average value and standard deviation for these error for the lead wire is assumed to be I1.O"F based
six measurements were 439.5"F and 0.55"F, respec- on engineering judgment and experience from similar
tively. The Precision Data Reduction Work Sheet pro- measurement systems. Depending on the location and
vided with this Code can be used to perform this fluid stratification where the temperature is measured,
calculation or the procedures presented in Section 5 there can be a bias error. The ambient conditions at
can be followed. A completed Precision Data Reduction the thermocouple and junction boxes were assumed to
Work Sheet for feedwater temperature is shown in have no effect on the measurement. In addition, electri-
Table B.l-l. The standard deviation is required as part cal noise and conductivity were assumed to have a
of the overall precision error calculation shown in negligible effect. The thermocouple was not recalibrated
Section B.4. after the test. so a drift of 0.1"F was assumed.
20 1
-- | ||| | || | || | | ||| |||| | || ||| | || || ||| | |---
--
ASME Pn= 4-1998 NONMANDATORY APPENDIX B

| ||| | || | ||
1439.301
|
| |||
|||| | || ||| | || ||
Intermediate
junction box
Junction fi Temperature
display
||| | |---
Feedwater pipe
FIG. 6.1-1TEMP ERATURE M EAS U REME NT
Based on the above bias errors, the overall bias error ambient conditions at transmitter
of the feedwater temperature was calculated to be ambient conditions at junctions
k3.16"F. electrical noise
It should be noted that there are a number of ways drift
to reduce the bias error of this example, including post- static and atmospheric pressure
test calibration or using a premium grade thermocouple.
Section 4 of this Code provides additional bias errors
which could be applicable for a pressure measurement.
B.2 PRESSURE MEASUREMENT Several of the above bias errors may not be applicable
__
for a particular pressure measurement. As this example
This example illustrates how feedwater pressure can
illustrates, several of the above bias errors are very
be measured and the uncertainty determined. Figure B.2-
small and could be ignored.
1 shows the pressure measuring system. The following
The Bias Data Reduction Work Sheet, provided with
pressures were recorded during the test: 1,672; 1,674;
this Code, can be used to summarize the bias errors
1,668; 1,678; and 1,691 psig.
The average value and standard deviation for these
A completed Bias Data Reduction Work Sheet for
five measurements were 1,676.6 and 8.82 psig, respec-
feedwater pressure is shown in Table B.2-2.
tively. The Precision Data Reduction Work Sheet pro-
The feedwater pressure was measured with a standard
vided with this Code can be used to perform this
transmitter. This transmitter has a span of 800 to 2,400
calculation or the procedures presented in Section 5
psig and a bias error of 5 1 % for reference accuracy.
can be followed. A completed Precision Data Reduction
This value is determined from published manufacturers'
Work Sheet for feedwater pressure is shown in Table
accuracy data. The transmitter was calibrated prior to
B.2-1. The standard deviation is required as part of the
the test which included corrections for static pressure
overall precision error calculation shown in Section B.4.
and ambient pressure. Depending on the location where
The bias error for this measurement is determined
the pressure is measured, there could be a bias error;
by evaluating the measurement system shown on Figure
however, this problem assumed the location effect was
B.2-1. Subsection 4.5.2 of the Code was reviewed to
negligible.
determine possible bias errors. The following individual
Published manufacturers' data were also used to
bias errors were evaluated for this example:
determine the drift and ambient temperature effects.
transmitter This bias of 9.6 psi was based on 2 1 % of maximum
0 calibration scale per 100°F. In addition, electrical noise was as-
0 location sumed to have a negligible effect. The transmitter was
202
STD-ASME PTC Ii-ENGL 1998 W 0359b30 ObL514L 329
NONMANDATORY APPENDIX B ASME PTC 4-1998
TABLE B.1-1
FEEDWATER TEMPERATURE PRECISION DATA REDUCTION WORK SHEET
J Measured Data
Conversion to Correction Cal ibrated
English Units Factor Data
I 440.00
440.00 I
439.00
1 439.00
440.00
i ( 439.00 I 1
n
n
Y
Z
--
| ||| | || | ||
|
| |||
|||| | || ||| | || ||
2 I Average Value (Clal + Clbl + Clcl + . . . Clz1)lz ! 439.50

Standard Deviation I 0.5477
+ (Clbl - C2IP2 + . . . + (Clzl - C21)A2))A(1/2)
((i/(z - 1)) x ((Clal - C2W2
I
||| | |---
~ ~~
UAME OF PLANT ASME PTC 4 Example Problems B . l AND B.5 IUNIT NO.
TEST NO. DATE LOAD
DATE
SHEET OF
203
STD-ASME PTC 4-ENGL 1998 0759670 06153142 265 W
ASME PTC 4-1998 NONMANDATORY APPENDIX B
TABLE B.l-2
FEEDWATER TEMPERATURE BIAS DATA REDUCTION WORK SHEET
Measured Parameter: Water Temperature, F Work Sheet No: 1D
Estimate of Bias Limit
II Measured Parameter
Source of Bias Limit
J
2
Percent*
Positive
Unit of Meas
3
J
Percent*
Negative
Unit of Meas
individual Biases
a TC or RTD type Manufacturers Data 3.00 3.0(
b Calibration Included in Item a 0.00 O.O(
c Lead Wires Engineering judgment 1.00 1.0(
d ice bath Negligible 0.00 O.O(
e Thermowell IocatiorVgeometry Negligible 0.00 O.O(
f 1 Pad weld (insulated/uninsulated) I Not ADDliCabk 0.00 I O.O(
--
| ||| | || | ||
|
| |||
|||| | || ||| | || ||
||| | |---
Total Bias Limit

i a 4 + bA2 + cA2 + . . .I A (1/2) 0.00 3.16 0.00 3.16
AME OF PLANT ASME PTC 4 EXAMPLE PROBLEMS B.l AND B.5 UNIT NO.
EST NO. DATE. LOAD
I M E START: END: CALC BY
(DATE
SHEET OF
204
STD*ASME PTC 4-ENGL 1998 H 0759670 Ob15143 I T 1 H
box
Junction 1-q - calibration of primary element
1 1676.65 I
stratification
ASME PTC 4-1998
temperature bias
I pressure bias
Pressure installation
transmitter Pressure
display condition of nozzle
nozzle thermal expansion
pressure correction (density effect)
temperature correction (density effect)
Reynolds number correction
measurement location
Section 4 of this Code provides additional bias errors
||| | |---
Feedwater pipe which could be applicable for a flow measurement.
Several of the above bias errors may not be applicable
|||| | || ||| | || ||
for a particular flow measurement. As this example
FIG. 6.2-1PRESSURE MEASUREMENT illustrates, several of the above bias errors are very
small and can be ignored.
| |||
The Bias Data Reduction Work Sheet, provided with
|
this Code, can be used to summarize the bias errors
| ||| | || | ||
not recalibrated after the test so a drift of 2 psi, based A completed Bias Data Reduction Work Sheet for
on 0.25% of maximum scale per 6 months, was used. feedwater flow is shown in Table B.3-2.
--
Based on the above bias errors, the overall bias error The feedwater flow was measured with a calibrated
of the feedwater pressure was calculated to be 21% flow nozzle with pipe taps. The nozzle was inspected
and 9.81 psi. prior to the test. This type of nozzle has a bias error
It should be noted that there are a number of ways of 20.4%. The test was run at a flow with a Reynolds
to reduce the bias error of this example, including number similar to the laboratory calibration results;
using a more accurate measurement device. therefore, the bias is considered negligible. The nozzle
is provided with flow straighteners, so the stratification
and installation effects are considered negligible. The
B.3 FLOW MEASUREMENT nozzle was not inspected after the test, so a bias
error of 20.5% was assigned. The differential pressure
This example illustrates how feedwater flow can be
transmitter bias is 20.12% based on an accuracy of
measured and the uncertainty determined. Figure B.3-
20.25%. The feedwater pressure bias was determined
1 shows the flow measuring system. The following
to be 9.81 psi, but has a negligible impact on feedwater
flows were recorded during the test: 437.0, 437.1,
density. The feedwater temperature bias was determined
433.96,428.7,461.9,428.3,434.8,438.28,431.2,427.5,
to have a bias of 23.16"F, which has an impact of
426.93,430.3,424.6,435.2,431.48,425.9,438.7,427.5,
20.27% on feedwater density for an uncertainty
434.43, and 441.7 Klbh.
10.14% measured feedwater flow. There is a bias of
The average value and standard deviation for these
50.10% due to thermal expansion and a measurement
20 measurements were 433,774 and 8,191.39 lbh,
system bias of 20.10% was assigned.
respectively. The Precision Data Reduction Work Sheet
Based on the above bias errors, the overall bias error
provided with this Code can be used to perform this
of the feedwater flow was calculated to be 50.68%.
calculation or the procedures presented in Section 5
It should be noted that there are a number of ways
can be followed. A completed Recision Data Reduction
to reduce the bias error of this example, including a
Work Sheet for feedwater flow is shown in Table B.3-
more accurate measurement device.
1. The standard deviation is required as part of the
overall precision error calculation shown in Section B.4.
The bias error for this measurement is determined
B.4 OUTPUT CALCULATION
by evaluating the measurement system shown on Figure
B.3-1. Subsection 4.7.2 of the Code was reviewed to The purpose of this example is to illustrate how
determine possible bias errors. The following individual steam generator output is calculated and the uncertainty
bias errors were evaluated for this example: of the result detennined. This Code recommends that
205
ASME F I T 4-1998 NONMANDATORY APPENDIX B
TABLE 6.2-1
FEEDWATER PRESSURE PRECISION DATA REDUCTION WORK SHEET
Measured Parameter: FEEDWATER PRESSURE, psig
Conversion to Correction Calibrated

1
Measured Data English Units Factor Data
--
| ||| | || | ||
|
| |||
|||| | || ||| | || ||
k
I
m
||| | |---
',
9
1 I I
~~
, Y
z
I
2 Average Value (Cia1 + Clbl + Clcl + . . . Cizl)/z 1676.60
3( Standard Deviation 8.8204
( ( l / í z - 1)) x ((Cial - C21P2 + (Clbl - C2W2 + . . . + ( C l z l - C 2 1 ) ~ 2 ) P i 1 / 2 )
NAME OF PLANT ASME PTC 4 EXAMPLE PROBLEMS 8.2 AND B.5 U N I T NO.
TEST NO. DATE LOAD
STD-ASME PTC 4-ENGL L778 = O757670 ObL5L45 T74 m
NONMANDATORY APPENDIX B ASME FTC 4-1998
TABLE B.2-2
FEEDWATER PRESSURE BIAS DATA REDUCTION WORK SHEET
Measured Parameter: Feedwater Pressure, psi9 Work Sheet No: 2A
4 Measured Parameter
2J Positive 3
J Negative
Individual Biases Source of Bias Limit Percent* Unit of Meas Percent* Unit of Meas
a Gauge, Manomtr or Transmitter Type Manufacturers Data 1.00 1.00
b Calibration Included in Item l a
c Tap location/geornetry/flow impact Negligible
e Amb conditions at junction Negligible

f Electrical noise Negligible
g Drift Manufacturers data 2.00 2.0'
h Static and atmospheric pressure Included in calibration
i
Total Bias Limit

iaA2 + bA2 + cA2 + . . .) A (U21 1.00 2.24 1.00 2.24
NAME OF PLANT ASME PTC 4 EXAMPLE PROBLEMS 8.2 AND 8.5 UNIT NO.
TEST NO. DATE LOAD
DATE
SHEET OF
207
-- | ||| | || | || | | ||| |||| | || ||| | || || ||| | |---
-
STD=ASME PTC Y-ENGL 1998 M 0753b30 Ob2514b 900
ASME PTC 4- 1998 NONMANDAMRY APPENDIX B
Differential
pressure
transmitter
Flow display
.transmitter
,,,ure
Prneel
I
4L----
___-
Feedwater pipe
\
'
.--I
,---I
I
I
4
Flow
nozzle
i V
Junction
box
-
FIG. B.3-1 FLOW MEASUREMENT
the uncertainty of steam generator output be calculated The steam generator output was calculated to be
independent of efficiency for several reasons: 558.22 Btuh using the output calculation form shown
in Table B.4-1. The use of this calculation form is
The output is typically a calculated parameter that is discussed in Appendix A. Sections B.l through B.3
guaranteed or determined independently of efficiency. show how the feedwater measurements and uncertainty
0 The individual measured parameters associated with were determined. The uncertainty for the other parame-
output typically have a very small effect on efficiency. ters was determined in a similar manner.
However, the overall uncertainty of output can have The Output Uncertainty Work Sheets provided with
a larger effect, especially in the case of steam genera- this Code can be used to calculate the uncertainty
tors that use sorbent. for the output measurements. The completed Output
0 Determining output uncertainty simplifies the calcula- Uncertainty Work Sheets are included in Tables B.4-
tions required for efficiency uncertainty. 2 and B.4-3. The average value, standard deviation,
number of readings, and positive and negative bias
Figure B.4-1 shows a schematic of the steam genera- limit for each of the measurements is required to
tor and the measurements recorded to determine output. complete the calculations.
The following measurements were recorded: The output total uncertainty was Calculated to be
0 barometric pressure +6.51 Btuh and -6.51 Btu/h. This includes a precision
0 feedwater flow component of 4.84 and a bias limit of +7.73 and -
0 feedwater temperature 7.73 Btu/h.
feedwater pressure
0 main steam spray flow
0 main steam spray temperature
B.5 COAL FIRED STEAM GENERATOR
main steam spray pressure
main steam temperature The purpose of this example is to illustrate how steam
main steam pressure generator efficiency is calculated and the uncertainty of
0 hot reheat outlet temperature the result determined.
0 hot reheat outlet pressure Figure B.5-1 shows a schematic of the steam genera-
0 cold reheat temperature tor and the measurements recorded to determine effi-
0 cold reheat pressure ciency. The following measurements were assumed or
0 cold reheat extraction flow measured:
208
-- | ||| | || | || | | ||| |||| | || ||| | || || ||| | |---
-~
STD-ASME PTC 4-ENGL 1498 0759b70 Ob15L47 847
TABLE B.3-1
FEEDWATER FLOW PRECISION DATA REDUCTION WORK SHEET
Measured Parameter: FEEDWATER FLOW, I b k r x 1,000

I
J
l Conversion to Correction Calibrated
Measured Data English Units Factor Data
a 437000
b 437100
C 433960
d 428700
e 461900
f 428300
a 434800
438280 I I
~~ ~~
427500 I
I I 430300 1
m 424600 I
X
I
Y
z
~~ ~~ ~
2 I Average Value (Clal + Clbl+ C i c l + . . . ClzI)/z I 433774.00

3 Standard Deviation 8191.3905
((i/íz - 1)) x ((Cial - C2W2 + (Clbl - C21)Q + . . . + (Clzl - C2l)A2)IA(112)
I I
~
NAME OF PLANT ASME PTC 4 EXAMPLE PROBLEMS 8.3 AND 8.5 IUNIT NO.
TEST NO. DATE LOAD
-. .. -
nATF
I ISHEET OF I
-- | ||| | || | || | | ||| |||| | || ||| | || || ||| | |---
STD-ASME PTC 4-ENGL 1998 0759b70 OblSL48 783 9
ASME Pn: 4-1998 N0"DATORY APPENDIX B
TABLE 8.3-2
FEEDWATER FLOW BIAS DATA REDUCTION WORK SHEET
Measured Parameter: Feedwater Flow, IWhr Work Sheet No: 3C I
I J
l
2
J Positive 3
J Negative
I
Measured Parameter
Individual Biases Source of Bias Limit Percent* Unit of Meas Percent* Unit of Meas
a (Calibration of primary element Calibration 0.40 0.40
I b IStratification I Nealiaible I 0.00 I I 0.001 I
Ic (DP Transmitter ICalculation I 0.12 I I 0.12 I I
Id IInstallation INealiaible I 0.00 I I 0.001 I
e Condition of nozzle or orifice Engineering judgment 0.50 0.50
||| | |---
f I Pressure correction Icaicuiation I 0.00 I 0.00 I
|||| | || ||| | || ||
| |||
|
| ||| | || | ||
--
O
Total Bias Limit

(aA2 + bA2 + c*2 + . . .) * W 2 ) 0.68 0.00 0.68 0.00
This is a percent of readins I
~~
NAME OF PLANT ASME PTC 4 EXAMPLE PROBLEMS B.3 AND 6.5 UNIT NO.
TEST NO. DATE LOAD
DATE
? SHEET OF
210
STD-ASME PTC 'I-ENGL L998 W 0759b70 ObLSL'IS bLT W
I
- ) Main stream spray
I Main steam
* Hot reheat
I 1
1
uperheater
- ?
--
Reheater A
Cold reheat
| ||| | || | ||
Economizer -- r' Feedwater

|
21
Furnace
| |||
-
|||| | || ||| | || ||
1
I
I
||| | |---
Air heater
I
FIG. B.4-1 OUTPUT SCHEMATIC
O fuel higher heating value furnace ash flow

o fuel flow O economizer ash flow
o barometric pressure 0 precipitator ash flow
0 ambient dry-bulb temperature O furnace ash carbon content
0 relative humidity O economizer ash carbon content
flue gas temperature leaving air heater 0 precipitator as carbon content
O combustion air temperature entering air heater 0 bottom ash residue temperature
O flue gas leaving air heater oxygen content O economizer ash residue temperature
0 flue gas entering air heater oxygen content O precipitator ash residue temperature
0 combustion air temperature leaving air heater 0 fuel temperature
O fuel carbon content
fuel sulfur content
0 fuel hydrogen content The steam generator efficiency was calculated to be
0 fuel moisture content 89.21% using the calculation forms included at the end
O fuel nitrogen content of this section (Sheets 1 through 8). The uses of these
0 fuel oxygen content calculation forms are discussed in Appendix A. In
O fuel ash content addition to the above parameters, the steam generator
0 flue gas temperature entering air heater output was Calculated as described in Section B.4. The
combustion air temperature leaving air heater uncertainty for the above parameters as well as output
21 1
STD-ASME PTC 4-ENGL L998 0759b70 Ob15150 33% =
TABLE B.4-1
STEAM GENERATOR OUTPUT CALCULATION FORM
111I Sootblowing Steam I 0.0001 0.0 I 0.0 I 0.00 I 0.00 I

112 I SH Steam Extraction 1 I 0.0001 0.0 I 0.0 I 0.00 I 0.00 I
13 I SH Steam Extraction 2 0.000 I 0.0 I 0.0 I 0.00 I 0.00
14 I Atomizing Steam 0.000 I 0.0 0.0 I 0.00
||| | |---
|||| | || ||| | || ||
16 1 Aux Steam 2 0.000) 0.0 1 0.0 1 0.001 0.00
17 I 0.000 1 I
| |||
|
| ||| | || | ||
--
1 2 9 I F W HEATER NO. 1 FLOW 1 O.OOOlW25 x (H26 - H25)/(H27 - H28) I
- W29 x (H28 - H33)1/(H32 - H33)

3 4 I F W HEATER NO. 2 FLOW
35 ICOLD
REHEAT FLOW I
IW35 x
0.0001W30 x C(H31 - H30)
363.745 IW18
- W23 - W24 - W29 - W34
(H20 - H21) + W22 x (H20 - H22)
I
36IREHEATOUTPUT I 68.02
37 /TOTAL OUTPUT IQ i 9 + 436 558.22
NAME OF PLANT ASME PTC 4 EXAMPLE PROBLEMS 8.4 AND B.5 IUNIT NO.
TEST NO. DATE LOAD
DATE
SHEET OF
~ _ _ _ _
STD.ASME PTC 4-ENGL 1998 0759b70 Ob15151 278
NONMANDATORY APPENDIX B ASME F1y3 4-1998
-- | ||| | || | || | | |||
COPYRIGHT 2002; American Society of Mechanical Engineers

|||| | || ||| | || || ||| | |---
213
i
Document provided by IHS Licensee=Fluor Corporation/2110503105, User=,
~
STD-ASME PTC 4-ENGL 1998 W 0759b70 Ob15L52 104 D
--
| ||| | || | ||
ASME PTC 4-1998
|
| |||
|||| | || ||| | || ||
||| | |--- NONMANDATORY APPENDIX B
214
STD-ASME PTC 4-ENGL 1998 W 0759b70 ObL5L53 040
NONMANDATORY APPENDIX B ASME P X 4-1998
-
Ambient Conditions
Barometric pressure -
Precipitator Ash
Flow
-Dry bulb temperature

Relative humidity - Temperature
Carbon
-
output
See Example 8.4
Fuel
- - -
i
Flow Furnace
' "V I
Carbon
@-wT%
9
9 Sulfur
Hydrogen
Moisture
Nitrogen
Economizer Ash
6 I Airheater 1 @@
Oxygen
Ash Flow
Temperature Flue gas
Carbon
Furnace Ash
Flow Air
Temperature
Carbon
FIG. B.5-1 EFFICIENCY SCHEMATIC

--
| ||| | || | ||
were determined in a manner similar to the methods energy balance method. The uncertainty of the efficiency
described in Sections B. 1 through B.4. is also calculated for each method in order to evaluate
|
| |||
The Efficiency Uncertainty Work Sheets provided the quality of each test method.
|||| | || ||| | || ||
with this Code can be used to calculate the uncertainty The same steam generator and boundary conditions
for the efficiency measurements. The completed Effi- used for the coal fired steam generator in Section B.5
ciency Uncertainty Work Sheets are included at the end are used except for the following differences which
of this section. The average value, standard deviation, are related to the fuel:
||| | |---
number of readings, and positive and negative bias

0 fuel properties
limit for each of the measurements is required to
0 fuel residue flow and associated properties are deemed
complete the calculations.
to be negligible
The efficiency total uncertainty was calculated to be
0 unburned combustibles are deemed to be negligible
+0.43% and -0.43%. This includes a precision compo-
nent of 0.10 and a bias limit of +0.42% and -0.42%. B.6.1 Efficiency by the Input-Output Method. The
Also included at the end of this section are four required data for this method consists of those measure-
Input Data Sheets. These sheets are used to document ments necessary to determine output (Section B.4) and
all measured or assumed parameters for the test. These input. Input is calculated from measured fuel flow and
input sheets are primarily for use in the computer the fuel higher heating value.
spreadsheet which was developed to complete the calcu-
Higher heating value (HHV) fuel was sampled during
lations. the test in accordance with Section 4, the samples were
mixed and one sample analyzed. The average higher
heating value for the test was determined to be 17,880
B.6 OIL FIRED STEAM GENERATOR BtuAbm. The biases for the higher heating value were
In this example, the efficiency of an oil fired unit considered to consist of the ASTM reproducibility
is determined by both the input-output method and the interval (89 BtuAbrn per ASTM D4809) and a 0.5%
215
STD.ASBE PTC 4-ENGL 1998 = 0757b70 ObL515Li T87
ASME PTC 4-1998 NO"DATORY APPENDTX B
EFFICIENCY CALCULATIONS
Data Required
1 I Reference Temoerature 77 I 1A I Enthalw Water (32 F Ref) 45

2] Average Entering Air Temp I 85.7 2A Enthalpy Dry Air 2.10
from CMBSTNa C161 or EFFa i441 28 Enthalpy Water Vapor 3.89
Average Exit Gas T (Excl Lkg) I 298.8 3A Enthalpy Dry Gas 53.00
from CMBSTNa C151 or EFFa C511 38 Enthalpy Steam O 1 PSIA 1195.08
3C Enthalpy Water Vapor 99.98
4 I Fuel Temperature I 84.0 4A Enthalpy Fuel 1.42
5 I Entering Gas Temperature 0.0 5A Enthalpy Wet Gas 0.00

6 I Leaving Gas Temperature 0.0 6A Enthalpy of Wet Gas 0.00
68 Enthalpy of Wet Air 0.00
6C Enthalov of Wet Air O T = C31 0.00
RESULTS FROM COMBUSTION CALCULATION FORM CMBSTN
10 I Dry Gas Weight i771 I 9.4701 18 ) Unburned Carbon, Oh c21 I 0.616
11 I Drv Air Weiciht C691 I 9.1181 19 I HHV Btu/lbm as-fired i11 I 11447.6
1
i 2 Water from H2 Fuel C34El 1 0.3371 HOT AQC EQUIPMENT I
13 Water from H20 Fuel C34Fl 0.088 20 Wet Gas Entering C75E1 0.00
14 Water from H20v Fuel C34G1 0.000 2 1 H20 in Wet Gas, % C76El 0.00
15 Moisture in Air Ib/lb DA C71 0.009 22 Wet Gas Leavinci C75L1 0.00
16 1 Moisture in Air Ib/lOKB C721 1 I
0.085 23 Residue in Wet Gas, % i 8 1E l 0.00
17 I Fuel Rate Est. KIWhr C31 1 54.76
25 I Excess Air, % C603 22.10
I
30 Unit Output, MKBtu/hr 1 558.221 31 ) Aux Equip Power, MKBtuhr 0.0
b
I
32 Loss Due to Surface Radiation and
,
--...- - -. - . _,o/n. -
...- Cnnvertinn 0.00
133A 1 Flat Projected Surface Area, ft2 I I I
O 3 3 ~Average Surface Temperature. F 0.0
338 I Average Velocity of Air Near Surface, füsec I 1 I
0.0 33D Average Ambient Temperature Near Surface, F I 0.0
ENT AIR TEMP (Units with orirnarv and secandarv air flaw) Itern Na'< CMBSTN
A I Pri Air Temp Leaving Air Htr. F CMBSTNa C511 I 511.41 368 I Enthalpy Wet Air, Btu/lb I 106.51
137A I Averaae Air Temo Enterina Pulverizers. F 1 511.41 376 I Enthalov Wet Air. Btu/lbm I 106.51
38A Average Pulverizer Tempering Air Temp, F I
84.9 I386 Enthalpy Wet Air, Btullbm 1.9
39 Sec Air Temp Entering, F CMBSTNa Cl6Al 85.91 40 I Primary Airfiow (Ent Pulv), Klb/hr 83.2
41 Pulverizer Ternwring AirRow, Klb/hr C401 X (C36Bl - C37BI)/(C36Bl - C38Bl) 0.0
44 I Average Entering Air Temperature, F I (C35A1 x (C401- C413) + C391 x C431+ C38Al x C411)/C421 85.7
46A Flue Gas Temp Lvg Pri AH, F CMBSTNc C881 1 293.51 466 I Enthalpy Wet Flue Gas, Btu/lbm 54.4
47 Flue Gas Temp Lvg Sec AH, F CMBSTNc E881 I 299.71 48 ) Total Gas Ent Air Htrs, KIWhr CMBSTNc i931 617.8
49 Flue Gas Flow Ent Pri Air Htr. KlWhr C401 x (C37B1- ~35BI)/(C4567- C4661) 90.9
50 Flue Gas Flow Ent Sec Air Htr, KIWhr C481 - C491 I 617.8)
51 Average Exit Gas Temperature, F (C46Al x C491 + C471 x C5Ol)/C481 298.8
Iteration of flue gas split, YOprimary AH flow Initial Estimate 1 0.11 Calculated I 14.7 I
TEST NO. DATE LOAD
DATE
SHEET OF
-- | ||| | || | || | | ||| |||| | || ||| | || || ||| | |---
STDOASME PTC 4-ENGL 1998 m 0759b70 ObL5L55 913 m
NONMANDATORY APPENDIX B ASME Prc 4-1998
--
| ||| | || | ||
|
| |||
|||| | || ||| | || ||
||| | |---
217
STDmASME PTC 4-ENGL 1998 m 0759670 ObL5L5b 85T W
Other Losses and Credits
The losses and credits listed on this sheet are not universally applicable to all
fossil fired steam generators and are usually minor. Losses/credits that have
not been specifically identified by this Code but are applicable in accordance
--
with the intent of the Code should also be recorded on this sheet.
Parties to the test may agree to estimate the losses or credits in lieu of
| ||| | || | ||
testing. Enter a ’T’ for tested or ‘E’ for estimated in the second column, and
the result in the appropriate column. Enter the sum of each group on Form
EFFb. Refer to the text of PTC 4 for the calculation method.
|
| |||
I IAl I BI
|||| | || ||| | || ||
Itm T or E ILOSSES, % Enter Calculated Result in % Column [ B I MKB %

llOA CO in Flue Gas O.Of
1106 Formation of NOx O.O(
ll0C Pulverizer Rejects o.oc
||| | |---
llOD Air Infiltration O.O(

llOE I IUnburned Hvdrocarbons in Flue Gas I I O.O(
llOF Radiation Loss to Hopper 0.11
llOG O.O(
110 Summation of Other Losses. YO Basis 0.2E
LOSSES, MKBtu/hr Enter in MKB Column CAI

111A I IWet Ash Pit I 0.0001
Ill16 1 ISensible Heat in Recycle Streams - Solid I 0.oool
111c Sensible Heat in Recycle Streams - Gas 0.000
1110 Additional Moisture 0.000
111E Coolina Water 0.000
~
I111F I IAir Preheater Coil (suDDiied bv unit) I 0.oool

I...* I I I I
1116 0.000
111 I (Summation
Summation of Other Losses, MKBtukr Basis I 0.oool
0.000
CREDITS, YO Enter Calculation Result in YOColumn C61

112A I 0.00
112 I (Summation of Credits, % Basis
~~
0.00
CREDITS. MKBtu/hr Enter Result in MKB Column CAI I

113A Heat in Additional Moisture (external to envelope) 0.000
1136 0.000
113 Summation of Credits, MKBtukr Basis 0.000
I
NAME OF PLANT ASME PTC 4 EXAMPLE PROBLEM 6.5 IUNIT
.~ NO.
-
TEST NO. DATE LOAD

- TIME START: END: CALC BY ,
I ]SHEET OF
218
~
STD-ASME PTC 4-ENGL 1778 m 0757b70 ObL5157 79b =

NONMANDATORY APPENDIX B ASME PTC 4- 1998
219
-- | ||| | || | || | | ||| |||| | || ||| | || || ||| | |---
STD-ASME PTC Y-ENGL 1998 W 0759670 0635158 622 =
||| | |---
|||| | || ||| | || ||
| |||
|
| ||| | || | ||
--
220
STD.ASME PTC 4-ENGL 1998 W 0759b70 ObLSLS9 Sb9
NONMANDATORY APPENDIX B ASME pM3 4-1998
||| | |---
|||| | || ||| | || ||
| |||
|
| ||| | || | ||
--
22 1
STD-ASME PTC q-ENGL I1998 07596713 Ob151b0 280 W
ASME PTC 4-1998
222
-- | ||| | || | || | | ||| |||| | || ||| | || || ||| | |---
STD-ASME PTC 4-ENGL 1998 m 0759b70 ObL51bl 117 m
INPUT DATA SHEET 1
- COMBUSTION CALCULATIONS - FORM CMBSTNa

1 1 HHV - Hisher Heatins Value of Fuel, Btu/lbm as fired I 11447.6
4
--
a. Measured Fuel Flow 61901.3

6 Fuel Efficiency, Yo (estimate initially) 89.05
| ||| | || | ||
8 Barometric Pressure, in Hs 29.5

9 Dry Bulb Temperature, F 83.2
|
10 Wet Bulb Temperature, F 0.0

| |||
11 Relative Humiditv, YO 38.0

|||| | || ||| | || ||
15 Gas Temp Lvg AH, F Primary/Secondary or Main 158 276.16 15A 280.68
16 Air Temp Ent AH, F Prirnary/Secondary or Main l6B 84.88 16A 85.88
17 02 in Flue Gas Ent AH, F PrimarylSecondary or Main 178 3.91 15A 3.88
||| | |---
18 02 in Flue Gas Lvg AH, F Primary/Secondary or Main 188 5.51 18A 5.59
18C Primary AH Lkg for Trisector Air Heater, YOof Total 0.00
20 Sorbent Rate. KIbmhr 0.0
1 A I Carbon 63.68
B Unburned Carbon in Ash 0.62
D Sulfur 2.93
E Hydrogen 4.32
F Moisture 10.05
I J I Ash 10.48
I
K Volatile Matter 10.00
I
L Fixed Carbon 45.00
50 Flue Gas Temperature Entering Primary Air Heater 658.50

Flue Gas Temperature Entering Secondary Air Heater 660.0
51 Combustion Air Temperature Leaving Primary Air Heater 511.22
Combustion Air Temperature Leaving Secondary Air Heater 493.89
I
NAME OF PLANT ASME PTC 4 EXAMPLE PROBLEM B.5 UNIT NO.
TEST NO. DATE LOAD
(DATE
ISHEETi OF I
223
~~~~
STD-ASME PTC ri-ENGL 3998 0759b70 Ob15162 053
ASME PM: 4-1998 NO"DAT0RY APPENDIX B
INPUT DATA SHEET 2

~
COMBUSTION CALCULATIONS - FORM CMBSTNC

None
UNBURNED CARBON & RESIDUE CALCULATIONS - FORM RES

I 5 I Residue Mass Flow Klbmhr SDlit. % I
A Furnace 0.0 15.0
B Economizer 0.0 10.0
C Precioitator 0.0 75.0
D I I 0.01 1 0.0
E l 0.0 I 0.0
6 Carbon in Residue, %
I I A I Furnace I 0.101
B Economizer 4.78
C Precipitator 6.75
D
7 Carbon Dioxide in Residue, %

A Furnace I 0.00
--
B I Economizer 0.00
| ||| | || | ||
C Precipitator 0.00
D
E
|
| |||
24 Temoerature of Residue. F
|||| | || ||| | || ||
A Furnace 2000.0
B Economizer 653.8
C Precipitator 276.5
D
||| | |---
7A SO2 in Flue Gas, ppm O

a O2 in Flue Gas at location where SO2 is measured, % 0.00
9 SO2 & O2 Basis, Wet COI or Dry C11 O
20 Sorbent Products, % Mass
B Ca(OH12 0.00
C MgC03 0.00
D Mg(OH)2 0.00
~~
F Inert
I 0.00
23A I Calcination Fraction
~~
1.00
I I
NAME OF PLANT ASME PTC 4 EXAMPLE PROBLEM 8.5 UNIT NO.

TEST NO. DATE LOAD
DATE
SHEET 2 OF
~ ~
STD-ASME PTC 4-ENGL I998 = 0759670 Ob15163 T9T

INPUT DATA SHEET 3
- - . .- -. .. -. .- - -. . . .- . . - ..- - .
I MEASURED C AND CO2 in RESIDUE - FORM SRBb I
SORBENT CALCULATION SHEET
EFFICIENCY - FORM SRBC
I
||| | |---
|||| | || ||| | || ||
| |||
|
| ||| | || | ||
--
ILosses,EFFICIENCY CALCULATIONS OTHER LOSSES AND CREDITS - FORM EFFC
%
I
85A IC0 in Flue Gas 0.00
I A i r Infiltration I 0.00
I
85E Unburned Hydrocarbon in Flue Gas 0.00
Losses, MKBtukr
86A I
Wet Ash Pit 0.000
866 Sensible Heat in Recycle Streams - Solid 0.000
86C Sensible Heat in Recycle Streams - Gas 0.000
86D Additional Moisture 0.000
86E Cooling Water 0.000
86F Air Preheat Coil (Supplied by Unit) 0.000
Credits, Oh
87A I I 0.00
Credits, MKBtuk
I
88A Heat in Additional Moisture (External to Envelope) 0.000
NAME OF PLANT ASME PTC 4 EXAMPLE PROBLEM 6.5 UNIT NO.
TEST NO. DATE LOAD
DATE
I SHEET 3 OF
225
~
STD*ASME PTC 4-ENGL 1798 m 0757670 ObLSLb4 92b m
INPUT DATA SHEET 4
W T P
FLOW TEMPERATURE PRESSURE
PARAMETER Klbm/hr F PSIG
2 ISH SPRAY WATER 26431 I 312.5 2006.4

3 I Ent SH-1 Attemp o1 0.0 I 0.0
4 Lvg SH-1 Attemp O 0.0 0.0
6 Ent SH-2 Attemp O 0.0 0.0

7 Lvq SH-2 AttemD O 0.0 0.0
iootblowing Steam O 0.0 0.0

;H Steam Extraction 1 O 0.0 0.0
I13 I SH Steam Extraction 2 I 01 0.0 I 0.0
15 I Aux Steam 1 o1 0.01 0.0
18 IMAIN STEAM 1 1005.4 1517.2
||| | |---
I - ,
23 ICOLDR E H E A T EXTRACTION FLOW 96460 I
|||| | || ||| | || ||
24 ITURB SEAL FLOW & SHAFT LKG 01
FWHEATERNO 1
| |||
|
| ||| | || | ||
FW HEATER NO. 2
30 I
--
F W Enterina ---nl
n n n
-.-
0.0 I 0.0
NAME OF PLANT ASME PTC 4 EXAMPLE PROBLEM 8.5 /UNIT NO.

TEST
~.NO. DATE I I--.
íJAD.-
I
. -~
TIME START: END: ICALCBY

IDATE
ISHEET
4 OF
226
~
STDmASME PTC iI-ENGL 1998 œ 0757670 Ob151b5 8 b t œ
of the measured value for sampling bias (89 Btdbm) 0 discharge coefficient
for a combined bias of 0.70%.
A unit output of 565,270 Btuh was determined in The bias for the discharge coefficient is the only
accordance with the description in Section B.4. In that bias not considered above. Note the low Reynolds
presentation, it was determined that the most critical number of the orifice on Work Sheet 1 . A bias of 0.6
item was the feedwater flow nozzle. While output has + @o' = 1.334% is assigned to the coefficient due to
a negligible impact on the uncertainty of efficiency the low Reynolds number and an uncalibrated orifice.
determined by the energy balance method (refer to the Items [27] and [28] on Work Sheet 2 report the
Efficiency Uncertainty Work Sheet 2B, Items [15a] and overall uncertainty of the measured oil flow. The result
[16a]), it is directly proportional to the uncertainty of is 2.05%, which was deemed to be unacceptable for
efficiency determined by the input-output method. In an input-output test.
In order to reduce the uncertainty of the measured .
order to minimize the uncertainty of the output, a
calibrated and inspected ASME PTC 6 flow nozzle oil flow, a positive displacement flow meter was pur-
with a flow straightener was purchased. A nozzle chased for the test and calibrated at several viscosities
coefficient uncertainty of 0.35% was used. A calibrated spanning the expected viscosity of the oil. The total
differential pressure transmitter with an uncertainty of bias limit of the result using the calibrated positive
0.1%of range was used and an uncertainty of 0.1% displacement meter was determined to be 0.6% of the
was assumed for system error. The total bias for measured flow based on a meter uncertainty of OS%,
feedwater flow was reduced to 0.38%. It was also an uncertainty of 0.33% due to SG, 0.1% due to
noted that the feedwater precision error was high. The viscosity and 0.1% assumed system bias. The precision
controls were tuned and more readings were taken, error was reduced to 0.2% by tuning the controls and
reducing the precision index of the result to 0.1%. This taking more readings. Thus, by improving the fuel
reduced the total uncertainty of the output result to measurement system and test techniques, the total uncer-
0.598%. tainty for the measured oil flow was reduced to 0.65%.
The plant oil flow measurement system utilized a The measured oil flow for the test was determined to
square edge onfice with D and D/2 taps. The orifice be 35,140 Ibm/h.
has a Beta value of 0.734 and installed in a 2 in., The efficiency by the input-output method is calculated
schedule 40 pipe. The bias associated with the orifice per the following equation.
was considered to be 0.5%.
The bias of the transducer and calibration error were output
Efficiency = 100 x
considered to be 0.6% and 1.90% of the full range Fuel Flow x HHV
of the transmitter respectively. The full range of the = IOOX 565'370'000 = 89,967,%
transmitter was 60 in. wg, thus the combined bias is 35.140 x 17880
0.6708 in. wg.
The oil analysis included the specific gravity, which The Efficiency by Input-Output Uncertainty Work
was determined to have a bias of 0.33% based on the Sheets were used to calculate the uncertainty of the
ASTM reproducibility limit. efficiency determined by the input-output method.
The following differential pressure readings across For this test, the overall uncertainty of the efficiency
the orifice were recorded during a pretest uncertainty result determined by the input-output method was
analysis: 45.85, 46.85,47.35,45.35,48.85,47.55,45.05, ? 1.07%.
45.08, 58.75, 48.25, and 46.15 in. water, for an average
of 46.80 in. wg with a resulting standard deviation of B.6.2 Efficiency by the Energy Balance Method.
1.368144. The uncertainty results and efficiency calculation forms
The Uncertainty Work Sheets were used to calculate for efficiency calculated by the energy loss method are
the precision and combined biases of the flow measuring shown below.
system (refer to the Oil Flow Uncertainty Work Sheets). The steadwater side measurements required to deter-
On Sheet 1, the basic flow equation is provided and mine unit output for an efficiency test by the energy
all parameters are defined. The parameters to be evalu- balance method are the same as for the input-output
ated in the calculation of the oil flow are: method. However, as can be observed by the uncertainty
results below, the influence of the output is insignificant
differential pressure, in. water on the efficiency determined by the energy balance
0 specific gravity method result. Thus, the accuracy of the instrumentation
0 orifice diameter required to determine output is less critical.
227
-- | ||| | || | || | | ||| |||| | || ||| | || || ||| | |---
--
| ||| | || | ||
ASME P K 4-1998 NONMANDATORY APPENDIX B
Measured fuel flow is not required. Any calculated

|
| |||
utilizing fuel flow are based upon the measured output

|||| | || ||| | || ||
and fuel flow determined from the calculated efficiency.

Fuel sampling requirements are comparable. The
fuel must be analyzed for ultimate analysis (elemental
constituents) in addition to the higher heating value
||| | |---
and density.
Air and flue gas measurements are the principle
measurements required in addition to those required
for the input-output method. The most common mea-
surements are defined in Section B.5.
The Uncertainty Work Sheets for the OIL FIRING
Example Problem lists the measurements required to
determine efficiency by the energy balance method for
this oil fired boiler example. The combustion and
efficiency calculation sheets follow the uncertainty work
sheets.
The quality of the test using the input-output method
versus the energy balance method is evaluated by
comparing the uncertainty of the result for the two
methods. Note that even with the precautions of using
calibrated feedwater and oil flow nozzles for the input-
output test, the uncertainty was 1.07% versus an uncer-
tainty of 0.41% for the energy balance method test
with reasonable quality instrumentation.
228
~
STDaASME PTC Ii-ENCL 1998 0759b70 ObL5Lb7 635 W
NONMANDATORY APPENDIX B ASME Fl'C 4-1998
||| | |---
|||| | || ||| | || ||
| |||
|
| ||| | || | ||
--
229
STDmASME PTC ‘I-ENGL 1998 0759b70 Ob153b8 5 7 1
ASME PTC 4-1998 NONMANDATORY APPENDM B
230
-- | ||| | || | || | | ||| |||| | || ||| | || || ||| | |---
~-
~
STDmASME PTC 4-ENGL 1998 9 0759b70 ObL5Lb9 408
ASME PTC 4-1998

-
1 y.
O
--
| ||| | || | ||
|
| |||
|||| | || ||| | || ||
c
W
W
-I
U
J
||| | |---
L
O
-
-
L
23 1
STD-ASME PTC 4-ENGL 1998 W 0759b70 Ob15170 L2T
ASME pT1= 4-1998 NONMANDATORY APPENDIX B
232
-- | ||| | || | || | | ||| |||| | || ||| | || || ||| | |---
~
STD-ASME PTC 4-ENGL 1998 0759b70 Ob15172 Obb W
||| | |---
|||| | || ||| | || ||
| |||
|
| ||| | || | ||
MEASURED AVE STD NO PREC DEG % INCR
PARAMETER VAL DEV RDGS INDEX FREE CHANGE CHANGE
IAIR
TEMP ENT ENT AH I 84.88 I 0.47 I 10 I 0.15 1 9 1 1.00 I 0.85 I
--
GAS TEMP ENT AH 658.50 1.87 10 0.59 9 1.00 6.59
GAS TEMP LVG AH (MEAS) 276.16 0.28 10 0.09 9 1.00 2.76
SURF RAD. & CONV. LOSS. 1E6 BT 1.77 0.00 O 0.00 O 1.00 0.02
UNIT OUTPUT, 1E6 BTU/HR 565.27 0.00 O 2.33 20 1.00 5.65
02 ENT AH, % 3.90 0.13 1 0.04 9 1.00 0.04
0 2 LVG AH, % 5.50 0.44 1 0.14 9 1.00 0.06
BAROMETRIC PRESS. I N HG 29.50 0.00 20 0.01 19 1.00 0.30
(MASS FRACTION OF REFUSE ENT AH I 0.75 1 0.00 I 0.00 I 1.00 I 0.01 I
O
'/ OXYGEN I N FUEL 0.55 0.00 1 0.00 O 1.00 0.01
Oh NITROGEN I N FUEL 0.35 0.00 1 0.00 O 1.00 0.00
FU E L TEM PE RATU RE 200.00 2.83 8 1.00 7 1.00 2.00
INAME OF PLANT: I UNIT NO. 1 I
TEST NO: 1 DATE 05/29/96 I LOAD 100% I
T I M E START: 13:OO END: 17:OO CALC BY tch
ASME PTC4 EXAMPLE PROBLEM DATE 10/08/96
O I L FIRING SHEET OF
233
STDmASME PTC 4-ENGL 1998 = 0759b70 ObLSL72 T T 2
ASME FTC 4-1998 NONMANDATORY APPENDIX B
UNCERTAINTY WORK SHEET NO. 2A

Efficiency
ABS REL PREC

MEASURED AVE SENS SENS INDEX +BIAS -BIAS
PA RAM ET ER VALUE COEFF COEFF MEAS LIMIT LIMIT
AIR TEMP ENT ENT AH 84.9 0.02443 0.02305 0.15 4.03 4.03
GAS TEMP ENT AH 658.5 0.00000 0.00000 0.59 6.77 6.77
GAS TEMP LVG AH (MEAS) 276.2 -0.02694 -0.08267 0.09 8.85 8.85
SURF RAD. & CONV. LOSS, 1E6 BT 1.8 -0.15840 -0.00312 0.00 0.35 0.35
UNIT OUTPUT, 1 E 6 BTU/HR 565.3 0.00067 0.00419 2.33 9.47 9.55
--
| ||| | || | ||
|
| |||
|||| | || ||| | || ||
||| | |---
234
~
STD*ASME PTC 4-ENGL 1998 W 0759b70 Ob15173 939 =

UNCERTAINTY WORK SHEET NO. 2B

Efficiency
ABS REL TOTAL PREC +BIAS -BIAS
M EAS U RED RECALC SENS SENS DEG FR INDEX LIMIT LIMIT
||| | |---
PARAMETER PARAM COEFF COEFF CONTR RESULT RESULT RESULT
AIR TEMP ENT ENT AH 90.001 0.02443 0.02305 0.0000 0.0037 0.0985 0.0985
|||| | || ||| | || ||
GAS TEMP ENT AH 89.980 0.00000 0.00000 0.0000 0.0000 0.0000 0.0000
GAS TEMP LVG AH (MEAS) 89.906 -0.02694 -0.08267 0.0000 -0.0024 -0.2384 -0.2384
SURF RAD. & CONV. LOSS, 1E6 BT 89.977 -0.15840 -0.00312 0.0000 0.0000 -0.0554 -0.0554
| |||
UNIT OUTPUT, 1E6 BTU/HR 89.984 0.00067 0.00419 0.0000 0.0016 0.0063 0.0064
|
02 ENT AH. Yo 89.980 0.00436 0.00019 0.0000 0.0002 0.0009 0.0009
| ||| | || | ||
O2 LVG AH, o/' 89.964 -0.29527 -0.01805 0.0000 -0.0413 -0.0723 -0.0723
BAROMETRIC PRESS, I N HG 89.981 0.00275 0.00090 0.0000 0.0000 0.0009 0.0008
MASS FRACTION OF REFUSE ENT AH 89.980 0.00000 0.00000 0.0000 0.0000 0.0000 0.0000
--
WET ASH PIT LOSS, 1E6 BTU/HR 89.979 -0.15873 -0.00111 0.0000 0.0000 -0.1500 -0.0500
DRY BULB TEMP 89.978 -0.00265 -0.00245 0.0000 -0.0013 -0.0027 -0.0030
RELATIVE HUMIDITY, Oh 89.979 -0.00211 -0.00089 0.0000 -0.0008 -0.0015 -0.0015
HIGHER HEATING VALUE. BTUILBM 90.075 0.00053 0.10560 0.0000 0.0000 0.0914 0.0914
% CARBON I N FUEL 89.944 -0.04038 -0.03990 0.0000 0.0000 -0.1075 -0.1075
HYDROGEN I N FUEL 89.920 -0.65750 -0.06723 0.0000 0.0000 -0.2063 -0.2063
Yo SULFUR I N FUEL 89.980 -0.01400 -0.00016 0.0000 0.0000 -0.0014 -0.0014
1% OXYGEN I N FUEL I 89.980 I 0.01455 I 0.00009 I 0.0000 I 0.0000 I 0.0015 I 0.00151
Yo NITROGEN I N FUEL I 89.980 I 0.00000 I 0.00000 I 0.0000 I 0.0000 I 0.0000 I 0.0000
FUEL TEMPERATURE 89.986 0.00273 I 0.00606 I 0.0000 0.0027 I 0.0234 1 0.0234
TOTAL UNCERTAINTY RESULTS

Efficiency
I DATE 10/08/96
ASME PTC4 EXAMPLE PROBLEM
OIL FIRING I SHEET OF I
235
STDmASME PTC 4-ENGL 1998 0759b70 Ob35lt74 875
ASME P K 4-1998 NONMANDATORY APPENLXX B
COMBUSTION CALCULATIONS
I IDATAREQUIRED I
1 HHV, BTU/LBM AS FIRED 17880.00000 9 DRY BULB TEMP, F 83.17000
2 UBC I N REFUSE, LB/iOO LB FUEL 0.00000 10 WET BULB TEMP, F 0.00000
3 FUEL FLOW. KLB/HR 35.13480 11 RELATIVE HUMIDITY. % 38.00000
5 OUTPUT, 1E6 BTU/HR 565.26500 12 SUM ADD MOISTURE, KLBIHR 0.00000
6 FUEL EFFICIENCY, % 89.98023 13 ADD MOISTURE, LB/lOO LB FUEL 0.00000
7 MOIS I N AIR, LB/LB DA 0.00930 14 ADD MOISTURE. LB/10 KBTU 0.00000
8 BAROMETRIC PRESS, in Hg I 29.500001 15 IMASS ASH, LB/ïOKBTU 0.00000
I
22 H20 FROM SORBENT, LB/lOO LB SORB I o.ooooo125 JSORBIFUEL RATIO, LB SORBILB FUEL 0.00000
35 ]TOTAL THEO AIR CHECK, LB/iOKBTU IC31Ml + C30Bl x 11.51 + C3OLl x 34.29/ I 7.49805
I
CORRECTIONS FOR SORBENT REACTIONS AND SULFUR CAPTURE
40 CO2 FROM SORB, LB/lOO LB FUEL C211 x C251 0.00000
41 H20 FROM SORB, LW100 LB FUEL C221 x C251 0.00000
42 SO2 REDUCTION, MOV100 LB FUEL
--
C32Dl x C231 0.00000

43 DRY PROD COMB, MOU100 LB FUEL C32M1 + C401/ 44.01 - C421 7.44585
| ||| | || | ||
44 WET PROD COMB, MOU100 LB FUEL C33M1+ C411/ 18.016 + C431 12.O0934
~ ~-
|
46 THEO AIR CORR, LB/lOO LB FUEL C31Ml+ 2.16 x C3ODl x C231 1340.65100
| |||
47 THEO AIR CORR, MOU100 LB FUEL C461/ 28.966 46.28361

|||| | || ||| | || ||
48 THEO AIR CORR, LWlOKBTU C461/ (ClY100) 7.49805

49 WET GAS FROM FUEL, LBIlOKB (100- C3OJl- C3OBl- C3OLl- C30D1 x C23I)/(ClY100) 0.55928
NAME OF PLANT: UNIT NO. 1
||| | |---
TEST NO: 1 DATE 05/29/96 LOAD 100%

TIME START: 13:OO END: 17:OO CALC BY tch
ASME PTC4 EXAMPLE PROBLEM DATE 10/08/96
OIL FIRING SHEET OF
236
=
~~
STD-ASME PTC 4-ENGL I978 D 0757670 Ob35375 703

NONMANDATORY APPENDIX B ASME PIK 4-1998
COM BU STION CALCU LATIONS
I
LOCATION
I
ENTAH
l II
LVGAH
2 l o l o l o l o
Il
~ 1 -
501 02, YO (BELOW rn = MEASURED 1 = LOCATION 3.9000 5.5000 0.0000 0.0000 0.0000 0.0000
51 I CO. I LOC CORR Com x (20.95 - 021) Ií20.95 - 02m) 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000
90 INPUT FROM FUEL, 1E6 BTU (FROM EFF FORM) 628.2 92 REFUSE RATE, KLB/HR C801 xE901/10 0.0
91 FUEL RATE, KLBIHR~~OOO X C ~ O I / C ~ I 35.1 93 WET FLUEGAS, KLBIHR C751xC901/10 614.0
95 EXCESS AIR LVG BLR, % 21.8 96 TOTALAIRTOBLR, KLB/HR (C691+C721) xC901/10 578.9
N A M E OF PLANT: U N I T NO. 1
TEST NO: 1 DATE 05/29/96 LOAD 100%
T I M E START: 13:OO END: 17:OO CALC BY tch
ASME PTC4 E X A M P L E PROBLEM DATE 10/08/96
OIL FIRING SHEET OF
237
-- | ||| | || | || | | ||| |||| | || ||| | || || ||| | |---
-~ ~ -
STDaASME PTC 4-ENGL 2998 0759b70 Ob1517b bY8
ASME FTC 4- 1998 NONMANDATORY APPENDIX B
FORM Effa EFFICIENCY CALCULATIONS

Data Required
TEMPERATURE, F
i IREFERENCE TEMPERATURE I 77.01 1 A 1 ENTH WATER (32 F REF) I 45.00
AAVE
ENT AIR TEMP I 84.9 2A ENTH DRY AIR 1.89
28 ENTH WATER VAPOR 3.51
AAVE
EXIT GAS T (EXCL LKG) I 293.4 3A ENTH DRY GAS 51.68
3B ENTH STEAM @ 1 PSIA 1192.61
3C ENTH WATER VAPOR 97.51
4 [FUEL TEMPERATURE I 200.0 4A ENTH FUEL 56.68
5 1 HAQC ENT GAS T E M P 0.0 I 5A I ENTH WET GAS I 0.00
238
-- | ||| | || | || | | ||| |||| | || ||| | || || ||| | |---
FORM EFFb EFFICIENCY CALCULATIONS

LOSSES Yo BASIS (ENTER RESULT IN Y COL) I MKBI
140 I DRY GAS I C101 x C3Al / 100 I 29.96 I 4.76981
41 WATER FROM H2 FUEL C121 x (C3B1 - ClAl) I 100 33.15 5.2772
42 WATER FROM H20 FUEL C131 x (C3Bl - ClAl) I 100 0.00 0.000
43 WATER FROM H20V FUEL C141 x C3Cl I 100 0.00 0.0000
44 MOISTURE I N AIR C161 x C3Cl I100 0.52 0.0828
45 UNBURNED CARBON I N REF Cl81 x 14500 / C191 0.00 0.0000
46 SENSIBLE HEAT OF REF from Form REF or REFS 0.00 0.0000
47 HOT AQC EQUIPMENT Irefer to text 0.00 0.0000
48 OTHER LOSSES, Yo BASIS Ifrom Form EFFc C851 0.00 0.0000
54 SUMMATION LOSSES, Yo BASIS 63.64 10.1298
LOSSES, MKBTUIHR BASIS (ENTER RESULT IN M K B COL) MK0 Oh
55 I SURF RADIATION & CONV I refer to text 1.77 0.2824

56 IBLOWDOWN IC351 x (C35Al - C32Al) 11000 0.00 0.0000
157 ISOOTBLOWING STEAM I C361 x (C3Bl - C32Al) 11000 I 0.001 0.0000
58 SORBENT CALCIDEHYD from Form SRBc C771 0.00 0.0000
59 WATER FROM SORBENT from Form SRBc C651 0.00 0.0000
60 OTHER LOSSES from Form EFFc C863 0.63 0.1003
||| | |---
62 I S U M LOSSES, MKBTU BASIS I 2.401 0.3827
|||| | || ||| | || ||
CREDITS, Yo BASIS (ENTER RESULT I N Yo COL) I MKBI yo
I63 1 ENTERING DRY AIR IC111 x C2Al I 100 I 1.091 0.17281
64 I MOISTURE
I64 -. - - - I.N AIR
. IC161
C 6 l x -C2Bl
- -l -. C2B1
--- I 100
-.. I 0.02
0.021
. .- 0.0030l
0.0030
. ....
| |||
65
5 ]SENSIBLE
SENSIBLE HEAT IN I N FUEL I 1100
0 0 x C 4 A l l C191 1.99
1.991 0.3170
|
66 I SULFATION
166 from Form SRBc
Ifrom C801 I 0.00 I
0.00 0.0000
0.0000l
| ||| | || | ||
67 IOTHER
167 OTHER CREDITS, BASIS
CREDITS. % BASIS from Form EFFc
Ifrom C871 I 0.00
0.001 0.0000
0.0000l
71 I S U M CREDITS, O h BASIS 1 3.10) 0.4927
--
CREDITS, MKBTU/HR BASIS (ENTER RES I N MKB COL) I MKBI YL.
172 I A U X EQUIPMENT POWER Ic311 I 0.00 I 0.0000l
173 ISENS HEAT FROM SORB Ifrom Form SRBc C851 I 0.001 0.0000
80 FUEL EFF. o/' (100 - C54I + C71I) X C3OII (C30I + C62I - C75I) 89.9802
81 INPUT FROM FUEL, MKBTU 100 x [301/ C801 628.2102
82 FUEL RATE. KLB/HR 1000 x C811 / C191 35.1348
I T I M E START: 13:OO END: 17:OO I CALC BY tch I
239
~ ~~
~ ~~
STD*ASME PTC 4-ENGL 1798 0759b70 Ob1SL7B 410

--
| ||| | || | ||
|
| |||
|||| | || ||| | || ||
TIE I LOSSES BASIS (ENTER RESULT I N Yo COL)

IC0 I N FLUE GAS 0.00 0.0000
I I
||| | |---
IAIR INFILTRATION 0.00 0.0000l

85D UNB HYDROGEN I N FLUE GAS 0.00 0.0000
85 E UNB HYDROGEN I N REFUSE 0.00 0.0000
85F U NB HYDROCARBONS 0.00 0.0000
856 MISC LOSSES. Oh - EFFc Item 0.00 0.0000
0.00 0.0000
I T/E I LOSSES, MKBTUIHR BASIS (ENTER RESULT I N MKB COLUMN) 1 MKB %

186A I I WET ASH PIT I 0.63 I 0.1003l
85BL SENS HEAT RECY - SOLID 0.00 0.0000
86C SENS HEAT RECY - GAS 0.00 0.0000
86D ADDITIONAL MOIS 0.00 0.0000
86E COOLING WATER 0.00 0.0000
86F APH COIL (FROM UNIT) 0.00 0.0000
86G 0.63 0.1003
TIE CREDITS, Yo BASIS (ENTER RESULT I N Yo COLUMN) MKB %

87A 0.00 0.0000
87 0.00 0.0000
TIE CREDITS, MKBTUIHR BASIS (ENTER RESULT I N MKB COLUMN) MKB Oh
88A HEAT I N ADD MOIS (EXIT ENVI 0.00 0.0000

886 0.00 0.0000
88 0.00 0.0000
I UNIT NO. 1
NAME OF PLANT:
TEST NO: 1
I TIME START: 13300
DATE 05/29/96
END: 17:OO
I LOAD 100%
I CALC BY tch
I
I
I DATE 10/08/96
ASME PTC4 EXAMPLE PROBLEM
O l l FIRING I9UFFT nF I
240
STDOASME PTC 4-ENGL L998 0759b70 ObL5379 357
ASME E*Iy: 4-1998
NONMANDATORY APPENDIX C
DERIVATIONS
C.l INTRODUCTION
The derivation equations utilize the same acronym format as used in Section 5. Section 5.20 shows the format,
definition of letters or letter combinations, and a summary of acronyms used.
C.2 DERIVATION OF SULFUR CAPTUREIRETENTION FROM MEASURED 0 2 AND SO1

The derivation below is shown for O2 and SOz measured on a wet basis. For a dry basis, substitute MODPP
for MOWPP and delete moles of moisture in air, MOWA. For the derivation below, CO and NO, in the flue gas
are assumed to be minimal such that they do not have a significant impact on the result. Refer also to Section
C.5 for derivation with CO and NO,.
VFOZ = -
“O2 --
- moles 02/mole wet gas (measured) (C.2-1)
100 MOWG’
VSFO2 = (’ - MFsc) moles S02/mole wet gas (measured SOz) (C.2-2)

MOWG
where MFSC is the fraction of sulfur in fuel captured or retained.
MOS02 = -
MPSF maximum moles
3206.4’
mass fuel (C.2-3)
MODPP MpcB
- - MPSF M
+
-PN2F
+ MODGSB,
+
(C.2-4)
1201 3206.4 2801.3
maximum moles of dry products from fuel and sorbent/mass fuel
MPH2F MPWF MFWADn MOWSB,

-+ -
+
MOWPP = MODPP
~
i- (C.2-5)
201.6 1801.5 18.015
maximum moles of wet products from fuel and sorbent/mass fuel
moles of theoretical air with 100% conversion sulfur in fuelhass fuel (C.2-6)
24 1
-- | ||| | || | || | | ||| |||| | || ||| | || || ||| | |---
~
STDDASME PTC 4-ENGL 3998 = 0759670 0635380 O79

ASME PTC 4-1998 NONMANDATORY APPFNDiX C
MOTHAC = MOTHAP +-
MFsc -moles theoretical O2 corrected for sulfur retentiodmass fuel (C.2-7)
2 0.2095
The corrected theoretical air requires one-half mole of O2 for every mole of sulfur captured to form SO3 in
the reaction C a 0 + SO, + Caso4.
The moles of wet gas (MOWG) is the sum of the maximum moles of wet products from fuel and sorbent less
the moles of SO, captured plus the moles of nitrogen in the theoretical air plus the moles of water in the
theoretical air plus the moles of wet excess air.
MOWG = MOWPP - MFSC MOS02 + 0.7905 MOTHAC + MOTHAC MOWA
+-MOO2 ( 1 + MOWA), moles wet gadmass fuel (C.2-8)

0.2095
MOWG = MOWPP - MFSC MOS02 + MOTHAP (0.7905 + MOWA) (C.2-9)
+--MFsc VF02
(0.7905 + MOWA) + MOWG - ( 1 + MO WA)
2 0.2095 0.2095
Let K = (0.7905 + MOWA) - -- 1 = 2.387 f0.7905 + MOWA) - 1

1 1
(C.2-10)
2 0.2095
1 -(i
vFo
0.2095 1
+ MOWA) 2 = MOWPP + MOTHAP (0.7905 + MOWA) + K MFSC MOS02 (C.2-1 I )
MOWG =
MOWPP + MOTHAP
-
(0.7905 + MOWA) + K MFSC MOS02
- (C.2- 1 2 )
1 - ( I + MOWA) 2
vFo
0.2095 J
VFSO2
(MOS02 - MFSC MOSO2)
MOWPP -ì-MOTHAP (0.7905

L
1 - (1 + MOWA) -
+ MOWA) + K MFSC MOS02
vFo2
0.2095
V.ZVY5 1 (C.2-13)
||| | |---
|||| | || ||| | || ||
| |||
VFSO2
|
LetB = (C.2-14)
I
| ||| | || | ||
1 - (I + MOWA) -
vFo2
0.2095
--
B [MOWPP + MOTHAP (0.7905 + MOWA)] iB K MFSC MOS02 + MFSC MOS02 = MOS02 (C.2-15)
242
~
STD-ASME PTC 4-ENGL 1996 0757b70 Ob15181 TO5
NONMANDATORY APPENDIX C ASME PTC 4-1998
MFSC MOS02 ( 1 + B K ) = MOS02 - B [MOWPP + MOTHAP (0.7905 + MOWA)] (C.2- 16)
VFSO2 [MOWPP + MOTHAP (0.7905 + MOWA)]
MFSC =
- [ [ l - ( I + MOWA) VF02/0.2095] MOS02
, mass/mass
1 (C.2- 17)
1 +K[
VFSO2
1 - ( I + MOWA) VFO2/0.2095 1
C.3 DERIVATION OF EXCESS AIR BASED ON MEASURED 0 2
The derivation shown below is for O2 measured on a wet basis. For a dry basis, substitute MODP for MOWP
and delete moles of moisture in air, MOWA. The resulting equation below is the same as presented in Section
5 and does not consider the impact of CO and NO, on excess air as they are offsetting and usually insignificant.
Refer to Section C.4 for excess air corrected for CO and NO,.
VP02 MO02
VF02 = -- -moles 02/mole wet gas (measured) (C.3-1)
100 MOWG'
MODP = -+ ( i - MFSC) - -+ MODGSB,

MPSF + MPN2F (C.3-2)
1201 3206.4 2801.3
moles of dry products from fuel and sorbentlmass fuel
F - MFWADn MOWSB,
MOWP = MODP + MPH
2
MPWF
+ + +
(C.3-3)
201.6 1801.5 18.015
moles of wet products from fuel and sorbentlmass fuel
MOTHAC = [,,,
0.2095 1201 403.2
MPSF MP02F
M P H 2 F + ( 1 + 0.5 MFSC) -- -
- -+ -
3206.4 3200 1 (C.3-4)
moles of theoretical air corrected for sulfur capture/mass fuel
Moles of wet gas (MOWG) is the sum of the moles of wet products from fuel and sorbent plus the moles of
nitrogen in the theoretical air plus the moles of water in the theoreticai air plus the moles of wet excess air.
MOWG = MOWP + 0.7905 MOTHAC + MOWA MOTHAC (C.3-5)

+ F X A MOTHAC ( 1 + MOWA), moles of wet gadmass fuel
--
| ||| | || | ||
28.966
MOWG = MFWA - = 1.608 MFWA, moles watedmole dry air (C.3-6)
|
18.015
| |||
|||| | || ||| | || ||
MOO2 = FXA 0.2095 MOTHAC, moles excess 02/mass fuel (C.3-7)

||| | |---
MOO2 FXA 0.2095 MOTHAC

VF02 = -- (C.3-8)
MOWG MOWP + MOTHAC (0.7905 + MOWA) + F X A MOTHAC ( 1 + MOWA)
243
~-
STDaASME PTC 4-ENGL I1998 D 0759b70 Ob35182 941 M
ASME PTC 4-1998 NONMANDATORY APPENDIX C
FXA 0.2095 MOTHAC - VFO;! FXA MOTHAC (1 + MOWA) = V F 0 2 [ M O W P + MOTHAC (0.7905 + M O W A ) ] (C.3-9)
V F 0 2 [MOWP + MOTHAC (0.7905 + MOWA)]

FXA = , mass fraction of excess air (C.3-10)
MOTHAC [0.2095 - VFO2 ( 1 + M O W A ) ]
V P 0 2 [MOWP + MOTHAC (0.7905 + MOWA)]

PXA = 100 , % excess air (C.3-1I )
MOTHAC [20.95 - V P 0 2 ( 1 + M O W A ) ]
C.4 DERIVATION OF 0 2 CORRECTED FOR CO AND NO, FOR DETERMINING EXCESS AIR
The excess air equations shown in Sections 5 and C.3 consider all of the carbon gasified, CB, to be converted
to CO2 and that CO for most combustion processes will be small and have an insignificant impact on calculated
excess air. The formation of NO, reduces the oxygen content of the flue gas and is also considered to have an
insignificant impact on calculated excess air.
In this paragraph, an oxygen content corrected for CO and NO, (VP0,C) is derived that can be substituted
for VPO, in the excess air equations presented previously.
Consider the following reactions:
2 0,+ 2 C + 2 Complete Combustion (C.4-1 )

--
| ||| | || | ||
2 0,+ 2 C + CO + CO2 + 112 N, + 112 Incomplete Combustion (C.4-2)

|
| |||
N2 + 0 2 + NO + 1/2 N2 + 5'202 (C.4-3)

|||| | || ||| | || ||
When CO is present, there is one-half mole more 0, present per mole of CO than there would be if all the
gasified carbon, CB, were oxidized to CO,. For simplicity, NO, will be considered in its most abundant form,
||| | |---
NO. When NO is formed, there is one-half mole less 0, than if there were no NO; however, the total number
of moles of gas does not change.
Referring to Section C.3, the equation for MOO, [Eq.(C.3-7)] becomes:
MOO2 = FXA 0.2095 MOTHAC +M O C O MONO,

-- - , moles excess Oillbm fuel ((2.4-4)
2 2
V P-0 2 - - M
- =O O 2 FXA 0.2095 MOTHAC +-----
1 MOCO 1 MONO,
(C.4-5)
100 MOG MOG 2 MOG 2 MOG
VPCO
--- - M O C O or--I M O C O
VPCO
=- (C.4-6)
100 MOG 2 MOG 200
VPNO, MONO, 1 MONO, VPNO,

-=- or---- =- (C.4-7)
1O0 MOG 2 MOG 200
244
~
STD-ASME PTC U-ENGL L978 œ 0757b70 ObL5L83 888 œ
NONMANDATORY APPENDIX C ASME Fn: 4-1998
Let-
VP02cI
- V p o 2 VPCO +--VPh'o, - FXA 0.2095 MOTHAC (C.4- 8)
1o0 100 200 200 MOG
where MOG is the moles of gas on a wet or dry basis.

--
Let MOTHG equal MOWG defined in Section C.3 (or MODG if measurement on a dry basis). Then the moles
| ||| | || | ||
of gas considering CO and NO, become:
MOCO
|
MOG = MOTHG +- = MOTHG + -MOG (C.4-9)

| |||
2 200
|||| | || ||| | || ||
1
Let MOGCF = (C.4-1O)
r. vpcoi
||| | |---
1' - 2001
then
MOG = = MOTHG MOGCF (C.4-11)

rit - -- 200 1
VPCOl
Dividing Eq. (C.4-8) by the moles of gas correction factor (MOGCF)yields
VPO2C = - FXA 0.2095 MOTHAC

VP02 CI -
(C.4-12)
100 MOGCF MOTHG
which is the same as Eq. (C.3-8). Thus, to correct excess air for CO and NO, substitute VP02C for V P 0 2 in
the excess air equations in Sections 5 and C.3. VP02C becomes:
VPOZ --
2
+-
vpNOx]
2
[ 1 "1,
-- O2 corrected for CO and NO, (C.4-13)
C.5 DERIVATION OF SULFUR CAPTURE/RETENTION FROM MEASURED O2 AND SO2

CONSIDERING CO AND NO, IN THE FLUE GAS
(Later)
(2.6 FUEL EFFICIENCY - MIXED UNITS FOR LOSSES AND CREDITS

Most losses and credits can be calculated conveniently on an input from fuel basis. However, some lossed
credits can only be calculated on an energy per unit of time basis such as radiation and convection loss. One
approach is to estimate the input from fuel and. convert the losdcredit on an energy per unit of time basis to an
input from fuel basis. This requires reiterating until the estimated input from fuel agrees with the calculated input
based on the calculated efficiency. The equation below allows solving for efficiency using losses and credits in
mixed units:
QRF + QRB = QRO + QRL (C.6-1)
Multiplying by 100/QRF:
245
ASME Pn: 4-1998
~
STDOASME PTC 4-ENGL 1998 - 0757b70 Ob15184 7.14
NONMANDATORY APPENDIX C
QRB QRO
100 + 100 - = 100 - +
(C.6-2)
QRF QRF QRF
By definition,
PFE = 100-QRO % (C.6-3)

QRF'
||| | |---
Q P L = 100- QRL % ((2.6-4)
|||| | || ||| | || ||
QRF'
| |||
QPB = 100-ISRB % ((2.6-5)
QR F'
|
| ||| | || | ||
.: PFE 100 - Q P L + QPB, % (C.6-6)
--
Losses calculated on an energy input basis can be converted to a percent basis:
100-QRL = Q P L = -
QRL PFE, % (C.6-7)
QRF QRO
As in Eq. (C.6-6), adding credits and losses:
PFE = 100 - QPL + QPB - PFE E

QRO
+ PFE -
QRB %
QRO'
(C.6-8)
which reduces to
PFE = (100 - QPL + QPB)

[QRO
QRo
+ QRL - QRB
1, % (C.6-9)
246
~
~
STDOASME PTC ‘I-ENGL 1978 0759b70 ObLSL85 b50
ASME PTC 4-1998
NONMANDATORY APPENDIX D
GROSS EFFICIENCY
||| | |---
D.l INTRODUCTION D.2 ENERGY BALANCE METHOD
|||| | || ||| | || ||
Efficiency is the ratio of energy output to energy To calculate gross efficiency (EGr) by the energy
input, expressed as a percentage. This Code recognizes balance method, the fuel efficiency (EF) should be
| |||
two definitions of steam generator efficiency: fuel effi- calculated first by the energy balance method in accord-
ance with Section 5 . Gross efficiency may then be
|
ciency and gross efficiency. The output term (QrO) is
| ||| | || | ||
the same for both definitions of efficiency and is defined calculated from one of the following equations:
in Sections 2 and 5 as the heat absorbed by the working
fluid to produce useful energy. For fuel efficiency (EF),
] (D.2-1)
--
the energy input to the system is defined as the total EGr = 100 Qro = loo[, - ‘PL
heat of combustion available from fuel or the fuel QrF + QrB 100 + QpB
input (QrF). For gross efficiency (EGr), the energy
input to the system is defined as the total energy added
= loo[, - QrL
QrF+QrB
% 1.
to the system or gross input (QríGr). The gross input
is the sum of the input from fuel (QrF) plus credits
(QrB) or the energy added to the system from other
sources with respect to the reference temperature, 77°F QrO
(25°C). Refer to Section 5 for a more complete definition QrF = 100 -
, Btu/h (W) (D.2-2)
EF
of credits.
where
EGr = 100 OUTPUT = 100 % E, (D.1-1) QrB= summation of credits, Btu/h (W) basis. Items
GROSS INPUT QrlGr
that result in a negative credit shall still be
considered as a “credit” in the calculation
of gross efficiency. It may be questioned why
QrlGr = QrF + QrB, Btulh (W) (D.l-2) exothermic reactions, in particular sulfation,
are considered a credit. This is a matter of
definition adopted by the Code committee, but
The advantage of gross efficiency versus fuel effi- it is interesting to note that they have no
ciency is that it is a measure of the total energy required impact on gross efficiency because the input
to produce a given output, and thus may have some from fuel will be reduced by the exact amount
meaning if the costs of the other energy sources are of the heat gained from sulfation.
not evaluated separately. The major disadvantage of QpB = summation of credits, percent (%) basis
gross efficiency is that it is not universally understood QrL= summation of losses, Btu/h (W) basis
by those evaluating a total system and may be used QpL= summation of losses, percent (%) basis
incorrectly. The major sources of energy added to the
system and credits are electrical and steam energy. The
cost of these energy sources is not the same on a Btu
D.3 INPUT-OUTPUT METHOD
basis as the energy cost of the fuel, and should be
(usually is) evaluated separately. If the cost of credits Efficiency calculated by the input-output method is
is evaluated separately, gross efficiency is not appro- based upon measuring the fuel flow and boiler fluid
priate for the evaluation of energy cost to produce a side conditions necessary to calculate output. Credits
given output. Therefore, fuel efficiency is the preferred are measured and/or calculated to determine total input
method in this Code for expressing efficiency. as defined above. The uncertainty of efficiency calcu-
247
STD-ASME PTC 4-ENGL I998 0759b70 ObL518b 597
ASME P K 4-1998 NONMANDATORY APPENDIX D
lated by the input-output method is directly proportional input from fuel basis, multiply by (QrF/lOO)to
to the accuracy of determining the fuel flow, a represen- convert to Btuh (W). Below are supplementary
tative fuel analysis, and steam generator output. There- comments on the calculation of credits that
fore, to obtain reliable results, extreme care must be are not measured directly.
taken to determine these items accurately: The credits due to heat in entering dry air (QrBDA)
and moisture in entering dry air (QrBWA) require the
mass flow rate of dry air. The mass flow rate of dry
EGr = 100 Qro ,% (D.3-I) air is calculated stoichiometrically from the ultimate
QrF+QrB
fuel analysis and unburned carbon in the refuse (refer
to Section 5 and the Combustion Calculation form,
Appendix B). For units that do not utilize sorbent for
QrF = MrF HHVF, Btülh (w) (D.3-2) reduction of sulfur emissions, it may be necessary to
calculate unburned carbon in the refuse (refer to the
where Unburned Carbon and Refuse Calculation form, Appen-
MrF= measured mass flow rate of fuel, lbm/h (kg/s) dix B). For units that do use sorbent, it will be necessary
HHVF= higher heating value of fuel, Btdlbm (Jkg). to calculate the mass fraction of sulfur capture as well
Refer to Section 5.8. as unburned carbon in the refuse (refer to the Sorbent
--
QrF= heat input from fuel, Btuh (W) Calculation form, Appendix B). The credit due to
QrB= summation of credits, Btufh (W) basis. Refer sulfation (QrBSZj) is calculated from the mass fraction
| ||| | || | ||
to Section 5 for the general method of calcula- of sulfur capture which is calculated above. The use
tion. For the credits calculated on a percent of sorbent also impacts the mass flow rate of dry air.
|
| |||
|||| | || ||| | || ||
||| | |---
248
STDmASME PTC 4-ENGL 1998 0759b70 Ob15187 423 W
ASME ITC 4-1998
NONMANDATORY APPENDIX E
THE PROBABLE EFFECTS OF COAL PROPERTIES
ON PULVERIZED COAL AND COAL AND SORBENT
PROPERTIES ON FLUIDIZED BED STEAM
GENERATOR DESIGN AND PERFORMANCE
E.1 INTRODUCTION Slagging, fouling, and combustion indices must be

developed for the design coal and compared to the test
This Appendix addresses the following:
coal before any performance test is begun. The test
0 Probable effects of coal properties on pulverized coal coal must have the same characteristics as the design
steam generator design and performance. coal. The analysis should be based on the application
0 Probable effects of coal and sorbent properties on flu- of several indices developed by the industry and found
--
idized bed steam generator design and performance. in sources such as Reference [4].
| ||| | || | ||
The Test Engineer is cautioned to use several slag-

ging, fouling, and combustion indices in making this
E.2 PULVERIZED COAL FIRED STEAM judgment, since no single index gives totally accurate
|
| |||
GENERATORS and indisputable results.

|||| | || ||| | || ||
This Section gives general guidance for identifying E.2.3 Coal Properties Determination
the relationship of steam generator design and effects Standard tests for coal are identified below. Examina-
on its performance when a fuel is other than the design tion of the results of these standard coal tests is used
||| | |---
generator acceptance test. This Section is not intended to infer the effects on steam generator design and
to be inclusive but rather to identify significant coal performance. The Test Engineer should use these stan-
properties and their impact on steam generator design dard tests to assess the coals to be burned before
and performance trends. undertaking steam generator performance testing. Major
coal property tests include the following:
E.2.1 Coal RanWEquipment Size
Steam, Its Generation and Use [7] provides a com- o proximate analysis
plete discussion of coal rank. Coal characteristics, and 0 ultimate analysis
coal rank in particular, have a dramatic impact on 0 ash fusibility
furnace sizing. Tuppeny [8] compares the size of a o hardgrove grindability index
furnace burning eastern bituminous, midwestern bitumi- o ash mineral analysis
nous/subbituminous, Texas lignite, and Northern Plains 0 combustion characteristics
lignite coals. Table E.2-1 summarizes the relative fur-
nace sizes, coal quantities, and pulverizer sizes based These and many other tests and indices are listed
upon the assumptions made in the reference. and discussed in Reference [4].
E.2.2 Slagging and Fouling E.2.4 Probable Effects of Coal Properties on Steam
Slagging and fouling, other than expected and ac- Generator Design and Performance
counted for by the boiler design, can significantly alter The complex effects of the coal properties, as assessed
steam generator performance and efficiency. It is thus by the above standard tests, on steam generator design,
very important that the coal selected for a performance thermal performance, and overall boiler operation are
test have substantially the same slagging, fouling, and listed in Table E.2-2. This table primarily lists effects
combustion characteristics as the design coal. that cannot be corrected to contract conditions.
249
~~
~
STD-ASME PTC Li-ENGL 3998 D 0759670 ObL5388 3bT m
ASME PTC 4-1998 NONMANDATORY APPENDIX E
TABLE E.2-1
EFFECTS OF COAL RANKS ON STEAM GENERATORS
Relative Relative Furnace Dimensions Relative
Coal Pulverizer
Coal Quantities Depth width Height Sizes
Eastern 1 1 1 1 1
Bituminous
Subbituminous 1.43 1.06 1.08 1.05 1.7
Texas Lignite 1.64 1.08 to 1.24 1.16 to 1.26 1.07to 1.30 1.84
Northern Plains 1.76 1.76 1.26 1.45 2.0
Lignite
GENERAL NOTE: From this Table it becomes obvious that a steam generator designed for one coal rank
will not operate well or may be totally unsuitable for other types of coals. This emphasizes the need to
evaluate test coals relative to the specified coals to establish their suitability for the unit being tested.
--
| ||| | || | ||
E 3 FLUIDIZED BED COMBUSTION COAL The following standard analyses should be conducted on
FIRED STEAM GENERATORS the fuel in question:
|
| |||
There are three main parameters for atmospheric e proximate

|||| | || ||| | || ||
fluidized bed combustors (AFBC): ultimate

0 coal mineral ash
Thermal efficiency - This is the combined effect of 0 higher heating value
combustion efficiency, heat transfer performance of ash fusion temperature
||| | |---
the heat surfaces throughout the steam generator, and

auxiliary power required to run the steam generation However, some of the key fuel characteristics perti-
operation. nent to combustion in AFBC boilers are different from
Sulfur dioxide capture efficiency. the characteristics pertinent to combustion in pulverized-
NO, generation rate - To determine these perform- coal and stoker fired boilers (References [9], [ IO], [ 1 i]).
ance parameters in the field, the Test Engineer inust The differences are a result of the distinct environment
be aware of and understand all factors which may in AFBC boilers (lower temperature, longer residence
influence these parameters. These factors can be inher- times, larger coal particles, and mechanical effects of
ent in the design parameters, operating conditions, bed material). Therefore, to obtain these A B C fuel
coal and sorbent material properties, or any combina- characteristics, tests specially designed for AFBC appli-
tion of these factors. Due to the complexity of such cations are suggested in addition to standard tests and
interrelations between these factors and the AFBC analyses (References [9] and [lo]). These tests are
performance parameter, this Section addresses only described below:
the major factors as reported by the industry.
Feed System Attrition Test (Underbed Feed) - This
This portion of Appendix E gives general guidance test indicates the extent of breakage of attrition of the
for predicting the effect on steam generator design and new fuel with respect to the design fuel due to transport
performance when the fuel and/or sorbent is changed through the coal feed system and feed point. High
from the design coal and/or sorbent. As with the attrition increases the fines content, which can reduce
previous section, this section is not intended to be combustion efficiency and increase emissions.
inclusive but rather to identify many of the design and Combustion-Enhanced Mechanical Attrition Test -
performance trends. In this section, standard tests for This test is important mainly for low reactivity fuels
coal and sorbent are identified. Examination of the and indicates the extent of attrition which occurs in the
results of these standard tests is used to infer the effects AFBC unit during combustion. Again, high attrition
on steam generator design and performance. increases the fines content, which can reduce combus-
tion efficiency.
EA1 Coal Properties Determination 0 DevolatilizatiodBulk Reactivity Test - This set of
Some of the coal property tests previously described tests provides the data to determine the volatile yield
for conventional coal units are applicable to AFBC units. (which may be different from the proximate volatile
250
STD-ASME PTC ‘+-ENCL 1998 0759b70 Ob15389 2Tb D
NONMANDATORY APPENDIX E ASME PTC 4-1998
TABLE E.2-2
EFFECTS OF COAL PROPERTIES ON STEAM GENERATOR DESIGN AND
PERFORMANCE
Coal Property Variable Affected Componentk) Probable Effect On
1. Coal Heating Value Silo Storage Coal Flow Rate

Feeders Equipment Capacity
Pulverizers Number of Components
Burners in Service
Emission Control Turndown Ratio
||| | |---
Equipment
Coal Handling System
|||| | || ||| | || ||
2. Coal Moisture Content Silo Storage Coal Flow Rate
Feeders Equipment Capacity
Pulverizers Coal Flow Ability
| |||
Primary Air System Pulverizer Outlet
|
I D Fans Temperature
| ||| | || | ||
Coal Handling System Primary Airflempering Air
Flow Quantities
Turndown Ratio
--
3. Volatile Content Burners Required Fineness
Furnace Burner Design
Pulverizers Flame Stability/Ignition
Ignitors Unburned Carbon Loss
Furnace Geometry
Firing Methods
Pulverizer Inerting Needs
Turndown Ratio
4. Grindability Index Pulverizers Capacity

Fineness
Power Requirements
5. Coal Abrasiveness Index Coal Handling System Equipment Outages

PuIver ize r Maintenance
Components Design Velocity Requirements
Coal Piping Material Selection
Burner Nozzles Tube Wear and Life
Convection Passes Reliability
Air Heater W H ) Heating Air Heater Performance
Elements and Seals
6. Nitrogen Content Burners Burner Design

Furnace Furnace Geometry
Air Distribution Air and Flue Gas System
NO, Emissions
Required Burner Zone
Stoichiometry
7. Sulfur Content Scrubber Corrosion Rate

Precipitators Equipment Sizing Requirements
Air Preheaters Stack Gas Temperature
Steam Coils Requirements
Emission Control Equipment
8. Reactivity Index Burners Combustion

PuIver ize rs Explosion Potential
Inerting System Unburned Carbon Loss
Ignitors Turndown Ratio
25 1
-~
ASME PTC 4-1998

~ -
STD.ASME PTC 4-ENGL 3998

~
- 0759670 Ob35390 TL8
NONMANDATORY APPENDIX E
TABLE E.2-2 (CONT’D)

EFFECTS OF COAL PROPERTIES ON STEAM GENERATOR DESIGN AND
PERFORMANCE
Coal Property Variable Affected Componentk) Probable Effect On
9. Ash Content Ash Handling Capacity

Pulverizers Performance
Soot Blowers Design Velocity Requirement
Precipitators Tube Wear and Life
Convection Passes Reliabi Iity
Soot Blowing Requirements
10. Ash Fusibility Furnace SlaggingiFEGTiSteam

Soot Blower Temperature
Water Lancing Fouling/Steam Temperature
NO, Emissions
Soot Blowing and Water
||| | |---
Lancing Operation
|||| | || ||| | || ||
11. Coal Ash Analyses Steam Generator S IaggingtF EGTISteam
Emission Control Temperature
Equipment Foul ingiSteam Temperature
Soot Blowers Precipitator Efficiency
| |||
Ash Handling Systems Design Tube Spacing
|
Requirement
| ||| | || | ||
Excess Air Requirement
NO, Emissions
Ash Split
--
GENERAL NOTE: For general information on steam generator design and operation, refer to References
Cil through C71. References [21 and L71 are texts used extensively in the industry.
yield resulting from the different combustion environ- cause the standard analyses are not entirely relevant
ment), devolatilizationrate, volatiles and char burnout to AFBC,comparing the standard analyses of the design
times, and activation energy and pre-exponential coef- fuel with the new fuel will not reveal the characteristics
ficient for reactivity determination. that may cause changes in performance and operation.
Coal Swelling Test - For coals that swell (caking
E.3.2 The Effect of Coal Properties on Steam Gen-
coals), this test establishes the size of a coal particle
erator Design and Performance
after devolatilization, which affects burnout time. The
One example of the unseen differences among coals
test also provides an indication of agglomeration po-
was shown in a coal selection study identified in
tential; if a coal swells, agglomerationmay be a poten-
Reference [121. Four medium-volatility coals appeared
tial problem.
similar by comparison of ultimate and proximate analy-
Fragmentation Test - This test establishes the ex-
ses, but AFBC fuels characterization tests revealed
treme of fragmentation for the planned coal feed size
significant differences in combustion efficiency resulting
distribution. Coal particles greater than a critical size
from differences in’the devolitilization rates and char
which is specified to each coal fragment during com-
reactivities. A fifth medium-volatility coal, Bradford,
bustion. The number and size of fragments affect the
had still different characteristics from the other four,
coal burnout time. This test is most important for
although the ultimate and proximate analyses were
overbed feed application.
similar. These characteristics were not disclosed by the
Ideally, the range of fuels planned for a unit would standard analyses.
be characterized prior to design to incorporate the Tables E.3-1 through E.3-4 show the performance
flexibility required to accommodate the fuels into the and design variations that could be expected from a
unit and auxiliary equipment. For a fuel not previously change in coal. The first column shows the specific
considered, neglecting to run the AFBC characterization coal property tests. In the second column, the steam
tests risks performance and operational problems. Be- generator component or process parameter is identified
252
___
STDOASME PTC 4-ENGL 1998 0759670 Oh315292 954 =

NONMGNDATORY APPEMIIX E ASME PM:4-1998
that is affected by a change in the listed coal property. The first step suggested for predicting the change
In the third column, the effect is described for a change of sorbent is to conduct the following standard chemical
in property from the coal test. In the fourth column, analyses for the sorbent: calcium, magnesium, moisture,
consequences are identified for the effect if action is and silica.
not taken to recti@ the problem created by the variation In addition, it is advisable to perform an abrasion
in the coal property. In the fifth and sixth columns, test for the sorbent and a particle size distribution.
general corrective actions are identified that could allevi- If the geological classification for the new sorbent
ate or minimize the consequence identified in the fourth is different from the design sorbent, the following tests
column. The fifth column is a process corrective action, are also recommended:
and the sixth column is an equipment corrective action. thermogravimetric analysis (TGA)
grain size
pore size
E.3.3 Sorbent Properties Determination 0 attrition
Determining sorbent characterizations from property 0 surface area (raw and calcined)
tests is not always conclusive. In some cases, there is 0 pore volume (raw and calcined)
more than one recognized test for the same property.
The purpose of this Appendix is to suggest sorbent E3.4 The Effect of Sorbent Properties on Steam
tests for guidance in characterizing sorbent for use in Generator Design and Performance
steam generator design and performance. Tables E.3-5 through E.3-7 show the performance
Tables E.3-5 through E.3-7 show the performance and design variations that would be expected from a
and design variations that would be expected from a change in sorbent. These tables have the same format
change in sorbent. These tables have the same format as the previously described tables for coal. Review
as the previously described tables for coal. References [13] and [14] for more information.
253
-- | ||| | || | || | | ||| |||| | || ||| | || || ||| | |---
STD-ASME PTC 4-ENGL 1998 W 0759b70 Ob15L92 890
ASME FTC 4-1998 NONMANDATORY APPENDIX E
TABLE E.3-1
PROXIMATE ANALYSIS FOR COAL
Corrective Action
Approximate Componenü
Analysis Process Parameter Effect Consequences Process Equipment
Moisture Underbed feed lines Excessive surface Extra maintenance Feed lower moisture install coal dryer
moisture (>6%) to alleviate line coal with flexibility to
could cause pluggage dry wetter coal
pluggage
Bed temperature Excessive moisture Higher SO, emis- increase firing rate; Fans. In-bed tube
could cause a sions drop bed level bundle design
drop below opti- (bubbling bed)
mum tempera- Lower combustion
ture range for pro- efficiency
cess performance
Coal feed equipment Higher coal feed Load reduction Upgrade feed equip-
rates required ment size
Volatile matter and In-bed/freeboard Change in either Change i n combus- Adjust firing rate; Adjust in-bed heat
fixed carbon combustion split fixed carbon or tion efficiency, adjust bed level. transfer surface.
volatile matter SO,, NO,, and CO Additional tests Install larger
could cause sub- emissions, and transport fans
stantially differ- heat transfer
ent bed temper-
--
ature
| ||| | || | ||
Adjust recycle íbub-

bling bed)
|
| |||
Adjust solids loading

(circulating bed1
|||| | || ||| | || ||
Furnace tempera- Vary particle size Install crusher with

ture profile distribution wider range
||| | |---
Ash Ash removal systems Higher ash content Load reduction Upgrade ash
could exceed capa- removal system
bilities of removal
systems
Recycle At a given recycle Lower combustion Adjust recycle Install ash

ratio, higher ash efficiency and classifier
content implies higher SO, emis-
lower combusti- sions
ble and sorbent re-
circulation
Multiclonel Inert ash could di- Combustion effi- install with higher
Cyclone lute recycle ma- ciency reduction. capacity: ESP,
terial Baghouse or ESP baghouse, recy-
over Ioad cle, andlor
multiclone
Ash coolers Higher ash content Load reduction Upgrade ash coolen
could exceed ash
cooler capabilities
254
STD-ASME PTC Li-ENGL 1998 0759b70 ObLSL93 727
TABLE E.3-2
ULTIMATE ANALYSIS OF COAL
Corrective Action
Component!
Ultimate Analysis Process Parameter Effect Consequences Process Equipment
Sulfur Sulfur retention An increase in sulfur Higher sulfur emis- Increase sorbent Upgrade sorbent
would increase sul- sions feed rate. In- feed system. Up-
fur emissions crease recycle grade limestone
(bubbling bed) feed system
Coal Ash Analysis
MgO Sulfur retention A decrease in Higher sulfur emis- Increase sorbent Upgrade sorbent
Ca0 either MgO con- sions feed feed system
tent and/or Ca0
content would in-
crease sulfur emis-
sions
Na,O Ash fusion temper- A lower Na,O con- Lower heat transfer Require repeated
ature tent could be indi- to freeboard outages to remove
cator of lower ash waterwall and slag
fusion tempera- lower boiler effi-
ture. I f freeboard ciency. Decreased
temperature ex- load
ceeds ash fusion
temperature, then
slagging could oc-
cur on freeboard
waterwall
An increase in so- Lower in-bed heat Requires repeated

dium content absorption. In- outages to remove
could cause ash ability to fluidize ash agglomer-
agglomeration in bed compartment ation.
bed
Na20 Fly ash resistivity An increase in Na,O Higher solids emis- Decrease backend Upgrade ESP de-
K2O
and K,O could in- sions temperature if pos- sign. Install am-
crease fly ash re- sible monia injection,
sistivity and de- water injection
crease ESP system for ESP
efficiency
255
-- | ||| | || | || | | ||| |||| | || ||| | || || ||| | |---
~
-
STD-ASME PTC 4-ENGL 1996 0759b70 ObL5L94 bb3
ASME E*Tc 4-1998 NONMAMIATORY APPENDIX E

--
| ||| | || | ||
TABLE E.3-3
SPECIAL TESTS AND SIZE ANALYSIS FOR COAL
|
| |||
Corrective Action
Special/ Component/
|||| | || ||| | || ||
Standard Tests Process Parameter Effect Consequences Process Equipment

Higher heating value Fuel feed rate Lower HHV requires Load reduction Increase firing rate Upgrade coal reed
("V) greater feed rate system capacity.
||| | |---
and capabilities of Upgrade ash re-

fuel feed or ash removal system
moval system
could be exceeded
Ash fusion temper- Ash fusion temper- if freeboard temper- Lower freeboard Reduce firing rate Upgrade freeboard
ature ature ature exceeded waterwall heat ab- or recycle rate heat transfer
ash fusion temper- sorption. Lower surface
ature, slagging boiler efficiency
could occur on
free board
waterwall
Size Analysis
Sieve Fines (coal particles Excessive fines (15- Slagging. Boiler not Double screen or Select crusher with
less than 30 20%) could result surfaced cor- wash coal flexibility to pro-
mesh) in higher free- rectly. Higher SO duce coarser
board tempera- emissions product
tures
Excessive carbon elu- Lower combustion Adjust crusher (re-

triated from com- efficiency move plates). Ash
bustor when feed- reinjection
ing overbed
Large coal sizes The underbed feed- Operating bed below

lines or splitters performance
could plug temperature. Re-
duction in load
Rocks could accumu- Reduction in load Upgrade in-bed rock

late in bed when removal system.
feeding overbed Coal preparation
system design to
selectively re-
move large par-
ticles
256
~
STD-ASME PTC 4-ENGL 1998 0759b70 Ob15195 5 T T m
TABLE E.3-4
SPECIAL AFBC TESTS FOR COAL
Corrective Action
Special AFBC Component/
Tests Process Parameter Effed Consequences Process Equipment
Feedline attrition co- Feedlines Feedline attrition More carbon elutri- Adjust transport ve- Adjust crusher. In-
efficients Combustion split causes increase in ated from combus- locity stall with more
Combustion effi- fines tor. Lower com- flexibility. Up-
ciency bustion efficiency grade fuel feed
system design
Bulk reactivity Reactivity Change of imbed/ imbalance in super- Adjust bed depth Upgrade fuel feed
Combustion split freeboard heat heat and evapora- (bubbling bed). system
Combustion effi split could cause tive heat duties. Adjust solids load-
ciency excessively high Attemperation ing (circulating
or low freeboard bed). Adjust recy-
and/or bed temper- Lower efficiency pos- cle rate
atures. sible for less reac-
tive fuel
Combustion en- Attrition Carbon particles can More freeboard com- Adjust fuel feed Adjust crusher
hanced mechani- Combustion split have excessive at- bustion; higher size. Adjust veloc-
cal attrition Combustion effi- trition in bed freeboard temper- ity to increase res-
(CEMA) ciency atures; possibly idence time
more carbon elu-
triated from com-
bustor. Lower
combustion effi-
ciency. More in-
bed combustion
and lower free-
--
board tempera-
| ||| | || | ||
tures
Swelling index Expansion of coals Bituminous coals Without this infor- An increase in swell- Decrease air velocity
|
Particles swell and then mation, less con- ing index tends t o or increase recy-
| |||
break fidence in results decrease overall cle rate

|||| | || ||| | || ||
from certain com- combustion effi-

bustion models. ciency
Fragmentation index Fragmentation Lignite and subbi- Without this infor- i s more important
||| | |---
Combustion split tuminous coals mation, less con- for overbed feed
Combustion effi- usually fragment fidence in results than for underbed
ciency less from certain com- feed, unless the
bustion models fuel is an agglom-
erate to start with
257
STD=ASME PTC V-ENGL 3998 M 0759b70 0635376 436
TABLE E.3-5
CHEMICAL ANALYSIS OF SORBENT
Corrective Action
Chemical Component/
Analysis Process Parameter Effect Consequences Process Equipment
Calcium Sorbent flow rate Decrease in calcium Increase in sulfur Adjust sorbent flow Increase sorbent
||| | |---
content in lime- emissions or cal- rate feed system ca-
stone cium to sulfur mo- pacity
|||| | || ||| | || ||
lar ratio
Magnesium Sorbent flow rate Decrease in magne- increase in sulfur Adjust sorbent flow Increase sorbent
sium content in emissions or cal- rate feed system ca-
| |||
limestone cium-to-sulfur mo- pacity
|
lar ratio
| ||| | || | ||
Moisture Underbed feedlines The occurrence of Segments of beds op- Maintain stricter
pluggages of feed- erating below opti- quality control on
lines and splitters mum tempera- limestone
--
could increase ture for process
performance. Re-
duced load could
occur
Boiler efficiency Additional heat will Lower boiler effi-

be required to ciency
evaporate
moisture
Silica Feedlines More silica content Possible replace- Choose fix.

might result in ment of limestone Refer to abrasion in-
more erosion in feed Iines dex below
Ii mestone feed-
Iines
Abrasion
Abrasion index Feedlines Higher abrasion in- Repair and replace- Use erosive preven-
dex would indi- ment of feedlines tion devices when
cate more erosion possible such as
blind tees. Use of
ceramic lining. Ad-
dition of wear
pads in areas
where high ero-
sion would be ex-
pected. Use of spe-
cial coatings
Heat exchanger Repair and replace- Install tube bundles.

tubes ment of tubes Install protective
devices on bottom
of tubes such as
balls or studs
258
STD-ASME PTC V-ENGL 1798 M 0757670 Ob15197 372
NONMANDATORY APPENDIX E ASME FI'C 4-1998
TABLE E.3-ó
SIZE AND TGA ANALYSIS AND GEOLOGICAL CLASSIFICATION OF SORBENT
Corrective Action
Particle Size Component/
Distribution Process Parameter Effect Consequences Process Equipment
S ¡eve Underbed feedlines Large particles can More feedline plug- Upgrade limestone Upgrade sorbent
cause pluggage gage. I f same preparation feed system de-
feedlines as coal system sign. increase bag-
feed, then local house capacity. In-
temperature be- crease ESP
low optimum for capacity
||| | |---
process per-
formance
|||| | || ||| | || ||
Sulfur capture Smaller particles Less sulfur capture
could blow out of and less calcium
bed and have uti Iization
| |||
lower sulfur cap-
ture. Large parti-
|
| ||| | || | ||
cles have less sur-
face area, thus
lower sulfur
capture
--
Multiclone Sufficiently small Increase fly ash bur-
particles cannot den on air pre-
be captured by heater and bag-
multiclones house
Limit recycle rate
Thermogravimetric (TGA)
Reactivity Sulfur capture Less reactive lime- Possibly more sulfur Possibly increase Increase sorbent
stone could have emissions sorbent feed rate. feed system ca-
lower sulfur Conduct other pacity
capture types of tests to
increase confi-
dence in reactivity
esti mate
GeologicaL Classification
Geological age Calcium utilization Younger limestone More sulfur emis- increase sorbent Increase sorbent sys-
would probably sions feed rate tem capacity
not be as efficient
259
STD-ASME PTC 4-ENGL 1996 0759670 0615198 209
TABLE E.3-7
ATTRITION, GRAIN, AND PORE SIZE ANALYSES OF SORBENT
Corrective Action
Component/
Attrition Process 'Parameter Effect Consequences Process Equipment
Attrition constant In-bed attrition Limestone with high Lower sulfur cap- Adjust velocity Install transport
attrition constant ture and calcium fans with flexible
Sulfur capture will attrite into utilization capacity
many pieces and
be blown out of Upgrade flyash re-
bed moval
I f attrition is severe Increase in fly ash Increase cleaning Install baghouse

then the fly ash to to be disposed frequency of bag- with higher ca-
disposal would in- house pacity
crease
Tem Micrographs
Grain size Grain size Generally, sorbents Lower sulfur cap- Increase sorbent Increase sorbent sys-
with smaller grain ture or higher cal- feed tem capacity
sizes have more cium-to-sulfur mo-
sulfur capture po- lar ratio Increase ash re-
tential. Twoexcep- moval system ca-
tions are very pacity
finely grained
dense limestones
and crenoidal
limestones
Mercury Penetration Porosimeters
Pore size Pore size Generally, sorbents Lower sulfur cap- Increase sorbent
||| | |---
with larger pore ture or higher cal- feed
sizes have more cium-to-sulfur mo-
|||| | || ||| | || ||
sulfur capture po- lar ratio
tential
| |||
|
| ||| | || | ||
--
260
STD-ASME PTC 4-ENGL 1998 0759b70 ObLSL99 145 =
ASME FT
' C 4-1998
NONMANDATORY APPENDIX F
REFERENCES
Section 1 Section 6
None. None.
Section 7
Section 2
[ i ] Gerhart, P.M., and R. Jorgensen. Uncertainty
[ i ] ASME SI-I, Orientation and Guide for Use of
Analysis: What Place in Performance Test Codes?
SI (Metric) Units (ANSI 2210.1).
ASME Paper 84-JPG-PTC-9, 1984.
[2] ASME SI-9, Guide for Metrication of Codes and
[2] ASME PTC 19.1, Measurement Uncertainty,
Standards SI (Metric) Units.
American Society of Mechanical Engineers, 1985.
[3] ASME PTC 11, Fans, American Society of Me-
Section 3
chanical Engineers, 1984.
[ i ] Scharp, C. Accuracy and Practicability: An
[4] Benedict, R. P., and J. S . Wyler. Engineering
Enigma in Performance Testing. ASME Paper 84-JPGC-
Statistics - With Particular Reference to Performance
F'TC-5, 1984.
Test Code Work. ASME Paper 78-WA-PTC-2, 1978.
[2] Entwistle, J. Definition and Computation of Steam
[5] Kline, S.J., and F. W. McClintock. Estimating
Generator Efficiency. ASME Paper 84-JPGC-PTC-6,
Uncertainties in Single Sample Experiments. Mechani-
1984.
cal Engineering, January 1953.
[3] Entwistle, J., T. C. Heil, and G. E. Hoffman.
[6] Sotelo, E. Atmospheric Fluidized Bed Combus-
Steam Generator Efficiency Revisited. ASME Paper
tion Performance Guidelines. EPRI Report GS-7164,
88-JPGC-F'TC-3, 1988.
1991.
[4] Davidson, P., E. Sotelo, and P. Gerhart. Uncer-
[7] ISA Standard ANSUISA S51.1.
tainty Analysis and Steam Generator Testing. ASME
[8] 90-JPGCPTC8, Effects of Spatial Distributions
Paper 86-JPGC-PTC-1, 1986.
for Performance Testing
Section 4 Appendix A
None. None.
Appendix B
Section 5
None.
[ i ] Jones, F. E. The Air Density Equation and the
Transfer of the Mass Unit. Journal of Research of the Appendix C
National Bureau of Standards. Vol. 83, No. 5, Septem- None.
ber-ûctober 1978.
Appendix D
[2] NBS Technical Notes 270-3 to 270-8 as cited
None.
in CRC Handbook of Chemistry and Physics, 65th
edition. CRC Press, Boca Raton, Florida. Appendix E
[3] JANAF Thermochemical Tables, Second Edition. [ i ] Burbach, H.E., and A. Bogot. Design Considera-
NSRDS-NBS 37. tions for Coal-Fired Steam Generators. Association of
[4] United States National Aeronautics and Space Rural Electric Generating Cooperatives, 1976.
Administration (NASA) Publication SP-273. [2] Combustion, Fossil Power Systems. Combustion
[5] Kirov, N. Y. Chemistry of Coal Utilization, Sec- Engineering, Inc., 1981.
ond Supplementary Volume. M. A. Elliott, ed. John [3] Durrant, O. W. Pulverized Coal - New Require-
Wiley and Sons, New York, 1981. ments and Challenges.
[6] Could, D. W. The Science of Petroleum, 1938, [4] EPRI CS-4283, Effects of Coal Quality and
as cited in ASME PTC 4.1-1964. Power Plant Performance and Costs, Volume 3, 1986.
26 i
-- | ||| | || | || | | ||| |||| | || ||| | || || ||| | |---
STD-ASME PTC 4-ENGL It998 m 0759b70 Ob15200 797
ASME PTC 4-1998 NONMANDATORY APPENDIX F
[ 5 ] Gray, R. J., and G. F. Moore. Burning the Sub- [i 11 Characterization of Coals for Fluidized Bed
Bituminous Coals of Montana and Wyoming. ASME Boilers. CSIRO v16/529, June 1989.
Winter Annual Meeting, 1974. [12] Duqum, J. N., R. R. Chandran, M. A. Perna,
[6] Sadowski, R. S., and P. J. Hunt. Consequences D. R. Rowley, J. Pirkey, and E. M. Petrill. Fuels
of Specifying a Boiler Design Fuel When Source Com- Characterization for AFBC Application. ASME 88-
mitments Are Not Firm. American Power Confer- JPGCFACT-4, September 1988.
ence, 1978. [13] Fee, D.C., et al. Sulfur Control in Fluidized
[7] Steam, Its Generation and Use. Babcock and Bed Combustor: Methodology for Predicting the Per-
Wilcox, 1992. formance of Limestone and Dolomite Sorbents. ANU
181 Tuppeny, W. H. Effect of Changing Coal Supply FE-80-10, September 1982.
on Steam Generator Design. American Power Confer- [14] Celentano, D., et al. Review Methods for Char-
ence, 1978.
acterizing Sorbents of AFBC’s. Ninth International Con-
[9] EPRI Fuels Characterization Project Facilities
ference on Fluidized Bed Combustion, May 3-7, 1987,
and Procedures. Babcock and Wilcox, RDD:90:4753-
pp. 501-510.
53-53-01:01, May 1989.
[ 101 Characterizing Fuel for Utility-Scale Atmo-
spheric Fluidized-Bed Combustor. Final Report RP 718-
2, June 1990.
262
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C
-- | ||| | || | || | | ||| |||| | || ||| | || || ||| | |---

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STD.ASME PTC 4-ENGL 1998 W 0759b70 0634938 IT4 W

STDOASME PTC 4-ENGL 3998 0759470 Ob34939 030

PERSONNEL OF PERFORMANCE TEST CODES COMMITTEE NO. 4

R. P. Allen S. J. Korellis C. B. Scharp

STD-ASME PTC 4-ENGL 1998 N 0759b70 Ob14742 625 M

1 Object and Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

-- | ||| | || | || | | ||| |||| | || ||| | || || ||| | |---

5.13 Air and Flue Gas Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

-- | ||| | || | || | | ||| |||| | || ||| | || || ||| | |---

FIRED STEAM GENERATORS ASME PTC 4-1998

performance characteristics: sampling and analysis of coal, oil, or gas.

ASME PTC 4-1998 FRED STEAM GENERATORS

Uti Iityllarge Industrial

7. The steam generator boundaries shown on these 1.4.3 Flue Gas

Boundary 27 - Feedwater Leaving Ecoñomizer

STD-ASME PTC '+-ENGL 3998 m 0759670 Ob34948 043 m

ASME FTC 4-1998 FIRED STEAM GENERATORS

STDeASME PTC 4-ENGL 1998 0759b70 Ob14949 T8T m

FRED STEAM GENERATORS

STD-ASME PTC 4-ENGL 1998 0759b70 Ob14952 574

ASME FTC 4-1998 FIRED STEAM GENERATORS

STD-ASME PTC 4-ENGL 1998 0759b70 Ob14953 400 =

STD-ASME PTC 4-ENGL 1998 O759670 Ob14954 347

ASME PTC 4-1998

FIRED STEAM GENERATORS ASME I'TC 4-1998

31B - Leaving 1st Stage SH Desuperheater 1.4.5 Miscellaneous

-- | ||| | || | || | | ||| |||| | || ||| | || || ||| | |---

STD-ASME PTC 4-ENGL 1998 = 0759b70 ObL495b LLT

SECTION 2 - DEFINITIONS AND

STD-ASME PTC 4-ENGL 1996 m 0759b70 Ob34958 T92 m

FIRED STEAM GENERATORS ASME PTC 4- 1998

be converted to a constant pressure value for use in

sorbent: chemical compound(s) that reacts with and

captures a pollutant or, more generally, a constituent that

STDOASME PTC 4-ENGL 1998 m 0759670 Ob14959 929 m

ASME FTC 4-1998 FRED STEAM GENERATORS

Na20: sodium oxide

NO: nitric oxide

The following abbreviations are used throughout

this Code. NOZ:

AH: air heater PA: primary air

FIRED STEAM GENERATORS ASME F'ïC 4-1998

item US Customary SI [Notes (U,(2)l

Temperature, absolute R K ("F + 459.67111.8

FIRED STEAM GENERATORS ASME PTC 4-1998

SECTION 3 - GUIDING PRINCIPLES

ASME PTC 4-1998 FIRED STEAM GENERATORS

Energy in fuel (chemical)

QDBDA Enerav in enterina d w air

QpBSIF Energy gain due to sulfation Credits

FIG. 3.1-1 STEAM GENERATOR ENERGY BALANCE

FIRED STEAM GENERATORS ASME F’TC 4-1998

ments to the unit or its operation. The energy balance

methods ciency when corrections to such conditions are required.

other input credits; however, they usually have a minor

STDmASME PTC 4-ENGL 1998 D 0759b70 Ob14964 79b

ASME PTC 4-1998 FIRED STEAM GENERATORS

Requires the use of energy balance calculation