Asme 1998

COPYRIGHT American Society of Mechanical Engineers
Licensed by Information Handling Services

STDOASME PTC 4-ENGL 1998 W 0759b70 Ob14936 321 m
ASME
PTC 4-1998
[Revision of ASME PTC 4.1 -1964(R1991)]
Fired Steam
Generators

STD-ASME PTC 4-ENGL L998 m 0759670 ObL4937 268 m
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.
Please Note: ASME issues written replies to inquiries concerning interpretationof technical
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.
ASME is the registered trademark of The American Society of Mechanical Engineers
Thiscode or standardwasdevelopedunderproceduresaccredited as meetingthecriteria for American

National Standards. The Consensus Committee that approved the code or standard was balanced to assure that
individuals from competent and concerned interests have had an opportunity to participate. The proposed code
or standard was made available for public review and comment that provides an opportunity for additional
public input from industry, academia, regulatory agencies, and the public-at-large.
ASME does not “approve,” “rate,” or “endorse” any item, construction, proprietary device, or activity.
ASME does not take any position with respect to the validity of any patent rights asserted in connection with
any items mentioned in this document, and does not undertake to insure anyone utilizing a standard against
liability for infringement of any applicable Letters Patent, nor assume any such liability. Users of a code or
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Three Park Avenue, New York, NY 10016-5990
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 L998 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
andtheTestCode for Stationary SteamGeneratingUnitswas reissued in revisedformin
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 revisionof 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 whichhaddeveloped test methods for large modemunits 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
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.
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
that the Code should be totally rewritten to reflect several changes in steam generator technology
(primarily the increasing usage of fluidized bed combustors andother technologies for emission
control) and in performance testing technology (primarily the widespreaduseof 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 thatthe new code should
discourage the almost universal use of an abbreviatedtest procedure (commonly knownas “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 smallindustrial and commercialunits 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 wassubjected 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 wasthenapprovedand
adopted by theCouncil 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 supportcalculations for this Code may be available
on the ASME web site (www.asme.org/pdf). Any such software has not been subject to the
ASMEconsensusprocessandASMEmakesno warranties, express or implied, including,
without limitation, the accuracy or applicability of the program.
...
111

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STD-ASME PTC 4-ENGL 3998 m 0759470 Ob34939 030 m
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 bestengineeringknowledge and practice
currently available.
They weredeveloped by balanced committees representing all concernedinterests. 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, yieldthebest available indication of theactual performance ofthetested
equipment. ASME Performance Test Codes do not specify means to compare those results to
contractual guarantees. Therefore, it is recommended that theparties 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 Administartive Meeting of March 13-14, 1995.

STD*ASME PTC 4-ENGL L778 m 0757b70 Ob34940 8 5 2 m
PERSONNEL OF PERFORMANCETESTCODESCOMMITTEE NO. 4

ON STEAMGENERATINGUNITS
OFFICERS
Philip M. Gerhart, Chair
Patrick G. Davidson, ViceChair
Jack H. Karian, Secrefaty
COMMITTEEPERSONNEL
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.

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 l. C. Westcott
J. R. Friedman R. R. Priestley J. G . Yost
G . J. Gerber
R. S. Hecklinger
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 DataRequired . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 EnergyBalance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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

STD-ASME PTC 4-ENGL 1998 m 0759670 ObL4943 56% W
5.13 Airand Flue Gas Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

5.14 Losses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
5.15 Credits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
5.16 Uncertainty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
5.17 OtherOperating Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
5.18 Corrections to Standard or Guarantee Conditions . . . . . . . . . . . . . . . 111
5.19 Enthalpy of Air, Flue Gas, and Other Substances Commonly
Required for Energy Balance Calculations . . . . . . . . . . . . . . . . . 119
5.20 Calculation Acronyms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
6 Report
of Test Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
6.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
6.2 Report Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
7 Uncet-@inty
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 forDeterminingPrecisionIndex ........ 152
7.5 Equations and Guidance for Determining Bias Limit . . . . . . . . . . . . . 157
7.6 Uncertainty of Test Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
Figures
1.4-1 TypicalOil
andGas
Fired Steam Generator . . . . . . . . . . . . . . . . . . . . . . . 4
1.4-2 Typical Pulverized Coal Fired Steam Generator,
Alternative 1 : Single Air Heater. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.4-3 Typical Pulverized CoalFired Steam Generator,
Alternative 2: Bisector Air Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.4-4 Typical PulverizedCoalFiredSteam Generator,
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
Runs
of ....................................... 24
3.2-2Illustration of Short-Term (Peak to Valley) FluctuationandLong-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
5.19-1Mean Specific Heat of Dry Air Versus Temperature . . . . . . . . . . . . . . . . 126
5.1 9-2Mean Specific Heat of Water VaporVersusTemperature . . . . . . . . . . . . . 127
5.19-3 Mean Specific Heat of Dry Flue Gas Versus Temperature . . . . . . . . . . . . 129
5.19-4Mean Specific Heatof 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
viii

STDaASME PTC 4-ENGL L998 m 0759b70 ObL4944 4 T 8
Tables
1.3-1 Typical Code Test Uncertainties forEfficiency . . . . . . . . . . . . . . . . . . . . 3
2.3-1 Units and Conversions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.1.1 Comparison of EfficiencyDetermination . . . . . . . . . . . . . . . . . . . . . . . . . 22
3.2- 1 Operating Parameter Deviations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.2-2 Minimum Test RunDuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4.2-1 Parameters RequiredforEfficiencyDetermination by EnergyBalance
Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
4.2-2 ParametersRequiredforEfficiencyDetermination by Input-Output
Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
4.2-3 Parameters RequiredforCapacityDetermination ................... 38
4.2-4 Parameters Required for SteamTemperature/Control Range
Determination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
4.2-5 ParametersRequiredfor Exit FlueGasandAirEntering Temperature
Determinations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
4.2-6 ParametersRequired for ExcessAirDetermination ................. 41
4.2-7 ParametersRequiredfor WatedSteam Pressure Drop Determinations . . . . 42
4.2-8 Parameters RequiredforAir/FlueGas Pressure Drop Determinations . . . . 43
4.2-9 ParametersRequiredforAir Infiltration Determination . . . . . . . . . . . . . . . 44
4.2-10ParametersRequired for Sulfur CaptureRetention Determination . . . . . . . 45
4.2-1 1 ParametersRequiredforCalcium to Sulfur MolarRatio
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 CoalProperties . . . . . . . . . . . . . . . . . . . . . . . . . 52
4.3-3 Potential Bias Limits forLimestone Properties. . . . . . . . . . . . . . . . . . . . . 53
4.3-4Potential Bias LimitsforFuelOil Properties . . . . . . . . . . . . . . . . . . . . . . 53
4.3-5 Potential Bias LimitsforNaturalGasProperties . . . . . . . . . . . . . . . . . . . . 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 ProbableEffects of Coal Properties on PulverizedCoalandCoal
and Sorbent Properties on Fluidized Bed Steam Generator Design
andperformance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
F References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
ix

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
Theobjectofthis Code is to establish procedures
forconductingperformancetests of fuelfired steam This Code also providesmethodsfor converting
generators. This Code provides standard test procedures certain performance characteristics attest conditions
whichcanyieldresultsgiving the highestlevel of tothosewhichwould exist underspecified operating
accuracy consistent with current engineering knowledge conditions.
and practice.
The accuracy of a particulartest maybe affected
by the fuel fired during the test or other factors within 1.2 SCOPE
thediscretion ofthe operator. A test isconsidered an
ASME Code testonly if the following conditions 1.2.1 General Scope. The rules and instructions pre-
aremet: sented in this Code applytofiredsteam generators.
These include coal, oil, and gas fired steam generators
e testprocedurescomplywithprocedures and allowed as well as steam generators fired by otherhydrocarbon
variations
defined by this Code fuels. The scope includes
also steam generators
with
O uncertainties of test results, determined in accordanceintegral fuel-sulfur capture utilizingchemical sorbents.
with Section 7 of this Code, donotexceedtargettestSteam generators whicharenotfired by coal, oil,
uncertaintiesdefined by priorwrittenagreement in Or gas maybe testedusingthe concepts of this Code,
accordance with
Section 3 of this Code but
should
it be notedthat
the
uncertainty
caused by
variability of the fuel may be difficultto determine
This ‘Ode can be used to determine the and
is ~~
like]” to be greater than
the uncertainties in
performancecharacteristics:
Y
sampling and analysis of coal, oil, or gas.

0 efficiency
Gas turbine heatrecoveryandotherheatrecovery
output steam generators designed to operate with supplemental
0 capacity
firing should be tested in accordance with Performance
o steam temperaturekontrol range Test Code (PTC) 4.4, Gas Turbine HeatRecovery
0 exit flue gas and entering air temperature
Steam Generators.
0 excess air
This Code does not apply to nuclearsteamsupply
0 waterkteam pressure drop
systems, which are specifically addressed in PTC 32.1,
o aidflue gas pressure drop Nuclear Steam Supply Systems. This Code does not
air infiltration apply to the performance testing of chemicalheat
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.
Municipalwaste fired steam generators can betested
These performance characteristics aretypicallyre- in accordance withPTC 34, Waste Combustorswith
quiredforthe following purposes: Energy Recovery.
Testing of auxiliary equipment isnotaddressed in
o comparing actualperformancetoguaranteedper- this Code, butshall be governed by the following
formance Performance Test Codes whichapplyspecifically to
o comparing actual performance to a reference the equipment in question:
o comparing different conditions or methods of oper-
ation 0 PTC 4.2, Coal Pulverizers.
e determining thespecific performance of individual 0 PTC 4.3, Air Heaters.
parts or components 0 PTC 11, Fans.

STD.ASME
PTC 4-ENGL 1998 m 0759b70 ObL49Yb 270
ASME PTC 4-1998 FIREDSTEAMGENERATORS
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 thesteam 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 andflue gas balancemethoduncertaintyresult.
constituents, are not equivalent to methods required by Table 1.3-1 shows typical values of uncertaintyin
EPA, New Stationary Source Performance Standards, steam generator efficiency as a function offueltype,
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 areshownto allow for definingatestwitha
mental regulations. cost consistent with the value of the project in accord-
This Code does not prescribe procedures for testing ancewith 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 foundin 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 theenergy balance
ASTM. method for a utility/large industrial unit are based upon
This Code specifically addresses equipment used for Code air temperature, gas temperature, andgas 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. industrialunitvalues are based on a small grid and
Certain types and sizes of equipment used for the obtaining data manually.
recoveryofheatreleasedbycombustionarenotad- The uncertainty of the input-output method isdirectly
dressed inany specific Performance Test Code. This proportional to the uncertainty of measurement of feed-
Code can beused as ageneral guide in developing watedsteam flow, fuel flow, andfuelheatingvalue.
performancetests for such equipment; however, such To achieve the uncertainties shown in Table 1.3-1, the
speciallydeveloped performance tests shall notbe metering must be selected, manufactured, installed, and
considered ASME Code tests. usedin strict accordance withthe applicable codes
and standards. Most importantly, therequired straight
1.2.2DesignVariations. This Code provides general lengths of differential pressure metering runsanduse
procedures for conducting combustible fuel fired steam offlow conditioners must be rigorouslyadheredto.
generator performancetests; however, it cannot possibly For coalflow, 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 thetest.
in developing thisCode include subcritical and supercrit- With the above guidelines, the input-output uncertain-
¡cal once-through steam generators and oil, gas, stoker, ties are baseduponthe following flowmeasurement-
cyclone, pulverized, and fluidized bed firing. For each system uncertainties andfuel sampling criteria:
performance test, a competent engineer must study the
actual steam generator and its relation to the remainder Feedwater, UtilityLarge Industrial - ASME PTC 6
of the steam cycle, and develop test procedures which Flow Nozzle - 0.38% System
are consistent withthis Code. Feedwater, Small Industrial - test orificdempirical
formulation - 0.80% System
1.23 Reports. Atest 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 -
plementalinformation in planning for a performance three viscosities (multiple tests for repeatablility) -
test in accordancewiththis Code. Those usedmost 0.63% system
frequently arelisted in Section 3.3. Rigorous calibration of coal feeders
Fuel Analysis - multiple samples analyzed individu-
ally -ASTM reproduciblity bias plus 0.5% sampling
1.3 TYPICALUNCERTAINTYFOR bias for oil and gas and 2% sampling bias for coal
EFFICIENCY
Fossil fuel firedsteam generators are custom designed 1.4 STEAMGENERATOR 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 L07 W
FIRED STEAM GENERATORS ASME PTC 4-1998
TABLE 1.3-1
TYPICAL CODE TEST UNCERTAINTIES FOR EFFICIENCY
Energy
Balance
Method
Input-Output
Method
Type of
Generator
(Percentage
Steam
(Percentage
Points)
Points)
UtilitylLarge Industrial
[Note - Coal fired (1)l 0.4-0.8 3.0-6.0
- Oil fired 0.2-0.4 1.0
- Gas fired 0.2-0.4 1.0
Fluidized Bed [Note ( 1 ) l 0.9-1.3 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 0.5-0.9 1.2
- Gas 0.4-0.8 1.2
NOTES:
(1) It is not recommended t o testcoal fired units using theinput-outputmethod because of the large
uncertainties measuring coal flow.
(2) Economizer/air heater.
7.Thesteam generator boundariesshownon these 1.4.3

Flue
Gas
figures encompass the equipment to be included in the 0 12 - Leaving Steam Generating Bank (not shown)
steamgeneratorenvelope for each case.
0 13 - Entering Economizer (not shown)
The following numbers are used to designate specific
0 14 - Leaving Economizer
locations.
o 14A - Entering Secondary Air Heater
1.4.1
FueVSorbent 0 14B - Entering Primary Air Heater
0 14C - Leaving Hot-Side AQC Equipment
1 - Coal Leaving Feeder or Bunker 15 - Leaving Air Heater(s)
0 1A - Sorbent Leaving Feeder or Bunker o 15A - Leaving Secondary AH
0 2 - Coal to Burners (leaving pulverizer) 0 15B - Leaving Primary AH
0 3 - Oil to Burners o 16 - Entering Cold-Side AQC Equipment
0 3A - Oil to Oil Heaters 0 17 - Leaving Cold-Side AQC Equipment
0 4 - Gas to Burners 0 18 - Entering ID Fan
0 19 - Leaving ID Fan
1.4.2 Air
o 20 -Entering Low Level Heat Exchanger (not shown)
0 5 - Pulverizer Tempering Air 0 21 -Leaving Low Level Heat Exchanger(not shown)
o 6 - FD Fan Inlet o 22 - Entering Gas Recirculation Fan

0 6A - PA Fan Inlet o 23 -Leaving Gas Recirculation Fan (entering boiler)
o 7 - FD Fan Discharge
1.4.4 S t e a f l a t e r
0 7A - PA Fan Discharge
0 7B - Other Air Entering Unit o 24 - Feedwater Entering
0 8 - Combustion (secondary) Air Entering Boundary 0 25 - Superheater Spray Water
0 8A - Primary Air Entering Boundary 0 26 - 1st Reheater Spray Water
0 8B - Combustion Air Leaving APH Coils Within o 26A - 2nd Reheater Spray Water (not shown)
Boundary 27 - Feedwater Leaving Ecohomizer
0 8C - Primary AirLeavingAPH Coils Within 0 28 - Feedwater Entering Drum
Boundary o 29 - Steam Generator Water Entering Circulating
0 9 -Combustion (secondary) Air LeavingA'ir Heater Pump
9A - Primary Air Leaving Air Heater o 30 - SteamGeneratorWaterLeaving Circulating
o 10 - Secondary Air Entering Steam Generator Pump
0 11 - Pulverizer Inlet Air 0 31 - Saturated Steam Leaving Drum
11A - Pulverizer Outlet Air and Fuel Mixture 0 31A - Entering Ist Stage SH Desuperheater

Hot Cold
reheat reheat
Main Spray Sway

steam water water Feedwater
t 1‘
----___ 32 25 -34 __
P-
Me “PH coils -1
Auxilliary steam 31 _ 33B
I,
28
31B~31A :
Sootblowing Secondary Reheater

steam - superheater
1, 1,
F kWh

Cooling I
water
Primary L-----
superheater
Other air
I

entering unit
Fuel/gas
conditioners
P
kWh
Water injection
--
Seal leakoff
48 ’ Circulating
pumps
‘=Y
II
IL----- 1__rl 42 &- -7--l
----_
Oil
4
kWh Condensate
Oil
FIG. 1.4-l TYPICAL OIL AND GAS FIRED STEAM GENERATOR

Hot
reheat
Main Spray Spray Cold

steam water water reheat Feedwater
_ _ 32 _25___34_- 4_--
---- 152 ) Economizer
46A 1 To APF coils
Auxilian/ 31 t I ash
steam
351 +-+--
I
I Secondary Reheater
461 T Fly ash
Sootblowing w superheater

steam
I kWh
401 I
Cooling
water

Other air
entering unit
Fuel/gas
conditioners
kWh
Water injection
Seal leakoff
1 11A
Pulverizers,
crushers,
and exhaust
I fans
~-----~gt-~7-~8-~~1.
Condensate
Ash Ash Ash Rejects
water kWh from kWh I 4sh
water feeders
Atmo heric
tempt 1g air
FIG. 1.4-2 TYPICAL PULVERIZED COAL FIRED STEAM GENERATOR

Alternative 1: Single Air Heater
Spray Spray
water water
Main
steam Feedwater
4
#4
---_-_ ---7
I--AOU
^^:I” ;52 Economizer
( 46A j I *
Auxiliary steam ash
I
I I - I
I
31Bj31Aj 1 j I
35 )
Blowdown 1 - I I --.---_
I
\46 !V Secondary Reheater

Sootblowing AE]bb Fly ash
I ) superheater ii
steam

control
equipment 1
Cooling
water I-

Other air 14c
entering unit 7%
Fuel/gas
Q\ conditioners
kWh 29
Water injection
n I
_ 47 ; 55
Seal leakoff 30
48’
j Circulating
I w-w
Ash Ash Ash 4 Condensate

Rejects 1 Coat KWn
water water kdh from Condensate
feeders

Alternative 2: Bisector Air Heater
Sprav Sprav
water water
Feedwater
--- ---
To APH coils ;52 Economizer
338 I * ash
Auxiliary steam I I I- I Ar I
31Bj.31A I
Blowdown I I HI
II__--__

Sootblowing
steam
40 ’
Cooling
water 41

7-A
Other air
entering unit
Fuel/gas
conditioners
4 Trisector
air heater(s)
kWh
Water injection Xack
Seal leakoff I A Flv ash
pump
nom KW”
Ash Ash Ash Rejects
feeders Condensate
water water
kWh

Alternative 3: Trisector Air Heater
Hot Cold Sprav
reheat reheat water
P
I
r--------------- 3#3-p?J+~--;
i2
To APH coils
46A I -I.
Auxiliary steam I
l,
I,
I
I
(3
I

I
152 kWh
Economizer
ash
I r

Combustion
chamber
Sorbent from
Crushed coal
Air heaters
Fuel/gas Air quality
conditioners I I 1 control 1 -
1 kWh
- I 29 I
Water injection 47 ;
I
,48 1
Seal leakoff I f t
qi+qJ Primary air
Fluid out
Fluid in
Other air
entering unit
Ash
Ash Condensate
FIG. 1.4-5 TYPICAL CIRCULATING BED STEAM GENERATOR

Main Spray Sootblowing
steam water steam
lwater
A A Auxiliary
A
steam
--- 32
___-_----- 25 46 46A_-_ 1---7
r-- ; 52 Economizer
I ash
I Hot
) flue gas
31
r, 28 I

r Superheater I
I kWh
46 !
Sootblowing 5 m I
I

steam
I I -- ----
I
Blowdown
15 ;I6*
Cold-side
Crushed _ 9 air quality
Air heater I control
coal
I I equipment
tieat from Heat frcI!I 55 Stack
kWh Jnde:re air 1
----- _----
37A
Ash Condensate
Ash
FIG. 1.4-6 TYPICAL STOKER-COAL FIRED STEAM GENERATOR

Hot
Auxiliary
steam
Blowdown
Hot
I flue gas -

_ kWh
Sootblowing
steam

Cooling
water
Air heater
9 equipment
Main stream 4 32 1 I I -
I I 55 tack
Heat from Lj
steam Heyxatt,f’Rd; Ash
A A A generator 1 source
I t
Bed ash
cooler
t
-------___ ----------_- ;
37 ,,8A
v
Ash
6A
Pish
11 Ash Condensate
FIG. 1.4-7 TYPICAL BUBBLING BED STEAM GENERATOR

STD-ASME PTC 4-ENGL 1998 m 0759b70 Ob14955 283 m
FIREDSTEAMGENERATORS ASME PTC 4-1998
31B - Leaving 1st Stage SH Desuperheater 1.4.5 Miscellaneous

0 31C - Entering 2nd Stage SH Desuperheater (not 0 37 - Furnace Refuse
shown) 0 38 - Ash Pit Water In
0 31D - Leaving2ndStage SH Desuperheater (not 0 39 - Ash Pit Water Out
shown) 0 40 - Cooling Water In
0 32 - Main Steam 0 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 0 44 - Steam Leaving Fuel Oil Heater
0 33C - Entering2ndReheatDesuperheater(not 0 45 - Pulverizer Rejects
shown) 0 46 - Soot Blower Steam
33D - Leaving2ndReheatDesuperheater (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)
0 36 - CondensateLeavingAPH Coils (internal to 51 - FueYGas Conditioners
boundary) 0 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 L998 0759b70 ObL495b LLT
SECTION 2 - DEFINITIONSAND
DESCRIPTIONOFTERMS
ThisSection contains abbreviations, unique terms, air,theoretical: theamount of air requiredtosupply

and variations on typically used engineering definitions the exact amount of oxygen necessary for complete com-
required fortheimplementation of this Code. bustion of a given quantity of fuel. Theoretical air and
stoichiometric air are synonymous.
air,correctedtheoretical: theoretical air adjusted for
2.1 DEFINITIONS unburned carbon andadditional oxygen required to com-
plete the sulfation reaction.
addirive: a substanceadded to a gas, liquid, or solid
streamtocause a chemical or mechanicalreaction to air hearer: a heat exchanger that transfers heat from a
enhance collection efficiency. high temperature medium suchas hot gas to an incoming
air stream. Regenerative air heaters include bisector and
air, excess: the air supplied to bum a fuelin addition
trisector types, with fixed or rotating heating elements.
to the corrected theoretical air. Excess air is expressedas
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 thattypically uses
casing.
steam, condensate, andor glycol to heat air entering the
air, primary: the transport anddryingair for the coal steam generator and isoften used to control corrosion in
from thepulverizersto 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. Oilandgasfiredsteam generators usually do not
have primary air. Primary air is the air used for fluidizing analysis,ultimate: laboratory analysis, inaccordance
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 percentagesof carbon, hydrogen, oxy-
gen, nitrogen, sulfur, moisture, and ash.
air,secondary: thebalance of the combustion air not
provided as primaryair 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 noncombustiblemineralmatter constituent of
steam generators. Secondary air may be split into overfire
fuel that remains after complete burning ofa 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 removedfrom the combustion
air, other: a number of other combustion air arrange-
chamber other than that entrained in the flue gas.
ments andsplits, e.g., overfireair, tertiary air, encountered
in the combustion processes covered by this Code. ash,fly: particles of residue entrained in the fluegas
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
is Blank
STDOASME PTC 4-ENGL 1998 0759b70 Ob14957 O56 m
ASME PTC 4- 1998 GENERATORS STEAM FIRED
ash fusion remperatures: four temperatures (initial de- coverage: thepercentage of observations(measure-
formation, softening, hemispherical, andfluid) deter- ments) ofa parameter that canbe expected todiffer from
mined for a given fuel ash as determined by the appro- thetruevalueof the parameter by nomorethan the
priate ASTM standard. Frequently used in the singular uncertainty.
to indicate only the softening temperature, the tempera-
credits: energy entering thesteamgeneratorenvelope
ture at which the test cone has deformed atoshape whose
other than the chemical energyin 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, andatomizing
residue is collected and removed. steam; energy from power conversion inthe pulverizers,
circulating pumps, primaryair fans, and gas recirculation
aftemperator: see desuperheater. fans:andchemical reactions such as sulfation. Credits
canbe negative, such as whenthe air temperatureis
biaslimit: the estimate of error.
below the reference temperature.
calcination: the endothermicchemical reaction which dehydration: theendothermicchemicalreactionwhich
takes place when carbon dioxide
is released from calcium takes place when water is released from calcium hydrox-
carbonatetoformcalcium oxide, or frommagnesium ide to form calciumoxide, or from magnesium hydroxide
carbonate to form magnesium oxide. to form magnesium oxide.
calciumto suIfur molarratio (CdS): thetotalmoles desuperheater: apparatus for reducingand controlling
of calcium in the sorbent feed dividedby the total moles the temperature of a superheated vapor (attemperator).
of sulfur in the fuel feed.
dilutephase: theportionofthebed in a circulating
calciumutilization: the percent of calciumin the sor- fluidized bed combustion chamber above the secondary
bent that reacts with sulfur dioxide (SO2)to form calcium air inlet ducts (madeup primarilyof 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 oftheoutputtotheinput as
the steam generatoris capable of producing ona continu- chemical energy of fuel.
ous basis with specified steam conditions and cycle con-
efficiency, gross: the ratio of the output to thetotal
figuration (including specified blowdown and auxiliary
steam). This isfrequentlyreferred to as maximumcontin- 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: themaximummainsteammassflow
efficiency by a detailed accounting of all energy entering
ratethat the steamgenerator is capableofproducing
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 ofthetotalpopulationandthetrue
value. The true systematic or fixed error which character-
combustionchamber: anenclosedspaceprovided for izes every member of any set of measurements from the
the combustion of fuel. population.
combusrionefficiency: a measureofthecompleteness error,precision: a statistical quantity that is expected
of oxidation of allfuel 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 samemeasuringsystemoperated by the same
combustion split: the portion of energy released in the
personnel do not yield identical values. Also called ran-
dom error.
dense bed region aoffluidized bed expressedas apercent-
age of the total energy released. error, total: sum of bias error and precision error.
controlrange: the capacity range over whichmain exit gus femperature: the averagetemperature 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
jìxed carbon: the carbonaceous residue less the ash re- occurring between two temperaturelevels. 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 whichexits the steamgeneratorenve-
dard. Also see volatile matter. lope other than the energy in the output stream(s).
flue gas: the gaseous products of combustion including maximumcontinuousrating: see capaciry.
excess air.
moisture: water, inthe liquid or vaporphase,present
fluidized bed: a bed of suitably sized combustible and in another substance. Moisture in fuel is determined by
noncombustible particles throughwhich a fluid (air in the appropriate ASTM standards.
fluidized bed steam generators) is caused to flow upward
at a sufficient velocitytosuspendthe particles andto outliers: a data point judged to be spurious.
impart to them a fluid-like motion. output: energyabsorbed bytheworkingfluidthat is
fluidizedbed,bubbling: a fluidizedbed in whichthe 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 ofthe precision error.
throughthe bed as bubbles.Thisresultsin a distinct
bed region because an insignificant amount of the bed is purge: to introduce airinto the furnace or the boiler
carried away by the fluidizing air. flue passagesin 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 velocityexceedsthe terminal velocityof 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: thevolumefromtheupper surface ofthe flow rate.
expanded bed to the exit of the furnace. This definition
applies to a fluidized bed of dense solids (bubbling bed) reinjection: thereturn or recycle ofmaterialbackto
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 fuelash, 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 atconstant volume, it must settinginfiltration: same as air, infiltration.
beconverted to a constant pressure value for use in
sorbent: chemicalcompound(s)that reacts withand
this Code.
captures a pollutant or, more generally, a constituent that
heatingvalue,lower: thetotalheat liberated perunit reacts with and captures another constituent.
mass of fuel minusthe latent heatof the water vaporin the
products of combustion as determined by the appropriate spent sorbent: solids remaining after evaporation of the
ASTM standards (not used in this Code). moisturein 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-outputmethod: a methodofdeterminingsteam
generator efficiency by direct measurement of output and sulfation: the exothermic chemicalreaction 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 dustsample,expressed in percent, sulfurcapture: see sulfurretention.
15

-~ ~
~~
STD.ASME PTC 4-ENGL 1998 m 0759670 Ob14959 929 m
surfur 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
suppiemenrul fuel: fuel burned to supply additional en-
RD: 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: theacceptable 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 adjustmentsto 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
uncerfuinty: the estimated error limit of a measurement LOI: loss on ignition
or result for a given coverage. Uncertainty defines
a band MB: megabyte
withinwhichthetruevalueis expected to liewith a MAF: moisture and ash free
certain probability. " W 2 magnesium hydroxide
MgC02: magnesium carbonate
volatile matter: the portionof mass, except water vapor,
MgO: magnesium oxide
which is driven off in a gaseous form when solid fuel is
N*: nitrogen
heated in accordance withthe 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
The following abbreviations are
used
throughout NO: nitric oxide
this Code. NOZ: nitrogen dioxide
NO,: nitrogen oxides
m: 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 3998 m 0759670 Ob34960 640 D
FIRED STEAM GENERATORS ASME W C 4- 1998
TABLE 2.3-1
UNITS AND CONVERSIONS
~ ~~
units Conversion
Item US Customary SI [Notes (U,(2)l
Area ft2 9.2903E-02

Convectionand/or radiation heat
transfer coefficient Btulft2 . h . 'F W/mZ . K 5.6779 E+OO
Density Ibmlft' kg/m3 1.6018E+01
Electrical energy kWh J 3.6000 E+O6
Energy per unit area Btulft2 Jlm2 1.1341 E+04
Energy per unit mass Btullbm Jlkg 2.3237E+03
Energy, flux Btulft' 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 "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 SI (Metric) Units ( A N S I 2210.1) Cl]. Also, refer to Table 2 of ASME SI-9, Guide
for Metrication of Codes and Standards SI (Metric) Units C21, for the number of significant digits to
be retained when rounding SI.
2.3 UNITS AND CONVERSIONS

The following units andconversions are used through-
outthisvolume. To obtain SI Units, multiply US
CustomaryUnitsbythe conversion factor given in
Table 2.3-l .
17

~~ ~
STD-ASME PTC 4-ENGL 1998 m 0759670 Ob14961 587 m
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-
Inpreparingtoconduct a steamgeneratorperform-
dix D.
ancetest,the parties tothetestmustmake a number
of decisions and establish certain agreements.This 3.1.2 Types of Efficiency. Steamgenerator efficiency
Section oftheCode describes these decisions and isdefinedby:
agreementsandprovidesguidance for performing a
testinaccordance with thisCode.
Allpartiestothetest are entitled andencouraged output
towitnessthe test toensurethat it is conducted in
efficiency = -* 100
input
accordance with this Code and any written agreements
madepriortothe test.
This single definition yields many different values
3.1.1SteamGeneratorPerformance. Theperform- for efficiencydependingupon the choice ofitemsto
ance of a steamgenerator at a particular operating beincluded as output, itemstobeincludedasinput,
condition is usually quantified by three main character- and higher or lower heating value of the fuel. Entwistle
istics: et al. discuss thisproblem at lengthanddemonstrate
0 capacity - themaximummassflowrateofsteam that at least 14 different valuesofefficiencycanbe
produced at specified conditions computedfromthesame data [2,3].
0 output - all energy absorbed by theworkingfluid This Code recognizes twodefinitions of steam genera-
except that recovered within the steam generator en- tor efficiency:
velope
0 efficiency -the ratio of output energyto input energy 0 Fuel efficiency includes allenergyabsorbed 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
ancemustaddressthefollowingtwo 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 0 Gross efficiency also includes all energy absorbed by
be determined (usually by calculation), e.g., exactly the workingfluid as outputandcountsallenergy
what should be included in the input and output? inputs entering the steam generator envelope asinput.
0 What are the most practicable and accurate methods Thus, gross efficiencyisusuallylessthan or equal
for measuring parameters and calculatingperformance to fuel efficiency.Procedures for calculating gross
characteristics andhow accurate musttheybe to efficiency are contained in Appendix D.
achieve the required test quality? [ l ]
Those energies that are considered outputs and inputs
Capacity is easily defined; the main problems associ- (including credits inthe case of gross efficiency) are
atedwith its determination arise frommeasurement. shownonFig. 3.1-1. In all cases, thisCodeuses the
Output, input, and thus efficiency are subject to several higher heating valueof the fueltodeterminefuel
possible definitions. This Code uses specific definitions energy input.
for these quantities. Figure 3.1-1 illustrates thedefini-
tions used for input and output. This figure shows that 3.1.3Methods of MeasurementandComputation
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 all energy absorbed by the working fluid. The figure are the input/output methodand the energybalance
also shows that energy credits (usually minor) are added method.
19
Previous Page
is Blank
~~
STD=ASME PTC 4-ENGL 1998 0759b70 Ob149b2 413 W
ASME PTC 4-1998 FIRED STEAM GENERATORS
Energy in fuel (chemical)
QpBDA Energy in entering dry air

r=
QpoSWA Energy in moisture in entering air
QpBF Sensible heat in fuel
QpBSIFEnergy gain due to sulfation
QrBX Energy from auxiliary equipment power
c;
QrBSb Sensible heat in sorbent
QrBWAd Energy in additional moisture
-v-Envelope
-------
Boundary ,--------c----+ Energy in primarysteam
I
L
t
"""" c ""
+ Energy in auxiliary steam and blowdown
I
I
,-k-"" Energy in desuperheater and
'-4:. I circulating pump injection water
.."L""-
ØR'
output
Energy in feedwater (aro!
I
I
I"""-- i-----+
Energy in reheat steam out
I *,"-k-"" Energy in desuperheater water
"
"""fr""- Energy in reheat steam in
QpLDFg Energy in dry gas

QpL WF Water in fuel
QpLHZFWater from burning hydrogen
QpL WA Moisture in air
QpLSmUbUnburned carbon and other combustibles
QpLRs Sensible heat in residue
QpLAg Hot air quality control equipment
QpLALg Air filtration
Losses
QDLNOXNOx formation
- (QPLI
QrLSrc Surface radiation and convection
QrL WAd Energy in additional moisture
QrLClh Calcination and dehydration of sorbent
QrL WS6 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 - QrL + QrB
QpL = 100 X E % QpB = 100 X QrB
- %
QrF ' QrF '
Fuel efficiency (percent) = €F(%) = 100 x m
INPUT
= 100 - QpL + QpB
FIG. 3.1-1 STEAM GENERATORENERGYBALANCE
20

S T D O A S M E PTC 4-ENGL L978 m 0759b70 ObL47b3 35” m
FIRED STEAM GENERATORS ASME PTC 4- I998
The inputloutputmethoduses the equation: than if the values were measured. Losses are sometimes
determined on a “percentinput” basis ratherthan an
output absolute basis.
efficiency = - * 100 Advantages and disadvantages oftheinputloutput
input
andenergybalancemethods 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 testuncertaintybecausethe quantities used to
as well as all input. The primary measurements required determine efficiency by theenergybalancemethod,
arethefollowing: i.e., losses, are a much smaller portion of the total
energythan is output, whichisusedto determine
0 feedwater flow rate entering the steam generator efficiencyintheinputloutputmethod. Thus, a given
0 desuperheating water flow rates uncertainty in measured or estimated valueshasless
o flowrates ofallsecondary output streams such as effect on the result in the energy balance method [4].
boiler blowdown, auxiliary steam, etc. The energybalancemethod also provides a means of
0 pressure and temperature of all working fluid streams examining thelossesto determine potentialimprove-
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 mendstheenergybalancemethodtodetermineeffi-
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 basedupon the available instrumentationand ex-
waste energy input pectedtestuncertainty.
Furthermeasurements maybe requiredtodetermine
other input credits; however, they usually have a minor
effect onthe results. 3.1.4 UnitDesignandConstructionConsiderations
The energybalancemethod combines theenergy to FacilitateTesting. Early planning andfrequent
balanceequation follow-up during design and construction of a steam
generating unit will help to minimize testing problems
and ensure thattestscan be performed in accordance
input + credits = output + losses withthis Code after construction is complete. Ideally,
provisions for conducting both acceptance testsand
withtheefficiencydefinition to arrive at
routineperformancetestsshouldbeincluded in the
design of a unit.Even if it is decided not to run an
input - losses + credits
efficiency =
input
* 100j acceptance test,theprovisions willbe valuablefor
gathering informationonthe unit’s operation and per-
= (I -
(losses - credits)
input
j
* 100 formance.
This Code should be used as a guide during prelimi-
nary engineering to determine therequiredtestpoints
Efficiency determination by the energybalance and sampling provisions. This determination will nor-
method requires the identification and measurement (or mallyrequire interaction betweentheintendedparties
estimation) ofall losses. Figure 3.1-1illustratesthese to thetest. The requiredtestpoints and sampling
losses. The primary measurements for efficiency deter- provisionsshouldbeincluded in thespecifications.
minationbytheenergybalance 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 thatfield installation does not jeopardize the
higherheatingvalue of the fuel; and air andflue gas testprovisions.
temperatures. One of theproblemsmostcommonlyencountered
Many other measurements are required to determine intheperformance of measurements during testing is
values for all of the losses; however,several ofthem interference with other structures. Thermowells, pressure
usuallyhave a minor effect on the results. Inmany taps, and duct portsfor air and gas measurements
cases, parties to the test may agree to estimate values should be oriented so thattest 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

ASME PTC 4-1998 STEAM FIRED GENERATORS
TABLE 3.1-1
COMPARISON OF EFFICIENCYDETERMINATION
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
measurementsfewer Requires uncertainty
Does not
require
estimation
of unmeasurable Does notaidinlocating 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 TESTPROCEDURES
probesmust also be considered. 3.2.1 Determination of Level of Test. Accurate deter-
Provisions should be made for obtaining the necessary minationofthe performance of a steamgenerator
samples of fly ash,bottomash,pulverizer rejects, requires a significant expenditure oftime and money.
sorbent, and fuel. The equipment and procedures to be Manymeasurements are required to account for all
used in obtaining the samples should be considered in losses, especially in the determination of efficiency by
thedesign of sampling provisions. theenergybalancemethod.At the same time,each
Provisions should be made for measurement ofauxil- individual loss or an error in its determination may have
iary power usedin determining energy credits. only a small effect on the results or their uncertainty.
Consideration should be given to the needs of person- It haslongbeenrecognizedthatnosingleset of
nel and instrumentation involved in conducting the test. procedures can yield the most cost-effective test for
Examples include safe access to testpoint locations, all cases. Previous editions of thisCodeprovided 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 balancemethod.Onelevelwas a complete test in
from extreme ambient conditions such as high tempera- which all losses were determined from measurements.
ture and vibrationshould be considered. The other was an abbreviated test in which only major
22

__
STDeASME PTC 4-ENGL L996 m 0759b70 Ob14965 L22 m
losses were determined from measurements while sev- ance characteristics. A testnormally consists oftwo
eralminor losses wereignored or aggregated into an ormore runs.
unmeasured loss termwithanestimatednumerical 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 dueto variations in either thetestmethodology (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 beingtested (process variations). It is recommended
performance, the parties tothe test are permittedto that, at the endofeach run thatmeetsthe criteria
design a lowerleveltest if appropriate. Typically, a for anacceptablerun,thedatabe consolidated and
lower level test uses less accurate instruments or fewer preliminary results calculated andexaminedtoensure
instruments or willuseassumed or estimatedvalues the results are reasonable. If the partiestothetest
for certain parameters rather than measuring them. This agree, the test may be concluded at the end of any run.
Coderequires calculation of the uncertainties of the
resultstodefine the quality levelof the test: 3.2.2.1 Repeatability. The criterion for repeatability
betweenruns is that the normalizedresults of two or
By agreement prior to the test, the parties to the test moreruns all liewithin the uncertainty intervals of
shall-define acceptable values for the uncertainties of each other. Referto Fig. 3.2-1forexamples of runs
the results (for example, they may decide that effi- thatmeet ordo notmeetthis criterion. The results
ciencywillbedeterminedwithan uncertainty of should be normalizedto a base set of conditions.
20.5% and that maximum capacity will be determined Forexample, efficiency for different runsshouldbe
with an uncertainty of 5 1.O% of the value). These calculated using a single representative fuel analysis
values arecalled 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. Thechoicesofwhichparametersto foreach runis applied tothenormalizedresult for
measure, which parameters may be estimated, what thatrunfor the purpose of evaluating repeatability
estimated values to use, the anduse of fewer or alterna- betweenruns.
tive instruments will strongly influence the ability to
meet target uncertainties. Parties tothe 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 mustbe
is strongly recommended to aid in this process. invalidated completely,or it maybe invalidated only
The parties to the test shall reach prior agreement on in part if the affected partisatthebeginningorat
the uncertainties of values that will not be measured theendof the run. A runthathasbeen invalidated
and on the bias limits of instrumentsand 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 designatedrepresentatives 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- thatmeet the criteria for repeatability and other Code
tainties thus calculated are greater than the previously requirements are averagedtodeterminetheaverage
test result. The uncertainties shall bereported 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 emphasizedthat the test uncertainties
thus calculated are not tolerances onsteamgenerator 3.2.3PriorAgreements. Prior to the test, the parties
performance. The uncertainties are to be used to judge tothe test shall prepare a definitewrittenagreement.
onlythe quality of theperformancetestandnot the Thisagreement shall state thespecific test objectives
acceptability of thesteam generator. including the acceptable range of uncertainty for each
result, as well as the method of operation during the
3.2.2Number of Runs. A run is a complete set of test. Foracceptance tests, theagreement shall identify
observationsmadeover a periodoftimewith one or any contract requirements pertinent to the testobjectives,
more of the independent variables maintained virtually e.g., guarantee provisions, and it must include estimated
constant. A testis a single run or the combination of valuesor other clarifications necessary to resolve any
a series of runs for the purpose of determining perform- omissionsorambiguities in the contract.
23

1 1
2
2
3
(a) (b) (C)
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 shallspecificallyincludethe 0 whether to conduct a pretest uncertainty analysis and
followingitemsandshould also address other items how to apply results of the analysis to improve the
considered pertinent by the parties tothetest. For test (refer to Subsection 3.2.5.1)
routine performancetests,someitemsmaynotbe 0 number of runs
applicable andmaybeomitted: 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 m 0759670 Ob14967 TT5 m
TABLE 3.2-1
OPERATING PARAMETER DEVIATIONS
Short-Term Fluctuation
Parameters (Peak to Valley) Long-Term
Deviation
Controlled Parameter
SteamPressure
> 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 (byVolume)
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
SuperheaUReheat Spray Flow 40% Spray Flow or 2 % Main NfA
Steam Flow
Fuel Flow ( I f Measured) 1o % NIA
Feedwater Temperature 20°F 10°F
FuelBedDepth (Stoker) 2 in. 1 in.
SorbenUCoal 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 ( I f 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.
parameters to be estimatedrather than measured, esti- 0 peak capacity determination:

mated valuesto be used, anduncertaintiesof 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 whichwillmakethefuel
- 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
distribution of residue quantities between various col- may also provide opportunities for economiesincon-
lection points and methods of residue sampling and ducting the test by identifying parameterswhich are
analysis less critical toattainment of target test uncertainties.
procedurestobeused for fluegassamplingand These parameters might then be candidatesfor measure-
analysis mentbylower quality instruments andor the existing
whether to determine the need for and methodsof flow plant instrumentation, or they might be considered for
weighting for flue gas temperature and oxygen content estimation of values rather thanmeasurement.
method for determining outliers Section 7 providesguidance for conductinguncer-
corrections to be usedfor comparison to contract con- tainty analysis includingdeterminationof 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 3.2.5.2PretestCheckout. 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
3.2.4AcceptanceTest. An acceptancetestshould problemswhichmight 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 ofthe parties to the test 0 Any departures from standard or previously specified
areencouragedtobe present to verifythatthetest is conditions in the physical state of equipment, cleanli-
conducted in accordancewith
this
Codeand the ness of heatingsurfaces, fuel characteristics, or stabil-
agreementsmade prior to the test. ity of load must be noted and corrected if possible.
3.2.5PreparationfortheTest 0 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 shouldbeperformedtoconfirm and for operability.
thatthe test, as it hasbeendesignedandplanned, is Parties to the test shall agree that the steam generator
capable of achieving the target test uncertainties. This is ready for testing, i.e., that its configuration and
uncertainty analysis willhelpavoidthe possibility of conditions conform to those specified in the pretest
conducting a testthatdoesnotachievethe 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 canbe achieved, the pretest uncertainty steam generator should be visually inspected for abnor-
analysis providesinformationwhichcanbeused to mal air infiltration.Air heater internal leakageshould
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 todeterminethe bemade for the following purposes:
relative sensitivity coefficients, i.e., the relationships of
overall test uncertainties to the uncertainty of each determining whetherthe steam generator andthe over-
parameter for which a valuewillbe either measured allplant are in a suitable condition for conducting
or estimated (refer to Sections 5 and 7). All parameters the test
for whichthe 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 thetest, establishing proper
are considered critical parameters. All critical parameters combustion conditionsfor the particular fuel and firing
should bemeasuredusing accurate instruments. These ratetobeemployed,andconfirming that specified
instruments should be selected and calibrated in accord- operating conditions and stability (in accordance with
ancewiththe criteria in Section 4. However,proper Subsection 3.2.6.1) are attainable
installation of the instruments and proper implementa- 0 checking instruments
tionof the chosensamplingschemes are at least as verifying attainability of the target test uncertainty
important as proper calibration in assuring that target acquainting test personnelwith the specific facility,
test uncertainties are attainable. The sensitivity analysis test instruments, and procedures
26

-
STD ASME PTC 4-ENGL 1998 m 0759670 0634969 878 m
After a preliminaryrunhas beenmade, it maybe quality of the control system.Table 3.2-1 provides
declared a testrun if agreed tobythe parties to the criteria for stability of operating parameters which are
test,provided all therequirements of a Ïestrunhave indicative of units which have reached equilibrium. For
beenmet. fluidizedbedunitsthatusean inert bedmaterialsuch
as sand, the stoker unit criteria shouldbeused.For
3.2.6Method of OperationDuringTest fluidizedbedunitswhichhavealreadybeen operating
3.2.6.1Stability of TestConditions. Prior toany 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
timeto 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 whentheagreeduponpretest
tics, as wellasall internal characteristics, do notvary stabilization period has been completed and monitoring
with time. This definition of steady-state isoverly indicates the controlled anddependentparameters are
restrictive for thepurposes ofthisCode. Steady-state maintained within agreeduponmaximum operating
isdefined by this Code as an operating condition in parameter deviations. Thepretestagreementshall in-
which the system is at thermal and chemical equilibrium. clude a table of allowablemaximum variations in
The criterion for thermal equilibrium is that, during operatingparameters similar toTable 3.2-1. Values
the period of the test, there is no net change in energy shown in Table 3.2-1 aretypicalandmaybeused
stored inside the steam generator envelope. Energy can directly or modified by agreementbetween 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. Ifthesteamgenerator is atthermalequilibrium continuouslyandused as anindicationofchemical
duringthe test, theaverageinputandaverageoutput equilibrium between the bed and recycled material, i.e.,
can be properlycalculated and compared. Forcirculating the SO2 trend should be reasonably flat. For circulating
fluidizedbedunits,thermalequilibrium includes the fluidized bed units, complying with the pretest stabiliza-
requirementthat size equilibrium ofthe 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 theaverage of the data duringthetest 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 thesetrendmeasurements.
Fluidizedbedunitsthatutilizelimestoneor other All parameters in Table 3.2-1, andany other condi-
sorbent forreducing sulfur (or other) emissionshave tions designated bythe parties to the test in which
a large inventory of reactive materialthatmustreach variations might affect the results of the test, should
chemical equilibrium, including the recycledmaterial be, as nearly as possible, thesame at theendofthe
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 thattheaverage of the data reflects
inthefuel (sulfation), the sorbent to fuel ratio during equilibrium between input from fuel and steam generator
the stabilization period shall be maintained within +5% output. Thus,gradualchanges in the critical operating
of the targeted ratio forthe test. parameters over a significantly long test period are not
The following are minimum pretest stabilization times necessarily groundsfor rejecting a test.
typicallyrequired for varioustypes of units: During a completetest run, eachobservation ofan
operating condition shall notvaryfromthereported
pulverized coal and gadoil fired units - 1 hr
average for that operating condition by more than
0 stoker units - 4 hr
theallowablevalueunder the “Long-TermDeviation”
0 fluidized bed units - 24 to 48 hr
column of Table 3.2-1, andthemaximum variation
Thepurposeofthepretest stabilization period is to betweenanypeakandan adjacent valley in the data
establish thermal, chemical,and recirculated material shall notexceedthelimitshown in the “Short-Term
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 providedonFig. 3.2-2. These limits
as long as theydonot interfere with safe operation. maybemodified by the partiesto the test but, in any
However,the entire steamgeneratorshouldbe essen- event, the established limits shall be tabulated in the
tially at test conditions throughout the entire stabilization pretest agreeihent. If operating conditions varyduring
period. The actualstabilization time required will depend any test run beyond the limits prescribed in that table,
uponthe specific unit operating characteristics andthe the test run is invalid unless the parties to the test agree
27

ASME PTC 4- 1998 FIRED STEAM GENERATORS
TABLE 3.2-2 to allow the deviation.Any such allowed deviations shall

MINIMUM TEST RUN DURATION be explained inthetestreport.
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, andtypicalunit
Pulverized Coal 8
Fluidized Bed 8
operating characteristics. The test duration shall not be
less thanthattabulated in Table 3.2-2.
The chief-of-test andthe parties tothetest may
determine that a longer testperiod is required. The
minimumtimes shown in Table 3.2-2 are generally
based upon continuous data acquisition and utilization
+15
.-
B
Pavg. Paverage
-1 5
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 fuelbed be accomplished some timebeforethe run
personnel available and the method of data acquisition, starts andagainthe same length of timebeforethe
it may be necessarytoincreasethelength of a test run is completed. Normal cleaning ofthe fuel bedis
to obtain a sufficient numberof samples of the measured permitted during the run. The ash pit must be emptied
parameterstoachievetherequiredtestuncertainty. 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
twofulltraverses.Testrunsusingblended or waste to thequantity of fuelburned.
fuels may also require longer durations if variations in In the case of runs to determine the maximum output
thefuel are significant. at whichthe unit can be operated for a short period,
The duration of runs to determine themaximum the run should be startedas soon as the maximum output
shortperiod output, whentheefficiencyis notto be is reachedand continue until thespecifiedduration of
determined,shallbeset by agreement of theparties the run is reached unless conditions necessitate terminat-
tothe test. ingthe run earlier. Referto Subsection 3.2.6.2.
The actual duration of all runs from which the final
3.2.6.4Frequency of Observations. The following
testdataare derived shallberecorded.
measurement and sampling frequencies arerecom-
mended for use during a test. The frequencies maybe
3.2.6.3Considerations for ConductingtheTest.
increased or decreased basedon a pretestuncertainty
Eachtestrunshould be conducted with the steam
analysis. Referto Sections 4, 5, and 7 foradditional
generator operatingas closely as possible to the specified
information:
conditions toavoidtheapplication of correctionsto
thetestresults or to minimizethemagnitude ofthe Readings shouldbe 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. Forunitsutilizing at 1 hr intervals.
sorbent,thesorbenttofuel ratio ( C d S molarratio)is If the quantities to bedeterminedareweighed,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 testsaredefined 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 quantitymeasurements,
facilitate communicationbetweenthesteamgenerator the flow indicating element should be read at intervals
operator(s) andthe parties to thetest. 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-
bilitieswithrespect to thetest.Thisincludesthe ance with guidance in Section 4.
requirements of the pretest stabilization period as well
3.2.6.5PerformanceCurves. If runsaremadeat
as the specified maximumdeviation of critical operating
different outputs, curves may bedrawntorelatethe
parameters. Communications between the test operations
test parameters to output. Such curves areuseful in
coordinatorandthe operator(s) shouldbesuch that,
appraising theperformance of the unit, becausethe
exceptunderemergencyoperating situations, thetest
desired outputs areseldomexactlyobtained during
operations coordinator isconsulted prior to changing
the test. If thereare enough testpoints to establish
operating parameters.
characteristic curves, the performance corresponding to
If soot blowing would normally beused during the
intermediate levels of output maybereadfromthe
period of a test run, it should beusedduring the
curves.
conduct of each test run. The pretestagreementshall
define the soot blowing planfor each run. Any soot 3.2.7CorrectionstoTestResults. Operating condi-
blowing conducted during a test run shall be recorded tions at the time of the test may differ from the standard
andincluded inthe analysis of thetest results. or specified conditions whichwereused to establish
For stoker firedunitswith a stationary grate, it is design or guarantee performance levels. Section 5 pro-
essential thatmajor cleaning and conditioning ofthe vides methods for applyingcorrections during the calcu-
29

~ ~~
~~
~
STD-ASME PTC 4-ENGL L998 W 0759670Ob14972 3b2 W
lation oftestresultstoaccount for manyof these be

used in conjunctionwith the followingASME
differences. Correction factors maybe obtainedfrom PerformanceTestCodesandSupplementson Instru-
varioussourcessuchas tables, correction curves, or mentsandApparatusand other pertinent publications
manufacturer’sdesign 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 basedupon the latest information avail-
ThisCodedoesnotprovide a method for calculating able when this Code was published. In all cases, care
the uncertainty of corrected results. Uncertainties calcu- shouldbe exercised to refer to the latest revision of
lated in accordance withthis Code apply to as-measured thedocument.
results only. A procedure for calculating the uncertainty
of corrected results will be provided in a future adden- 3.3.1ASMEPerformanceTestCodes
dumto this Codewhen 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
gingispreferredtomanual recording, provided all Coal and Coke, PTC 3.2
required points are recorded. Followingcompletion of Gaseous Fuels, PTC 3.3
the test, a permanentrecord of the data shall be Coal Pulverizers, PTC 4.2
submitted in a mutuallyagreeduponformattoeach 0 Air Heaters, PTC 4.3
partyofthe test. Gas Turbine Heat Recovery Steam Generators, PTC
Anymanuallyrecorded data shall beenteredon 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. Eachpartyto the test shall begiven a Fans, PTC 11
complete set of unaltered log sheets, recorded charts, Instruments and Apparatus: Part 1 Measurement Un-
or facsimiles. Theobservations shall includethe date certainty, PTC 19.1
andtime 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 completerecord of the test. It is recommendedthat 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 recordaverage reading, correction for instrument NOTE: Atthe time this Code was published, a revision of F’TC
calibration, and conversion to desired units for calcula- 19.5 was being prepared. This revisedversion or a later version
tions. should be consulted.
Recordsmadeduring tests mustshowthe extent of Measurement of Shaft Power, PTC 19.7
fluctuations (i.e., minimumandmaximumvaluesof Flue and Exhaust Gas Analyses, PTC 19.10
instrument readings) of the instruments so that data 0 Steam and Water Sampling, Conditioning, and Analy-
willbe available for use in determiningtheinfluence sis in the Power Cycle, PTC 19.1 1
ofsuchfluctuationson the uncertainty of calculated Particulate Matter Collection Equipment, PTC 21
results. 0 Gas Turbine PTC 22
Everyeventconnectedwiththeprogressof 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 recordedonthetest log sheets together withthe
timeofoccurrenceand the nameof the observer. 3.3.2
ASME
Standards
Particular care should be takento 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 0 Measurement of GasFlowbyTurbineMeters,
shall bestated in thetest record. MFC-4M
3.33 ASTMStandard Methods
3.3REFERENCES TO OTHERCODESAND 0 TestMethod for ChemicalAnalysisofLimestone,
STANDARDS
Quicklime, and Hydrated Lime, C 25
The necessary instruments and procedures for making Test Methodfor Heat of Combustion of Liquid Hydro-
measurements are prescribed in Section 4 andshould carbon Fuels by Bomb Calorimeter, D 240
30

~
STDaASME PTC 4-ENGL L998 m 0759b70 Ob14973 2 T 9 m
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
Test Methods for Collection of a Gross Sample of Test Method for Calorific Value of Gases in Natural
Coal, D 2234 GasRange by ContinuousRecording Calorimeter,
0 Test Method for Carbon Dioxide in Coal, D 1756 D1826
0 TestMethod for GrossCalorificValue, D 1989, D Test Methodfor Analysis of Natural Gasby Gas Chro-
2015, D 3286 matography, D 1945
0 MethodofPreparingCoalSample 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 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 3.3.4IEEE 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 3.3.5NationalInstitute of StandardsandTech-
0 Method for Calculating Calorific Value and Specific nology
Gravity (Relative Density) of GaseousFuels, D 3588
Test Method for Major and Minor Elements in Coal 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-
0 Test Method for Ash in the Analysis Sample of Coal
ization
and Coke from Coal, D 3 174
0 Practice for Calculating Coal and Coke Analyses from Flow Measurement, IS0 5167
As-Determined to Different Bases, D 3180
Test Method for Total Sulfur in the Analysis Sample
of Coal and Coke, D 3177
0 TestMethodfor Sulfur in the AnalysisSample of 3.4TOLERANCESANDTEST
Coal and Coke Using High Temperature Tube Furnace UNCERTAINTIES
Combustion Methods, D 4239
0 Test Method for the Proximate Analysisof the Analy- Tolerances or marginsonperformanceguarantees
sis Sample of Coa! and Coke by Instrumental Proce- are not within the scope of this Code. The test results
dures, D 5142 shall be reported as computed fromtest observations,
0 Practice for Manual Samplingof 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 TestMethod for Water in PetroleumProductsand with Sections 5 and 7. The calculated uncertainties
Bituminous Materials by Distillation, D 95 shall be reported with the results ofthetestandthe
Test Method far Ash from Petroleum Products, D 482 uncertainty analysis shall bepart of therecordofthe
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 thequality of the test and the accuracy of thetest
Petroleum Products by Hydrometer Method, D 1298 results. They are not tolerances onperformance.
31

FIREDSTEAMGENERATORS ASME PTC 4- 1998
SECTION 4 - INSTRUMENTSANDMETHODS OF
MEASUREMENT
4.1 GUIDING
PRINCIPLES exit flue gas and air entering temperatures
excess air
This Section provides guidance in test measurement.
0 waterhteam pressure drops
Whenplanning a test, the engineer hasmany choices
0 aidflue gas pressure drops
regardingtheparameters to bemeasured,themethod
air infiltration
of measurement, calculations, assumptions, andvalues
sulfur capturehetention
for anyassumed variables. Because thetechnology of
I measurement
test is constantly improving, this Code calcium to sulfur molar ratio
fuel, air, and flue gas flows
permits flexibility in thedesignandselection oftest
instrumentation, yet maintains a prescribed quality level.
Tables 4.2-1 through 4.2-12 listtheparametersre-
A test can be designed within the guidelines provided
quired to determine each of these performancecharacter-
here to suittheparticularneedsand objectives ofall
istics for typical units as definedby the Steam Generator
parties tothetest.
System Boundaries on Figs. 1.4-1 through 1.4-7 in
This Sectionaddressesthreeitems:
Section 1. Eachtable lists theparametersrequired,
For each Code objective, theparametersneededto their relative importance, andtheparagraph in this
compute the final result are identified. Section covering the applicable measurement procedure
0 The relative importanceof each parameter isindicated, for thespecific measurementhest objective. The user
and several methodsfor quantifying the parameterare of this Code is responsible for identifying any features
identified. of theunittobetestedthatare not included in the
Appropriate bias limits are suggested for each method typical examples andfor applying the principles of
used to measure the required parameters. this Code for measuring the appropriate parameters to
accomplishthe objective of thetest.
Itisthetest engineer’s responsibility to select the On the line with the majorparameter,the “typical
method for measuring each parameterwhich, when influence”and “typical source” entries relate to the
considered with allthe other parameters, produces major parameter. The typical sources are either mea-
resultswithintheuncertainty requirements ofthetest. sured, calculated, or estimated. Measured isintended
Inthis Code, wherethereis a choice among several to indicatetheparameter as determinedfrom direct
methods, a preferred method is identified. If a preferred observation of a physicalpropertysuchasvoltage 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
uponbyall parties tothetest. 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 agreedto bythe parties to
the test. In general, estimated means that a reasonable
This Code addresses themethodologyto determine
order of magnitude estimate can bemadebased on
separate performance characteristics including the fol-
experience from similar units, or, preferably, on previous
lowing:
.
tests on theunit.Examples are a contractuallyagreed
efficiency ash split or radiationloss.
output In these tables, the “Typical Influence” columndesig-
0 capacity nates those parameters thattypicallyhave a major
steam temperaturekontrol range (primary) affect on the result and those items that are
33
Previous Page
is Blank
STDOASME PTC 4-ENGL 3998 I0759670 0634975 0 7 1
ASME PTC 4-1998 GENERATORS STEAM FIRED
TABLE 4.2-1
PARAMETERS REQUIRED FOR EFFICIENCYDETERMINATION BY ENERGY BALANCE METHOD
Calculation Typical
Acronym Parameter Influence
Section [Note (113 Source [Note (2)l Remarks
LOSS QpLOFg
GAS DRY 5.14.1 PR1
Fuel Analysis 4.12.3 PR1 M
PR1
% O2 in Flue Gas 4.13.4 M See4.2-6
Table
Flue Gas Temperature 4.4.3 PR1 M See Table 4.2-5
MpUbc UNBURNED CARBON 5.10.3 SEC MIE See QpLUbc,

4.2.1 Table
% Carbon in Residue PR1 4.12.3.5 M
PR1
Residue Split 4.7.8 CIM
Sorbent Analysis PR1 4.12.3.2 M
Sorbent Rate 4.8 PR1 M
FuelRate PR1 4.7.7 CIM See 4.2-12
Table
Yo CO, in Residue 4.12.3.5 PR I M
S0,/02 in Flue Gas 4.13.4 PR1 M See Table 4.2-10
QpLHZF WATER FROM FUEL

H2 IN LOSS PR15.14.2 M
Analysis Fuel M
PR1Flue Gas
4.4.3
Temperature M 4.2-5 See Table
QpLWF WATER FROM HO , IN FUEL LOSS 5.14.2 PR I M

QpL WvF Fuel Analysis 4.12.3 PR I M
PR1 Flue Gas
4.4.3
~
QpLWA MOISTURE I N AIR LOSS 5.14.3 SEC MIE

Flue Gas O, 4.13.4 PR1 M See Table 4.2-6
Dry-Bulb Temperature 4.15 PR1 M
Wet-Bulb Temperature 4.15 PR1 M
Or Relative Humidity 4.15 PR I M
Barometric Pressure 4.5.5 SEC M
Flue Gas Temperature 4.4.3 PR1 M See Table 4.2-5
QpLUbc UNBURNED CARBON 5.14.4

RESIDUE PR1 M
LOSS
Fuel Analysis PR1 4.12.3 M
%O Carbon in Residue PR1 4.12.3.5 M
Residue Split
PR1 4.7.8 M
Sorbent AnalysisPR1 4.12.3 M
Sorbent Rate 4.8 PR1 M See
4.2-12
Table
FuelRate 4.7.5 PR I CIM
Yo CO2 in Residue 4.12.3 PR1 M See4.2-10
Table
S02/02 in Flue Gas
PR1 4.13.4 M
QpfHZRs UNBURNED H, I N RESIDUE

SEC5.14.4
LOSS E Normally zero
Items for Qpf Ubc PR1 M See Qpf Ubc, Table 4.2-1
O h H2 in Residue
PR1 4.12.3 M
QpLCO CO I N FLUE GAS LOSS 5.14.4 SEC MIE

Items for Excess Air PR1 M See Table 4.2-6
CO in Flue Gas 4.13.3 PR I M
QpLPr PULVERIZER REJECTS LOSSSEC 5.14.4 E

Pulverizer Rejects
PR1 Rate 4.7.5 MIE
Pulverizer Rejects
PR1Analysis 4.12.3 MIE
Pulverizer Outlet
PR1 Temperature 4.4.3 M
FuelRate 4.7.7 PR I CIM See Table 4.2-12
QpLUbHc UNBURNED HYDROCARBONS

SEC IN 5.14.4 E
FLUE GASLOSS
Hydrocarbons PR1
in Flue Gas 4.13.4 M
HHV of Reference Gas ... PR1 M
(continued)
34

FIRED PTC 4-1998
TABLE 4.2-1 (CONT'D)

Calculation Typical
Section [Note (1)l Source [Note (2)l Remarks
QpLRs HEAT
SENSIBLE OF RESIDUE PR1 5.14.5 MIE
LOSS
Residue SplitPR1 4.7.8 MlClE
Temp of Residue PR1 4.4.5.1 M
QpLAq HOT AIRQUALITY PR1CONTROL 5.14.6 M

EQUIPMENT LOSS
Flue Gas Temperature
PR1 Entering 4.4.3 M
Flue Gas Temperature
PR1 Leaving 4.4.3 M
?LO Oz in Flue Gas
PR1Entering 4.13.4 M See Table 4.2-6
O h O2 in Flue Gas
PR1Leaving 4.13.4 M See Table 4.2-6
Wet Gas WeightPR1 Entering 5.12.9 C See Table 4.2-12
Wet Gas WeightPR1 Leaving 5.12.9 C See
4.2-12
Table
QpLALg
INFILTRATION
AIRSEC 5.14.7 LOSS M Normally NIA
Infiltrating Airflow
PR1 5.14.7 M See Table 4.2-12
Infiltrating Air
PR1Temperature 4.4.3 M
Exit Gas Temperature
PR1 4.4.3 M See Table 4.2-6
QpLNO, FORMATION
NO, OF LOSS 5.14.8 SEC MIE
NO, in Flue Gas PR1 4.13.4 MIE
Wet Gas Weight P 5.12.9 R1 C See Table 4.2-12
QrLSrc RADIATION
AND CONVECTION 5.14.9 PR1 M lE Normally estimated based
LOSS on suface area within
Steam Generator Surface Area ... PR I C envelope. See
Local Ambient
PR1Air Temperature 4.4.3 MIE 5.14.9
Subsection
Local Surface
PR1
Temperature 4.4.3 Ml€
Local PR1
Surface Air Velocity 4.7 E
QrL WAd ADDITIONAL

MOISTURE SEC5.14.10 LOSS MIE
Mass Flow of Moisture PR1 4.7.4 MIE
PR1 Flue Gas
4.4.3
4.5.4 Pressure Feedwater M
4.4.4 Temperature Feedwater M
Fuel Flow 4.7.514.7.7 PR I CIM See Table 4.2-12
QrLClh CALCINATION DEHYDRATION OF 5.14.11 PR1 M

SORBENT LOSS
Sorbent Analysis 4.12.3 PR1 M
FuelRate 4.7.514.7.7 PR1 CIM See Table
4.2-12
Carbon i n Residue
PR1 4.12.3 M
O h CO2 in Residue
PR1 4.12.3 M
Residue Split 4.7.8 PR1 MIE
S02/Oz in Flue PR1
Gas 4.13.4 M See Table 4.2-10
WSb QrL WATER I N SORBENT

SEC5.14.12
LOSS M
12.3 Analysis Sorbent M
Flue Gas Temperature PR1 4.4.3 M See Table 4.2-5
QrLAp SEC
WET ASH
5.14.13
PIT LOSS E Normally estimated.
QrApW 5.14.14 See Section
QrRs WLv for parameters
required when
measured.
QrLRY RECYCLED STREAMS LOSS 5.14.14 SEC M

Recycle
PR1
Flow 4.7 MIE
PR1
Recycle Temperature Entering 4.4.3 M See Table 4.2-5
PR1
Recycle Temperature Leaving 4.4.3 M
(continued)
35

~ ~~~
STD-ASME PTC 4-ENGL L998 m 0759670 Ob14977 944
TABLE 4.2-1 (CONT'D)

Calculation Typical
Acronym Parameter rnfluence
Section [Note ( U 1 Source [Note (2)l Remarks
QrLCw COOLING WATER LOSS 5.14.15 SEC MIE

Cooling Water Flow Rate 4.7.4 PR1 MIE
Temperature of Water Entering 4.4.4 PR1 M
Temperature of Water Leaving 4.4.4 PR1 M
FuelRate 4.7.514.7.7 PR1 CIM See Table 4.2-12
~
QrL
Ac AIR
PREHEAT COIL LOSS (Energy
5.14.16 SEC M
Supplied from within Boundary)
Condensate
APC Flow4.7.4
Rate PR1 MIC
Condensate
APCTemperature
4.4.4 PR1 M
Condensate
4.5.4
Pressure
APC PR1 M
4.4.4
Temperature
Feedwater PR1 M
4.5.4 Pressure Feedwater SEC M
~~~~ ~
QpBOA ENTERING DRY AIR CREDIT 5.15.1 PR1 M

Entering Air Temperature
4.4.3 PR1 M See Table 4.2-5
EXCESS AIR 5.11.4 PR1 M See
4.2-6
Table
Analysis Fuel PR1 M
UNBURNED
5.10.4 CARBON SEC M/E See Qpf Ubc Table 4.2-1
CAPTURE
SULFUR 5.9.5 PR1 M See Table 4.2-10
QpBWA MOISTURE I N ENTERING

AIR SEC 5.15.2 MIE
CREDIT
Items for QpBDA PR1 M
Moisture inPR1
Air 4.15 MIE
Dry-Bulb Temperature 4.15 PR1 M
Wet-Bulb Temperature 4.15 PR1 M
or Relative Humidity 4.15 PR1 M
Barometric Pressure 4.5.5 SEC M
QPBF SENSIBLE
HEAT FUEL IN CREDIT 5.15.3 SEC M
FuelTemperature Entering 4.4 PR1 MIE
QpBSlf SULFATION
CREDIT 5.14.4 PR1 M
S02/02in Flue Gas 4.13 PR1 M See Table 4.2-10
Sorbent Rate 4.7.7 PR1 M
FuelRate 4.7.5 PR1 CIM See Table 4.2-12
% Carbon in Residue 4.12.3 PR1 M
Oh COp in Residue 4.12.3 PR1 M
QrBX EQUIPMENT
AUXILIARY POWER 5.15.5 SEC MIClE
CREDIT
Steam Driven Equipment
Mass Flow of Steam 4.7.4 PR I M
PR1 Pressure
Entering Steam 4.5.4 M
Entering Steam Temperature 4.4.4 PR I M
Exhaust Pressure 4.5.4 PR1 M
Drive Efficiency NA PR1 EIM 19.7 PTC
Electrical DrivenEquipment
For Large Motors:
Watt Hour Reading NA PR1 M IEStandard
EE 120
Drive Efficiency NA PR1 EIM 19.7 PTC
For Small Motors:
Volts NA SEC M
Amps NA SEC M
QrBSb SENSIBLE
HEAT I N SORBENT
SEC 5.15.6 M
CREDIT
Sorbent Rate 4.7.5 PR I M
Sorbent Temperature
PR1 4.4.5 M
(continuedl
36

~~~~ ~
STD.ASME PTC 4-ENGL 3978 m 0759b70 0634978 880 m
FIRED PTC 4-1998
TABLE 4.2-1 (CONT‘D)

PARAMETERS REQUIRED FOR EFFICIENCY DETERMINATION BY ENERGY BALANCE METHOD
Calculation
Section [Note (111 Source [Note (2)l Remarks
QrBWAd ENERGY SUPPLIED BY 5.15.7 SEC MIE

ADDITIONAL MOISTURE
CREDIT
MassFlowRate 4.7.4 PR1 M
EnteringTemperature 4.4.4 PR1 M
EnteringPressure M 4.5.4 PR1
NOTES:
(1) Typicalinfluence:PR1 = Primary, SEC = Secondary.
( 2 ) TypicalSource:M = Measured,C = Calculated,E = Estimated.
TABLE 4.2-2
PARAMETERS REQUIRED FOR EFFICIENCY DETERMINATION BY INPUT-OUTPUT METHOD
Calculation
Acronym Parameter [Note
Influence
Section (111 Source [Note (2)l Remarks
QrF HEAT INPUT FROM FUEL 5.5 PR1 M

FuelRate 4.7.514.7.7 PR1 M
Heating Value of Fuel M 4.12 PR1
FuelAnalysis M 4.12.13 PR1
5.4QrO OUTPUT
Table See C PR1 4.2-3
NOTES:
(1) TypicalInfluence:PR1 = Primary,SEC = Secondary.
( 2 ) TypicalSource: M = Measured,C = Calculated, E = Estimated.
required but have a lesser (secondary) affect on result. starting with“SorbentAnalysis”and separated within
Insomecases,the general parameter may have a themajorparameterwith a line.
secondary impact on the results, but the items required
to determine theparameterhave a primaryimpact on
theparameter itself. For example, see “Unburned H2 4.3 GENERALMEASUREMENT
in Residue Loss” in Table 4.2-1. REQUIREMENTS
The “Typical Source” column identifies acceptable
The methods for obtaining the requireddata detenhine
options for determining the parameter. These options are
the quality of the test. There are usually several ways
“measured,” “cakulated,” and“estimated.”“Typical”
tomeasureanygivenparameter.Each of these ways
indicateswhat is usual or common industry practice
has inherentmeasurement errors attributable to both
for this measurement. In many càses, the typical source
the process involved and the measurement system used.
choice maynot be relevant for a particular unit;the
The test engineer musttakeall of this into account
test engineer’s responsibility is then to choose a method
whendesigningthetestprogram.
whichis consistent with the principles of thisCode.
The method of obtaining the data typikally involves
The determination of some parameters such as flue
theuseof a measurement system. This measurement
gas constituents canbe 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 isused, 0 data collectiodmeasurement device
parameters related to sorbent are groupedseparately data storage device
37

~
STD-ASME PTC 4-ENGL L998

0759670
Ob14979
717 m
ASME PTC 4-1998 FIRED STEAMGENERATORS
TABLE 4.2-3
PARAMETERS REQUIRED FOR CAPACITY DETERMINATION
Typical
Influence
Typical
Calculation [Note Source
Acronym Parameter Section (111 [Note (2)l Remarks
QrO OUTPUT 5.4 PR1 C

Saturated Steam Generator 5.4.1.1
Saturated Steam Flow 4.7.4 PR1 M
Feedwater Flow 4.7.4 PR1 M
Blowdown Flow 5.4.5 PR1 MIE
Extraction Flow 4.7.4 PR1 M
Saturated SteamPressure 4.4.4 PR1 M
Feedwater Temperature 4.4.4 PR1 M
FeedwaterPressure 4.5.4 SEC M
Superheated Steam Generator 5.4.1.2
Main Steam Flow 4.7.4 PR1 M
Blowdown Flow 4.7.4 SEC Ml€
Extraction Flow 4.7.4 PR1 M
Desuperheating Spray Flow 4.7.4 PR1 CIM
Main Steam Temperature 4.4.4 PR1 M
Main Steam Pressure 4.5.4 PR1 M
Feedwater Temperature 4.4.4 PR1 M
Desuperheating Spray Water Temperature 4.4.4 PR1 M
Desuperheating Spray Water Pressure 4.5.4 SEC M
Reheat Steam Generator 5.4.2
Reheat Steam Flow 5.4.2.1 PR1 CIM See PTC 6
Reheat Desuperheating Spray Water Flow 4.7.4 PR1 M
Feedwater Heater Extraction Flow 5.4.2.1 PR1 CIM
Feedwater Heater Extraction Temperature 4.4.4 PR1 M
Feedwater Heater Extraction Pressure 4.5.4 PR1 M
Feedwater Heater Entering Water Temperature 4.4.4 PR1 M
Feedwater Heater Leaving Water Temperature 4.4.4 PR1 M
Feedwater Heater Water Pressure 4.5.4 SEC M
Feedwater Water Drain Temperature 4.4.4 PR1 M
Turbine Leakage NA SEC E
Steam Extraction Flow (Other) 4.7.4 PR1 M
Reheat Out Steam Temperature 4.4.4 PRI M
Reheat Out Steam Pressure 4.5.4 PR I M
Reheat I n Steam Temperature 4.4.4 PR1 M
Reheat I n Steam Pressure 4.5.4 PR1 M
Reheat Desuperheating Spray Water Temperature 4.4.4 PR1 M
Reheat Desuperheating Spray Water Pressure 4.5.4 SEC M
Auxiliary Steam 5.4.3
Auxiliary Steam Flow 4.7.4 PR1 MIE
Auxiliary Steam Temperature 4.4.4 PR1 M
Auxiliary Steam Pressure 4.5.4 PR1 M
Feedwater Temperature 4.4.4 PR I M
NOTES:
(1) TypicalInfluence: PR1 = Primary, SEC = Secondary.
(2) Typical Source: M = Measured, C = Calculated, E = Estimated.
38

STD-ASME PTC 4-ENGL 1998 m 0759b70Ob34980 439 m
FIRED ASME PTC 4-1998
TABLE 4.2-4
PARAMETERSREQUIRED FOR STEAMTEMPERATURUCONTROL RANGE DETERMINATION
~~~ ~~ ~ ~~
Calculation Typical Typical Reference

meter Acronym 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
listedare
Blowdown Flow 4.7.4 PR1 MIE here. All items needed
Extraction Flow 4.7.4 PR1 M for
required.
output
are
Main Steam Temperature 4.4.4 PR1 M
Main SteamPressure 4.5.4 PR1 M
Drum Pressure (if applicable) 4.5.4 PR1 M
Drum Level
Feedwater Temperature 4.4.4 PR I M
Feedwater Pressure 4.5.4 SEC M
Desuperheated Spray Water Flow 4.7.4 PR1 M
Desuperheated Spray Water
Temperature 4.4.4 PR1 M
Desuperheated Spray Water Pressure 4.5.4 SEC M
Other Items Required to Determine
output 5.4 SEC MlClE
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 PR1 M
ReheatOut Steam Pressure 4.5.4 PR1 M
Reheat I n Steam Temperature 4.4.4 PR1 M
Reheat Out Steam Pressure 4.5.4 PR1 M
Reheat Desuperheating Spray Water
Flow 4.7.4 PR1 M
Temperature 4.4.4 PR1 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 increasetestuncertainty
effect which the sensing device measures, typically by beyondagreed-upon limits. All instruments must be
converting it to a proportional electrical signal. This checked to verifythatthey are thespecifiedtype,
electrical signal is then either converted to a digital properly installed, working as designed, and functioning
value and stored electronicallyor sent to a chart recorder over the range of input expected.
or analog meter.
4.3.2 Calibration. The parties to thetest shall agree
4.3.1 Type of Equipmentnnstallation. In general, onwhich instruments willbe calibrated for the test.
measuringequipment should be selected to minimize This Code requires that, as a minimum, relevant compo-
test uncertainty. In particular, critical parameters should nents of all instrumentation loops havebeen initially
be measured with instruments that have sufficient accu- aligned (the zero offsets or spanshavebeenadjusted
racy to ensure that target uncertainties will be achieved. to their respective specifications). Calibrations prior to
Typical stationrecording 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

STD=ASME PTC 4-ENGL 1998 D 0759b70 ObL49BL 375
ASME Fl'C 4-1998 FIRED STEAM GENERATORS
TABLE 4.2-5
PARAMETERSREQUIRED FOR EXIT FLUE GAS AND AIRENTERING
TEMPERATUREDETERMINATIONS
Typical
Typical
Calculation Source
Acronym Parameter Section [Note (111 [Note (2)l Remarks
No Air Heater
Flue Gas Temperature Leaving Steam Generator 4.4.3 PR1 M
Air Temperature Entering Steam Generator 4.4.3 PR1 M
Single Bisector Type Air Heater

O2 Entering Air Heater 4.10 PR1 M
Oz Leaving air Heater 4.10 PR1 M
Flue Gas Temperature Entering Air Heater 4.4.3 PR1 M
Flue Gas Temperature Leaving Air HeaterPR1 4.4.3 M
Air Temperature Entering Air Heater 4.4.3 PR1 Flue
M gas temperature
enter-
ing is ony required for
correction to reference.
Primary Secondary Air Heaters

Items Above for Bisector Air Heater PR1
Plus:
Air Temperature Leaving Each Air HeaterPR1 4.4.3 M
Primary Air Flow Leaving Air Heater PR1 4.7.3 CIM
Tempering Air Flow SEC 4.7.3 C
Tempering Air Temperature PR1 4.4.3 M
Mixed Air Flow PR1 4.7.3 CIM
Mixed Air Temperature PR1 4.4.3 M
Items Required for Efficiency PR1 See Table 4.2-1
Items Required for Output PR1 See Table 4.2-3
Trisector Type Air Hdters

Items Above for Single Air Heater PR1
Secondary Air Temperature Entering Air Heater 4.4.3 PR1 M
Secondary Air Temperature Leaving Air Heater 4.4.3 PR1 M
Primary Air Temperature Entering Air Heater 4.4.3 PR1 M
Primary Air Temperature Leaving Air Heater 4.4.3 PR1 M
Primary Air Flow Leaving Air Heater 4.7.3 PR1 CIM
Tempering Air Flow 4.7.3 PR1 M
Tempering Air Temperature 4.4.3 PR I M
Mixed Air Flow 4.7.3 PR1 M
Mixed Air Temperature 4.4.3 PR1 M
Items Required for Efficiency PR1 See Table 4.2-1
Items Required for Output PR1 See Table 4.2-3
NOTES:
(1) Typical Influence:PR1 = Primary, SEC = Secondary.
internationalstandard.Allmeasurements should be used plus other bias influences. These influencesmay

corrected for any calibrations beforeuse in the perform- include environmental influencesonthe instrument as
ance calculations; otherwise, the bias estimate must be well as bias introduced due to nonuniformity of mea-
increased tothe reference accuracyplus other bias suredmedium.
influences described below. Reference accuracy is the Certain instrumentation should be calibrated immedi-
bias a user may expect to achieve in the absence of atelypriorto and immediately followingthetesting
a calibrationafterthe instrument is initially adjusted period to determine the amount of drift. If the pretest
in accordance withthe manufacturer's specification. andpost-test calibrations differ,theamountofdrift
This bias is reduced when adjustments are made to an shall be determined and one halfaddedtothebias
instrument to align it to a reference standard. The bias estimate for the instrument. Drift is assumed to be
thenbecomestheaccuracyofthe reference standard linear with time. Therefore, the average of the pretest
40

~~
STD-ASME PTC 4-ENGL L998 0757670 ObL498,Z 2 0 1 W
FIRED PTC 4-1998
TABLE 4.2-6
PARAMETERSREQUIRED FOR EXCESS AIR DETERMINATION
Calculation
Acronym Parameter [Note
Influence
Section (1)l Source [Note (2)l Remarks
XPA EXCESS AIR 5.11.4 M

Analysis Fuel M
4.12.3 PR1
MpUbc UNBURNED CARBON 5.10.3 CIE PR1

Residue in Yo Carbon 4.12.3 M PR1
Residue Split 4.7.8 PR1 M/€
Flue % O2 in Gas 4.13.4 PR1 M
Oz WET BASIS
MFr WA MOISTURE I N AIR 5.11.2 PR1 CIE
Temperature
Dry-Bulb 4.15 PR1 M
Temperature
Wet-Bulb 4.15 PR1 M
OrRelativeHumidity 4.15 P RI M
BarometricPressure 4.5.5 SEC M
AdditionalMoisture 4.7.4 PR1 M
MoFrCaS Sorbent
Analysis 4.12.3 PR1 M
CdS MOLAR RATIO 5.9.6 PR1 C/€
SorbentRate 4.7.7 PR1 M
FuelRate 4.7.5/4.7.7 PR1 TableSee C/M 4.2-12
MFrClhk CALCINATION 5.10.8 PR1 C/E
YOCOz in Residue 4.13.4 PR1 M
MFrSc CAPTURE
SULFUR 5.9.5 PR1 C/ E
Gas in Flue
S02/02 4.13.4 P RI M Table See 4.2-10
NOTES:
(1) TypicalInfluence:PR1 = Primary,SEC = Secondary.
( 2 ) TypicalSource:M = Measured, C = Calculated,E = Estimated.
and post-testcalibrations shall be used for the

calibration device should be calibrated against a standardwhich
value. has a calibration traceable to the NIST or other interna-
In general, the best methodology for calibrating the tionally
recognizedstandard. The sensing element
testinstrumentation 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 ofthe anticipated values expected during
recording device to theknownvalue. An example of the test. Thermocouples must be heat soaked prior to
this istheintroduction of a knownpressure to a calibration to ensure that shifts in output do not occur
transmitter mountedat its measurementlocationand after calibration.
connected tothe 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 withanNIST
wiring connections are thus included in the calibration traceable pressure standard at fivedifferentpressures.
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% fullscale, 75% full scale, and
and lowest value in the range expected to be measured full scale. The pressure should be recordedat each point
during the test. while pressure is increased and again while pressure is
decreased and the average should be used. The differ-
4.3.2.1Temperature. Temperature sensing devices ence should be considered in the bias estimate.
can be calibrated when it is desired to reducethe
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

STDmASME PTC 4-ENGL L998 9 0759b70 Ob14983 L48 9
ASME PTC 4-1998 FRED STEAM GENERATORS
TABLE 4.2-7
PARAMETERS REQUIRED FOR WATEWSTEAM PRESSURE DROP DETERMINATIONS
Calculation Typical Typical Reference
Acronym Parameter Section
Influence
[Note ( U 1 Source
[Note (211 Remarks
SUPERHEATER PRESSURE DROP 5.17 M/C
Superheater Outlet Pressure 4.5.4 PR I M
Superheater Inlet (Drum) Pressure 4.5.4 PR1 M
Main Steam Flow 4.7.4 PR1 M
Blowdown Flow 4.7.4 SEC MIE
Exraction Flow 4.7.4 PR I M
Superheater Spray Flow 4.7.4 PR1 CIM
Superheater Outlet Steam 4.4.4 SEC M
Temperature
Superheater Inlet Steam 4.4.4 SEC Supercritical
Units M
Temperature
REHEATER PRESSURE DROP 5.17 M/C

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 PR1 CIM See Table 4.2-3
Feedwater Heater Extraction Flow 5.4.2.1 PR1 CIM
Turbine Leakage NA SEC E
PR1 Flow
Steam Extraction 4.7.4 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
ECONOMIZERPRESSURE DROP 5.17 M/C

PR1Inlet Pressure
Economizer Water 4.5.4 M
Economizer Water Outlet (Drum) 4.5.4 PR I M
Pressure
Feedwater Flow 4.7.4 PR I M
M/C Superheated Spray
PR1Water Flow 4.7.4
Economizer Water Inlet 4.4.4 SEC M
Temperature
Economizer Water Outlet SEC 4.4.4 M
Temperature
NOTES:
to a test, and calibration shall be checked for drift calibrated on one rangeand the measurement during
immediately following atest. These calibrations are the test is performed on another, a post-test calibration
performedusingcertified calibration gases for zero, check shall be performed on the second range. Potential
full span, and midpoint. Calibration gases must be EPA biasesintroducedbythe sampling system should be
Protocol Iquality gases or gases whichhavebeen verified by theintroductionof calibration gases into
compared to EPAProtocolI 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
whenthe pressure in the cylinder is lowerthan 100 what the instruments readwhen the gas is introduced
psi to ensure that atmospheric air does not contaminate directly versuswhenfedthroughthesampling 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 designshould 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 L998 m 0759b70 Ob14984 O84 m
FIRED PTC 4-1998
TABLE 4.2-8
PARAMETERS REQUIRED FOR AIWFLUE GAS PRESSURE DROP DETERMINATIONS
Typical Typical
Parameter Calculation
Acronym [Note (1)l Section [Note (211 [Note (3)l Remarks
AIRSIDERESISTANCE 5.17.3 M/C

Forced Draft Fan DischargePressure 4.5.3 PR1 M
Air Heater Air Inlet Pressure 4.5.3 PR1 M
Air Heater Air Outlet Pressure 4.5.3 PR1 M
Windbox Pressure 4.5.3 PR I M
Furnace Pressure 4.5.3 PR1 M
Air Flow 5.11.6 PR1 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 M/C

Furnace Pressure 4.5.3 PR1 M
Superheater Inlet Pressure 4.5.3 PR1 M
Superheater Outlet Pressure 4.5.3 PR1 M
Reheater Inlet Pressure 4.5.3 PR1 M
Reheater Outlet Pressure 4.5.3 PR I M
Generating Bank Inlet Pressure 4.5.3 PR1 M
Generating Bank Outlet Pressure 4.5.3 PR1 M
Economizer Inlet Pressure 4.5.3 PR1 M
Economizer Outlet Pressure 4.5.3 PR1 M
Air Quality Control Equipment Inlet Pressure 4.5.3 PR1 M
Air Quality Control Equipment Outlet Pressure 4.5.3 PR1 M
Air Heater Gas Inlet Pressure 4.5.3 PR1 M
Air Heater Gas Outlet Pressure 4.5.3 PR1 M
Flue Gas Flow Rate 5.12.9 PR1 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 ) TypicalInfluence: PR1 = Primary, SEC = Secondary.
( 3 ) Typical Source: M = Measured, C = Calculated, E = Estimated.
( 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, thetimeinterval
withmore inert material. between data collections should be decreased to no
4.3.3 Frequency of Measurements. Because of fuel longerthan 2 minutes. The resultingincreasein 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 thetestto reduce precision errors in the data The useof automated data collection devices is
collected. The frequency of data collection has a direct preferred.Inmostmodem data acquisition devices,
correlation to the testuncertainty.Quantitymeasure- AID accuracy is no longer an issue; most have at least
ments, e.g., fuelmeasuredbyvolumetric 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 inthevalueisreportedunless it
minutes or less. If fluctuations are noted on any impor- exceeds a given percentage. This type of system is
43

STDmASME PTC 4-ENGL L998 0759b70 Ob14185 T10 H
ASME FIT 4- 1998 GENERATORS STEAM FIRED
TABLE 4.2-9
PARAMETERS REQUIRED FOR AIR INFILTRATIONDETERMINATION
Typical Typical
Calculation Reference Influence Source
Acronym Parameter Section [Note (1)l [Note (211 Remarks
INFILTRATION BASE0 ON MEASURED O:, 5.17.6

EXGESS
ENTERING
AIR COMPONENT PR1
5.11.4 C See
4.2-6
Table
Flue Gas O, Entering Component PR1 4.13.4 M
EXCESS
LEAVING
AIR COMPONENT PR1
5.11.4 C See Table 4.2-6
Flue Gas O2 Leaving Component PR1 4.13.4 M
INFILTRATION BYENERGY BALANCE 5.17.6 C
FLUE GAS RATEENTERING
HEATER
AIR PR1
5.12.9 C See 4.2-12
Table
Flue Gas O2 Entering Air Heater 4.13.4 PR1 M
Fuel Analysis SEC 4.12.3 M
Flue Gas Temperature Entering Air Heater 4.4.3 PR1 M
Flue Gas Temperature Leaving Air Heater 4.4.3 PR1 M
Air Temperature Entering Air Heater 4.4.3 PR I M
Air Temperature Leaving Air HeaterPR1 4.4.3 M
Moisture in Air 4.15 SEC MIE
NOTES:
(1) Typical Influence:PR1 = Primary, SEC = Secondary.
unacceptableunlessthe deadband can be set toapproxi-point-by-point data results in fewer complete sets of
mately
zero for measurements.
test 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
weightingissignificantlylarge.
is needed to determine the sensible heat in aflue gas
stream. Because the temperature varies across the duct 43.4.1 Applicability of Flow Weighting. The exis-
cross section, the proper temperature touse is an tence of stratification of the flue gas and its effect on
integrated average (see Subsection 7.2.3). Becausethe uncertainty can be determined by a temperature or by
sensible heatisthe objective, thevariationinmass a preliminary traverse.
flow or stratification should betaken into account. The temperature traverse is useful when an existing
Ideally, this is done by simultaneously measuringthe 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 inthegrid. Weighting factors basedonthe an estimate for the flow weighted temperature is made
relative mass flow in the local area can be applied to using the ratio of absolute temperatures to approximate
the measured temperatures. Weighting factors based on thevelocityweightingfactors:
velocity are also applied to flue gas oxygen concentra-
tionmeasurements.
"V=_ TT, ++ 459.7
Althoughthetheoretically correct weightingisby
-VI 459.7
mass flow (weighting factors are the product of density
and velocity) for temperatureand by volume flow
(weighting factor isvelocity) for oxygen, this Code
recommendsthat only velocityweighting be usedin If the difference between the weighted and unweighted
either case so thatthe procedure is as simple and as temperatures (AT) calculated using this approximation
practical as possible. exceeds 2°F (i.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
inthe results of aperformancetest; 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 flowweighting.
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 stratificationwill result inhighbias
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 OhL498b 957 H
FIRED STEAM GENERATORS ASME PM3 4-1998
TABLE 4.2-10
PARAMETERSREQUIRED FOR SULFUR CAPTURURETENTIONDETERMINATION
Calculation Typical Typical
[Note
Influence
Section
Parameter
Acronym (111 Source [Note (213 Remarks
MF& SULFUR
CAPTURE
RETENTION 5.9.5
SOz in Flue Gas PR1 4.13.4 M
O, in Flue (Same Location
PR1 as SOz) 4.13.4 M
~ ~~ ~~ ~ ~
MFrWA GAS ANALYSIS WETBASIS

PR1 5.11.2 CIE
MOISTURE I N AIR
Dry-Bulb Temperature 4.15 PR I M
Wet-Bulb Temperature 4.15 PR I M
Or Relative Humidity
PR1 4.15 M
AdditionalMoisture 4.7.4 PR1 MIE
Fuel Analysis PR1 4.12.3 MIE
~ ~~~
MpUbc UNBURNED CARBON CIE 5.10.3 PR1

% Carbon in Residue 4.12.3 PR1 M
~~ ~~ ~~ ~~ ~
MoFrCaS Cals MOLAR

RATIO CIE 5.9.6 PR1
Sorbent Rate PR1 4.7.7 M
Fuel Rate 4.7.5 PR1 C
MFrClhk CALCINATION CIE 5.10.8 PR1

PR1 % CO2 in Residue
4.12.3 M
NOTES:
( 2 ) Typical Source: M = Measured, C = Calculated, E = Estimated.
TABLE 4.2-11
PARAMETERSREQUIRED FOR CALCIUM TO SULFUR MOLARRATIO DETERMINATION
Calculation
[Note
Influence
Section
Parameter
Acronym (111 Source [Note (2)l Remarks
MoFrCaS RATIO CdS MOLAR 5.9.6 C

PR1 CO2 in Residue
YO4.12.3 M
PR1OO/ Carbon
4.12.3in Residue M
Residue Split 4.7.8 PR1 FIM
Fuel Analysis PR1 4.7.514.7.7 M
4.7.7 Sorbent Rate P RI M
Fuel Rate 4.7.5 PR1 C
CAPTURESULFUR SEC 5.9.5 CIE See Table 4.2-10
S02102 in Flue Gas 4.13.4 PR1 M
NOTES:
45

STD.ASME PTC II-ENGL It998 0759670 Ob14987 893 9
TABLE 4.2-12
PARAMETERSREQUIRED FOR FUEL, AIR, AND FLUE GAS FLOW RATE DETERMINATIONS
Calculation
[Note
Influence
Section
Parameter
Acronym W1 Source [Note (2)l Remarks
Qrl INPUT FROM FUEL 5.5

Fuel Rate (measured) 4.7.7 PR1 M
Fuel
5.7.7
Rate (calculated) PR1 C
QrO output
PR1 5.4 M See Table 4.2-3
€F 5.7.1Fuel Efficiency PR1 C See Table 4.2-1
OW @?A
AIR WET 5.11.6 C
MrA EXCESS AIR PR1 5.11.4 C See
4.2-6
Table
MOISTURE I N AIR 5.11.2 PR1 C See
4.2-6
Table
W& RATE
WET GAS FLOW 5.12.9 C
MrFg Fuel Analysis 4.12.3 PR I M
UNBURNED CARBON 5.10.3 PR1 MIE
YO Carbon in Residue 4.12.3.5 PR1 M
EXCESS AIR PR1 5.11.4 MIE See Table 4.2-6
MOISTURE I NPR1 AIR 5.11.2 M/E
Moisture Additional PR1 4.7.4 M/E

C d S MOLARRATIO 5.9.6 PR1 MIE
CALCINATION 5.10.8 PR1 MIE
SULFUR CAPTURE
PR1 5.9.5 MIE
NOTES:
thedifferencesbetweenflow-weighted averages and toflowweight,flow weighting shall be applied as

non-weighted averages are calculated: follows.
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
traverseplane. The (space and time) average velocity
should be calculated so thattheweightingfactorsare
V;/ï?
where A B S is the absolute valuefunction. (These Two approaches may be considered for flow
differences estimate the
bias
due
not
to flow weighting using velocity factors. The first is to use the
weighting.)Then: preliminary velocityweightingfactorswiththetest
0 If AT is less than 3°F and/or AO2 is less than 0.2%,
measurements for temperature and(lessfrequently)
flow weighting should not be used. oxygen, as discussed intheprevious 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
thentheparties to thetestshall decide ifflow flowweighted.)Eachmethodhasthepotential for
weighting is to be used. introducing errorinthe averages calculatedfrom 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
thatflow weighting is applicable andthepartieselect test-timevelocitiesareidenticalto those measured in
46

~
~
STD*ASME PTC 4-ENGL 3998 0759b70 Ob14988 72T m
thepreliminary traverse(s). The error associatedwith sample. Obviously, all leaks should be foundand
the second method is more subtle. The timerequired 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 fewrepeatedmeasurements at eachpoint (that test, or a very small leakmaynot be found prior to
is,only a fewrepeated traverses) aremade, thus testing. All of these biases must then be combined into
increasing the precision error. An additional error may a single value for theparameter.
be introduced by thevariation of thetest conditions Since data collection and storage are often the same
over time so that values measured at a point near the for many parameters, thebiasesassociatedwiththese
end of a traverse do not correspond to those measured portions of the measurement system warrant discussion
at another pointnear the beginningofthe traverse. next. Followingthe discussion ofthe data collection
The following rules should be used when performing system, each of the different types of process measure-
simultaneous velocity, temperature, andoxygentra- ments will be discussed along with the biases associated
verses during a testrun: with their primary elements and sensing devices. Other
sources which may be referenced for typical values of
0 There should be no fewer than threecomplete traverses bias include other ASME publicationssuch 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, andVenturi; PTC 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 5167, FlowMeasurement;ap-
0 The values of ATand AO2must berepeatable 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- Estimatingthe bias in a measurementinvolvesthe
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 thoselistedin Tables 4.3-1 through4.3-5.
rejected. These biases, however, may not be representative of
During eachtestrun, a velocityprobeshouldbe anyspecificmeasurementsituationandtend to be
located at a fixed point where the velocity is approxi- conservative. It would be misleading for this Code to
mately equal totheaveragevalue,the temperature is mandatespecific values for bias and valuesmust be
approximately equal to the average value, andthe agreed uponbyparties to the test.
oxygen content isapproximately equal to the average Manyinstrument specifications provide a reference
value. The velocity, temperature, and oxygen at this accuracy. This accuracy is only a part of the potential
pointshouldberecordedwiththe same frequency as bias ofthat instrument. Other factors such as drift,
the traverse points (that is, the data should be recorded nonuniformity of flowingfluid,vibration,and differ-
each time the data atany traverse point is recorded). ences betweenassumedand actual water leg density
The resulting large number of data for the single point can influencethemeasurement.Oftenthereference
can be used to estimate the precision error ofthe accuracyof an instrument can be improvedthrough
weighted average, as described in Subsection 7.4.1.3 calibration. After a calibration, theaccuracy 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 BiasDue 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 fullknowledgeof the testmeasurement system, the
with a particular measurementis the result of several process being tested, andall other factors whichmay
biases in the measurement system. Section 7.5 describes influence thebias of the measurement. The test engineer
the process of combining the biases. For each parameter is in thebest position to evaluate these factors, and
in the test program, all possible sources of measurement can use Tables 4.3-1 through 4.3-5 as a tool to assist
system error associated with that parameter should be inassigningvalues for measurementbiases.
determined. All of the components of the system should When parameters are estimated rather than measured,
be examined to estimate their bias. thevalues for estimates and for bias limits shall be
Outside factors whichinfluencethemeasurement 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 thattheprobabilityisapproximately 19:l (95%confi-
as a one-sided bias, since a leak can only dilute the dence level) that the upperand lower limits willnot
47

~~~ ~~

075qb70
Ob14989 bbb m
ASME P X 4-1998 FIRED STEAM GENERATORS
TABLE 4.3-1
POTENTIALINSTRUMENTATION BIAS LIMITS
Bias Instrument [Note Limits (1)l
Acquisition Data (2)
Logger Digital Data
Control Plant Computer 2 0.1%
Temperature
Hand-Held Indicator 2 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
600-1,600°F
Premium Grade Type K
32-530°F
530-2,300°F
Standard Grade Type E
32-600°F 2 3OF
600-1,6OO0F 2 0.5%
Standard Grade Type K
32-530'F 2 4°F
530-2,300°F 2 0.8%
Resistance Temperature Device (RTD)
NIST Traceable Calibration Standard Note (4)
32OF 2 0.3%
ZOOOF 2 0.0%
4OOOF t 1.3%
570°F 2 1.8%
75OoF 2 2.3%
93OOF 2 2.8%
l,lOO°F 2 3.3%
1,3OO0F 2 3.8%
Temperature Gauge 2 2% of span
Mercury-in-Glass Thermometer t 0.5 gradation
Pressure Note (5)

Gauge
Test 2 0.25% of span
Standard 2 1%of span
Manometer & 0.5 gradation
Transducer and Transmitter
Accuracy High 2 O.1Y0 of span
Standard 2 0.25% of span
Barometer Aneroid 2 0.05 in. Hg
Weather Station Note ( 6 )
(continued)
48

STD-ASME PTC 4-ENGL 1998 m 0759b70 Ob14990 388 m
FIRED STEAM GENERATORS ASME F E 4-1998
TABLE 4.3-1 (CONT’D)

Instrument Bias Limits [Note (111
Velocity
Standard Pitot Tube
Calibrated 2 5% [Note ( 7 ) l
Uncalibrated t 8% [Note (713
S-Type Pitot Tube
Calibrated 2 5% [Note (713
Uncalibrated 2 8% [Note ( 7 ) l
3-HoleProbe
Calibrated 2 2% [Note (7)1
Uncalibrated 2 4% [Note ( 7 ) l
Hot Wire Anemometer c 10%
Turbometer t 2%
Flow (Air and Gas)

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

Flow Nozzle
PTC 6 (With Flow Straighteners)
Calibrated and Inspected t 0.25%
Uncalibrated and Inspected 2 2.5%
Uncalibrated and Uninspected 2 5%
Pipe Taps
Calibrated and Inspected t 0.50% steam 2 0.40% water
Uncalibrated and Inspected 2 2.2% steam t 2.1% water
Uncalibrated and Uninspected New plant: see above
Existing plant: variable
Venturi
Throat Taps
Calibrated and Inspected 2 0.50% steam 2 0.40% water
Uncalibrated and Inspected t 1.2% steam t 1.1% water
Orifice
Calibrated and Inspected f 0.50% steam t 0.40% water
Uncalibrated and Inspected 2 0.75% steam f 0.70% water
Weir t 5%
Blowdown Valve f 15%
(continued)
49

~~
STD=ASME PTC 4-ENGL 1998 m 0759670 Ob14991 214 m

[Note Limits Bias Instrument (111
Liquid Fuel Flow (Calibrated)
Flow Meter
Displacement
Positive Meter 2 0.5%
Meter Turbine 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 2 0.5%
Calibrated and Uninspected 2 2%
Uncalibrated and Inspected 2 0.75%
Turbometers
Non Self-correcting
Self-correcting
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%
Uncalibrated t 15%
Screw, Rotary Valve, etc.
Calibrated
Tank
with Weigh -t- 5%
Uncalibrated 2 15%
WeighBins
Weigh Scale f 5%
Strain Gauges t 8%
Level t 10%
Impact Meters t 10%
Residue Flow
Isokinetic Dust Sampling t 10%
WeighBins
Weigh Scale 2 5%
Strain Gauges 2 8%
Level 2 20%
Screw Feeders, Rotary Valves, etc.
Calibrated
Tankwith Weigh 2 5%
Uncalibrated 2 15%
Assumed Split (Bottom Ash/Fly Ash) 10% of total ash
FuelSolid andSampling
Sorbent 4.3-3 and 4.3-2
Tables
Stopped Belt ? 0%
Full Cut 2 1%
“Thief” Probe 2 29b
Time-Lagged 2 5%
andLiquid Gaseous
Sampling
Fuel and 4.3-4
Tables 4.3-5
50

FIRED STEAM GENERATORS ASME PM3 4-1998

POTENTIALINSTRUMENTATION BIAS LIMITS (Continued)
Limits Bias Instrument [Note (113
Flue Gas Sampling
Point-by-Point Traverse Section 7
Section Composite Grid 7
Residue Sampling
Isokinetic Dust Sampling 2 59/0
Probe ”Thief” 2 200%
Bottom Ash 2 50% [Note ( 9 ) l
. Bed Drain 2 20%
Fuel Handling and Storage - 10% of Moisture Value

Limestone Handling and Storage + 5% of Moisture Value
Residue O
Flue Gas Analysis
Oxygen Analyzer
Analyzer
Electronic
Continuous span
2 1.0% of
Orsat Analyzer 2 0.2 points
Analyzer Portable 2 5% of reading
2 2% of span
Calibrated on Air
Calibrated on Cal Gas
Carbon Monoxide
Continuous
Analyzer
Electronic 2 20 ppm
Orsat Analyzer 2 0.2 points
Sulfur Dioxide
Continuous
Analyzer
Electronic 2 10 ppm
Analyzer
CEM Electronic 2 50 ppm
Oxides of Nitrogen
Chemiluminescent 2 20 pprn
Analyzer
CEM Electronic 2 50 ppm
Hydrocarbons
Detector Ionization Flame 2 5%
Electric Power
Voltage or Current
Transformer Current 2 10%
Transformer Potential 2 10%
Hand-Held Digital Ammeter 2 5%
Watts
Wattmeter 2 2%
Humidity
Hygrometer Z 2 % RH
Psychrometer Sling 2 0.5 gradation
Station Weather (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 areference junction.
Also,the algorithm for conversionofthermocouple millivolts to temperature may introduceerrors.
See ASME 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

~~~
STD-ASME PTC U-ENGL L778 m 0757b70 ObLU773 O77 m
TABLE 4.3-2
POTENTIAL BIAS LIMITS FORCOAL PROPERTIES
Property Coal Limit Comments
Sampling 2234 D ASTM t 10% of Ash Content c 5% ash 2 0.5%

t 2 % of other constituents
Sample Preparation ASTM D 2013 None
Air Dry Moisture ASTM D 3302 t 0.31%Bituminous

2 0.33%Subbituminous
Ash Content ASTM

3174
D t 0.15%
Bituminous with carbonate
no
2 0.25% Subbituminous with carbonate
t 0.5% > 12% ash with carbonate and pyrite
Proximate ASTM
5142
Moisture
D = 0.12 + 0 . 0 1 7 ~ Automated Method
Ash = 0.07 + 0 . 0 1 1 5 ~
VM = 0.31 + 0.0235X
Moisture
Total
ASTM D 3173 2 0.15%
for fuels < 5 % moisture
t 0.25%for fuels 5 % moisture
Carbon 5373 D ASTM t 1.25% (1 - %H,0/100) > 100 mg sample

ASTM
3178
D 2 0.3% [Note (1)l
Hydrogen ASTM D 5373 0.15% (1 - %H,0/100) > 100 mg sample

ASTM
3178
D 2 0.07% [Note (1)l
373 D ASTM
Nitrogen 2 0.09% (1 - %H,0/100) > 100 mg sample
3179 D ASTM t 0.205X- 0.13 Method B
Sulfur 4239
ASTM
D It 0.05% Bituminous
2 0.07% Subbituminous
ASTM
3177
D 2 0.5% for fuels < 2 % sulfur
2 0.1% for fuels > 2% sulfur
HHV 2015 D ASTM B t d lt

b 54 dry basis-Anthracite/Bituminous
2 70 Btu/lb dry basis-Subbituminous/Lignite
Converting
Analysis
3180 D ASTMto None
Different Basis
GENERAL NOTE:
All bias limits are absolute unless otherwise indicated.
NOTE
(1) Estimated based on repeatability.
be exceeded, andbynotingthatmost 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 electricalinterference.
RTDs have a narrower operating range and a slower
response timethan thermocouples, but are potentially
4.4 TEMPERATURE MEASUREMENT moreaccurate.
Mercury-in-glass thermometers arelimitedtomea-
4.4.1 General. Temperature is typically measured with surement of temperatures lower than the boiling point
thermocouples (Tcs), resistance temperature devices of mercuryand 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 forfurther information on temperature measurement
or data logger. techniques.
52

STDaASME PTC 4-ENGL 3998 m 0759670Ob34994 T23 m
TABLE4.3-3
POTENTIALBIAS LIMITS FOR LIMESTONEPROPERTIES
nalysis Property' Limestone Limits Comments
Constituents
Limestone ASTM C 25 Calcium Oxide t 0.16% Test Method 31
Magnesium Oxide C 0.11% Test Method 31
Free moisture t 1 0 % Value
Inert by difference C 5.0% of Value
Sampling Subsection 4.8.2 C 2.0% thief sample

C 5.0% 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 FUELOILPROPERTIES
Bias Fuel Oil Procedure Analysis Limits Comments
~~
Sampling ASTM D 4057 t 0.5% for multiple samples

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

D 95 f 0.1% for fuels c 1% Water
2 5 % of measured value for > 1%Water
Ash D ASTM 482 2 0.003% for fuels < 0.08% Ash

f 0.012% for fuels 0.08-0.18% Ash
D ASTM Sulfur 1552 %S
_. -
IR Iodate
< 0.5 0.04% 0.07%
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% 0.27%
Carbon ASTM D 5291 t ( x + 48.48) 0.009

ASTM
D 3178 [Note (1)l C 0.3% [Note (211
Hydrogen D ASTM 5291 C (-&X) 0.1157
ASTM
D 3178 [Note (1)l 2 0.07% [Note (2)l
N itrogen ASTM D 5291 -C 0.23 Reported to 0.00

ASTM D 3228 2 0.095 4 ~ ~ ~~~~~~~~~~ ~ ~~ ~~~
Heating Value D ASTM 240 86 Btu/lbm

ASTM
D 4809 C 49 Btu/lbm all fuels
C 51 Btu/lbm non-volatiles
C 44 BtuAbm volatiles
GENERAL NOTE:
NOTES:
(1) Modified for oil.
( 2 ) Estimated based on repeatability.
53

STD-ASME PTC 4-ENGL L998 m 0759b70 Ob34995 9bT m
ASME PTC 4-1998 GENERATORS FIRED STEAM
TABLE 4.3-5
POTENTIALBIAS LIMITS FOR NATURAL GAS PROPERTIES
Natural GasProcedure
Bias Analysis Limits Comments
~ _ _ _ _ _
Sampling ASTM D 5287 f 0.5% for multiple sample

f 1.0% for single sample
2 2.0% for supplier analysis
on-line analysis-use supplier specification
for Guidance
Gas Constituents ASTM D 1945 Mole

constituent:
Oh of
0.0 - 0.1 2 0.01%
0.1 - 1.0 2 0.04°/o
1.0 - 5.0 2 0.05%
5.0 - 10.0 2 0.06%
> 10 2 0.08%
eating Higher ASTM D 3588 None Perturbated with

Value, calculated
Higher
Heating Value ASTM D 1826 0.3 - 0.55%
GENERAL NOTE:
4.4.2 Bias for TemperatureMeasurement. When temperature uncertainty can be reduced either by sam-
estimating thebias of a temperature measurement, pling more points or by using more sophisticated calcu-
testpersonnelshould consider the following potential lation methods. To compensate for stratification and to
sources. Not all sources are listed, and some of those obtaina representative average, multiple points must
listed may not be applicable to all measurements. These be sampled in a plane perpendicular to theflow. 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-
tionis severe, mass flow weighting as described in
TC type
Subsection 4.3.4should be applied to reduce potential
RTD type
errors in the average temperature. Thermocouples shall
0 calibration
be readindividuallyandnotbe grouped together to
lead wires
produce a single output.
thermowell location/geometry/condition
0 pad weld (insulatduninsulated) If flue gas temperature is measured at a point where
stratification of flowing fluid the temperature ofthe gas is significantly different
grid size fromthe temperature ofthe surrounding surface, an
0 grid location error is introduced. This situation occurs when the gas
ambient conditions at junctions temperature is high,andthe 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 tioninmeasured temperature should be takeninto
0 heat conduction and radiation account. A High Velocity Thermocouple (HVT) probe
. potentiometer/voltmeter can be used to reducethis error.

reference junction accuracy
drift 4.43.1 Method of Measurement. This Code recog-
0 thermometer nonlinearity
nizes three different methods for calculating average
parallax valuesfrom multiple point samples as discussed in
Subsection 5.2.3:
4.43 Air and G_asTemperatures. Air andflue gas
flowing through a duct have nonuniform velocity,.tem- multiple midpoint
perature, and composition. This is especially true near a triple midpoint
flow disturbance, such as a bend or transition. Generally, 0 composite midpoint
54

STD=ASME
PTC
4-ENGL L998 W 0759b70 ObL499b 8 T b m
FIREDSTEAM GENERATORS ASME PTC 4-1998
Allof these methods require specific placement of (c) AdditionalRules for Using theTripleMidpoint
sampling points. The minimumnumber of pointsis Calculation Merhod. When the triple midpoint sampling
given; in all cases, uncertainty can be reduced by methodisbeing used to determine averagevalue, the
increasingthenumberofpoints. The followingrules 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 pointstheremust still be a multiple of three in
based on the cross-sectional area of the duct. Each equal each direction forrectangular ducts and three in each
area should be no larger than 9 aq ft unless there m 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 thecomposite 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 andwidth) 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, theremay be any number of points
mendedthatpointsbeadded inthe direction ofthe in thesector. 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 mustbeused in one
more points has a significant effect on that component direction.
of the uncertainty.
The shape of the equal areas shouldbe one of the 4.43.2 Estimating Bias. An estimate of thebias
following: from a temperature measurement grid is a combination
of bias limits fromtemperatureprimaryelementand
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 flowweighting.
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
any rectangle, as shown on Fig. 4.4-1 sketch (b), that methodaresuggested in Section 7.5.
is morenearly square thanthe 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
0 a square, as shown on Fig. 4.4-1 sketch (c) more streams at different temperatures, theimpactof
the bias associated with the determination of the mass
If the shape of the equal area is not square, the flow rate shall beincluded in the overall bias for the
long dimension should align withthelongdimension average aidgas temperature.
of the cross section. If a greater number of measurement
points are being usedthan is recommended, the addi-
4.4.4 SteamandWaterTemperatures. Steam and
tionalpointsmaybeaddedwithoutconcern for the
water flowing in pipes typically have an approximately
aspectratio.
uniform temperature distribution. A potential exception
(b) Circular Ducts. Circular ducts should be divided
is inthepipingfrom a desuperheater inwhichspray
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. Steamandwater temperatures areusually
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 thermowelllocatedinthepiping.Alternatively,“pad”
sectors. There must be at least one point per sector. or “button”thermocouplescanbelocatedaround the
55

STD.ASME PTC 4-ENGL 1998 m 0759b70 Ob14997 732 m
(a) Same Geometric Shapeas Cross Section
in sketch (a) above

(b)More Nearly Square Than Shown
A > A
- and 8 r b
B b

FIRED STEAM GENERATORS ASME FTC 4-1998
GENERAL NOTE: Indicates points

of location of sampling tube.
Formula for determining location points in circularduct:

., .:' ,
= n ,
,. ... -,"S .'
_ ,
..,
. . . ~
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.Allfourpointsonsamecircumferencehavesame fiurii ,, ,
n = total number of points

STDmASME PTC 4-ENGL L998 0759b70 0bL4999 505 m
pipe and insulated, but use of this method substantially should be assigned. If stratification is suspected in the
increases theuncertaintyofthemeasurement. solid stream, this should be incorporated into the bias
estimate.
4.4.4.2EstimatingBias. An estimate ofthebias
from a temperature measurementis a combination of 4.4.6Liquidand Gaseous Fuels. Liquid or gaseous
bias limits from the temperature primaryelement, 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.
4.4.6.1Method 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 atthe entrance to theunit,preferablynearthe
to measure. The parties te, the test shoulddecide whether flow measurement device. If thefuelisheated by a
the temperature sf these streams willbe 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 thisheater. If thefuel 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 bemeasuredbefore the heater.
streams should be massflowweighted.
4.4.6.2Estimating Bias. An estimate of thebias
4.4.5.1Method of Measurement. The following from a temperature measurement is a combination of
locations andmethodsofmeasurement shall beused: bias limits from temperature primary element, sensor
(a) Fuel. A rigidly supported temperature measuring type,and data acquisition. Section 4.3 andSubsection
instrument should be inserted into the solid fuel stream 4.4.2 discuss potential sources of these biases.
as close as practicalupstream of the pointwhere 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
4.5.1General. Total pressure is thesumof static
stream as close as practical upstream of the point where
pressureandvelocity 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. Velocitypressureisusually
(c) Residue. Residue that carries over in the flue gas
calculated from average fluidvelocityand density. If
stream (fly ash) can beconsidered to be the same tempera-
velocityis to be measured, refer to Section 4.6 for
ture as the gas at the extraction point. An exception is
guidance inmaking these measurements. This section
ash leaving an airheater. The temperature ofthe gas
addressesthemeasurement 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. Notall sources are listed, andsome of those sources
Refer to Section 5.14 for estimating bottom ash tempera- listed may not be applicable to all measurements. These
ture. Iftheresiduetemperatureismeasured (such as factors should be considered in conjunction withthe
residue leaving a grate), a rigidly supported temperature factors listed in Table 4.3-1.
measuring instrument should be inserted into each flow- e gauge type
ing residue stream as close as practical to thepoint where e manometer type
the residue leaves the boundary. e transducer type
4.4.5.2EstimatingBias. An estimate of the bias e calibration
from a temperature measurementis a combination of e tap location/geometry/flow impact
bias limits fromtemperatureprimary 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 thanif the e specific gravity of manometer fluid
parameter is directly measured.Ifthemass flows of e ambient conditions at sensor
multiple streams are notapproximately equal andthe e ambient conditions at meter
average temperature is not flow weighted, a higher bias e hysteresis
58

STD-ASME PTC q-ENGL L998 0759b70 Ob15000 925 m
FIREDSTEAMGENERATORS ASME F'TC 4-1998
electrical noise Pressure measurement connections should be short and

0 potentiometerholtmeter direct.
drift All pressure measurementconnections should be leak-
0 transducer nonlinearity proof, with provisions for cleaning and drainage.
parallax Pressure connections should be located and installed
with care to exclude velocity effects.
4.53 AirandGas - StaticandDifferentialPres- 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 performedusing differential calculations.
measuring apparatus ratherthantwo separate instru-
ments. 4.5.4.2EstimatingBias. An estimate of thebias
from a pressuremeasurementis a combinationof
4.53.1 Method of Measurement. Pressure ismea- .bias limits fromprimary element, taptype,and data
suredwith gauges, manometers, or transducers. The acquisition. Potential sources of these biasesare dis-
output of these devices is either visual or a signal cussed in Section 4.3 and Subsection 4.5.2.
which canbe read with a hand-held meter or data logger.
PTC 19.2 provides further information on pressure 4.5.5BarometricPressure. Barometric pressureis
measurement techniques. required to determine ambient conditions.
4.5.5.1Method 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 velocityimpingement. barometer at thetest site. An alternate methodisthe
This may be accomplished by proper location of taps useofthebarometricpressure,notcorrected to sea
around the perimeter of the duct or by use of specially level,reportedatthenearestweather station. The
designed probes. Measurements shouldbe made at more elevation of the weather station's reading andthetest
than one location in or aroundtheplane.Piping or site should be notedand corrections madeforany
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- 4.5.5.2EstimatingBias. The useof a barometer
ment to the pressuretapshould slope downwardto or other suchmeasurement device at thesitewillbe
allow condensate to flow backintothe duct. When considered to have a negligible bias limit. Datafrom
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 beused to if usedanappropriate bias should be assigned.
keeppressure sensing lines clear. If purging is used,
a constant lowflowshould be maintained.
4.5.3.2EstimatingBias. An estimate ofthebias 4.6 VELOCITY TRAVERSE

from a pressure measurement is a combination of bias 4.6.1General. A velocitytraverse consists ofmea-
limits fromprimary element, installation effects, and surements taken atnumerous 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, andmay also include velocity vector angles. The
4.5.4SteamandWater - StaticandDifferential usershouldreferto Sections 4.4 and 4.5 related to
Pressure. The static pressure in steam and water piping temperature and pressure measurementsfor guidelines
may be requiredto determine fluid propertiesor 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
aremade at a numberof locations corresponding to
apparatusratherthantwo separate instruments.
the centers of equal areas. The probeisusually one
4.5.4.1Method of Measurement. Pressure mea- of several types which sen% the velocity pressure and
surement devices shouldbelocated to minimizethe pressure differentials indicating yawand pitch.Users
effects of temperature andvibration.Adhere to the of this Code are referred to PTC 19.5 (see Note below)
following in theinstallation of pressuremeasuring and PTC 11, Fans, for further information on velocity
devices: measurementtechniques.
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 offlow rates. If an individual streamflow
4.6.2Bias for Velocity Traverse. When estimating
rateis to be determined byvelocity traverse referto
thebias of avelocity traverse, testpersonnelshould
Section 4.6.
consider the following potential sources. Not all sources
are listed, and some of those listedmay not be applicable For multiple streams wherethetotal flow canbe
to all measurements. These factors should be considered calculated more accurately thanmeasured(e.g., air,
in conjunction withthe factors listed in Table 4.3-1 flue gas, residue, etc.), all but one stream may be
and Subsections 4.4.2and4.5.2: measuredandtheunmeasured stream flow rate calcu-
probe type lated by difference. If all streams aremeasured,the
0 calibration mass flow fraction of each stream shall becalculated
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 fromthe
0 yaw productof the mass flow fraction oftheindividual
0 pitch streams andthetotal calculated mass flowrate.
0 grid size 4.7.2Bias for Flow Measurement. Flow is often
0 grid location measured indirectly, ¡.e., usingmeasureddifferential
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 flowmeasurement.When estimating thebias of a
0 temperature errors flow measurement, testpersonnelshould consider the
4.63 Method of Measurement. Measurementsare following potential sources. Notall 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. PTC 19.5 and ASME PTC 11 may be conjunction withthe factors listedin Table 4.3-1:
consulted for information on velocitymeasurement.
Numerous types of probesare used for velocity measure- 0 calibration of primary element, e.g., orifice, nozzle,
ment,such as standard pitot, S-type, three-holeand venturi, airfoil, and differential sensing probes
five-hole,turbometermassflow probe, andothers. 0 stratification of flowing fluid
Determination which accounts for the direction of flow 0 temperature biases
at the plane of ,measurement is preferred. 0 pressure biases
0 installation
4.6.4EstimatingBias. An estimate of thebias 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 theprobeused for the measurement location
velocitytraverse does not account for theapproach 0 fadpump curve
angle to theplane of measurement,thevelocity 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
4.7.1General. Numerous methods are employed in and flue gas crossing the steam generator boundary is
industry to determine the flow rate of solid, liquid, or calculated stoichiometrically. It may be necessary to
gaseous streams. PTC 19.5 is theprimary reference measure the air or flue gas flow inaddition to the
for flow measurements. ASME document MFC3M, temperature of the stream to account for an individual
PTC 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 0635002. 7T8 W
boundary. The energycrossing the boundary in that that the differential produced by theorifice or nozzle
air or gas stream thenmay be calculated. is at the lower range of the system, a measuring device
and transmitter which is accurate at the spray flow rate
4.7.3.1Methods of Measurement. There are nu-
oran energybalance calculation shouldbeused.
merousmethods for the measurement of airand gas
flow (e.g., venturi,airfoil, velocity traverse, heat balance, 4.7.4.1Method of Measurement. The following
etc.). Ifplantinstrumentationisused, it shouldbe methods of measurement are typically used to determine
calibrated. The flowmay be calculated fromvelocity, steam and waterflows:
as measured accoding to Section 4.6, the density of
the fluid, and the duct cross-sectional area. The use of Flow masurement througha nozzle, venturi,or orifice.
sophisticatedtraversing 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 energybalance 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 feedwaterheaters, and possibly, superheater desup-
output, flue gas weight per pound of fuel, and heating erheating sprayflow. 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 andflue gas flowis subject to from the ASME 1967 Steam Tables, using pressures
significant error. Using a standard pitottube or a and temperatures measured with test instrumentation.
Stauschibe (S-type or forward-reverse) tube can result Estimated flows. Insome cases, it may not be feasible
in overestimating the flow if the flow is not perpendicu- to quantify a flow usinganyofthemethodslisted
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 accuratelybecause known flow or a valve position may be used. Steam
of obstructions within the ductor inaccurate dimensions. flow based on first-stage pressure, estimated turbine
An estimate of thebiasfrom an air or gas flow leakage based on mainsteam 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 performancedata also may be used. Allparties
and Sub section 4.7.2 discuss potential sources of these involved inthe performance testmust agree to the
biases. If theprobeusedforvelocity traverse does method of calculation prior to the test, and an appro-
notaccountforthe approach angle to theplane of priate uncertainty must be assigned.
measurement,thevelocitymay be overestimated, and
4.7.4.2Estimating Bias. An estimate of the bias
an appropriate bias limit shouldbeincluded.
from a flow measurement is a combination of bias
4.7.4Steam and Water. Certain steam andwater limits fromprimary 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 Subsection4.7.2 discuss potential sources of these
is required, the preferred method is to use a calibrated biases.
and inspected flowelementsuch as theASMEthroat 4.7.5 Liquid Fuel. The input-outputmethod for effi-
tap nozzle, as described in PTC 6, Steam Turbines. ciency determination requires the quantity of liquid fuel
On large units, the PTC 6 nozzle is preferred because
burned.
of the potentially high Reynolds numbers of the mea-
suredflow. The requirement for the PTC 6 nozzleis 4.7.5.1Method of Measurement. The quantity of
eliminated if the flow element can be calibrated at the fuel may be determined byflowmeasurement device,
Reynolds numbers that will be encountered during the weigh tank, or volume tank. Refer to Subsection 4.7.4.1
test. The PTC 6 flow nozzleshould be usedifflow 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, accuratedensity
able for determining the superheat desuperheating spray determination is required.ASTM D 1298 provides
flow, reheatdesuperheating spray flowshould be directly procedures to determine APIGravityand density.
measured rather than calculated by energy balance. If Recirculation of fuel between the point of measure-
the reheat desuperheating spray flow islow enough ment and point of firingshall be measured and accounted
61

ASME PTC 4- 1998 FIREDSTEAMGENERATORS
for in the flow calculation. Branch connections on the It is evenmoredifficultto assess theaccuracy 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 maynot be
4.7.5.2EstimatingBias. An estimate ofthe bias full, the density may vary as a result of size distribution
from a flow measurementis a combination of bias or other factors, andall these parameters mayvary
limits from primary element type, sensor type, and data over time.
acquisition. Section 4.3and Subsection 4.7.2 discuss Calibrations of solid flow measurement devices
potential sources of these biases. shouldbe conducted just prior to the testing andat
frequent intervals to ensure theminimumbias.
4.7.6Gaseous Fuel. For the input-output method,the
quantity of gaseous fuel burnedmust be determined. 4.7.7.2Estimate of Bias. The biasfrom a solid
4.7.6.1Method of Measurement. Measurement of flow measurement is one of the most difficult parameters
the relatively largevolumes of gaseous fuelnormally to determine. Bias limits from instrument response
encountered while testing steam generators requires the variation resulting from size distribution, uneven loading
useof an orifice, flow nozzle, or turbine meter. The on the weigh scale, or varying densities shouldbe
pressure drop shall bemeasuredusing a differential considered. Section 4.3andSubsection4.7.2 discuss
pressure gauge or differential pressure transmitter. Out- other potential sources ofbiases.
puts from these devices can bereadmanually,via 4.7.8Residue Splits. The amount of residueleaving
hand-held meters, or with data loggers. When gas flow the steam generator boundary is required to determine
is measured,thetemperatureandpressureused in the the sensible heat loss in theresidue streams and the
calculation ofdensityare extremely important. Small weighted average ofunburned 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 isremovedperiodically or
has a significant effect on the determination of gas continuously are furnace bottom ash (beddrains), econo-
density. mizer or boiler hoppers, mechanical dust collector re-
jects, andfly ash leavingtheunit.
4.7.6.2EstimatingBias. An estimate ofthebias
from a flow measurement is a combination ofbias 4.7.8.1Method 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 directmeasurement. Therefore,
potential sources of these biases. The impact of pressure the percent of the total residue that leaves each location
and temperature measurements on thegas density should must be determined. Severalmethodscanbeusedto
be evaluated at thetest operating conditions because determine the split betweenthevariouslocations:
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 FuelandSorbent 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 thequantity at the other locations should be calcu-
Latedby difference. Where thereismorethan one
4.7.7.1 Method of Measurement. Numerous meth- unmeasured location, the split between theselocations
ods are available tomeasurethe flowof 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 reduceuncertaintyofany of these fuel and method of firing.
methods below 5 to 10% requires extensive calibration
against a reference. The calibration caninvolvethe 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 valuesfor any estimated
can beweighted rather than placing weights onthe 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, isused to calculate
and the rate offeed indicated bythe feeder canthen residue mass flow rate leaving the unit. See Section 5
be compared to thetimed catch inthe container. for calculating the massflow rate from the grain loading.
62

~
STD-ASME PTC 4-ENGL 1778 0759670 Ob15004 570
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, impactmeters, etc. generator, a timelag maybe incurredbetweenwhen
See Subsection 4.7.7.1 for considerations regarding the sample istakenandwhen it is actually injected
calibrationand sources of uncertainty. or removed from thesteam generator. This timelag
Determining the mass flow rate of residue discharged mustbedeterminedbasedon estimated flow rates
from sluice systems is even more difficult thandetermin- betweenthe sample locationand the steamgenerator.
ingthe dry state. Generally, thetotal 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 materialinjected or removedfrom
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
leavetheunitin a dry state, moisture content of the bias errors. Onepossible exception to thisis sorbent,
sample must be determined, andthemeasuredwet whichinmost cases is homogenous. Parallel streams
mass flow rate correctedformoisture. such as coal feedwith belt feeders havethepotential
for variation from stream to stream because of different
4.7.8.2 Estimating Bias. When splits are estimated, flow rates, particle sizes, andchemical composition.
a meanvalueshouldbe selected suchthatthe same Therefore, unless the chemical constituents of the sam-
positive and negative estimate of bias can be used. A plescan be showntobeuniform,the samples must
bias thatwouldproduce a split of less thanzero or be taken from eachof the parallelstreams and combined.
morethan 100% mustnotbeused.Refer to Section If theflows for theparallel streams are unequal, the
4.11 regarding bias for dust loading (residue sampling). amount of samples of each parallel stream mustbe
Where massflow is determined from volumetricdevices, 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-
thevolume chamber anddensityand size distribution outthetest.
of thematerial. Also refer to Subsection4.7.7.2. Dependingonthe costs associatedwithlaboratory
analyses and the availability of a historical data base,
different options maybe selected for different sample
4.8SOLIDFUELANDSORBENTSAMPLING constituents (¡.e., coal, sorbent, residue).
Fuel or sorbent samples collected from upstream of
4.8.1General. The methods of sampling shall be
silos, tanks, or hopperstypicallyhavelarger biases
agreed uponby allparties to thetestandmustbe
than samples collected downstream from the silos, tanks,
described in the test report. An appropriate uncertainty
must be assigned for the method of sampling used for and hoppers. Samplings from upstream of silos, tanks,
andhoppers are classified as alternate procedures be-
a test.
cause of the possibility of samples not being representa-
The sampling program conducted during the perform-
ance test has a significant effect on the steam generator tive of fuelfired during thetest. Alternate procedures
efficiency result. Of all the data collected during a test, should not be used for acceptance tests. For other test
purposes, if alternate procedures are used,the parties
the higher heating value (HHV) of the solid fuel is the
to thetest shall assign appropriate biases.
variable having the most influence on steam generator
efficiency. Further, on some units, unburned combusti-
bles loss in the residue (based on carbon concentration) 4.8.2.1
SampleSize. 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 composition of theactual stream as possible.
of the respective solid streams, the steamgenerator
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
uncertaintyof the steam generator efficiency. Inthis
Section, the methods used to determine variances, stan- variance.
dard deviations, and precision indices for the samples Generally, a complete cross section of theflowing
stream is the most representative. This criterion, how-
obtained during thetestare discussed. The estimation
of bias limits is also addressed. ever, canmean different sample size requirements for
different types of solid streams. For example, the fly
4.8.2Methods of Solid Sampling. Fuel, sorbent (if ashresidue stream sample shouldbe obtained from
applicable),and residue solids shall besampledfrom isokinetic particulate sampling. This sample is typically
63

~~~~ ~~
STD-ASME PTC 4-ENGL 1998 m 0759670 Ob15005 407
ASME PTC 4- I998 FIRED S T E W GENERATOPS
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 represenMk samples are
is representative. In this case, the smallquantity is a obtained and to prevent contaminatj9p in samplin$
minor factor in regard to the reliability of the sample. devices and storage containers. S
Another example of the acceptability of a small doors must be protected from e
quantity of sample is sorbent sampling. The size of influences during collection. Airtight, noncorrosive stor-
sorbent may vary,but it is likelythatthe chemical age containers prevent degradation of &e sample until
composition does notvary across the size range or it is analyzed. Each sample should be s@d immediately
among different lotsof sorbent. Therefore, a small after beingtaken. Samples should rid be mixed’ in
sample can be representative of the entire sorbent feed open air prior to analysis for moisture because ofthe
during the test. potential for moisture loss.
In summary, the actual sample size mustbebased Samples mustbeproperlylabeled qnd described in
on several factors, including size distribution, chemical terms of their significance to the test. The label should
composition variability,feedmethods, 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 inthe 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 weightingfrom
4.8.3 Bias for SolidFueland Sorbent Sampling.
2 to 8 lb are collected. For automatic sampling devices,
Whenthe bias of a sampling procedure is estimated,
much larger samples canbe collected.
the test engineer should consider the following potential
The weight of the individual test sample mustbe
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 allmeasurements:
from a historical database. Otherwise, thevariance of
the test database could be greater than the variance of sampling locatiodgeometry
the historical data. probe design
The factors previously noted, combined withgood stratification of flowing stream
engineering judgment, costs, agreement between parties, number and location of sample points
and desired accuracyof sample analyses, should be ambient conditions at sample location
used by the testing participants to determine the proper fueYsorbent variability
sample size. Table 2 ofASTM Standard D 2234 fueYsorbent size
provides moreinformation 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 “stoppedbelt”
technique isthepreferred or reference method. Zero An estimate of the bias from a sample is a combina-
sampling bias should be assigned if the “stopped belt” tionof 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 thanthoserecommended
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 beltsamplingisnot 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,
toidentifyand alleviate potential problems in the the errors must be corrected, or the parties must assign
sampling techniques. conservative (higher) bias limits.
4.8.2.3Handling Samples. Sampling must be car- 4.8.4Type of Samples. Coal or sorbent samples
ried out only under the supervision of qualified person- may be individual, partial-composite, or full-composite
64

FIREDSTEAMGENERATORS ASME PTC 4- 1998
Solids storage bin
: Solids conveyor
J
r 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 thefirst sample.
(5) Collect 5 gallon bucket andseal container. Prepare for riffling,
crush, and size.
FIG. 4.8-1 FULL-CUT SOLIDS SAMPLING METHOD
65

~~
STDOASME PTC 4-ENGL 3778 m 0759670 Ob35007 28T m
ASME PTC 4-1998 GENERATORS FIRED STEAM
- Typical thief probe sampling location.

Care must be taken to get a
representative sample.
A n n A
II
I,-
U U
I 1 I/
L
Section A -A
DESIGN:
Consists of two concentric pipes with thesame sample hole configuration.
The probe is inserted into a flowing solids stream with thesample ports
closed. (The inner tube rotates 180 deg relative to theouter tube from the
sample position.) The inner tube is rotated to align thesample holes and is
rotated back with theinner 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 L998 W 0759b70 Ob15008 L L b
FIRED STEAM GENERATORS ASME F’TC 4-1998
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 l . 0 historical data are the analyses ofindividual (not
mixed) sample’increments for the coal (sorbent)
4.8.4.1 Individual Samples. Separate analysis sam-
the historical and test samples are collected and pre-
ples are preparedfromindividual 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
StandardMethods 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, heatingvalue,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 calculatedusing 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
therearenohistorical data available to estimate the
0 the size of the historical samples is the same as the
precisionindex of the samples.
size of the samples collected during the test
4.8.4.2 Partial-CompositeSamples. This is an al-
ternativeto analyzing individual samples, predicated If the historical samples weretakenat a different
on the availability of valid historical data. The objective location, an additional bias likely has been introduced.
is to reducelaboratory costs. The constituents are Two sets of individual analysis samples are prepared.
grouped into “composite” (cg., carbon, hydrogen, and One set is individually analyzed for the variable constit-
nitrogen) and “variable” (cg., water, ash, and possibly uents, such as ashandmoisture. The averagevalue
sulfur) constituents. The precision indices of the “com- andprecisionindex 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 underlyingpremise for this alternative isthat stituents. The average value of each variable constituent
“composite” constituents for both the historical and test isthemeasured value of themixed analysis sample.
data are fromthe 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 multiplyingtheas-received
index derived from historical data may be used for the percentages (other than the variable constituents, ash
testuncertainty analysis. Subsection 7.4.1.4 provides andmoisture) by
additional background for this alternative.
To simplify this discussion, coal constituents and 1O0
(4.8- 1)
terminology are used; sorbent constituents and terminol- 100 - MpH2OF; - MpAsFi
ogy can besubstituted as appropriate.
As coalistypically stored outdoors, the moisture
content ofas-firedcoalmayhavegreatervariability where
thanas-received coal. This increasedvariability may MpH20Fi = moisture content, in percent, of historical
invalidate the premise that the historicalas-received sample increment i
data and the test data are fromthe same statistical MpAsFi = ash content, in percent, of historical sam-
population. However, changes inmoisture content do pleincrement i
not affect constituents on a dry-and-ash-free basis. For carbon content, the conversion equationis
Where sulfur retention is an important consideration
inthe test, sulfur content should be included in the MpCFdafi
variable constituents. The variability of sulfur content
is often relatively large.
This alternative isnot suitable for residue samples.
= MpCFi
(100
1O0
- MpHIOFi - MpASFi 1 (4.8-2)
The composition of residue is affected by operating

conditions withinthe steam generator. There is no where
simple way to ensure thathistoricalandtest data for MpCFi= carbon content of thefuel in percent,
residue would be from the same statistical population. as-fired basis
Historical data should satisfy the following criteria MpCFdaf;= carbon content ofthefuelinpercent,
to bevalid for estimating precision: dry-and-ash-free basis
67

STD-ASME PTC 4-ENGL L998 m 0759b70 Ob15009 052
ASME PTC 4- 1998 FIREDSTEAMGENERATORS
MpH@Fi= 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- W1 L 1
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.
Usingthe dry-and-ash-free values oftheindividual 4 2.3719
historical samples, estimate themaximum probable 5 2.2141
standard deviation, soj, of each composite constituent. 6 2.0896
Use Appendix A2, Methodof Estimating the Overall
Variance for Increments, ofASTM D 2234 to deter- 7 2.0096
mine soi. 8 1.9384
The use of this Appendix requires for each composite 9 1.8799
constituent 20 or more analyses of individual increments.
1.8307calculate the standard
If fewer than 20 are available, 10
deviation, STDDEV,, of each 1.7522composite constituent 12
using m. (5.2-11). 15 1.6664
~~ ~~
The precision index for each composite constituent,

1.5705
Prj, isfor 20 or more analyses: 20
1.3940 40
1.2214 120
(4.8-3)
Infinity 1.0000
or for less than 20 use:
PIj = ( F,,- N
*STDDEV:)”I (4.8-4) constituents. The average value of each constituent is
themeasuredvalue of themixed analysis sample.
The criteria and calculations given above for partial-
where composite samples are applicable to full-composite sam-
F,,-,,== the upper 5% point of the F distribution ples except thatthe conversion factor (4.8-1) andEq.
for n - 1 and degrees of freedom. (4.8-2) are excluded.
Table 4.8-1 provides selected values of
the distribution 4.8.4.4 SystematicSampling. 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 knownthatthe
N = the number of sample increments taken collection sequence corresponds with “highs” or “lows”
during the test in the fines content. In that instance, randomtime
The degrees of freedom of this precision index are intervals should be used.Each sample should be of
infinite. the same weight. The elapsedtimeto collect allcoal
samples must equal the duration of thetestrun.
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 maybe using the precision indices of the constituents. The
applicable for sorbents and coal whenhistorical data preferredmethoduses a complete pretest uncertainty
are available and changes in moisture or ash content analysis, as discussed in Section 7.3. The numberof
are either verysmall or ofminor concern. samples is varied parametrically. A number of samples
A composite analysis sample is prepared fromthe is selected suchthat the target test uncertainty can
samples taken during thetestandaflalyzed for ali be met.
68

FIRED STEAM GENERATORS ASME PTC 4-199X
An alternative method is to examine the direct effect by GasChromatography.shouldbeconsulted for the

ofchangingthenumber of samples on the precision properproceduresandequipmentforsamplingliquid
index of a resultant. The result may be steam generator or gas. The type of sample vesselandprocedureis
efficiency,aheatcredit or loss, or the valueofthe illustrated for variouscasesandtypes of liquidfuels
constituent. A heat credit or loss is a way of highlighting i n PTC 3.1.
theeffectofa constituent. For example,thecarbon An estimate of the bias from a sample is a combina-
content of residue has a primary effect on the unburned tionofbiaslimitsfromsampleacquisition.location,
carbon loss andrelatively lower effect on efficiency. andstream consistency.
The contribution of constituent j to the precision index
of aresultant PìRj is

S T D - A S M E PTC 4-ENGL L998 M 0759670 Ob15011 700
ASME PTC 4- 1998 GENERATORS STEAM FIRED
when the number of points is not so large as to reduce on the filter.Theweightofthesampleandthe flue
thenumber of complete traverses duringthetest. gas volume recorded during this process determine the
particulate concentration in the Aue gas stream. To
4.10.3.1SampleCollectionandTransport. The
avoid altering the concentration ofthe 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
Thelayout of points in thegridmustbethesameas
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
nonuniformvelocity distributions and stratificationof
thesystem must be checked for leaks priortoand
the particulate concentration.
throughoutthe test.
Largenumbers of grid points are not required for 4.11.2 Bias for ResidueSampling. Isokinetic sam-
SO? andtotalhydrocarbons (THC). Thesesamples pling is the reference method prescribed by this Code,
require heated samplelines 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 still an associated bias for theash
shall agree on sampling procedures for these two gases. collected in thebottom ash aswell as any hoppers
It should benotedthatfiltering the sample may eause locatedupstream of the fly ash collection point. If
a bias for SO2 if C a 0 ispresent in the particulate multiple samples are analyzedusing multiple analysis
filter. Ca0 reacts with the SOz andreduces it. Inthis for thebottom ash, an estimate of the associated bias
case thefiltersshouldbecleaned frequently. canbemadefromthis information. Theprocedure
should also bereviewed to determine if other sources
of bias may also be present.
4.11 RESIDUE SAMPLING 4.11.3Methods of Sampling Fly Ash. Allapparatus
Thosefuelswhich contain ash necessitate a sample andtestprocedures shall be in accordance with either
of the various streams leaving the unitcontainingthe 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 EPAReference
ash. Obtaining representative samplesfromeach of Method 17 asdescribedbelow:
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 fluegasmakes its way to sists of a nozzle, probe, filter, condenser, dry gas me-
the stack. Theheaviest particles fall outfirst,withthe ter, orifice meter, and vacuum pumpor aspirator. PTC
smaller particles beingremovedbymechanical forces 38 illustrates different configurations of sampling
resulting fromtheturningofthegas 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.
outthe particle size range. The relative distribution of e US EPA Method17.The US Environmental Protection
theashintothevarioushoppers is also not accurately Agency has established two methods for particulate
known. The best method for obtaining a representative sampling. Thesereference Methods 5 and 17 are simi-
fly ashsampleisto isokinetically sample the ash in larexceptthatMethod 17 usesan in-stack filter,
the flue gas upstream of as many ash collection hoppers whereas Method 5 uses an external filter. Method 17
as possible. Thisusuallymeansattheeconomizer is preferred since all of the particulate catch remains
outlet. This obtains a sample which has a representative in the filterholder. Method 5 requires an acetone wash
cross section of particle size andcarbon content. It of the probeassembly,whichmaynotbe suitable
also ensuresthatthesample 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 chunksandpoor distribution. A number of Isokinetic sampling of the flue gas is both the refer-
samplesandseveral analyses of eachsample maybe enceandthe preferred method for sampling fly ash.
required to obtain representative results. A single sample The numberof grid points on thetraverse sampling plane
may contain a chunk ofcoalnot typically found in mustbe in accordance with PTC 38, Determination of
other samples or mayhavenocarbon content. the Concentration of Particulate Matter in a Gas Stream.
4.11.1 General. Fly ash may be sampled isokinetically 4.11.4Methods of SamplingBottomAsh. For a
as particulate by drawing a fluegassamplethrough a bottomash sluice stream, thepreferredmethodof
filterandweighingtheamountof particulate gathered sample collection is to take the sample witha 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,and2-5ofEPRI Report EA-3610 illustrate E, Coal Properties, offers additional information.
a multihole probe. Alternatively a portion of the sluice
4.12.3.2Sorbentand Other Additives. The mini-
stream may be diverted to a collection device where
mum information needed to determine the sulfur capture
theashisallowed to settle and a sample then taken.
and efficiency is the sorbent ultimate analysis (calcium,
4.11.5OtherResidueStreams. Insome cases, the magnesium, moisture, and inert). The determination of
parties to thetest 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 ofthe
the energy loss. Possible examples of such streams are particulartest.
air heater disposal drains or vent lines, where the flow 4.12.3.3LiquidFuel. For liquidfuelfiredsteam
rate isnegligible, or bottom ash drains, whichmay generators, the minimumfuelinformationneeded to
have insignificant sensible heat and unburned combusti- determine efficiency is the ultimate analysis and higher
ble losses. Alternatively, samples of bottom ash sluiced heatingvalueofthe fuel. The determination of other
to a settling pond can yield a result which is no more liquidfuel qualities such as API Gravityanddensity
certain than using an assumed value. If a solid stream may be required depending onthe objectives of the
isnot sampled, the appropriate bias limitshall be test. The procedures for these determinations are found
assigned and the historical evidence documented in the inASTM D 1298.
final report.
4.12.3.4 Gaseous Fuel. For gaseous fuel fired steam
generators, the minimumfuelinformationneeded to
4.12FUEL,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 isconvertedto an elementalmass
4.12.1General. It is theintent of this Code thatthe analysis as detailed in Subsection 5.8.2. Higher heating
samples be analyzed in accordancewiththelatest 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 thetestshould choose a certifiedlabo- the testshall agree onwhichmethodwillbeused.
ratory.
4.12.3.5Residue. 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. Thesevalues are listed in Tables 4.3-2to rected for carbon dioxide as determined in accordance
4.3-5 for use in estimating the bias of a sample analysis. withASTM D 1756. Use of a loss on ignition (LOI)
Ingeneral,thebiaslimit is taken as one-halfthe analysis isnotpermitted for the determination ofun-
reproducibility. burned combustible loss, because several reactions may
occur in the combustion processwhich reduce or in-
4.12.3
Methods of Fuel,
Sorbent,
andResidue
crease theweightof the sample andwhichhave no
Analysis
heating value.
4.12.3.1SolidFuels. For solid fuel fired steam The test for total carbon in the residue includes the
generators, theminimumfuel information required to determination of hydrogen,andthehydrogenresult
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 testisnotmandatory for testing carbon in
4.3-5 identifytheASTM procedures to beused for residue, and experience indicates that H, in fuel volatil-
analysis. ASTM D 3180 definestheprocedures for izes readily and no significant quantity of H2 exists in
converting the analysis from one basis to another. The residueinthenormal combustion process. This test
latest versions of these procedures shall be utilized. If may result in a measuredhydrogen content on the
ASTM adds a new or revised procedure whichis order of 0.1%or less. Hydrogen quantities of this order
agreeable to both parties to thetest,thatprocedure of magnitude shouldbe considered as zero in the
maybeused. combustion and
efficiency calculations. A potential
The determination of other solid fuel qualities such source for error inthe determination of free hydrogen
as fusion temperature, free swelling index, grindability, is that, as with carbon, this test method yields the total
ash chemistry, andfuelsizing 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 hydrogenpresent in the free
71

moisture accompanying the sample as well as hydrogen manual instruments are permitted, operator skill, chemi-
present as waterofhydration of silicates or calcium cal freshness, and other factors related to manual instru-
oxide [Ca(OH)2]. ments contribute to potentially high biases. In addition,
it is recommended that flue gas composition be moni-
toredon a continuous basis throughoutthe test. Fuel
4.13FLUEGASANALYSIS variations, control system tuning, and other factors
cause variations influe gas constituents. Therefore, a
4.13.1General. It isthe intent of this Code thatthe continuously analyzed composite sample taken from a
samples be analyzed in accordance withthelatest representative grid best represents the true average gas
methods andprocedures. composition.
4.13.2BiasforFlue Gas Analysis. A number of 4.13.4.1Oxygen. Several methods are employed
factors need to be considered in determining thebias to measure oxygen; among them are paramagnetic,
of a flue gas analysis system. Some ofthepotential 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
0 cal gas accuracy found in the flue gas can be used to minimize the error.
sample temperature and pressure influence on analyzer 4.13.4.2
Carbon
Monoxide. The most common
undetected leaks method for carbon monoxide analysis is nondispersive
interference gases infrared. The main disadvantage of thismethodology
ambient temperature influence on analyzer is that CO, CO2, and H20 allhave similar infrared
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 (SO,), oxides of nitrogen heat loss due to CO, the inaccuracy resulting from
(NO,), andtotal 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 inrelation to environmental protection regulations.
sample collection and transport system andflue gas 4.13.4.3SulfurDioxide. The analysis of sulfur
analyzers. The sample collection andtransportsystem 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 canbeused in the sampling and analysis system.
flue gas constituent. Since an extractive sample removes
watervaporfromthe 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 thepreferredmethod 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 thenmix the NO with ozone (O3) and produce NOz
basis, in which the moles of the constituent of interest in thereaction chamber. This reaction process emits
are divided bythetotalmoles present. The difference light, which is measured to determine the concentration
betweenthe wet and dry basis is thatthe wet basis of NO,. Even though NOz represents a verysmall
includes both the dry moles and water vapor moles in percentage ofthe NO, emissions (typically less than
the denominator. 5%), NO, is reported as NOz. This has negligible effect
on steam generator efficiency.
4.13.4Flue 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 (THC) measurement by flame ionization detector (FID)
72

STD-ASME PTC 4-ENGL 1998 m 0759b70 Ob15014 4 1 T m
FIRED STEAM GENERATORS ASME FTC 4-1998
based instrumentis the preferred method. Either methane limits fromprimarysensor type, wattmeter,anddata
or propaneshould be used for calibration and the acquisition. Section 4.3 andSubsection 4.14.2 provide
resulting THCvaluereportedasTHCppmmethane potentialsources of these biases. Theuncertaintyof
or THCppmpropane. protectionCTs is typically ?10 to20%.Measurement
CTsvarybutusuallyhave uncertainty in the range of
1 to 5%. TheseCTs are used to send a signaltothe
4.14
ELECTRIC
POWER operator. Usuallyonlyonephaseuses a measurement
CT andtheassumption is madethatthepowerused
4.14.1General. The accurate measurement ofthree- onthe other twophases is thesame(balancedload).
phasepower is a complex issue. Fortunately, highly This assumption is not necessarily accurate due in part
accurate electrical measurement is of minor importance to varyingpower factors.
for determiningsteamgenerator efficiency. Ifpower
measurements are usedtodetermine auxiliary power
consumption a moreexhaustiveprocedureshouldbe 4.15
HUMIDITY
used. The best approach is to measure the current and
voltage in each phase of the circuit and sum the power 4.15.1General. The moisture carried by the entering
in eachphase to determine the total. In practice this air must be taken into consideration in calculations of
is difficultand costly. steamgenerator efficiency.
4.14.2
Bias for Electrical PowerMeasurement. 4.15.2Bias for HumidityMeasurement. 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 nelshouldconsider the followingpotential sources.
ofpotential sources. Not all sources are listed, and Notallsources are listed, andsome of those listed
someof those listed maynot be applicable to all maynotbe applicable toallmeasurements:
measurements: 0 hygrometer
current transformer (CT) accuracy wet/dry bulb thermometer type
0 potential transformer (PT) 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 4.15.3Method of Measurement. Thedry-bulband
4.14.3Method of Measurement. For themeasure- wet-bulbtemperaturesshouldbedetermined at the
ment of electrical power for steam generator efficiency, atmosphericair inlet to the unit. Sincethespecific
measurement of a single phase current andvoltage humiditydoesnotchange with heatadditionunless
alongwith the assumption ofbalancedload for the there is a moisture addition, the specific humidity of
auxiliaries is sufficiently accurate. Should a highly the combustion air leaving the air heateristhesame
accurate determination of auxiliary powerbe required as the specific humidity entering. To determine specific
for other purposes, the determination shall be made in humidity, either dry-bulb and wet-bulb, or dry-bulb and
relative humidity, are needed.Subsection 5.1 1.2 ad-
accordance withthe 2 wattmeter or 3 wattmeter methods.
dresses absolute or specific humidity (pounds of mois-
IEEE120should be consylted for methods to usein
ture perpoundofdry air).The moisture maybe
making electrical powermeasurements.
determinedwiththeaidof a sling typepsychrometer,
4.14.4 Estimating Bias. An estimate of the bias from hygrometer with temperature or similar device, and an
an electrical measurement isa combination of bias observedbarometric pressure reading.
73

STD*ASME PTC 4-ENGL L998 m 0759b70 ObL50L5 35b
GENERATORS FIRED STEAM 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 requiredand the
resultprior to averaging.
computation procedures for determining theperform-
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-
fluidflowis a common example. The flow resultis
l surement aregiven.in Sections 3 and 4. Derivations
of certain equations are detailed inAppendix C.
a square root function of differential pressureand
approximately linear function of temperature and pres-
The computation equations use acronyms for variables
sure. The calculated result should be usedinthe 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 shouldbeincorporated 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 sensitivitycoefficient 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 ontheSteam agevalue for a measurement is torejectbad data
Generator Boundary Data Identification List in Section points or outliers. Outliers are spurious data that are
1 and shown schematically on Figs. 1.4-1 through 1.4-7. believed to benotvalidandshouldnot be included
This Sectionis generally arranged inthe sequence as part of the calculations anduncertainty analyses.
required to compute steam generator performance after Causes of outliers arehuman errors in readingand
completion of a test. The testmeasurementsrecorded writingvaluesandinstrument 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 themareASME PTC 19.1 andASTM
ingtestmeasurements to average values. Section 5.2 E178. This Code does notrecommend a particular
also presentsthe equations to determine theprecision 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 5.1 5 present the equations to determine steam outliers can produce unrealistic results dependingon
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 recordedfor a givenparameter 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/orpretest agreements by the parties in-
present guidance fordetermining 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 ofany outliers.
5.2.3 Averaging Test Measurement Data. The aver-
age value of a parameter measuredduring a performance
5.2 MEASUREMENTDATAREDUCTION
test is determined before or after the rejectionof outliers.
5.2.1 CalibrationCorrections. When an instrument The average valuecanprovide 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 varywithrespect to timeand spatial location. The
7'5
Previous Page
is Blank
STD-ASME PTC 4-ENGL L998 m 0759b70 O.hL5OLh 292
majority can be averaged on the basis that the parameter 5.23.2 SummaryData. 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 testperiod.
a steady-state performance test(asdefined in Section These are called summarydata. The total set of measure-
3), somesingle-point parameters may exhibit time ments for a test consists of m sets ofmeasurements.
dependency. However, for purposes of this Code, such Each set has n readings. The average value, XAVEk,
parameters are assumed to have a constant value equal for set k is givenby Eq. (5.2-1) withtheaddition of
tothearithmetic average. a subscript to denote the set. The overall average value
However,some parameters, measured during a test of suchparameters is:
run, mustbe considered with respectto space as well
as time (i.e., parameters which are not uniform within
a planeperpendicular to the direction of flow). This
would include any measured parameterdetermined from
XAVE =
1
-
m
x XAVEk
m
k=l
(5.2-2)
morethan one pointat a given location. Air heater
flue gasoutlettemperaturemeasurementsusing a grid
of thermocouples isa 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
fromparameterswhichvaryonlywith time. are available for each set of measurements. If this
The average value of theparameters, along with informationis not available, the subsets should be
theirstandard deviations of themeanand degrees of treated as individualsamples.
freedom,areusedto calculate the overall precision
uncertainty. 5.2.3.3 AverageValueforSpatiallyNonuniform
Average Parameters. The average value of parameters
5.2.3.1 AverageValue for SpatiallyUniform Pa- having spatial variations can be determined using nu'mer-
rameters.' The average value of a parameterthatis ical integration methods. This Code recognizes three
not expectedto exhibit spatialvariations is calculated methods for this calculation:
by averaging readings taken over time.
For parametersmodeled as constant irdover space multiple midpoint
(e.g., feedwatertemperature or pressure), or values of triple midpoint
a parameterat a fixedpointin space (e.g., exit flue 0 composite midpoint
gas temperature at one point in the thermocouple grid),
the equationused to calculate average values is: Numericalintegrationmethods 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 = - (X, + XZ + + . . . + 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
aremultiplied by a weighting factor,
where
&IVE= arithmeticaveragevalueof a measured pa-
rameter xi, = FiXi (5.2-3)
xi= valueofmeasuredparameter i atanypoint
in time
n = number of times parameter x is measured where
X ; = arithmetic average value of parameter at mea-
surementpoint i
'Some parametersmeasured at asinglepointin space mayexhibit
a time dependency, e.g., combustion air temperature due to ambient [NOTE: If Xi is temperature, it must be in
air temperature changes. This C,ode 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-
thenumber of readings to reducetheprecisionindex.However, at
theoption of theparties to the test, apolynomialmay be fittedto surementpoint i
the data for afixed point inspace. If a cume fit is utilized, the Fi= weighting factor for point i
user must (1) statisticallyvalidatethemodel; (2) mathematically This Code usesonly one type of weightingfactor:
integratethefitted curve to determine the averagevalue of the
parameter; and (3) develop themethod for calculating the variance velocity.
of theaveragevalue for determining the precisionindex. The individualweighting factor is:
76

STD-ASME PTC 4-ENGL L998 m 0759670 ObL50lt7 L29 m
FIREDSTEAMGENERATORS ASME €TC 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-
- mentpoint i
V = average velocity at traverse plane
and
-
v = -1r , v i"
(5.2-5)
=
P- I
x [3 (U3j.t + 2U3j+l,tl(5.2-7)
n i=l zk u 3 j + 2 , k ) -b
j=O
where
where
P = number of rows in grid
n = number of pointsonthetraversemeasuring
4 = number of columns in grid
plane
Up,q=arithmetic (or flow/velocity weighted if appli-
This Code does not requirethatintegrated-average
cable) average value of eachrow, p , and
parameters bemassflow or velocityweighted. If the
column, q. measurementpoint
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 methodbecan used
7.5.3 provides guidance for estimating thebias.
if the number of grid points in either the horizontal or
Finally, after averagingtheparameter at eachgrid
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 iscomputed in accordance withthe
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 thesame as the arithmetic aver-
age of all individual point measurements, as shown in and
the following equation:
U = ( X w l+ X,, + X,, + .._.+ X,,,,)/n

or (5.2-6)
U = (Xi + X z + X 3 + ..._+ X n ) / n
5.2.4 PrecisionUncertainty. General guidelines for
calculating the precision index for individual measure-
where ment parameters are givenbelow. A more detailed
U = integrated average value of measuredpa- description of uncertainty analysis calculations along
rameter with derivations is included in Section 7. Section 7
(b) TripleMidpointAveragingMethod. 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 numberof columns and of degrees of freedom. There is also an overall precision
rows being multiples of three: index and numberof degrees of freedom for all measure-
ment parameters combined. These cannot be calculated
until after the steam generator performancecomputa-
tions shown in Sections 5.3 through 5.15 are completed.
The calculation of the overall test precision index and
theprecision component of uncertaintyarepresented
in Section 5.16.
77

STD-ASME PTC 4-ENGL L9q8 0759b70 Ob15018 Ob5
The first step in determining the precision index and programs calculate thepopulation 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 ofthemean. With theuseof 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 themean 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 degreesof freedom for theprecisionindexof
a spatially uniform parameter is determined fromthe
STDDEVMN = (STDDEVZJ”~ (5.2- 1 ) following equation:
\ n /
-
”
[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 = [L
(n - 1)
i
i = l
( x i - XAVE)2
1 (5.2-12)
associated standard deviation of set k is:
1 “
or .,[
STDDEVk = c
i=, (xi - XAVE# ] (5.2- 15)
(PSTDDEV)’ -
(n - 1) I’” (5.2-13) where n isthenumberof measurements withineachset.
The precision index is given by Eq. (5.2-lo), where
the standard deviation of themean is:
where
PI =precision index for a measured pa- STDDEVMN =
rameter m
1
STDDEVMN=standard deviation ofthemean for (mn(mn-l)n=~
E
( ( n - 1 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 isthenumber of sets ofdata.

measured parameter The degrees of freedom for the precision index and
n =number of times parameter is mea- standard deviation of the meanare:
sured
x; =value of measured parameter i at DEGFREE = m n - 1 (5.2-17)
any point intime
XAVE=arithmetic average valueof a mea- The o&rall 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 thesame. The model is a
because some electronic calculators and spreadsheet constant value parameter for both.
78

~~~ ~~
STD-ASME
PTC
4-ENGL 1998 m 0759b70 Ob35039 T T 3 m
5.2.4.2 Precision IndexforSpatially 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 (fewerthan six), giving only a small
determined in a manner consistent with the integration number of readings at each point,thentheprecision
methods discussed in theprevious Sections andthe index oftheweighted average is estimated using a
use of weighted or unweightedaverages. 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 measurevelocity
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 fixedpoint. There are n readings at the single
index and degrees of freedom with the triple midpoint point. The readings are multiplied:
and composite midpointarepresented in Section 7.
The precision index for multiple midpoint rule aver-
age is:
XfW,i = [ L
VA VE
xi ] (5.2-20)
mL m
PI = - x PIZ 1'"
;=I
(5.2-18)
The sample standard deviation of X,,, STDDEV, is
calculated from Eq. (5.2-12) or (5.2-13). The precision
indexfor the weighted average parameteris:
The associateddegrees of freedom are:
PP
DEGFREE = (5.2-19)
PI 4
5 m4 DEGFREEi
=I
where
n = readings at the single point
N = number of traverses
where
F,- I,cc= F distribution as read in Table 4.8-1
Pl= precision index for average parameter
PI,= precisionindex of
the
parameter at The standard deviation is determined from the stan-
darddeviation of the single point. The degrees of
point i
freedomforthe single point are taken as infinite;
DEGFREE= degrees of freedomfor average pa-
rameter therefore,the F-distribution table isused.
If weighted averages are to be employed in perform-
DEGFREE,= degrees of freedom of the parameter at
point i ance calculations withweighting factors (velocities)
m = number of grid points determined separately from the weighted parameter, then
The degrees of freedom mustfall between a minimum the precision indexof 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 degreesof freedom is the smaller PI = [PIUW* + (PARAVEUW - PARAVEFW)'
of the following: V E 2 ] 'x/ 2P l V 2 N A (5.2-22)
0 number of points in the grid, m
where
number of readings taken at each grid point minus 1,
PIUW=precision indexofthe unweighted
N - 1
average
The maximumpossible degrees of freedom is the PARAVEUW= the unweighted average value of the
productof the two items listed above. parameter
Equations (5.2-18) and(5.2-19) are for unweighted PARAVEFW='the weighted average value ofthe
averages and also forweighted averages whenthe parameter
weighting factors are measured simultaneously with the PIV=the precision index of thevelocity
parameters so thattheprecision indexes at the grid VAVE =the average velocity
points are calculated by usingweighted parameters If the velocity distribution is determined by a limited
[X,, = F, X,, see Eq. (5.2-3)]. This calculation should number of traverses, PIV can be estimated from a large
beused for weighted averages onlywhen 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 V; 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 SuperheatedSteamGenerators. Outputin
ing on a continuous basis with specified steam conditions main steam is equal to the difference between the main
and cycle configuration (including specified bbwdown steam and spray mass flow rates multiplied by the
and auxiliary steam). This is also frequently referred difference between themain steam and feedwater enthal-
to as maximum continuous rating (MCR). pies andadded to the spray mass flow rate multiplied
by the difference betweenthemain steam andspray
5.3.2Capacity, Peak. Peak capacity is themaximum water enthalpies:
main steam mass flow rate the steam generator is
capable of producingwithspecified steam conditions
and cycle configuration (including specified blowdown Q r O = (MrSt32 - MrW25)(HSt32 - H W 2 4 ) (5.4-3)
and auxiliary steam) for intermittent operation, i.e., for + MrW25tHSt32 - HW25), Btulh (W)
a specifiedperiodoftimewithout affecting future
operation of the unit.
5.4.2ReheatSteamGenerators. 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), Btu/h (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 andleavingand added tothereheatspray
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 spraywater enthalpies:
waterto produce saturatedsuperheated steam, reheat
steam, auxiliary steam (refer to Subsection 5.4.3) and
QRh = MrSt33(HSt34 - HSt33) (5.4-4)
blowdown. It does not include the energy supplied to
preheat the entering air such as air preheater coil steam + MrW26(HSt34 - HW26). Btulh(W)
supplied by the steam generator.
The generalform of the output equation is:
5.4.2.1Reheat 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 andany other flows extracted after themain 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= enthalpyoffluidleavinglocation 22, flow. The preferred method for determining extraction
B t d b m (J@) flowto feedwater heaters is calculated by energy bal-
HEnzl= enthalpy offluid entering location z l , ance. Turbine shaft and seahleakages may be estimated
Btu/lbm (J@) from the manufacturer’s turbine heat balances or recent
turbine test data. Extraction flows that cannot be calcu-
5.4.1 OutputinMainSteam. 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 spraywater 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-stagereheatflowleaving the unit is usedinlieu
inghigh-pressure feedwater. ofmain steam flow.
Consult PTC 6, SteamTurbines; for guidance in
5.4.1.1 SaturatedSteamGenerators. Output in
determining reheatflow.
main steam is equal to the steam mass flow rate leaving
theunittimes the difference betweenthe enthalpy of 5.43 AuxiliarySteam. Auxiliary steam includes
the steam leaving the unitandthe feedwater entering steam which exits the steam generator envelope as well
theunit: as miscellaneous steam, such as atomizing steam and
80

~ ~~ ~~
STD-ASME PTC 4-ENGL 1998 0759670

Ob15021 b5T m
FIRED WC 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, addthefollowingterm
Energy entering the system is the energy associated
to the output equation:
with the entering mass flow streams andauxiliary
equipment motivepower.Energyleavingthesystem
QrAxSt = MrSt46A(HSt46A (5.4-5) is theenergyassociatedwiththeleavingmass flow
- HW24). B t d h (W) streams and heat transfer to the environment from the
steam generator surfaces.
where MrSt46A and HSt46A are themass flow rate Expressing theenergy balance in termsthatcan be
andenthalpyatthe extraction point. readily measured and calculated, Eq. (5.6-1) becomes:
5.4.4 Blowdown. The term

added to the output
equation whenblowdown 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. Energybalance
closure is the net sum of the energy associated
with entering and leaving mass flow streams
(excluding inputand output), energy due to
5.5 INPUT chemical reactions that occur within the steam
Input is the potential combustion energy. It isthe generator envelope, motive power energy, and
maximum amount ofenergy available whenthefuel radiative andconvectiveheattransfer to the
is completelyburned: environment.
In keepingwithconventionalpractice,energy balance
closure may be dividedinto credits and losses:
Qr! = QrF = MrF
HHVF, Btulh (W) (5.5-1)
where Qb = QrL - QrB, Btulh (W) (5.6-3)

Q r l = input, Btdh (W)
QrF= inputfrom fuel, Btuh (W) where
MrF= mass flow rate of fuel, Ibmh (kg/s) QrL= losses, Btu/h (W). Losses are the net sum of
H H V F = 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 thesteam 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 QrB= credits, Btuh (W). Credits arethenetsum
can be stated as: of energy transferred to thesystem 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 energyof
auxiliary equipment within the steam generator
Since a steam generator should betestedunder envelope.
steady-state conditions, such that accumulation is zero, Substituting the above in Eq. (5.6-2), the overall energy
the equation is: balancebecomes:
Energy entering
system
the QrF + QrB = QrO + QrL, Btulh (W) (5.6-4)
= Energyleavingthesystem
where
or @ - F +total
QrB= the energy
to added the system
81

~~
~~
STD-ASME PTC 4-ENGL L998 0759670 Ob15022 59b
5.7 EFFICIENCY Whilemost 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 efficiencyusingmixed
output QrO units for losses and credits is:
EF = 100 -= 100 - (5.7-1)
QrI Input
EF = (100 - SmQpL (5.7-6)
= loo=,%
QrF QrO
+
(QrO + SmQrL - SmQrB
Wheninput (&I) is defined as thetotalenergyof
combustion available from the fuel ( Q r F ) , the resulting where
efficiencyiscommonlyreferred to as fuelefficiency
( W . SmQpL and SmQpB are the sum ofthelossesand
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 tothe calculated on a Btuh (W) basis (refer to Appendix C
steam generator envelope (QrF + &B). This is com- for derivation)
monly referred to as gross efficiency (EGr). Appendix The mass flow rate of fuel (MrF) may be calculated
D addressescalculation of gross efficiency. from output andfuel efficiency determined by the
5.7.1 Efficiency -Energy BalanceMethod. In the energy balancemethod:
energybalancemethod,the energy closure lossesand
credits are usedto calculate efficiency. Equation (5.6-
4) can be rewritten as follows:
MrF = 100 (EFQro
HHVF
), Ibm/h ( k g l s ) (5.7-7)
QrF = QrO + QrL - QrB, Btulh (W) (5.7-2) The calculated mass flow rate of solid fuel is generally
more accurate thanthemeasured flow.
The energy balance method isthepreferredmethod
Thus, fuelefficiencyexpressed in terms ofthe losses
for determining efficiency. It is usuallymore accurate
and credits becomes:
than the input-output method (refer to Subsection 5.7.2)
because measurement errors impact the losses and
QrO EF = 100 QrO
- = 100 (5.7-3) credits ratherthan 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 O. 1%
QrF - QrL + QrB
= 100 ,% error in efficiency, where a 1% error in measuring fuel
QrF flow results in a 1% error in efficiency. Another major
advantage to the energy balance method is that reasons
Most losses andcredits can be calculated on a percent for variations in efficiencyfrom 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: theefficiency to reference or contract conditions for
deviations from test conditions such as the fuel analysis.
QrL
QpL = 100 -and QpB = 100 -
QrB % (5.7-4) -
5.7.2 Efficiency Input-Output Method. Efficiency
QrF Q~F’ calculated by the input-outputmethodisbasedupon
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 (C!;:
P - -QrL
+ P QrB) =
QrF QrF
100 (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 betaken to determine these items
accurately:
82

STD-ASME PTC 4-ENGL L998 m 0759b70 Ob15023 422 m
FIRED STEAMGENERATORS ASME PTC 4-1998
output isnormally expressed on a volumebasis, Btdscf (J/

EF = 100- = 100 % (5.7-8)
Input HHVF’
MrF Nm3), HHVG. For compatibility with the unitsused
in thecalculation procedure, thehigherheatingvalue
where MrF is the measuredmass flow rate of fuel. must be converted to a energy per unitmassbasis,
Btdlbm (Jkg):
5.7.3 EfficiencyCalculationConvergence. The cal-
culation procedure is iterative for most types of units.
That is, an efficiency or fuelrate (input) is estimated HHVF = HHvGF, BtuAbm (J/kg)
~ (5.8-2)
to initiate theefficiency calculations. The calculations DnGF
arerepeateduntiltheefficiency (fuel ratehnput) is
withinan acceptable limit. The calculation processis where
relatively insensitive to theinitial 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 &mm3)
theefficiency result is onlyrequiredforthefirst or For fossilfuels,thereasonableness of thehigher
second decimal place, a convergence limit of 0.1% heating valuecan be checked based on the theoreticalair
efficiencyissufficient (1.0% for hand calculations). calculated from theultimate 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 coefficientis air values can beestimated using the followingequation:
determined from the difference between the base effi-
ciency and the efficiency calculated with the perturbed MFrThA
data. Since theperturbation may be small, the change HHVF = IO6 - Btullbm (J/kg) (5.8-3)
MqThA F’
in efficiencymay be small. For developing sensitivity
coefficients, anefficiency convergence limitonthe
where
order of efficiency
recommended.
is
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, Ibm/MBtu. (Refer toSub-
5.8.1 HeatingValue of Fuel. Higherheating 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 pressurebasis.For solid andliquid fuels,
of solid andliquid fuels is required to determine
HHVF is determined in a bomb calorimeter, which is
themassofthe individual elements involved in the
a constant volume device. Since fuel is burned in
combustionprocess,andthemass of inert ash. The
a steam generator under essentially constantpressure
total as-fired moisture content must also be determined.
conditions, thebomb calorimeter valuesmustbe cor-
When the ultimateanalysis is on an air dried or moisture
rected to a constant pressure basis:
free basis, it mustbe converted to anas-firedbasis.
A gaseous fuel analysis isusuallyreported on a dry
HHVF = HHVFcv + 2.644 MpHZF, (5.8-1) or saturatedbasis. The amount of moisture as-fired
BtuAbm (J/kg) should be determined and the chemical analysis and
HHVGF shouldbe adjusted to theas-firedcondition.
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 theultimateanalysis is expressed on a percentmass
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
thefuel analysis has notmadethis correction. For (SF), oxygen (02F),water (H20F), andash(AsF).
gaseous fuels, thehigher heating valueis determined Trace gaseous elements, such as chlorine, which is not
under constant pressure conditions; therefore, the calo- considered inthe calculations, should be added to the
rimetervalues do notneed 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 thehydrogen in thewater in
lbm (Jkg). For gaseous fuels, the higher heating value thefuel.
83

For some combustion processes, those involving solid VpCj Mokj

fuels in particular, all of the carbon maynot be MvFk = M w k 2 (5.8-6)
100 ’
burned. When there is unburned carbon, the combustion lbmlmole fuel (kg/mole)
calculations utilizethecarbonburned, 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 massbasis.
actual hydrogen in the fuel), the hydrogen burned, H2b, For this Code, these are C, Hz, N2, S, 0 2 ,
should be used in the calculations rather than the actual H20. For a gaseous fuel, it isassumedthat
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 ofvolatile matter, fixed or molebasis, such as CH4, C&, etc.
carbonandash, as well as theas-fired moisture. The VpCj=.as-fired fuel components (such as CH,, C2&),
sulfur content may also be reported. A complete proxi- percentbyvolume
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 = HZ, Mokj
tify the uncertainty these
of constituents.A large num- = 3.
ber of proximate analyses can be used to determine Mwk= molecular weightof constituent k, lbdmole
ash, moisture, and possibly sulfur in lieu of a large (kg/mole)
number of ultimate analyses. MwCF=molecular weight ofthe 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 unitmole (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 difficulta coal is to burn. Ingeneral, 5.8.3 MultipleFuels. Whenmorethanonefuelis
the lower the volatile matter with respect to the fixed fired, the ultimate analysis and higher heating value is
carbon, themoredifficultthefuelisto bum. For theweighted average basedupon the massflow rate
guarantee tests,this ratio maybe considered when of each fuel. For the initial calculation, thetotalfuel
evaluating whether the testfuel is suitably equivalent input is estimated from measured fuel flow or calculated
to the contract fuel. from output and estimated efficiency. The inputfrom
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 isused. The mass flow rate of theunmeasured
calculations in this Code, thegaseous fuel analysis is
fuel is then calculated fromthe HHV andinput from
converted to a mass basis. The Gaseous Fuel Calculation
that fuel. The efficiency calculations must be reiterated
Formincluded in Appendix A maybeused for this
conversion. The calculations followthegeneral 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- % mass (5.8-4)

MWCF’ 5.9 SORBENT AND OTHERADDITIVE
PROPERTIES
This Section addresses solid and/or gaseous material
MwGF = 2 MvFk, Ibm/mole (kg/mole) (5.8-5) other thanfuel that is added to the gas side of the
84

~~
STDOASME PTC 4-ENGL 1’4’48 m 0759b70 ObL5025 2T5 m
AM FIRED PTC 4- 1 9 8
steam generator envelope. Additives canimpactthe MrF= mass flow rate of fuel, Ibmh (kg/s). Repeat
efficiencyand combustion process in severalways: efficiency calculation until the calculated MrF
converges withinthe guidelines of Subsec-
additives may increase thequantity of residueand
tion 5.7.3.
“sensible heat of residue” losses
additives may introduce moisturewhich increases 5.9.2 MFrSbk - Mass of Constituents in Sorbent,
“moisture in flue gas” losses and alters the flue gas l b d b m Fuel (kgkg). The important constituents in
specific heat the sorbent are the reactive products, the moisture, and
additives may undergo a chemical change andalter the the inerts. The mass of each constituent isconverted
flue gas composition or may alter the air requirement to a masdmass fromfuelbasis:
0 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 iswidelyusedfor sulfur removal, k = constituent in the sorbent. The reactive constituents
this Code specificallyaddressesthe 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 refertoanymaterialadded to theflue gas CU(OH)~ = calcium hydroxide (Ch)
(within the steam generator envelope) that is not fuel. Mg(OW2= magnesium hydroxide (Mh)
The calculations for limestone demonstrate the princi- MpSbk= percent of constituent k in the sorbent
plesof 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 onflue gas constituents or carbonate and magnesium carbonate, CO2 isreleased.
particulates are independently demonstrated and rneasur- This increases thedry gas weight:
able or calculable, the parties tothetestmay include
theassociated 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 belowshould be made as if limestone
containing only inert material and moisture were used.
5.9.1 MFrSb - MassFraction of Sorbent, lb&
MFrC02Sb = 44.01 MoCOZSb,
lbm/lbm fuel (kg/kg)
(5.9-4)
Ibm Fuel (kgkg). Combustion and efficiency calcula-
tions are sensitive to themeasured sorbent mass flow
rate. Therefore, the mass flow rate of sorbent must be
determined accurately.
To simplifythe combustion andefficiency 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 H H VF
of fuel is measured or estimated initially. The efficiency
calculations are repeated until the estimated and calcu- where
lated fuel mass flow rates arewithin the convergence k = constituents that contain carbonates, typi-
tolerance of Subsection 5.7.3: cally calcium carbonate (Cc) and magne-
sium carbonate (Mc)
MFrSb = MrSb, lbmllbm 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= measuredmass flow rate of sorbent, Ibmh (Mc) calcines readily at partial pressures
(kgW of CO2typicalofcombustionwith air
85

andnormaloperating temperatures of MqWSb= mass of total water from sorbent on an

atmospheric fluidized bed steam genera- inputfromfuelbasis,Ibm/Btu (kg/J)
tors and thus the calcination fraction is MrWSb= mass flow rate of total water from sor-
normallyconsidered to be 1.0. Notall bent, lbm/h (kgls)
of the Caco3 (Cc) is converted to C a 0
5.9.5 MFrSc - SulfurCapture/RetentionRatio,
and CO2, however. Refer to Subsection
l 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 measured0, 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 AreMeasured
MFrCO2Sb = mass fraction of gas (CO,) from sorbent, on a Dry Basis
lbdlbm fuel (kg/kg), andwhere 44.01
is the molecular weight of carbondioxide
MqCO2Sb= mass of gas (CO,) from sorbent onan MFrSc =
inputfromfuelbasis,Ibm/Btu(kg/J)
(DVpSO2 (MoDPcu + 0.7905 MoThAPcu)\
5.9.4 MqWSb - WaterFromSorbent,lbm/Btu 1-
\ 100 ( 1 - DVp02/20.95)MoSO2
(kg/J). The total moisture added due to sorbent is the
sumofthemoistureinthesorbentandthe moisture (1 + 0.887 ( Dvpso2/100 ))
1 - DVp02/20.95
released due to the dehydration ofcalciumhydroxide
andmagnesiumhydroxide: Ibm/lbm (kg/kg) (5.9-10)
MoWSb = MFrH20Sb + MFrSbk (5.9-6) MoThAPcu =

18.015 Mwk
moles/lbm fuel (moledkg)
rnoles/mass fuel (5.9-1 1)

MFrWSb = 18.015MoWSb, Ibm/lbm fuel (kglkg) (5.9-7)
MODPCU= MpCb
-+ - MpSF + MpN2F
- (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 = -rnoles/lbm 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- tionof fuel (CO,, SO2, N2from fuel)
idesthatare dehydrated, typically cal- with 100% conversion of the sulfur to
ciumhydroxide (Ch) andmagnesium SO2 plus the drygas from sorbent (CO,),
hydroxide (Mh) moledmass fuel
MFrH2OSb= massfractionofthewater in sorbent, MuThAPcu= moles of theoretical air required for the
l b d b m fuel (kgkg) gasified products in the fuel withtotal
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 waterfrom sorbent, the fuel, CB (carbon burned), HZ, S, and
IbmAbm fuel (kgkg) 0, are on a percentmassbasis.
86

~ ~
STD-ASME PTC 4-ENGL 1998 W 0759b70 Ob15027 078 W
FIRED STEAMGENERATORS ASME €TC 4-1998
Mos02 = moles of SO2 per Ibm fuelthatwould vp02,

be producedwith 100% conversion of V p S 0 2 = measured O2 and SO2 in theflue gas,
the sulfur in the fuel to SO2, moledlbm percent volume. They must be measured
fuel(molesflcg) at the same locationandexpressed on
DVpO2, a wet basis. SO2 is usually measured in
DVpSO2= measured O2 and SO2 inthe .flue gas, ppm. To convert to a percent basis,
percent volume. They must be measured divide ppm by 10,OOO.
at the same locationand 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 percentbasis,
divide ppmby 10,000.
MwS
MoFrCaS = MFrSb -2- MpCak (5.9-18)
5.9.5.2 MFrSc When SO2 and O2 Are Measured MpSF MwCak'
on a Wet Basis
moleshole
MFrSc =
where
VpSO2 [MoWPcu + MoThAPcu (0.7905 + MoWA)] MpCak= percent of calcium in sorbent in form
-( 100[1 - (1 + MoWA) Vp02/20.95]MoS02 of constituent k, percentmass
MwCuk= molecular weight of calcium compound
1 + K ( VpS02/I O0 k, lbdmole (kg/mole)
1 - (1 + MoWA ) Vp02/20.95
Cuco3=calcium carbonate (Cc) MW = 100.089
Ibm/lbm (kglkg) (5.9-14) Ca(OH)2= calciumhydroxide(Ch) MW = 74.096
MwS= molecularweight of sulfur, 32.064
Ibndmole
MpH2 F Mp WF 5.9.7 MFrSsb - Mass Fraction Spent Sorbent, I b d

MOWPCU= MODPCU+
+
~ - (5.9-15) IbmFuel (kgkg). Spent sorbent isthe solid residue
1801.6
201.6
remaining from the sorbent after evaporation of the
moisture in the sorbent, calcination/dehydrationand
+ MFrWAdz + M ~ W S B moles/mass
, fuel
massgain due to sulfation:
18.016
MFrSsb = MFrSb - MFrC02Sb

K = 2.387(0.7905 + MoWA) - 1.0(5.9-16)
- MFrWSb + MFrS03, (5.9-
19)
lbmllbm fuel (kgkg)
MoWA = 1.608 MFrWA, moles/mole (5.9-17)
Mo W P C U = MoDPcu plus moles of water from flue, MFrS03 = 0.025 MFrSc

MPSF, (5.9-20)
plus moles of water from sorbent, plus Ibm/lbm fuel (kg/kg)
molesof additional water,moles/mass
fuel
M F r W A = mass of moisture in air per mass of dry where
air, Ibdlbm (kgkg) MFrSO3= massfraction of SO3 formed in the
M o W A = moles moisture permole 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 molecularweight of sulfur divided
atomizing steam and sootblowing steam, by the molecularweight of SO3 and
lbdlbm fuel as-fired. Also refer to Sub- divided by 100 to convert percent mass
section 5.12.7. tomass fraction.
87

ASME F'TC 4-1998 FIRED STEAM GENERATORS
5.10 RESIDUE PROPERTIES mass flow rate of fuel should be measured or

estimated initially and thecalculations repeated
Residue is the ash and unburned fuel removed from
untilthe calculated mass flow rate of fuel
thesteam generating unit.When a sorbent such as
basedonefficiency is withinthe guidelines
limestone or an inert material suchas sand is introduced,
of Subsection 5.7.3.
the residue includes thespent sorbent (solid sorbent
The mostuniversal measurement location for the
productsremaining after evaporation ofthe moisture
massof residue is the dust loading orfly ash leaving
in the sorbent, calcinatioddehydration, and weight gain
the unit, refer to Section 4.1 l . 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
offlue gas basis. While the dust loading result from
a fossil fuelfiredsteam generator.
this test is considered accurate, the flue gas mass flow
5.10.1 MFrRs - Mass of Residue, lbmhbm 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 permass of fuel basis: this Code. Accordingly, themass flow rate of residue
basedon 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/lbm fuel (kg/kg) CI DnFg
where where
MpAsF= ashinfuel,percentmass MvRs= dust loading results tested in accordance with
MFrSsb= mass fraction of spent sorbent per mass Section 4.1 1, grains/ft3 (dm3)
of fuel, lbdlbm fuel (kgkg) MrFg = mass flow rate of wet fluegas, refer to Subsec-
MpCRs= unburnedcarbon in the residue, per- tion5.12.9, Ibmh (kds)
cent mass DnFg= densityofwet flue gas at conditions MVR
above reported, Ibm/ft3(kg/m3)
5.10.2 MqRsz - Mass of ResidueatLocation .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 andforthe 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 andisusedto determine
MpRsz MFrR unburned carbon from fuel. The residue contains carbon
MqRsz = , lbm/Btu (kg/J) (5.10-2)
100 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 isthepercentoftotal residue exiting carbonate content in the ash. The standard tests for
the steam generator envelope at location z, percent. carbon in the residuedetermine total carbon (MpToCRs).
It may be impracticalto measure the residue collected It is also necessary to determine the carbon dioxide
at all extraction points. In such cases, the unmeasured content inthe residue ( M P C O ~ R S )and
, correct the
residue maybe calculated by difference from the total total carbon results to a free carbonbasis (MpCRs).
calculated residue and the measured residue. The esti- Referto Section 4.12 regardingthe analysis methods
mated split between the unmeasured locations must be to be specified. If the lab analysis is not clear whether
agreedupon by all parties to thetest: totalcarbon (MpToCRs) or free carbon (MpCRs) is
reported, it should be clarified. Whensorbentwith
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 thecalcination fraction of calciumcarbonate
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, lb& (kg/s) 12.01
"
MpCOZRs, lbm/100 Ibm residue
MrF= mass flow rate offuel, lbmh (kg/s). The 44.01
88

~~
STD.ASME PTC 4-ENGL L778 W O757670 Ob35027 940 m
When residue is collected at more than one location, MpCb

MpCbo = 100 - % (5.10-10)
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 - CalcinationFraction of Cal-

NOTE: Ifmeasured,unburnedhydrogen is to bereported on a dry cium Carbonate, molesC02/mole Caco3.Calcination
basis. On units utilizing limestone sorbent, there is a strong potential is the endothermic chemical reaction when carbondiox-
thathydrogen in theresidue is from thewaterofhydrationof ide is releasedfromcompounds containing carbonate
calciumoxidewhichwill not be detectedby the normalmethod of
testing for free moisture. If it is ascertained that unburned hydrogen (CO,) such as calcium carbonate to form calcium oxide
in theresidue is real and significant and it cannotbecorrectedby andmagnesiumcarbonate to formmagnesium oxide.
operatingtechniques,thehydrogen in thefuelshouldbecorrected Magnesium carbonate, MgCO,(Mc), calcines readily
for unburned hydrogen for the combustion and efficiency calculations
in the same manner as unburnedcarbon.Refer also toSubsection 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 - UnburnedCarboninFuel,per- The calcination fraction isdeterminedfromthemea-
cent mass. The unburned carbon in the residue is used
sured COz in the residue. Assuming that the principal
to calculate thepercent of the carboninthe fuel that
carbonates in the sorbent are magnesium carbonate and
is unburned:
calcium carbonate, these calculations assumethat the
COz in the residue is in the form of calcium carbonate.
MpUbC = MpCRs MFrRs, % mass (5.10-8) If a sorbent is usedthat contains significantamounts
of a carbonatethat is moredifficultto calcine than
calcium carbonate, the principles ofthisCodeshould
5.10.5 MpCb - Carbon Burned, percent mass. The be followedbut the amount of CO2 in the residue
actual percentcarbon in the fuel that is burned is the should be proportioned amongthe carbonate compounds
difference between the carbon in the fuel from the inviewofthedifficultyof calcination:
ultimate analysis and the unburned carbon. The actual
carbonburned ( M p C b ) is usedin the stoichiometric MrRs MpCO2Rs MwCc
MoFrClhCc = 1 - (5.10-12)
combustion calculations in lieu of
carbon
in fuel MFrSb MpSbCc MwC02
(MpCF):
where
M p C 0 2 R s = mass of CO2 in residue, percentmass
MpCb = MpCF - MpUbC, % mass (5.10-9)
M F r S b = mass fraction of sorbent, lbdlbm fuel
NOTE: If it is determined that there is unburned hydrogen, MpUbH2, M p S b C c = mass of Caco3 (Cc) in sorbent, percent
the actual hydrogen burned, MpHZb, must be used in the combustion
and efficiencycalculations in lieuof MpH2F;
MwCc= molecular weight of Caco3 (Cc),
100.089 Ibdmole (kgmole)
M w C 0 2 = molecularweight of CO2, 44.01 I b d
MpH2b = MpH2F - MpUbH2 mole(kglmole)
RefertoSubsection 5.10.3.
5.11 COMBUSTIONAIRPROPERTIES
5.10.6 MpCbo - Carbon Burnout, percent. Carbon
burnout is the carbonburneddivided bythecarbon 5.11.1 Physical Properties. The calculations and deri-
available andexpressed as a percentage: vation of constants usedin this Code are basedupon
89

ASME PM: 4-1998 FRED STEAM GENERATORS
a composition of air as follows [l]: 0.20946 02,0.78102 bulb temperature (PsWvTdb), psia. The
N2, 0.00916 Ar, 0.00033 CO2 moles per moleof 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- Cl = 0.019257
tions (N2) includes the argon and other trace elements, C2 = 1.289016E-3
and isreferred to as “atmosphericnitrogen” (NZa), C3 = 1.211220E-5
having an equivalent molecularweight of 28.158. C4 = 4.534007E-7
Belowis a summary of the nominalproperties of C5 = 6.841880E-11
air usedinthisCode: 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, l b d b m Dry z, “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 humidityismeasured:
amounts of CO and nitrous oxides (NO,) areformed
and commonly measured. Also, small amounts of SO3
and gaseous hydrocarbons areformed but less frequently
PPWvA measured. The impact of these minor species is negligi-
MFrWDA = 0.622 (5.11-1)
(Pa - PP WVA)’ bleonthe combustion calculations addressed bythis
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,
issignificant (greater than 1,000 ppm):
PpWvA = PsWTwb 1-2) (5.1
- ( f a - PsWvTwb)(Tdbz - psis MqThAf MFrThA, lbm/Btu (kglJ)

~ (5.1 1-5)
HHVF
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 + C2T + C3T2 + C4T3 (5.1 1-4)
+ C5T4 + C6T5, psia wherefuel constituents MpCF,MpH2F,MpSF, and

M p 0 2 F areon a percentmassbasis.
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 watervapor in air, fuel analysis. Expressedon 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 watervapor at Oil 735-755 IbdMBtu
wet-bulb temperature (PsWvTwb) or dry- Natural Gas 715-735 IbmlMBtU
90

STDOASME PTC 4-ENGL 1998
The theoretical air forcarbonandhydrogen, 816 the steam generator envelope. Refer to
and 516 lbm/MBtu respectively, are the practical maxi- Subsection 5.9.5 for calculation.
mumandminimumvalues for hydrocarbon fuels.
5.11.4 XpA - ExcessAir,percent. Excess air is
For monitoring operation and analysis of combustion,
the actual quantity of air used,minusthetheoretical
thetheoretical air required to produce the gaseous
air required, divided by the theoreticalair, and expressed
products of combustion is moremeaningfulthanthe
as a percentage:
ideal value definedabove.Incommercial applications,
particularly for solid fuels, it is not feasible to bum
the fuel completely.The gaseous productsof combustion (MFrDA - MFrThACr)
XpA = 100 (5.1 1-10)
are theresult of thefuelthat is burned or gasified. MFrThACr
When additives are used, secondary chemical reactions
(MqDA - MqThACr)
may also occur. For example, when C a 0 reactswith = 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 theactual is used as the basis for calculating excess air. Defined
combustion processisused. as such, zero percent O2 in theflue gas corresponds
Corrected theoretical air is defined as the amount of to zero percent excess air. Excess air may alsobe
definedbasedonidealtheoretical air, andcalculated
air required to complete the combustion of the gasified
by substituting ideal theoretical air [Eq. (5.1 1-5) or
fueland support secondary chemical reactions with
zero excess 02.By definition, the theoretical products of (5.11-6)] in Eq. (5.11-10) above.
For efficiency calculations, excess air must be deter-
combustion would have noCO or gaseous hydrocarbons:
minedatthe 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 thesteam 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 theflue 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
usingmeasured O2 is that for a giventype 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 stronglydependenton
thefuel analysis due to the amount ofCO2produced
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 removalprocessis
even on a wet basis, O2 versus excess air is essentially
employed, the excess air and combustion
constant for typical variations in moisture influe gas
calculations are dependent uponwhere
producedfrom a givenfuel source.
the sulfur removal occurs in relation to
the flue gas composition measurements. 5.11.4.1 O2 Analysison DRY BASISWherethe
MoThACr = theoreticalair (corrected), moledmass MoistureintheFlue Gas Is CondensedSuch as
fuel as-fired WhenanExtractiveSamplingSystem Is Used
MpCb= MpCF - MpUbC = carbon burnedon
a mass percentage basis
MFrSc= sulfur capture ratio, I b d b m . This item DVpOZ(MoDPc + 0.7905 MoThACr)
XpA = 100 ,%
isnormallyassumed 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 0759670Ob15032435 m
MpCb MpSF DVpN2a = 100 - DVpO2 (5.11-17)

MoDPc = -+ ( 1 - MFrSc) -
1201 3206.4 - DVpCO2 - DVpSO2 - DVpN2J 9%
F
+ MpN2 - (5.1 1-12)
2801.3
+ MoCOZSb, moledmass fuel
MoDFg = MoDPc + MoThACr
moles/mass fuel (5.11-18)
where
DVpO2= oxygen concentration in theflue gas,
percent by volume,drybasis where
M o D f c = moles of dry products from the combus- DVpCO2= carbon dioxide in the flue gas, percent.
tionoffuel (CO, fromcarbon burned, Notethat for comparison toanOrsat
actual SO2 produced (excluding sulfur analysis, DVpSO2 must be added.
retained due to SO, capture techniques), DVpSO2 = sulfur dioxide in theflue gas, percent
N, fromfuelandthedry gas from volume
sorbent, CO2, moledmass fuel DVpN2f = nitrogen from fuel in the fluegas, percent
M F r S c = mass fraction of sulfur capture, lbm/lbm volume. This term is shown separately
f d (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 thequantityof
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 ona DRY BASIS omitted.
WhenExcessAirIsKnown DVpN2a = atmospheric nitrogen (refer to Subsection
5.1 1.1) in the flue gas, percent volume
M o D F g = moles of dry gas per lbm of fuel as-fired
5.11.4.3 O2 Analysis on WET BASISWherethe
XpA MoThACr 0.2095
DVp02 = ,% (5.11-13) FlueGasSampleIncludesMoisture,Such as In-
MoDFg SituMonitorsandHeatedExtractiveSystems
XpA = 1-19) (5.1
100 [ Vp02[MoWPc + MoThACr(0.7905 + MoWA)]

MoThACr(20.95 Vp02(1 + MoWA))
-
MoWA = 1.608 MFrWA, moles/mole dry air (5.1 1-20)
MpSF
p H2 F
32.064
( 1 - MFrSc)
MoWPC = MoDPc +M
-
DVpSO2 = ,% (5.11-15) 201.6
MoDFg
+-MpWF + MFrWAdz
(5.1 1-21)
1801.5 18.015
+ MoWSb, moles/lbm fuel
DVpN2f = ,% 1-16) (5.1 where

MoDFg MFrWA = moisturelbm
in air, H20/lbm dry air
92

STD.ASME PTC 4-ENGL 1998 m 0759b70Ob15033 371 m
FIRED ASME l'TC 4-1998
MoWA = moles of moisture in air,moles H201

moledry air \ 28.013 J
1.608= molecular weight of dry air divided by VpN2f = ,% (5.11-26)
MoFg
themolecularweightofwater
MpWF= H,O in fuel, percentmass 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 fuelas-fired.Refer to Subsec- - VpSO2 - VpH2O - VpNZf, %
tion 5.12.7. Measuredvalues of steam
and fuel flow are usuallysufficiently
accurate for this calculation. If the mass
flow rate of fuel is reiteratedbasedon MoFg = MoWPc
calculated efficiency, thisitemshould
be included. 0.7905 + MoWA (5.1 1-28)
MoWPc = MoDPc plus moles of wet products from
thecombustionfrom fuel, plusthewet + XPA
-( 1 + MoWA)
products from sorbent, plus any addi- 100
tional moisture, moles/massfuel
V p 0 2 = oxygen concentration intheflue gas,
percent by volume,wetbasis where
MoFg= moles ofwet gas perlbmfuelas-fired
MoWSb = total water from sorbent, molesllbm fuel..
Referto Section 5.9. 5.11.5 MqDAz - DryAir,lbm/Btu (kg/J). The
5.11.4.4
Calculation of Vp02,VpCO2,VpSO2, quantity of dry air entering the steam generator ahead
of location z is calculated from theexcess air determined
VpH20, VpN2f, and VpN2a on a WET BASIS When
to bepresent at location z as follows:
Excess Air Is Known
XpA MoThACr 0.2095 MqDAz = MqThACr 1-29) (5.1

vp02 = ,% 1-22)
(5.1
Mo Fg
lbrn/Btu (kglJ)
12.01 + ;:F;C02Sb
vpco2 = ,% (5.11-23) MFrDAz = MFrThACr (5.1 1-30)
lbmllbm fuel (kglkg)
MpSF
( 1 - MFrSc) 5.11.6 MrAz - Wet Air, lbmh (kg/s). The quantity
32.064 (5.11-24) of wet air atanylocation z is, the sum of thedryair
vpso2 = ,%
Mo W C plus moisture in air:
MqAz = (1 + MFrWA)
MqDAz, (5.1
1-31)
lbm/Btu (kglJ)
+ MFrWAdz + 100 MoWSb

0.18015 MrAz
QrF, = MqAz
1-32) (5.1
lbrnlh (kgls)
where
(5.1
1-25) QrF= input
from fuel, Btu/h (W)
93

ASME WC 4-1998 FIREDSTEAMGENERATORS
Note that to determine the air mass flow rate leaving Wet flue gas isrequired for calculations such as air
the air heaters (to theburners),the excess air leaving heater leakage, hot air quality control equipment energy
theboiler or economizer must be reduced by the losses and draft loss corrections. The total gaseous
estimatedamountof 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 ofwet air is calculated usingtheideal gas wetflue gas isthesumof the wet gas from fuel
relationship: (fuel less ash,unburned carbon and sulfur captured),
combustion air, moisture inthe combustion air, and
any additional moisture, such as atomizing steam and
DnA = Ibm/ft3
1-33)
(kg/m3)
(5.1 moisture and gas added from the addition of sorbent.
Rk (C3 + TAz)
+
Dry flue gas is determined by subtracting all moisture

from the wetflue gas.
5.12.1 MqFgF - Wet Gas FromFuel,lbm/Btu

Rk = -,-
R ft . Ibm -
Mwk Ibm. R kg. K
( J ) (5.11-34) (kg/J)
MqFgF =
(100 - MpAsF - MpUbC - MFrSc MpSF)
100 HHVF
MwA = -+ MFrwA Ibm/mole
(kglmole)
(5.11-35) ibmmtu (kglJ) (5.12-1)
1 MFrWA’
+-
28.963
18.015
where
MpAsF= ashin fuel, percent mass
where
R = universal molar gas constant, 1,545 ft . Ibf/lbm- MpiJbC= 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
=
I b m - RFK)
MwA = molecularweight
kg.
ofwet air, lbdmole (kg/
5.12.2 MqWF, MqWvF - Moisture
From H,O
(water)inFuel,Ibm/Btu(kg/J)
mole)
Pu = barometric pressure, psia (Pa). . To convert in.
Hgtopsia, divide by2.0359. Mp W F
MqWF = lbm/Btu (kg/J) (5.12-2)
PAZ= static pressure of air atpoint z, in. wg (Pa) 100 HHVF’
TAz= temperature of air at point z, “F (“C)
Cl = 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 thewater in the fuel, percentmass.
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 HydrogenintheFuel,lbm/Btu(kg/J)
the fuel analysis and excess air. Computations are not
valid if significant quantities (incomparisonto flue
gas weight) of unburned hydrogen or other hydrocarbons MqWH2F = 8‘937 IbrnBtu (kg/J) (5.12-3)
are presentin the Rue gas. 100 HHVF
The total gaseous products are referred to as “wet
fluegas.” Solid products, such as ash from the fuel,
unburned carbon, and spent sorbent, are considered 5.12.4 MqCO2Sb - Gas FromSorbent,Ibm/Btu
separately and are not a part of the wet flue gas mass. (WJ)
94

STDmASME PTC 4-ENGL L778 M 0757b70 ObL5035 L44 D
MqCO2Sb =
MFrC02Sb
, lbm/Btu (kg/J) (5.12-4)
MqWFgz = MqWF + MqWvF + MqWH2F
HHVF + MqWSb + MqWAz (5.12-9)
+ MqWAdz, IbmlBtu (kg/J)
5.12.5 MqWSb - WaterFromSorbent, Ibdtu
WJ) 5.12.9 MqFgz - Total Wet Flue Gas Weight,
I b d t u (kg/J). The total wet gas weight at any location
MqWSb = MFrwsb, lbm/Btu (kg/J)
~ (5.12-5) z is thesumofthedry air, moisture in air, wet gas
HHVF from the fuel, gas from sorbent, waterfromsorbent
and any additional moisture:
5.12.6 MqWAz - MoistureinAir,lbm/Btu(kg/J).
Moisture in air isproportionalto excess airandmust MqFgz = MqDAz + MqWAz + MqFgF
be calculatedforeachlocation z where excess airis + MqCO2Sb + MqWSb (5.12-10)
determined. + MqWAdz, Ibm/Btu (kg/J)
MqWAz = MFrWAMqDAz, IbmlBtu (kg/J) (5.12-6) The mass flow rate ofwetflue gas atanylocation
z may be calculated from:
5.12.7 MqWAdz - AdditionalMoistureinFlue
MrFgzQrF
= MqFgz (5.12-11)
Gas, lbm/Btu (kg/J). This item accounts for any mois-
tureadded to the flue gas notaccountedforabove. = MqFgz MrF HHVF, Ibmlh (kgls)
Typical sources are atomizing steam and sootblowing
steam. Additional moisture measuredon a massflow 5.12.10 MqDFgz - Dry Flue Gas Weight, lbm/Btu
basis is converted to a massper unit massoffuel (kg/J). The dry flue gas weight is thedifference between
basis for the stoichiometric calculations. For the initial thewetflue gas andthetotalmoisture:
calculations, either themeasured or anestimatedfuel
rate is used. Where the quantity of additional moisture
is small compared to the total moisture, this is usually
sufficiently accurate. If the efficiency calculations are
reiterated for other purposes,themassfraction of
additional moisture withrespect to massrateoffuel 5.12.11 MpWFgz - MoistureinFlue Gas, percent
shouldbe also corrected: mass. The percent moisture in wet flue gas is required
for determining theflue gas enthalpy:
MFr WA dz
MqWAdz = , Ibm/Btu (kg/J) (5.12-7)
HHVF MpWFgz = 100 -% mass (5.12-13)
MqFgz
5.12.12 MpRsFg - Residue(Solids)inFlue Gas,

MrStz
MFrWAdz = - , Ibm/lbm 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 lb&
MBtu input from fuel or when sorbent is utilized, the
where MrStz is the summation ofthemeasuredaddi- mass of solids in gas should be accounted for:
tional moisture sources entering thesteam generator
upstream of location z, lbm/h. MpRsFgz =
MpRsz MFrRs
% mass (5.12-14)
Moisture due to evaporation of water in the ash pit M q Fgz HH VF’
is considered negligiblewithregard to themassflow
rate of flue gas, and ignored in
this calculation. However, where MpRsz is thepercent of totalresidue (solids)
if measured, it shouldbeincluded here. intheflue gas atlocation z, percent wet gas.
5.12.8 MqWFgz - TotalMoistureinFlue Gas, 5.12.13 DnFg - DensityofWetFlue Gas, lb&
lbm/Btu (kg/J). The total moisture influe 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 L998 m 0759b70 Ohla5036 080 m
ASME FIT 4-1998 FIRED STEAM GENERATORS
for calculationof the flue gas constituents on avolumet- MwFg= molecular weightofwetflue gas, I b d
ric basis and calculation of the density ofmoleair: (kghole)
MwDFg= molecular weight of dry flue gas, I b d
mole (kghole)
DnFgz = c'(c2 Pa PFg), Ibm/ft3 (kg/m3)
+ (5.12-15) P u = 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- (Pa)
TFgz = temperature of flue gas at point z , "F ("C)
Rk=-- R f t . lbf
M w F g ' lbm . R
(-
.K
kg
)J (5.12-16) MoDFg = moles dry gas. Refer to Eq. (5.1 1-18)
for calculation.
MoFg= moleswet gas. Refer to h.(5.1 1-28)
When
flue
the gas constituents have
been calculated for calculation.
on wet
a basis, the molecularweight of wet
flue gas CI = 5.2023 lbf/ft (US Customary), 1.0 J/m3
is calculated as follows: Pa (SI)
C2= 27.68in.wg/psi (US Customary), 1.0
M w F g = 0.32 Vp02 + 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 VpH20, 5.13 AIRANDFLUEGASTEMPERATURE
rnass/mole 5.13.1 TRe - Reference
Temperature,
"F ("C). The
reference temperature is the base temperature to which
Whenthe
flue gas constituents have
been calculated (air, fuel, and sorbent) entering he
on adry basis? the mokcular weight of wet flue gas generator envelope are compared for calculation of
can be calculated as follows: sensiblelosses
heat
and credits. The reference tempera-
ture for this Code is 77°F (25°C).
MwFg = MwDFg
MoDFg
, (5.12-18)
5.13.2 TMnAEn - Average Entering Air Tempera-
MoFg ture, "F ("C). The air temperature entering the steam
generator envelope isrequired to calculate thecredit
Ibm/mole (kghole)
due to the difference between the entering air tempera-
ture and the reference temperature. When air preheating
coils are utilizedand the energy is supplied from
M w D F g = 0.32DVpO2 + 0.4401DVpCO2(5.12-19) outside the envelope, the entering air temperature is
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 DVpH20, tor), the entering air temperature is the temperature
masslmole
entering the air preheating coils (TA7). W h p there is
morethan one fanof the same type, such as two
forced draft fans, it is normally sufficiently accurate
to assume balanced air flows between the fans and use
D V p H 2 0 = 100
MOFg - MODFg, %O2 dry (5.12-20)
the arithmetic average of the air temperatures in each
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 isthat 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-
latedby difference from the total air flow (calculated
96

~~
STDmASME PTC 4-ENGL 3998 m 0759670 Oh35037 TL7 m
stoichiometrically).It should be noted that some amount are repeated until the estimated and cal-
of air(usually not morethan 2 or 3% at full load) culated fuel massflowratesarewithin
enters theunit as leakage throughthe setting andthe 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= totalwet air entering steam generator
infiltration air is considered to enter theunitat the envelope upstream of
location (14),
same temperature as the measurable air streams and lbm/Btu (kglJ)
the uncertainty accounted for in the measurement bias. M r A l l = measured primaryair flow to pulverizers,
Typical examples of units with multiple air sources lbm/h (kg/s)
are pulverized coal firedunitswithcoldprimaryair where secondary air is the only other significant source
fans (TA8A) or pulverizer tempering air supplied from of air, themassflowfraction of theremaining air
the environment ( T A 5 ) . The weighted average air tem- equals (1 - MFrAll ). For the equation above,itis
perature entering the unit TMnAEn, must becalculated: assumedthatthetempering air to thepulverizersis
the same temperature as the air entering theprimary
air heater. Refer to the tempering air calculation below
if itisnot.
For units with hot primary air fans or exhauster fans,
andwherepulverizer tempering air is suppliedfrom
Whenthe entering air temperature atthevarious
the environment (TA5), themass flow rate of the
locations differs significantly, itismore correct to
tempering air may be calculated as follows:
determine the average entering air temperaturefrom
the average entering enthalpy of the entering air:
MrA5
HMnAEn = MFrAzl HAzl + MFrAz2 HAz2 . . . (5.13-2) MFrA5 = (5.13-4)
M q A l 4 M r F H H V F'
+ MFrAzi HAzi, Btu/lbm (J/kg)
Ibm/lbm (kglkg)
where
HMnAEn= average enthalpy of wet air entering the
boundary,Btu/lbm (Jkg). The average
air temperature is determinedfromthe 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 tototal wet air flow
leavingthe steam generator basedon
where
excess air at location (14), lbdlbm
MrAS= pulverizer
tempering air mass flow rate,
(kgkg) lbmh (kg/s)
TAz= temperature ofwet air atlocation z ,
"F ("C) 5.13.3 TFgLvCr - Corrected Gas Outlet Tempera-
HAZ= enthalpy of wet air at temperature TAz, ture (Excluding Leakage), O F ("C). On units with air
Btdlbm (Jkg) heaters, air leakage within the air heater depresses the
For pulverized coal units with cold primary air fans, exit gas temperature withoutperforminganyuseful
themassflowfractionoftheprimary air, MFrAl1, work. For the efficiency calculations, the measured gas
maybe calculated as follows: temperature leaving the air heater must be corrected
to the temperature thatwould exist if therewereno
MrAll airheater leakage, TFgLvCr.
MFrAl1 = (5.13-3) The correction calculation method below utilizes the
MqAl4 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, lbm/h (kg/s). Esti- When there are two or more air heaters with approxi-
mate or use the measuredmass 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

~~~ ~ ~ ~~~
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 primaryandsecondary air heater, the corrected MqFgLv= wet gas weight leaving theairheater
gas temperature must be calculated separately for each from Subsection 5.12.8 using the excess
and a weighted average usedforefficiency. 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), "F ("C). 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, waterfrom fuel
(5.13-6) loss, etc.). On unitswheretheflue gas exits at more
than one location, the weighted average gas temperature
x (TFgLv - TAEn), "F ("C) mustbe determined. The general philosophy for de-
terminingthemassfraction of individual flue gas
streams isthatall gas streams maybemeasured or
some streams maybemeasured (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 ofthesametypeand
Btullbrn F (J/kg K) size, it is normally sufficiently accurate to assume equal
gas flows,andusethe arithmetic average of the gas
temperature leaving each air heater (excluding leakage),
where TFgLvCr. When there is evidence of unbalance,
MnCpA= meanspecificheatof wet air between weighted averages should beused.Forunitswith
TAEn and TFgLv, BtuAbm, "F (Jkg K). multiple air heaters notof the same typewherethe
This is equal to the enthalpy of wet air gas massflow and gas temperature leaving the air
at themeasured 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, "F 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 beincluded in the determination of the average
that calculates specificheat),usethe exit gas temperature.
instantaneous specific heat for the mean The following addresses pulverizedcoalfiredunits
temperature. with separate primary air heater@)(usedtoheatthe
TAEn= air temperature entering the air heater, air to the pulverizers) and secondary air heater(s) and
"F ("C). Location (7), (7A), (8), or @A), is a typical example ofhowthe calculations for two
Figs. 1.4-1 through 1.4-7. For air heaters different types of air heaters mightbehandled. The
thathavetwo air inlets and one gas methodology is based upon measuring the primary air
outlet (a trisector air heater, forexample), flow to the pulverizers and calculating the gas flow
this item is the weighted average of the throughtheprimaryair 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, "F ("C)
air.
TFgLv= gas temperature leavingthe air heater, When there is a significant difference inthe gas
"F ("C). 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 ofthe exiting wetgas:
98

FIRED ASME PM: 4-1998
HMnFgLvCr = MFrFgl4B HFglSBCr measured and conveniently calculated. In the first cate-
+ ( 1 -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 = (5.13-10) In the second category are lossesnotrelated to fuel
MqFgl4 MrF HHVF'
input, which are more readily calculated on an energy
Ibm/lbm (kg/kg) per unit of time basis, such as the loss due to surface
radiation and convection. The losses in eachcategory
are grouped generally in order of significanceand
where
universalapplicabilitywithapplicabilitytakingpref-
HMnFgLvCr=average enthalpy of wet gas leaving the
erence.
boundary (excluding leakage), Btdlbm
The logic for calculating losses thatare a function
(Jkg). The average temperature is deter-
of fuel inputis described below:
minedfromthe average enthalpy.
MFrFgl4B= massfraction ofwet gas entering the
primary air heater to total wet gas enter-
ingthe air heaters, Ibdlbm (kgkg) QpLk = 100 Mqk x (HLvk - HRek) (5.14-1)
MqFgl4 = total wet gas entering air heaters, Subsec- = 100 Mqk x MnCpk X (TLvk - TRe), ?6
tion 5.12.8, lbm/Btu (kglJ)
MrF= fuel massflowrate,lbmlh (kg/s). Esti-
mate or usethemeasuredmass flow
rate initially. Refer to Subsection5.7.3 Ibm constituent
QpLk = 100 x X- Btu x "F (5.14-2)
regarding convergence tolerance. Btufuel input Ibm "F
MrFgl4B= mass flow rate ofwet gas entering the
primaryairheater, lbmh (kg/s). This - Btu loss ,%
item may be calculated by energy 100 Btu In
balance.
where
(HAI1 - HA8A)
MrFgl4B = MrAll (5.13-11) QpLk= loss from constituent k, percent of input
(HFgl4B - HFglSBCr)? from fuel, Btu/100from
input
Btu fuel
(J/lOOJ)
Ibm/h (kgls)
Mqk= mass of constituent k per Btuinput
in fuel. This is theunitsystemused
where
throughout this Code for items that are
MrAll = measuredprimary air massflowrate,
relatedtothefuelsuch as air andgas
lb& (kg/s)
quantities.
HFglSBCr= enthalpy of wet gas for the gas tempera-
TLvk= temperature of constituent k leaving the
tureleaving the primaryairheater ex-
steam generator envelope, "F ("C)
cluding leakage (corrected), usingthe
TRe = reference temperature, "F ("C).The refer-
moisture inwet gas entering the air
ence temperature is 77°F (25OC).
heater
MnCpk= mean specific heat of constituent k be-
HA11 = average enthalpy of wetair entering
tween temperatures TRe andTLvk, B t d
pulverizers. If the pulverizers arenot
lbm, "F (Jkg . K). Whenever practical,
operating at the same primary air flow,
enthalpyisused inlieuof themean
thisshould be a flow weighted average
specific heat and the difference intem-
ratherthan an arithmetic average.
perature.
HLvk= enthalpy of constituent k at temperature
TLvk, Btuhbm (Jkg)
5.14 LOSSES HRek= enthalpy of constituent k at temperature
The calculation of losses falls into two categories TRe, Btuhbm (Jkg). For water thatenters
in accordancewith the method inwhichthey are the steam generator envelope as liquid
99

ASME PTC 4-1998 STEAM FIRED GENERATORS
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 basedon a where
32°F reference temperature for enthalpy. HStLvCr= enthalpy of steam (water vapor) at 1 psia
The enthalpy ofwater at TRe is 45 at temperature TFgLvCr or TMnFgLvCr.
Btu/lbm (105 kJ/kg). For all other con- The enthalpyof steam (water vapor)
stituents, the enthalpy isbasedupon does notvary significantly at thelow
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, specificallycalculating
zero and does not appear inthe loss/ the actual partial pressure of water vapor
credit energy balance equation as shown is notwarranted. Refer to Subsection
above. 5.19.5 for curve fit.
HWvLvCr= enthalpy of water vapor at TFgLvCr or
5.14.1 OpLDFg - Dry Gas Loss,percent
TMnFgLvCr, Btu/lbm (Jkg). The dis-
tinction of enthalpy of steam (HSr) ver-
QpLDFg = 100 MqDFg HDFgLvCr, % (5.14-3) sus the enthalpy of water vapor ( H W v ) ,
is that HSr is the enthalpy of vapor with
where respect to liquid water at 32°F (OOC) as
MqDFg= dry gas mass flow leavingthe steam the reference in accordance with ASME
generator basedonthe excess air at Steam Tables, and includes thelatent
location (13) or (14). Notethatwhen heat of vaporization of water,where
hot air quality control equipment (e.g., HWV is the enthalpy of water vapor with
precipitator) is located between thesteam respect to the enthalpy ofwater vapor
generator exit and the air heater gas at 77'F (25OC) as the reference (which
inlet, there maybe a dry gas loss due is zero). Refer to Subsection 5.19.4 for
to air infiltration. This lossis included curve fit.
in the loss calculated for the hotAQC HWRe= enthalpy of water at the reference tem-
equipment. perature TRe, BtuAbm (Jkg)
HDFgLvCr= enthalpy ofdry gas atthetemperature HWRe= TRe - 32 = 45, Btu/lbm
leaving the boundary corrected for !eak- 5.14.3 QpLWA - LossDuetoMoistureinAir,
age (excluding leakage).Refer to Sub- percent
section 5.19.3 for curve fit.
5.14.2 QpLH2F, QpLWF, QpLWvF - WaterFrom QpLWA = 100 MFrWA MqDAHWLvCr, % (5.14-7)
FuelLosses,percent
where
5.14.2.1 b s Due~ to WaterFormedFromthe MqDA = mass of dry air corresponding to the excess
Hz
Combustion ofFuel
the in air used for dry gas loss, Ibm/Btu (kg/J)
5.14.4 QpLSmUb - Summation of LossesDue to
QpLH2F = 100 MqWH2F (HStLvCr - HWRe), % Unburned Combustibles, percent. The loss due to
(5.14-4) unburned combustibles theis sum of
the applicable
losses for the individual unburned constituents.
5.14.4.1LossDue to UnburnedCarboninResi-
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 theheatingvalueofcarbon as it
occurs in residue.
5.14.23 Loss DuetoWaterVaporina Gas- Whenunburnedhydrogen in the residue is considered
mus Fuel (normal
insignificant case, refer hydrogen
to unburned
100

STO-ASME PTC 4-ENGL L998 m 0759b70 Ob1504L 448 m
FIREDSTEAM GENERATORS ASME R C 4-1998
below), a value of 14,500 Btu/lbm (33,700 l d k g ) 5.14.4.4 Loss Due to PulverizerRejects,percent.

should be used for HHVCRs. Any unburned carbon is mis loss includes the chemical and sensible heat loss
expected to be in an amorphous form. The NBS Techni- 1,n pulverizer rejects:
cal Nores does not list the heat of formation of carbon
in the amorphous form; onlythe heats offormation
of carbon in the graphite and diamond forms ire listed QpLPr = 100 MqPr (HHVPr + HPr), % (5.14-1 1)
[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 inthe residue andisaccounted for MrPr
separately, a value of 14,100 Btu/lbm (32,800 I d 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 “Pr= measuredmass flow rate of pulverizer
established that unburned hydrogenis present and cannot rejects, lbmh (kg/s)
be eliminated by operating adjustments: HHVPr = higher heating valueof pulverizer rejects
fromlaboratory analysis of representa-
MrRs MpH2Rs HHVH2 tive sample, BtuAbm (Jkg)
QpLH2Rs = ,% (5.14-9)
MrF HHVF HPr= sensible heat or enthalpy of pulverizer
rejects leaving the pulverizer, Btdlbm
where MpH2Rs isthemassweighted average ofun- (Jkg). Usetheenthalpy ofash at the
burnedhydrogen in residue,percent,and HHVH2 = mill outlet temperature.
61,100 Btu/lbm (142,120 l d k g ) .
5.14.4.5 Loss Due to Unburned Hydrocarbons in
5.14.4.3 Loss Due to CarbonMonoxideinFlue Flue Gas, percent. Where it is established that unburned
Gas,percent hydrocarbons are present and cannot be eliminated by
operating adjustments:
HHVCO %
QpLCO = DVpCO MoDFg MwCO - HHVHc
HHVF QpLUbHC = DVpHc MODFg MWHC - ,%
HHVF
or (5.14-10)
or (5.14-13)
HHVCO %
QpLCO = VpCO MOFR MwCO ~
HHVHc
HHVF ’ QpLUbHc = VpHc MOFg MWHC ~
HHVF ’
where where
DVpCO= quantity of CO measured on a dry basis, DVpHc= quantity of hydrocarbonsinflue gas
percentvolume measured on a dry basis, percent volume
VpCO = quantity of CO measured on a wet basis, VpHc= quantity of hydrocarbons influe gas
percentvolume measured on a wet basis, percent volume
MoDFg= moles of dry gas with excess air mea- HHVHc= higher heating value of thereference gas
suredatthesamelocation as the CO, used to determine the volume percentage
moles/lbm fuel (moleskg). Refer to Sec- of total hydrocarbons, BtuAbm ( J k g )
tion 5.11 for calculation.
MoFg= moles of wet gas with excess air mea- 5.14.5 QpZXs - Loss Due to SensibleHeat of
suredatthe same location as the CO, Residue,percent. For unitswith a wet furnace ash
molesAbm fuel (moleskg). Refer to Sec- hopper,refer to Subsection 5.14.13:
tion 5.11 for calculation.
MwCO= molecularweight CO, 28.01 lbdmole QpLRs = 100 ZMqRsz
HRsz, % (5.14-14)
(kg/mole)
HHVCO= higher heatingvalue
of CO, 4,347 where
BtuAbm (10,111 kJkg) MqRsz = mass flow rate of residue at locationz, 1bmBtu
101

STD.ASME PTC 4-ENGL 3998 0759b70 Ob35042 384 m
(kg/J) from Section 5.10. For units with a wet 5.14.7 &Z.,AZg- Loss Due to Air Infiltration,
furnace ashhopper, when thetotal 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 fluegas inlet, excluding
sensible heat of residue totheashhopper air infiltration in hotAQC equipment which is accounted
should be omitted here. Whenthe loss due for separately:
toradiationtothe wet ashpitis estimated,
QrLRsAp, the loss due to sensible heat in QpLALg = 1O0 MqALg (HALvCr (5.14-16)
residue leaving theashpit is calculated in
accordancewiththisparagraph. - HALgEn), %
HRsz= enthalpyofresidue at location z, Btdlbm
(Jkg). For locations other thanbottom ash, where
theresiduecan 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.
(1,100°C) ifnotmeasured. For wetbottom HALgEn = enthalpy of infiltrating wet air, normally
ash, a typical enthalpy of 900 Btdlbm (2,095 air inlet temperature, Btdlbm (Jkg).
kJkg) isrecommended.Refer to Subsection
5.14.8 &LIVOX - Loss DuetotheFormation of
5.19.3 for curve fit.
NO,, percent. This item refers to the loss associated
withthe formation of NO, during the combustion
5.14.6 lzpLAq - Loss From Hot Air Quality Con-
process. This loss isusuallysmall, 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 hotprecipitator. The calculationbelow is thetotal the analyzer converts the NO2 inthe gas sample to
NO and gives a totalreading of NO, as NO. The
ofthedry 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.RefertoAppendix C for derivation. based on theheatof 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)
theheatof formation of N 2 0 in the equation below:
- (MqFgLv - MqFgEn) (HAAqLv HrNOx
- HALvCr)], % QpLNOx = DVpNOx MoDFg - (5.14-17)
HHVF
HrNOx
where or VpNOx MoFg - ,%
HH VF
MqFgEn= massofwet gas entering with excess
air entering, Ibm/Btu (kg/J)
MqFgLv= mass of wet gas leaving with excess air HrNOx
leaving,Ibm/Btu (kg/J) QpLNOx = 100 MqNOx ~ ,% (5.14-18)
MwNOx
HFgEn = enthalpy ofwet 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- percentvolume. NO, is normallymea-
tentleaving,Btu/lbm (Jkg) sured on a ppm basis. Divide by 10,OOO
HAAqLv= enthalpy ofwet air at a temperature to convert to percent.
corresponding to the gas temperature VpNO,= quantity of NO, as NO on a wet basis,
leavingthe hotAQC device, Btu/lbm percentvolume
(JW MqNO,= quantity of NO, expressed on an energy
HALvCr= enthalpyof wet air atthe average gas basis, Ibm/Btu(kg/J).Whenexpressed
temperature (excluding leakage) leaving on an energybasis,theunitsused are
the steam generator envelope, Btu/lbm usuallyMBtu(J). Divide by 1E6 to
(J49 convert to Btu (J).
102

STDmASME PTC 4-ENGL 1998 m 0759670 Ob15043 210 m
MoDFg= moles ofdry gas with excess air mea- Hraz = 0.841 + 2.367E-3 TDi (5.14-21)
sured at the same location as the NO,, + 2.94 E-6 TDi2 + 1.37E-9 TDi3
moles/lbmfuel (moleskg)
MoFg= moles ofwet gas with excess airmea-
sured at the same location as the NO,, where
moledlbm fuel (moleskg) Hcaz= convectionheattransfercoefficient 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- usedinthis correlation arebasedupon

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 biasuncertainty for the correlation of
(kg/mole). The molecular weight of N 2 0 +20% is suggested.
is 44.013 lblmole (kg/mole). Hraz = radiation heattransfer coefficient for area
z, Btu/ft2 . h . F. The constants used in
5.14.9 QrLSrc - Loss DuetoSurfaceRadiation thisequationarebaseduponusingUS
and Convection. This loss is determined indirectly by Customary Units ("F). This correlation
measuring2 the averagesurface temperature of the steam is basedonanambient temperature of
generator andthe ambient conditions near it. Surface 77°F (25OC) and an emissivity of 0.80.
temperature, ambient temperature, and ambient air ve- A biasuncertaintyfor the correlation
locityshouldbedetermined at a sufficientnumberof of 220% is suggested. The uncertainty
locations to determine representative averagevalues. 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 ontheactualareaof the support steel.
unitandthestandard surface and ambient conditions Afz= flat projected surface area of the casing/
described below. The parties to thetest shall decide lagging over the insulation (circumferen-
whether to measure thesurface and ambient conditions? tial area for circular surfaces) for location
including thenumberandlocation of measurements, z, ft2. For protuberancessuch 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 specifiedfor face adjacent to the hot surface is to be
design of unit insulation shall not be permittedfor included in theflatprojected surface
loss evaluation; test conditions or thestandardvalues area. The areas to be considered are the
specifiedhereinaretheonly allowable options. steam generator, fluesand ducts within
The loss is calculated by: theenvelope,majorpiping(Le., size
with respect to the steam generator), and
QrLSrc = C1 2 (Hcaz + Hraz) Afz (TMnAfz majorequipment such as pulverizers.
Hot air quality control equipment (such
- TMnAz), B t d h (W) (5.14-19) as hot precipitators) shouldnotbein-
cluded if this loss is accounted for sepa-
rately.
where
T M d f z = average surface temperature of area z
T M d z = 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
~ tureisthetemperaturewithin 2 to 5 ft
of thesurface.
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, ftl
notprecludeestimation of parameters by qualifiedpersonnel. sec (m/s)
)It is not mandatory that this test be performed in conjunction with
theefficiency test. Itmaybeperformedseparately to establishthe
CI = 1.0 (US Customary Units); CI = 0.293
actual
setting
heat and
loss results
the
corrected
standard
to or W NBtu (SI Units).
guaranteeconditionsinaccordancewithSection 5.18 for use with If values for TA$ TA, and VA arenotmeasured,
an efficiencytestperformed at a differenttime. When so used, the
corrected QrLRc results
shall
criteria
meet
the for repeatability in this loSS be using the
Section 3. values:standardfollowing the areas and
103

'STDmASflE PTC 4-ENGL L778
(a) VA = 1.67ft/sec (100 fdmin); 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 thesituationwarrants 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 areused,
a biaslimit of rf: 50% is suggested for QRLRC.
QrLWSb = MrWSb (HStLvCr - HWRe), (5.14-24)
5.14.10 QrLWAd - Loss DuetoAdditionalMois-
ture, Btuh (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
moistureareatomizingand soot blowing steam. It is 5.14.13 QrLAp - WetAsh Pit Loss, Btu/h(W).
noted that when air is utilized as the atomizing or soot Onunitswith a wet ash pit,there is a loss due to
blowingmedium, the loss is included inthedry gas heat absorbed. by the water from radiation through the
andmoisture in air loss since it is includedin the furnace hopper throat, in addition tothe sensible heat
measured O2 in theflue 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 leavingtheash pit.
MrSrz= mass flow rate of additional moisture at Due to thedifficulty of determining themass flow
location n, lbmh (kg/s) rate of the residue leaving the ash pit and the uncertainty
HStLvCr= enthalpyof steam in gas leavingthe 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). RefertoSubsection 5.14.2. for estimating this loss is described in Subsection
HWRe= enthalpy water at the reference tempera- 5.14.13.2
ture, Btdlbm (J@)
5.14.13.1 QrLAp - Wet AshPit Loss When
5.14.11 QrLCZh - Loss Due to Calcinationand Tested. By energy balance, the ash pit loss is the sum
Dehydration of Sorbent, Btuh (W) of theenergygain by the water leaving the ash pit,
energy loss due to evaporation of pit water and sensible
QrLCIh = L? MrSbk MFrCIhk Hrk, heatinthe residue/water mixture as it leavesthe 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, lb& (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 ofcalcium or magnesiumhy-
droxide
Caco, (Cc) 766 Btu/lbm (1,782 kJkg) 5.14.13.1.1EnergyIncreaseinAshPitWater
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)

~
~
STD-ASME PTC 4-ENGL L998 m 0759670 ObL5045 093 m
FIREDSTEAM GENERATORS ASME PTC 4-1998
5.14.13.1.2 Loss DuetoEvaporation of Pit QrLRy = QrLRyRs + QrLRyFg, Btu/h (W) (5.14-30)
Water
5.14.14.1RecycledSolids. Residue may be recy-

(5.14-27)
cled to utilizeunburned carbon intheresidueand/or
+ MrRsW37 ( I M+FrMjWRs
WRs
)) (HSrLvCr reducetheamount of sorbentadded. If the recycle
piping and hold up bins are included in the area used
to calculate the surface radiationandconvection loss
- HW38), B t d h (W)
(QrLSrc), Subsection 5.14.9, thenthiscalculation is
omitted.
5.14.13.1.3
Sensible
Heat
in ResidueNater
MixtureLeavingtheAshPit QrLRyRs = MrRyRs (HRsLv - HRsEn), (5.14-31)
Btu/h (W)
37
QrRsWLv = MrRsW (HRs37
1 + MFrWRs where
MrRyRs= mass
flowrateofrecycled 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
mittedtothe steam generator, Btdlbm
MrRs W37= mass flow rate of the residue/water mix-
tureleavingtheash pit, Ibmh (kg/h) (JA&
MFrWRs= mass fraction of water in residue in the 5.14.14.2RecycledGaseousStreams. An example
residue/water mixtureleavinglocation of a recycledgaseous stream isflue gas recirculation
(37), Ibm H20/lbm dry residue (kgkg) after the air heater (typically ID fan gas recirculation).
HRs37 = enthalpy of dry residueat 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
HWz= enthalpy of water at location z, gaseousstream is differentfromthe excess air upon
BtuAbm (Jkg) whichthedry gas weightisbased.
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 duetoradiation to the ashpitmaybe Btu/h (W)
estimated. Whenthe loss due to radiation to theash
pit is estimated, the sensible heat in residue loss must where
also be calculated (estimated) in accordance with Sub- MrRyFg= mass flow rate oftherecycled gas,
section 5.14.5. lb&(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 fluegas entering
QrAp= equivalent heatflux through furnace hopper the steam generator, Btdlbm (Jkg)
opening absorbed by ash pitwater.Based
5.14.15 QrLCw - Loss From Cooling Water, Btu/h
onlimiteddata of apparent water usage,an
(W). This loss occurs when cooling water (external to
estimated equivalent heat flux of 10,000 B t d
thesteam generator steadwater circuits) removes en-
ft2h (31,500 W h 2 ) is recommended. A bias
ergy from the steam generator envelope. Typical equip-
limit of ?50% issuggested.
mentthatuses cooling water are watercooled doors,
ApAf= flat projected area of hopper opening, ft2 (m2)
ash coolers, and boiler circulating pumps. Care should
5.14.14 QrLRy - Loss FromRecycledStreams, betakennot 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 uponthe temperature
sum of the loss due to recycled solids and recycled gas. of residue entering the ash cooler, therewouldbeno
105

loss associated withthe ash cooler; however, if the QpBDA = 1 0 0 MqDA HDAEn. % (5.15-1)
temperature of theresidue is measured after the ash
cooler, the energy absorbed by the ash cooler must be where
added to thesteam generator losses: MqDA = total dry air entering the steam generator
corresponding to the excess air leaving
QrLCw = ZMrCwn (HWLv - HWEn), (5.14-33) the boiler used to calculate dry gas
Btulh (W) weight,Ibm/Btu (kg/J)
HDAEn= enthalpy ofdry 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 theweighted average of the
various sources of the airflow contribut-
5.14.16 @ Z A C - Loss Due to InternallySupplied 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 issupplied 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 thatportion of the air
sate flow from the air preheat coils and the difference entering the steam generator.
in enthalpy ofthe air preheat coils condensate and
entering feedwater. The condensate flow should not be 5.15.2 @BWA - Credit Due to Moisture in Enter-
included intheboiler output: ingAir,percent
Q r U c = MrSt36(HW36 - HW24), (5.14-34) QpBWA = 100 MFrWA MqDA HWvEn, % (5.15-2)

Btulh (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
InputFuelBasis. The loss calculated on a rate or generator envelope (TMnAEn),
unit of time basis may be used to calculate efficiency. Btu/lbm ( 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 - CreditDue to SensibleHeatin
calculations usingthe calculated fuelinput: Fuel,percent
(5.14-35) QpBF = -loo HFEn, % (5.15-3)

HHVF
where
5.15 CREDITS HFEn = enthalpy of the fuel at thetemperatureof
fuel entering the steam generator envelope at
As in the loss section, the calculation of credits falls
locations (l), (3), or (4), Btdlbm ( J k g )
into two categories in accordance withthemethodin
whichthey are measured and conveniently calculated. 5.15.4 QpBSIf - Credit Due to Sulfation, percent.
In the first category are those credits that can be readily Sulfation isthereaction of sulfur dioxide (SO,) with
expressed as a percent of inputfrom fuel, such as calcium oxide (Cao) and oxygen to form calcium
energy in entering air; and second, thosewhich are sulfate (Caso,). The reactionis 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 -HRSIJ; % (5.15-4)
HHVF
ofsignificanceanduniversal applicability, withthe
latter taking precedence.
where
5.15.1 @BDA - CreditDue to Entering Dry Air, HrSlf= heat generated in the reaction of sulfur dioxide,
percent oxygen, and calcium oxide to formcalcium
106

STD-ASME
PTC
4-ENGL 1998 m 0759b70 Ob15047 9bbW
sulfate perpound of sulfur capture, 6,733 5.15.7 QrBWAd - Credit Due to Energy Supplied
BtuAbm (1 5,660 kJkg) by Additional Moisture, Btdh (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, Btdh (W). Typical auxiliary equipment in- QrBWAd = ZMrStz (HSrEnz - HWRe). (5.15-8)
cludes pulverizers, gas recirculating fans, hotprimary Btuth (W)
air fans, and boiler circulating pumps. Note that credits
shall notbe calculated for forced draft fans, cold where
primary air fans, and other equipment when credits are MrSrEnz= mass flow rate of additional moisture,
calculated basedonthemeasuredfluid temperature Ibmh (kg/s) atlocation 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, Btdlbm (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,addingthe 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 ForSteamDrivenEquipment 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 usingthe calculated fuelinput:
where QrBk
QpB = 100 -, % (5.15-9)
HSrEn= enthalpy of thesteamsupplied 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
E X = overall drive efficiency, percent; includes tur-
of the precisionindexand degrees of freedom for
bineand gear efficiency
individual parameters.This Section presents calculations
5.15.5.2 ForElectricallyDrivenEquipment for overall precision index and degrees of freedom for
the test. This Section also presents calculation methods
EX for sensitivity coefficientsandtheprecision and bias
QrBX = QX Cl -, B t d h (W) (5.15-6)
1O0 components of uncertainty. For post-testuncertainty
calculation, all steamgenerator performance calculations
where must be complete prior to the beginning of the uncer-
QX= energyinput to the drives, kWh (J) tainty calculations presented in this Section. The uncer-
E X = overall drive efficiency, percent; includes such tainty calculations presented in this Section, as well as
items as motor efficiency, electric and hydrau- thosepresented in Subsection 5.2.3,can be used for
lic coupling efficiency, and gear efficiency pretest as well as post-testuncertainty analysis.
CE= 3,412 Btu/kWh (1 J/J) The pretest uncertaintyanalysis can provide important
information and reduce the effort required to calculate
5.15.6 QrBSb - CreditDue to SensibleHeatin uncertainty after completion of a performancetest.
Sorbent,Btu/h (W) Referto Section 7 for additional guidanceonpretest
uncertainty analysis. The majority of bias limit estimates
QrBSb = MrSb HSbEn, Btuth (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
MrSb= mass flow rate of sorbent, Ibmh (kg/s) estimates oftheparameterstandard deviation andde-
HSbEn=enthalpy of the sorbent entering the steam grees of freedom can be used to determine the frequency
generator envelope, BtuAbm (Jkg) andnumber of measurementsrequiredfor a given
107

ASME PTC 4- 1998 RRED STEAMGENERATORS
variable during the test. This Code does not require a RECALEF - EF
ASENSCO = (5.16-2)
pretest uncertaintyanalysis;however, it is important CHGPAR
to notethatwaitinguntil after a performance testis
complete to calculate uncertaintycan result in actual where
test uncertainties in excess of expected or agreed upon ASENSCO = absolute sensitivity coefficient for a mea-
values. sured parameter, percent efficiencyper
This Section provides general guidelines for calculat- measuredparameterunits
ingtheuncertaintyassociatedwith a steam generator EF= steam generator fuelefficiency, calcu-
performance test. A more detailed description of uncer- lated for the actual (measured) parameter
taintyanalysis calculations alongwith derivations is RECALEF = recalculated steam generator fuel effi-
included in Section 7, which should be reviewed prior ciency using (X + CHGPAR) or (U +
to beginninganyuncertainty calculations. CHNGPAR) in place of X (or U >while
5.16.1SensitivityCoefficients. Sensitivity coefficients all other measuredparameters are held
represent the absolute or relative effect of a measured fixed
parameter on the calculated steam generator efficiency. Inno case shall an absolute sensitivity coefficient
Sensitivity coefficients can also be used for determining smaller thanthe 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- vergencetolerance.
minewhat parameters havethelargest impact onthe The above equation gives the sensitivity coefficient
desired result (e.g., efficiency, output, gas temperature). associatedwith steam generator efficiency.However,
Sensitivitycoefficients are calculated by arbitrarily thisform of equation can be used for any calculated
perturbing the value of a parameter. The change in the result such as output, fuelflow, calciudsulfur 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) or each measured parameter from the following equation:
CHGPAR = (5.16-1)
1O0
(ASENSCO XA V E )
(PCHGPAR v) RSENSCO = or (5.16-3)
PFE
1O0
(ASENSCO v)
where PFE
CHGPAR= incrementalchange in thevalue of a
measuredparameter
PCHGPAR= percent change in the value of a mea- where
sured
parameter. The recommended RSENSCO= relative sensitivity coefficient for a mea-
valueof 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- 5.16.2PrecisionIndexand Degrees of Freedom.
itycoefficients, care must be taken to The precision index of the calculated steam generator
useunitsthatwill not be zero such as efficiency is obtained by combining theprecision in-
absolute temperatureandpressure. dexes of all measured parameters according to the root-
U = integrated average value of a measured sum-squarerule:
parameter. Refer to note above regard-
ing units. N
Alternatively,such as when XAVE is very small or PIR = (ASENSCOiPIi)2]"2 (5.16-4)
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

STD*ASMEPTC4-ENGL 1998
FIRED STEAM GENERATORS ASME F’TC 4-1998
ASENSCOi = absolute sensitivity coefficient for mea- TABLE 5.16-1

suredparameter i TWO-TAILED STUDENT’S t-TABLE FOR THE
N = number of measured parameters 95% CONFIDENCE LEVEL
The numberof degrees of freedom for theoverall
test result is calculated from the following equation:
Degrees of
Freedom
1
t
12.706
I
2.120
Degrees of
Freedom
16
t
PIR~ 2 4.303 2.110 17

DEGFREER = N (5.16-5)
3 3.182
x (ASENSCOiPIi)4
i=I DEGFREE,
4
5
2.776
2.571 2.086
18
19
20
2.101
2.093
where 6 2.447 2.080 21

DEGFREER =overall number of degrees of free- 7 2.365 2.074 22
domfortest 8 2.306 2.069 23
9 2.262 2.064 24
DEGFREE, =degrees of freedom formeasured 10 2.228 2.060 25
parameter i
11 2.201 2.056 26
5.16.3PrecisionComponent of Uncertainty. The 12 2.179 2.052 27
precisioncomponent of uncertainty is calculated2.160
from 13 2.048 28
theprecisionindexand degrees offreedom of2.145the 14 2.045 29
result usingthe following equation: 2.131 15 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 arethe same as theunits of the
STDTVAL = two-tailed Student’s r-value. measuredparameter.
The two-tailed Student’s r-value is based on the 95th BZASj= biaslimitof individual components used to
percentile point distribution and the degrees of freedom determine thevalue of parameter i. Refer to
of the result. Table 5.16-1 shows the Student’s r-value noteonunitsabove.
as a function of degrees of freedom. Interpolation in M = number of components inthemeasurement
the table is done using reciprocal degrees of freedom. system of parameter i
A curve fit for r is:
NOTE: “Measure” and “measurement syjtem” are used in a general
sense and do not excludeestimation of parameters.
2.3717 3.1213
r = 1.9588 + -I- (5.16-7)
DEGFREE DEGFREE2 5.16.4.1
Bias
Limit
Associated With Spatially
0.7993 -I- 4.4550 NonuniformParameters. The bias limits associated
+ with spatially nonuniformparameterswhichvary 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 associatedwiththesetypes
tions are estimated based on the method used to deter- of parameters. These modelsuse a variable called
mine the valuesof a measured parameter. Recommended Spatial Distribution Index (SDZ). Spatial Distribution
procedures for estimating bias limits are presentedin Index is calculated from thefollowingequation:
Sections 4 and 7. Elementary bias limits for each
measuredparameter are combined according to the
root-sum-square rule:
1 (5.16-9)
(5.16-8)
Eq. (5.16-10) issuggested for multiple midpoint

where average:
109

SDI recommendations in Subsections 3.2.5.2, 3.2.5.3, and

Multiple Midpoint BIAS; = (5.16-10) 3.2.6.
( N - 1)’
~
5.17.1PeakCapacity. Peak capacity isdefined as

where themaximum steam mass flow rate, at a specific
SDI = spatial distribution index pressureand temperature, thatthe steam generator is
N = number of points in the measurement grid capable of producing {includingspecifiedblowdown
z = time averaged valueof the measured parameter and auxiliary steam) for a limited time period without
Z= integrated average value of z damaging the steam generator components.
It shouldbenotedthat although SDI is calculated Peak capacity can be either measured directly (MrS231
identically to standard deviation, thereis a significant for saturated steam generators, “932 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 limitof heater water, andblowdownmass flow rates.
a resultis also calculated according totheroot-sum- When desuperheater waterflowisnot measured, it
square rule: may be determined by an energy balance. When blow-
down flow is not measured, it may be determined from
i=l
(ABSENCO;
BIAS;)* 3’” (5.16-11)
the setting of a calibrated valve or by energy balance
around a blowdownheat recovery system.
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 testresult agreedupon:
The biaslimit of the result can be positive andor
negative. If thepositiveandnegativebias limits are Duration of the “limited time period.”This determines
not symmetrical, the positive and negative values must the minimum run time.
be calculated separately. The signof the product Steam pressure and temperature for superheated steam
(ABSENCO, x BIAS,) determines whetherthetermis generators
summedwiththepositive or negative bias limits. Steam pressure for saturated steam generators
Feedwater pressure and temperature
5.16.5TotalUncertainty. The totaluncertaintyof a Blowdown rate
testiscalculatedfrom the overall testprecisionaqd
components:
limit bias Temperature.
Steam
5.17.2 required
Data for the
determination of superheater and/or reheater steam tem-
UNC = ( U P @ + BIASR~)’/Z (5.16-12) perature characteristics and control ranges are given in
Table 4.2-4.
where 5.17.3Pressure Loss. Instruments andmethodsof
UNC= total uncertainty measurement for steam and water differential pressure
The uncertainty be separately tests, Le., pressure loss across the steam generator or
for bothpositiveand negative ranges if the biaslimits a particular section of the generator, are given
arenotsymmetrical. 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
5.17OTHEROPERATINGPARAMETERS section of the generator, are given in Subsection 4.5.3.
It is sometimes desirable to test a steam generator 5.17.4StaticPressures. Instruments and methodsof
for performanceparameters other than rated capacity measurement for steam water static pressure tests are
andefficiency. This Section covers suchtests. given in Subsection 4.5.4. Instruments and methods of
Instrumentsto be used,methods of measurement, measurement for air and gas static pressure tests are
and acceptablevalues for uncertainty of results shall given in Subsection 4.5.3.
be the subject of pretestagreements. Instruments and
methodsofmeasurement 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 mentsand methods of gas temperature measurement
thetests, particular attention shouldbe given to the are given in Subsection 4.4.3.
110

STDmASME PTC
4-ENGL 1998
FIREDSTEAM GENERATORS ASME FTC 4-1998
Computational procedures for obtaining the corrected 5.18CORRECTIONSTOSTANDARDOR

gas outlet temperature (TFgLvCr) are given in Subsec- GUARANTEECONDITIONS
tion 5.18.2. Computational procedures for obtaining the
average exit gas temperature (TMnFgLvCr) aregiven It isusuallynotpossible to test a unitwiththe
standard or guarantee fueland at the exact standard
in Subsection 5.13.3.
or guarantee operating conditions. By correcting the
5.17.6AirLeakage or AirInfiltration. 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 moremeaningfulcomparisonand
or infiltrationthroughthe steam generator casing, or evaluation ofefficiencyandperformance.
any section of the casing downstream ofthe furnace The corrections to efficiency described in this Section
exit, is accomplishedby comparing excess air or air specifically address efficiency calculated by the energy
mass flow rate. Data required for excess air determina- balance method. Subsection 5.18.10discusses correcting
tion are given in Table 4.2-9. Excess air and mass flow input-output efficiency testresults to contractconditions.
rate computational procedures are givenin Section 5.1 1. Corrections to efficiency described in thisSection
The amount of air infiltration, or leakage, is expressed consist of usingthestandard 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 (XpAz2 - X p A z l ) , % (5.17-1)
and repeating the efficiency calculations utilizingthe
standard or guarantee fuel and other operating variables
describedbelow. The corrections describedhereinare
where
for themostcommonvariables. In accordancewith
M p A h L g = mass percent air infiltration
Subsection3.2.3,the parties to thetest shall agree
XpAz2 = mass percent of excess air at the down-
upon other corrections for a specificunit,including
stream sampling location
correction curves.
XpAzl = masspercentof excess air at theup-
The corrections address off-design test conditions,
stream sampling location
notchanges in load. Variations betweenthetargeted
The previousparagraphaddressed calculating air
test load and actual test load should not be more than
infiltrationbetweentwo points wherethe O2 inthe
5%. It is expected that the difference between the test
flue gas canbemeasured entering and leavingthe
efficiencyand corrected efficiencywillusuallybe no
section in question, for example, a hot precipitator. On
morethantwo to threepercentage points.
unitswith recuperative air heaters (air to gas heat
exchangers), the setting infiltrationbetween the air
heater air exit and the pointofmeasuring O2 in the 5.18.1 Entering Air Temperature. Corrections to the
flue gas canbe calculated. The combustionairflowto credits for changes in test entering air temperature to
theburners(andpulverizers, if applicable) can be standard or guarantee conditions are made by substitut-
calculated by energy balance aroundtheairheater ingthe standard or guarantee temperature for thetest
basedonthe flue gas flow entering the air heater(s) temperatureinthe applicable credit equations.
andmeasured air and gas temperature entering and
leavingtheair heater(s). Setting infiltrationbetween
5.18.2Exit 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 thecorrected 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.
mentandthe wet airflowleavingtheair 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 morethan one air heater ofthe same type, it is may be corrected based upon themanufacturer’s correc-
usuallysufficiently accurate to assume equal flows tion curves for deviations from design conditions if
betweenthe air heaters. If gas flow or airflowis 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 pulverizedcoalfired (refer to Subsection 5.18.3)might include deviations
unitswith cold primary air systems, refer to Section from design fuel, significant difference in entering air
5.1 3 for calculation of air and gas weights. temperature, and feedwater inlet temperature.
111

~~~
STDmASME PTC CI-ENGL L778 m 0757b70 Ob15052 223 m
5.18.2.2 Units With Air to Gas HeatExchanger TDiTAEn = (5.18-2)

Type AirHeater(s). The exit gas temperatureshall
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)
fromstandard or guarantee conditions. The parties to
thetest may agree to use PTC 4.3, Air Heaters, as - TFgLvCr, "F ("C)
described below, or a different model if the corrections
describedcan be accomplished: where
TAEnd= design entering air temperature, "F ("C).
Refer to Subsection 5.18.1.
TAEn= air temperature entering air heater(s),
TFgLvCrd = TFgLvCr + TDiTAEn + TDiTFgEn "F ("C)
TFgEn= gas temperature entering air heater(s),
+ TDiMrFgEn + TDiXr, "F ("C) (5.18-1) "F ("C)
(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, "F ("C) 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 andused for calculation drop across the terminalpoints shall be used to determine
of efficiency(as tested), "F ("C) the corrected air heater entering gas temperature based on
TDiTAEn= temperature correction for entering air the measured gas temperature entering such equipment.
temperature, "F ("C) (2) Feedwater inlet temperature. The entering feed-
TDiTFgEn = temperature correction for entering gas water temperature is significantlydifferent from the stan-
temperature, "F ("C) dard or guarantee conditions.
TDiMrFgEn = temperature correction for entering gas (3) Deviations from contract fuel. The test fuel is
massflow, "F ("C) significantly different from the contract fuel.
TDiXr= temperature correction for off-design X- The exit gas temperature correction due to off-design
ratio, "F ("C) entering gas temperature may be calculated fromthe
PTC 4.3-1968, Air Heaters, does not covercorrections following equation:
to trisector air heaters (partitioned sections to separate
primaryand secondary air). Until PTC 4.3-1968, Air
TDiTFgEn = (5.18-3)
Heaters, is revised,this Code will handle the corrections
as astandardbisector 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, "F ("C)
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 temperatureleavingthe air design conditions, "F ("C)
heater is required for some calculations such as pulver- (c) Entering Gas Mass Flow. For determining cor-
izer temperingairflow 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 thegas mass flow enter-
to assume the primary and secondary air temperatures ing theair heater for the test conditions and thegas 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 betweenthe steam generator air
The terms for Eq. (5.1 8-1) 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 inwhichthetested air infiltration across
112

~~~
STD-ASME PTC 4-ENGL L998 0759b70 0635053 LbT W
FIREDSTEAMGENERATORS ASME F'TC 4- 1W8
the equipment may be different than specified. The air flow and corresponding corrected secondaryairflow
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 withefficiencyand 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 shouldbe repeated untilthe 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- Corrections f o r Pulverizer Tempering Airflow, Units
(j)
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 flowand
operation); thus, no correction is requiredfor 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 isused to correct the secondary airheater izer tempering airflow 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 arecontrolled to a fixed exit gas tempera-
thetest should agree uponhowto determine the split ture. The parties to the testshall agree upon thecontrolled
betweenthe 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 theairheatervendor. the primary airflow tothe 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 HAI 1d - HA8Ad
generator output. The most typical reason for the heat MrFgl4BCr = MrAIl
HFgl4Bd - 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 pulverizertemperingairflow.For where
units with separate primary and secondaryair heaters (as MrFgl4BCr= corrected mass flow rate offlue 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 M r A l l = primaryairflow entering pulverizers,
to pulverizer tempering airflow are not required because Ibm/h (kg/s)
ofthe difference inthemoisturebetweenthetestand H A l l d = enthalpy of the design air temperature
contract coal, it is recommended for simplification of the entering the pulverizer, Btu/lbm (Jkg)
calculations that the test X-ratiobe 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, Btu/lbm (Jkg)
mary air heater correction. Subparagraph (f) below ad- HFg14Bd= enthalpy of the design gas temperature
dresses calculation of corrected pulverizer tempering airentering the primary air heater,
flow and corrected mass flow rate of flue gas entering Btu/lbm (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 heatervendor. leakage), Btu/lbm (Jkg)
( e ) Corrections for PulverizerTemperingAirflow, This energy balance procedure is onlyvalid 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 higherthan the desired control exit gas temperature,
on the corrected conditions. A corrected tempering air- the actual air temperature leavingwillbe lower than
113

STDmASME PTC 4-ENGL L998 m 0759h70 Ob15054 OTh m
ASME F'TC 4-1998 FIRED STEAM GENERATORS
the required pulverizer inlet temperature. This indicates water in coal) the pulverizer tempering airflow and air
thatthe air heater is not capable ofperforming in heater performance shouldbe corrected for themill
accordance with the energy balance, andthe 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 heatermodel. required unless tempering air is utilized during the test.
The parties to thetest shall agree uponwhetherthis
5.18.3FuelAnalysis. Corrections to credits, losses correction is required, and if it is required, either agree
(efficiency),and air andflue gas mass flow rates for upon a design mill inlet air temperature or a method
differences in fuel constituents betweenthetestand of correcting thetest mill inlet temperature for off-
contractfuelaremadebyutilizingthestandard or design moisture in coal.
contract fuel analysis inthe applicable computations.
Corrections to air heater performance for pulverized 5.18.4 Sorbent Analysis and Sorbent Reactions. The
coalfiredunits (units with controlled air temperature actual sulfur content of the coal during a test is not
for drying the fuel) and air and gas resistance resulting knownuntil after the test. Therefore, thecalcium to
from differences in air andflue gas massflowrates sulfur molar ratio during the test is likely to be different
are described below. Additional corrections should not from the agreed upon target valuefor the test. Deviation
be required if the test and contract fuels are equivalent; fromthetarget calcium to sulfur molar ratio impacts
i.e.,havesimilarultimateand proximate analyses and the sulfur capture/retention result. Also, differences
similar slagging, fouling, and combustioncharacteristics. betweenthetestandthe standard or contract sulfur
RefertoAppendix E for guidance regarding equiva- content of the fuel and sorbent analysis impactthe
lentfuels. sorbent mass flow rate required ( W S ratio) as well
Equivalent fuels do not affect the thermalperformance as the sulfur capturehetention. These differences also
of the steam generator. Thermal performancewith impact efficiency and air and flue gas mass flow rates.
regard to efficiency refers to the gas temperature exiting 5.18.4.1
Correctionsfor
Sorbent Analysis
and
the steam generator pressure parts, but also applies to SorbentReactions. In accordance with Subsection
furnace, superheat,andreheatabsorptionand may 5.18.4.2, agreed upon values for the calcium to sulfur
includeotherparameterssuch as steam temperature ( W S ) molar ratio and sulfur capture are used to make
andspray 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 havethemostsignificantimpact on thermal with the standard or contract fuel analysis to calculate
performance.Differencesin fuel moisture content (on the corrected sorbent rate,lbm/lbmfuel (kgkg fuel).
the order of 2 5 points) and ash content ( 210 points) The corrected sorbent rate, agreed upon sulfur capture/
have minimal impact onthe gas temperature leaving the retention, standard or contract sorbent analysis, and
pressure parts, but may affect component absorptions. calcination fraction determined fromthetestareall
For manufactured or process gases and/or synthetic substituted for the test values to calculate the required
fuels, differences in constituents may impactflue gas input data for the corrected efficiency calculations.
mass flow rate and yet have a minimal impact on the
gas temperatureleaving the pressureparts.However, 5.18.4.2Guidelines 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.
morethan 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 targetcalcium 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
Onpulverizedcoalfired units, the air temperature tested sulfur capturdretention result. There may be
entering the pulverizer is controlled to maintain a design occasions whenthe 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 versusthe
moisture in the coal. If the test coal is appreciably off design sorbent, overfeeding of sorbent to meet a lower
design (more thantwo or three percentage points of than contract sulfur emissions level, etc. In such cases,
114

~ ~~
STD-ASME PTC 4-ENGL 3998 m 0757b70 Ob35055 T32 m
FIREDSTEAM 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.
retentionvalues to use for thecorrected efficiency If the unit must operate at an excess air level other
results. The testcalciumto sulfur molarratio ( W S ) thanthestandard or contract valuetomeetother
may be corrected for the changes between the test and performance parameters suchas unburned carbon, emis-
the standard or contract sulfur capture and sulfur content sions, steam temperature, etc., thennocorrection to
of thefuel by use of correction curves or equations the “as tested” excess air value should be applied.
agreed to by the parties to thetest.Notethat the
purpose of this Section is to calculate a normalized 5.18.7OtherEnteringStreams
efficiencythatreflectstheunit’s capability. 5.18.7.1MoistureinAir. Substitute the standard
or guarantee value for the test value in the applicable
5.18.5Residue. The considerations for residue are
calculations.
losses related to unburned combustible in the residue,
sensible heat of residue losses, residue split between 5.18.7.2FuelTemperature. Substitute the standard
the various boiler collection points, the quantity of ash or guarantee value for the testvalue.
inthe fuel, andthequantityof spent sorbent, which
are discussed in thefollowing sections. 5.18.7.3 Sorbent Temperature. Substitute the stan-
dard or guarantee value for thetestvalue.
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
andConvection Loss.
for the corrected conditions. The unburned carbon mass When this itemismeasured,theresultsshall be cor-
permass of fuel basis forthe standard or guaranteed rected to the standard or guarantee ambient conditions
fuel is calculated by multiplyingtheunburned carbon (air temperatureandvelocity). This is a three step
measured during thetest by theratioofthehigher process. For each incremental area measured:
heating value of the standard or guarantee fuel divided Solve for the insulation andlagging heat transfercoef-
by thehigherheating value of the test fuel. ficient, Hwz, based on the measured parameters.
5.18.5.2ResidueQuantity. The residue quantity Based on the assumption that Hwz is constant, solve
is the sum of theash in the fuel, unburned carbon, for the corrected surface temperature, TMnAfCrz, for
and spent sorbent, andiscalculated for the standard the standard or guarantee ambient conditions.
or guarantee conditions usingthe reference fuel and 0 With the correctedsurface temperature and standard or
sorbent analysis, and other corrected conditions in the guarantee ambient conditions, solve for the corrected
same manner as calculated forthetest conditions. surface convection and radiation loss, Q r U r c C r z .
5.18.5.3ResidueSplit. The residue split between 5.18.8.1InsulationandLaggingHeatTransfer

thevarious collection locations shouldbeassumedto Coefficient, Hwz
be thesame as testedunless otherwise agreedupon.
For fluidized bed units, the quantity of ash in the fuel
andsorbentusedcanimpacttheashsplit.In
where this may besignificant, a correction curve or
procedure should be agreedupon.
cases
Hwz =
(QrLSrcz\
Afz ’
Thfz - TMnAfz
, Btu/ft2hoF (W/m2soC) (5.18-5)
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 andlagging (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 ofthe following equation:
cable).
Hwz (Thfz - TMnAfCrz) = Hrcaz (TMnAfCrz (5.18-6)
5.18.6ExcessAir. Minor deviations in excess air
betweenthetestand standard or contract valuethat - TMnARe)
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

ASME PTC 4-1998 FRED STEAMGENERATORS
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 unitwithair-to-gas-heat exchangers). Correcting
6) usingthe standard method for calculating Hrcuz. for thetestfuel versus the designfuel requires that
The solution can be simplified by using a linear curve the ultimate analysis be determined for thetest fuel
fit for Hrcuz in the range of thecorrected 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
referencevelocity. 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°Ffor standard reference with Subsection 5.18.2. Any other corrections discussed
ambient conditions: above can be applied if measurements ofnecessary
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 flowoftheflowing
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:
fromthefollowing equation:
-B+-\jB2-4AC
TMnAfCrz =
2A
, "F ("C) (5.18-8) (MrA FgCr
MrA Fg
)2 + Se).
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 2.3 1
Se = c2 -Ht(DnAFg - DnA),
+ 0.00593 TMnARe2 (5.18-10) 12
where TMnARe is the reference surrounding air temper-
ature. in. Wg (Pa) (5.18.12)
5.18.8.3 CorrectedSurfaceRadiationandCon-
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 MiscellaneousEfficiencyCorrections. Other PDiAFg= measured air resistance or draft loss, in.
minorlossesand/or credits that are measuredshould wg (Pa)
be reviewed by the parties to thetestand agreement MrAFg= mass flow rate of air or flue gas for
reached as to whether corrections to the efficiency are test conditions, lb& (kg/s)
applicable. MrAFgCr= corrected mass flow rate of air or flue
gas, lb& (kg/s)
5.18.10 CorrectedInput-OutputEfficiency. When Se= stack effect or difference in static pres-
efficiency is determined by theinput-outputmethod, sure betweenthe aidgas side of boiler
the test result is corrected to the standard or guarantee and surrounding ambient air. Se will be
conditions by addingthe difference between the cor- negative if the fluid is flowing upward.
rected efficiency and test efficiency (both as calculated H f = heightbetweenthepressurelocations,
by the energy balance method) to the input-output test i.e., the difference in elevation between
results. Designboundary conditions (such as entering the downstream andupstreampressure
air and exit gas temperatures) shall be usedif they locations, ft (m). Hf will be positive if
are not measured. The most significant corrections are thefluid is flowingupward.
116

STD-ASME PTC 4-ENGL 1998 m 0759670 Ob15057 805
FIREDSTEAMGENERATORS ASME FTC 4-1998
C1 = unitconversion factor, 1.0 for in. wg

VhCr = C2 -
1 -(
[[(TT sr] (5.18-14)
(2.4884E + 02 for Pa) DnSt
C2 = unit conversion factor, 1.0 for in.wg
(2.4884E + 02 for Pa)
DnAFg= density of air or fluegas, lbdft3 (kg/
m3). For the furnace shaft, use a value
+ VhCf (-r],
MrStd
Aidd
psi (pa)
of 0.0125 lbdft3 (0.20 kg/m3). where

DnA = density of ambient air in vicinity of VhCf = loss coefficient for the change in cross section
pressure measurement, lbm/ft3(kg/m3) geometryinvolvedbasedonthediameterof
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 specificsystem be devel- utilizing fluid flow referencetext.
oped. The above generalpressure drop equation may Ai&= area of thepipeat the contractual terminal
not be applicable forall equipment (pulverizers, for point, ft2 (m2)
example) andsystems (for example, wherepressure Aid= area of the pipe where pressure tap isinstalled,
drop is controlled, such as cyclone furnaces). ft2 (m2)
C2= unitconversion factor, 8.327E-12 for psi
5.18.12 Steam or Water Pressure Loss. The general (5.741E-8forPa)
equations for correcting steadwater pressure drop be- The measuredpressure differential across a steam
tweenthetestanddesign or contract conditions are generating unit or a portion of the unit shallbe corrected
as follows: to standard or guarantee conditions due to the difference
in mass flowof the flowingfluidandthe specific
volumebetweenthetestconditionandthereference
PDiStCr = (PDiSr
conditions. A correction for velocity pressure may also
be requiredif the static pressuremeasurement tap is
- Cl Ht DnSr) - - (""'")z
DnStd MrSt
(5.18-13) located at a point with a cross sectional area different
from the terminalpoint for theguarantee.
+ CI Ht DnStd - VhCr, psi (pa)
5.18.13 Steam Temperature and
Desuperheating
Spray. Steam temperature and desuperheating spray
guarantees must be evaluated based on actual anddesign
where
superheater(and reheater if applicable) absorptions
PDiSt= themeasuredpressure drop, psi (Pa)
rather than actual temperature due to potentialdeviations
PDiStCr= thecorrectedpressure drop, psi (Pa)
from the target steam temperature during the test andor
Hr= heightbetweenthepressure locations,
deviations from the design cycle conditions. The actual
¡.e.,the difference in elevation between
main steam andreheatmass flow ratesutilized to
thedownstream and upstreampressure
calculate actual absorptions are corrected for off-design
locations, ft (m). Hr willbepositive if
test conditions. Ingeneral:
thefluid is flowingupward.
DnSt = density of the s t e d w a t e r atthetest 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 steamlwater at the design design required superheaterheheater absorption.
conditions, lbdft3 (kg/m3) 0 Desuperheating spray shall be evaluated based on the
C1 = 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 ofthe steadwater at 0 The test main steam and reheat mass flow rates utilized
thetest condition, lbm/h (kg/s) to calculate actual absorptions are corrected for off-
MrSrd= mass flow ratesofthe steadwater 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 steamflow,
and intermediate superheater flows, cal- MfStCr.
culated basedonthecorrectedspray O Main steam temperature and superheater spray attemp-
waterflow),lbm/h (kg/s) eration for once-through steam generators are not
VhCr= velocityhead correction (if applicable) functions of surface arrangement, and corrections are
calculated as follows: not necessary. Main steam temperature is a matter of
117

STD-ASME PTC 4-ENGL L998 m 0759b30 Ob15058 7 4 1
steam generator controls and shouldbe 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
requiretestand/orcorrection procedures not addressed QrRhCr = MfstCr ~ ~ ( H 9 ~3 4 - 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)
Actualand design required superheat andreheater where MfsrCr is the ratio ofthedesignmain steam
absorptions are definedbelow. The main steam and flow divided by the test main steam flow
reheat steam massflow rates usedto calculate actual
absorptionsarecorrected for off-designmain steam 5.18.13.4
Required
Reheater
Absorption,
flowbymultiplyingthetestmain 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 calculatedfrom:
by thetestmainsteamflow (MfsrCr). The resulting
absorption term generally referred to as "actual absorp- RqQrRh = MrSt33d (HSt34d - Hst33d),
tion"aboveisreferred 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 firststageofreheat. where all terms are the contract or design conditions
forthedesignmainsteamflow.
5.18.13.1
Superheater
Absorption
Corrected,
QrShCr. The superheater absorption corrected for design 5.18.13.5 Corrected Superheat and Reheat Steam
mainsteam flow is calculated from: TemperatureandDesuperheatingSpray. Whenthe
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 spraybased
is
on
+ MrSt46A(HSt46A - HSt31). Btulh (W) excess absorption of the specific component and is
calculated in accordance withthe following equations:
where
MrSt32d= designmain steam flow, Ibh (kg/s) QrShCr - RqQrSh
MrW25= desuperheatingwaterflow
conditions, lb/h (kg/s)
for thetest MrW2SCr =
HSt3lCr - 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. Therequired superheater absorption for the
designmain 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 - HSt31Cr), B t d h (W)

Subsection 5.18.13.6 discusses divided gas flow units
where steam temperatureis controlled by exchanging
where energy betweenthereheaterand superheater.
HSt46A = enthalpy of auxiliary or extraction steam Ifthecorrectedcomponent absorption is less than
atthetest conditions, Btu/lbm (Jkg) the required absorption, the corrected spray flow is
HSr31Cr= 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 andabsorption

required
reheat
and the reheat absorption is controllable.
+ QrShCr - QrAxStCr The reheat
absorption is deemed to be controllable
MrSt32d if the gas biasing dampers are an within operating
range capable of achieving the required change in reheat
Btu/lbm (J/kg) (5.18-21) absorption. The required change in reheat
absorption
is the difference between the corrected reheat absorption
and the required reheat absorption, QrRhCr - RqQrRh.
Basedupon these assumptions, thecorrected super-
QrAxStCr = MrSt46Ad (HSt46A - HSt31Cr), heater sprayis calculated fromthe following equation:
Btulh (W) (5.18-22)

MrW25Cr = (5.18-24)
(QrShCr - RqQrSh) + (QrRhCr -

HSt3lCr - HW25d
HSt34Cr = HSt33d (5.18-23)
lbmlh (kgls)
+- QrRhCr , Btullbm (J/kg)
MrSt34d
For corrected steam temperature for under absorption
conditions, the main steam temperatureisnormally
where deemed to be met and the reheat outlet steam tempera-
QrAxStCr= energy in the superheated auxiliary or
ture determined fromtheenthalpycalculatedbased
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-
TemperatureandDesuperheatingSpray,Divided tionlesstherequiredsuperheat absorption.
Gas Flow Units. On divided gas flow units,reheat
steamtemperatureis controlled by exchanging energy HSt34Cr = (5.18-25)
betweenthereheater and superheater by biasing gas
flow betweenthereheatandsuperheatpass. Tests are HSt33d + QrRhCr + (QrShCr - RqQrSh)
normally conducted by controlling to the design reheat MrSt33
temperature. Superheat absorption can be impacted if
thereheatboundary conditions are different fromthe Btu/lbm (J/kg)
design conditions. Therefore, superheat and reheat ab-
sorptionmust be evaluated collectively. 5.18.14Uncertainty of CorrectedResults. The un-
For differences in correctedversusrequiredreheat certaintyvalues calculated andusedinthis Code are
absorption onthe order of 5%, a direct exchange in for the as-measured test results only. Several technical
energybetweenthe superheat andreheatcan be as- issues need to be resolvedregardinguncertainty of
sumed. The following corrected results are basedon corrected results. So as not to delay the issuance of
this assumption. this Code, this calculation is not included. When such
An alternate testmethodis to controlto a target a procedureis developed, itwillbeissued as an
reheat outlet steamtemperature andor reheater attemper- addendumandbecome a partofthisCode.
ation flow equivalent to the designrequired reheat
absorption, RqQrRh. This method may be required if
the differences betweenthecorrectedand required
5.19 ENTHALPY OF AIR,FLUEGAS,AND
reheat absorption are larger than 5%. Due to normal
OTHERSUBSTANCESCOMMONLY
deviations betweenthe desired setpointand actual
REQUIREDFORENERGYBALANCE
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 maynot be knownatthetimeofthetest. 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 bemet if thesum 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 andspentsorbent).Specific
119

energyof a flowstreamis evaluated by the enthalpy are recommended for users interested in general heat
of theflowingmaterial. 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. J A N A F Thermochemical Tables [3], and curve fit coef-
Enthalpyisrelated to temperature andpressure by ficients developed in accordance with NASA Publication
relationships that are simple for some ranges of tempera- SP-273 [4]. Abbreviated JANAFNASA correlations are
tureandpressureand complicated for other ranges. presentedbelow.
Accurate determination of enthalpy at allvaluesof For convenience inhand calculations, curves are
temperatureandpressurerequirestheuseof tables, provided at the endofthis Section for calculating
charts, or computer software. Engineers who deal with enthalpy of air, flue gas, watervapor,and residue.
steam almost invariablyobtainthe enthalpy of steam Refer to Subsection 5.19.12 for a description ofhow
using tables or software. these curves are used.
Frequently, changes ofspecific 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.
andtemperature difference: To convert to Jkg, multiplythe 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
andwatervaporin air. To determine the enthalpy of
where dry air, use a watervapor content of zero:
MnCpk= the mean specific heat between the two
temperatures
The mean specific heat is usually taken as the value HA = ( 1 - MFr WA) 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 relatedby: MFrWA = MFrWDA I (1 + MFrWDA), (5.19-2)
Ibm/lbm (kg/kg)
Hn - HP =
IT: MnCpk dT
As specific heat is usually nonlinear, MnCpk is not where

equal to thespecificheat at temperature Tmn. The HA = enthalpy of wet air, Btdlbm (Jkg)
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, Btuflbm (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 H20flbm 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.
neglectedbecauseall streams other than watedsteam MFrWA = mass fraction of water vapor in wet air,
are at lowandnearlyconstantpressure: lbm H20/lbm wet air (kgkg)
When the mean specificheatis required, it is ob-
5.19.2Enthalpy of Flue Gas, BtuAbm (Jkg). “Wet
tainedfrom
flue gas” as definedby the calculations in this Code
is composed ofdry gaseous products of combustion
MnCpk = [H(Tn)- H(Tp)]/(Tn- T p ) andwatervapor. Solid residue may also be entrained
in the gas stream. The enthalpy of wet flue gas accounts
The enthalpy correlations presentedin this Section for the enthalpies ofallof these components. If the
120

GENERATORS FIRED STEAM PTC 4-1998
enthalpy of dryflue gas is desired, thewaterand solid 5.19.4Enthalpy of WaterVapor, Btdlbm. The coef-
residue components are zero: ficients for
JANAF/NASA
the fifth order curve fit
are given in Subsection 5.19.10 below. The following
HFg = ( 1 - MFrWFg) HDFg + MFrWFgHWV simplified curve fit for calculating credits andlosses
due to moisture may also be used. The resultsare
+ MFrRsFg
HR, Btu/lbm J/kg) (5.19-3)
within 0.3% the
of -JANAF values for temperatures
between 0°F and 1,000"F (-2O"C-54O0C):
where
HFg= enthalpy
wet
offlue 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 inwet gas, Ibm
H20/lbm wet gas (kgkg). Refer to Sub- 5.19.5 Enthalpy of Steadwater at 1 psia,Btul
section5.12.10for calculation. lbm. The enthalpy of steam at 1 psiaisrequired to
MFrRsFg= mass fraction of residue inwet 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 5.12.1 1 for calculation. The sen- gas in a vaporous state. An example is the calculation of
sible heat of residue may be omitted if thewater from fuellosses. The followingequation
sorbentisnotutilizedandtheash in may beusedinlieuoftheASME 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 = 0.43297 + 3.958E - 5T2 (5.19-6)
5.19.3Enthalpy of Dry Residue, Btdlbm. Residue
is composed of numerous complexcompounds and may
+ 1062.2. Btullbm
include spent sorbent products when sorbent is utilized.
One approach fordetermining 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 theenthalpyfor each component to determine the
average enthalpy. In the interest of simplicityand where
considering theinsignificantimpact of inaccuracies in T= temperature, "F
calculating the enthalpyof 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 determinedfrom a ProximateAnalysis. It is
dryresidue 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 CoalUtilization [ 5 ] . The original
ble from 0°F to 2,000"F (-20°Ctol,lOO°C). This
specificheat equations wereintegrated to obtain en-
Code adopts thefifth 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 fitmaybeused for handcalculations:
Si02 for consistencywith enthalpy ofresidue.
The correlation is not applicable for frozen coal or
HRs = 0.16T + 1.09E-4 (5.19-4)
Tz 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 FIRED STEAM GENERATORS
+ MFrWF HW + MFrAsF HR, Btullbm MFrVmI = MFrVm - MFrVm2 (5.19-19)
where
MFrFc= mass fraction offixed carbon, ibdlbm
HFc = 0.152T + 1.95
E-4 T2 (5.19-9)
coalas-fired
- 12.860, Btullbm MFrAsF= massfractionof ash, lbdlbm coal as-
fired
MFrWF= massfractionof water, Ibdlbm coal
as-fired
HVml = 0.38T + 2.25E-4
Tz
(5.19-10) MFrVm= mass fraction of volatile water, Ibdlbm
- 30.594, Btullbm coalas-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 T 2 (5.19-1 1) ter, lbdlbm coal, as-fired
- 54.908, Btullbm MFrVmCr= mass fraction of volatile matter on a dry
andash free basis, Ibdlbm coal, dry-
ash free
T= temperature, "F
HRs = 0.17T + 0.80E-4 T 2 (5.19-12) H k = enthalpy of coal component k, Btu/lbm
- 13.564, Btullbrn 5.19.7 Enthalpy of Fuel Oil, Btdlbm. The enthalpy
of fuel oil has been correlated as a function of specific
gravity at 60°F (16°C) in "AP1[6].
HW = T - 77, Btu/lbm (5.19-13)

HF0 = 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 =(5.19-22)
Dn162.4
lbrn/lbm fuel dry-ash free (5.19-15)
where
If MFrVmCr S 0.10, then HFo= enthalpy of fuel oil, Btdlbm
T = temperature, "F
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 = -0.1 1426
MFrVml = 0.0 (5.19-17) c3=M.373
C4 +O. 143E-2
If MFrVmCr > 0.10, then C5 = 4 . 2 184E-3
Cd= +7.0E-7
5.19.8 Enthalpy of Natural Gas, Btdlbm. The fol-
MFrVm2 = O. lO(1 - MFrAsF (5.19-18) lowing curve fit was developedfrom the JANAFDJASA
- MFrWF) data for a typicalnatural gas fuel analysis of 90%
122

methane (CH,), 5% ethane (Cz&),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-
nearthereference 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
basedupon 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 10oO K:
where
T = temperature, "F CO = -0.11777238+03 CI = +0.37167868+00
5.19.9 Enthalpy of LimestoneSorbent, BMbm. 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 lo00 K:
HSb = (1 - MFrH20Sb) HCc (5.19-24)
+ MFrH20Sb ( T - 77), Btu/lbm CO = -0.2394034E+03 C l = +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 C1 = +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, "F 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 basedupon the following composition of 15.3% COz, 3.5% Oz, 0.1% SO,, and
abbreviated enthalpy correlation andthecoefficients 81.1% atmospheric nitrogenbyvolume. The enthalpy
tabulatedbelow. The reference temperature is 77°F of dry flue gas does not vary significantlyforfossil
(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 heatcapacity
H k = CO + C l TK + C2TK2 + C3TK3 (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 than300% excess air, the
following coefficients are sufficiently accurate for most
heattransfer calculations. For unusualfuelssuch 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 5.19.11 below.
H k = enthalpy of the constituents, Btdlbm Coefficients for dry flue gas for temperaturesfrom
T= temperature, OF 255 K to 1,OOO K:
123

STDOASME PTC 4-ENGL L978 m 0759b70 Ob15064 T 4 5 m
CO -0.1231899E+03 C l = +0.4065568E+00 to calculate the dry flue gas coefficients once for an
C2 = +0.5795050E-05 C3 = +0.6331121E-07 averagefuel.
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 = -0.1 189196E+03 C1 = +0.4229519E+00
C2 = -0.1689791E-03 C3 = +0.3707174E-06
CO = -0.1 180095E+03 C l = +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 0,temperatures above 1,000 K:
Coefficients for residue of unknown composition and CO = -0.1338989E+03 Cl = +0.4037813E+00

sand for temperaturesfrom 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 Si02 around the discontinuous point at approxi-
mately 1,000 K.
Coefficients for N2 (elemental) temperaturesfrom
255 K to 1,OOO 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
sandfortemperatures above 1,OOO K:
Coefficients for N, (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 C l = +0.3643229E+OO
c 4 = +0.4839543E-30 C5 = -0.4614088E-14
C2 z= +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:
coefficientsforgaseousmixturesnot covered above
may be calculated from the mass fraction of theconstit-
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
CAmix= Zh4Fr-k C& (5.19-28) C4 = -0.3771498E-10 C5 = -0.35026408-I5
where Coefficients for Nh (atmospheric) temperatures above

C&= coefficient i for the constituent k as listed in 1,OOO K:
this text or derived from an appropriate source
If the longprocedure is usedto derive coefficients CO = -0.1 129166E+03 C1 = +O,3620126E+OO
for a specific flue gas mixture from a specific fuel (or C2 = +0.1006234E-03 C3 = -0.2635 1 13E-07
oxidant), it isrecommendedthatthe mixture be on a
C4 = +0.3592720E-11 C5 = -0.1960935E-15
dry gas basis based on a typical excess air. The moisture
content (andresidue, if applicable) at thelocationin
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 wetflue 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 C l = +O.l951278E+OO
range of excess air; therefore, it is usually only necessary C2 = +0.3549806E-03 C3 = -0.179001 1E-06
124

STD-ASME PTC 4-ENGL 1398 0753b70 ObL50b5 981 W
C4 = +0.40682858-10 C5 = +0.1028543E-16 CO = -0.17340278+04 C1 = +O.S222199E+01

C2 = +0.3088671E-02 C3 = -0.4596273E-05
Coefficients for CO2 temperatures above 1,OOO K: C4 = +0.3326715E-08 C5 = -0.8943708E-12
CO = -0.1327750E+03 C1 = +0.362560IE+OO Coefficientsfor Hz temperatures above 1,OOO K

C2 = +O. 1259048E-03 C3 = -0.3357431E-07
C4 = +0.46208598-11 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 C5 = +0.8940907E-15
1,OOO K:
CO = -0.6674373E+02 CI = +0.2238471E+00
Coefficients for H2S temperaturesfrom 255 K to
1,OOO K:
C2 = +0.0000000E+00 C3 = +0.0000000E+00
C4 = +0.0000000E+00 C5 = +0.0000000E+00
CO = -0.1243482E+03 CI = +0.4127238E+00
Coefficients for Ar temperatures above 1,OOO 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 H2S 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 = +0.2121929E-03 C3 = -0.5382326E-07
1,OOO K: C4 = +0.7221044E-11 C5 = -0.3902708E-15
CO = -0.6741655E+02 CI = +O. 1823844E+00

C2 = +0.1486249E-03 C3 = +0.3273719E-07 5.19.12 Curves for Calculating Enthalpy. The abbre-
viated JANAWNASA correlations for air andflue gas
C4 = -0.7371521E-30 C5 = +0.2857647E-13
are fifth order polynomials.For convenience inhand
calculations, specificheat curves for dry air, water
Coefficientsfor SO2 temperatures above 1,OOO K vapor, dry flue gas andresidueareprovidedon Figs.
5.19-1 through 5.19-4.These curves showthe mean
CO = -0.1037132E+03 CI = +0.2928581E+00 specific heatof the constituent between the temperatures
C2 = +0.5500845E-04 C3 = -0.1495906E-07 desired and 77°F (25°C). To obtainenthalpy ( H ) for
C4 = +0.2114717E-11 C5 = -0.1178996E-15 anyofthe constituents (77'F reference), multiplythe
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 thecalculated
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 approximationofmeanspecificheat over a
CO = -0.1215554E+03 CI = +0.3810603E+OO
small temperature band) ataspecific temperature is
C2 = +0.9508019E-04 C3 -0.24645628-07 required, such as forthe calculation of corrected air
C4 = +0.3308845E-11 C5 = -0.1771265E-15 heater exit gas temperature. Instantaneous specific heat
can be obtained fromthemeanspecificheat curves
Coefficients for Hz temperatures from 255 K to by entering the curve withatemperature (Tc) equal
, OO K:
1O to two times the temperature ( T ) desired minus 77°F:
125

~ ~~
STD-ASME PTC 4-ENGL L998 m 0759b70 ObL50bb 818
Dry air (77°F reference)
FIG. 5.19-1 MEANSPECIFICHEAT OF DRY AIR VERSUS

TEMPERATURE
126

Water vapor (77°F reference)
Temperature, F
FIG. 5.19-2 MEANSPECIFICHEAT OF WATER VAPOR VERSUS

TEMPERATURE
127

STDOASME PTC 4-ENGL 1998 m 0759b70 ObL50bB b90 m
ASME Pn= 4-1998 GENERATORS STEAM FIRED
Water vapor (77'F reference)

0.499
0.498
0.497
0.496
0.495
,E
5
i:
0.492
0.491
p 0.490
c, 0,489
t;;T 0.488
Q) 0.487
0.486
5 0.485
v 0.484
0.483
0.482
m 0.481
f 0.480
0.479 -
0.478 - /I
0.477 y
0.476 -
1000
1050
1100
1150
1200
1250
1300
1350
'
1400
1450
1500
' 1 1 1 1 1 1 1 1
Temperature, " F
Water vapor (77°F reference)
1 1 1 1 1 1 1 1
1500
1550 1600 1650
1700
1750
1800
1850
1900
1950 2000
Temperature, F
FIG. 5.19-2 MEANSPECIFICHEAT OF WATER VAPOR VERSUS

TEMPERATURE (CONT'D)
128

~~ ~ -~ -
STD.ASME PTC Y-ENGL 1998 0759670 0615069 527
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
xV 0.242
0.241
0.240
0.239
5 0.238
5 0.237
0.236
0.235
0.234
O 100 200 300
600500400 700 800 900 1000
Temperature, F
Dry flue gas (77°F reference)
1000 1100
1200
1300
1400
1500
1600
1700
1800 1900 2000
Temperature, O F
FIG. 5.19-3 MEANSPECIFIC HEAT OF DRY FLUE GAS VERSUS

TEMPERATURE
129

STDOASME PTC 4-ENGL L998 0759b70 Ob15070 249 m
ASME l'TC 4-1998 FIRED STEAM GENERATORS
Dry residue (77°Freference)
0.218
0.214
.
F
0.210
S3E 0.206
g 0.202
0.198
0.194 I I I
I
l I I I I l I
0.190
O. 186
0.182
O. 178
O. 174
0.170
1 l 1 l 1 l 1 1 1 l 1 1 l 1 1 1 1 1 1
0 150
100
50 200 250 300 350 400 500
450
Temperature, F
Dry residue (77'F reference)
0.217 -
'
,
' I I I I I I I I I
0.215
500
550
600
650 700 750 800 850 900 950 1000
Temperature, O F
FIG. 5.19-4 MEAN SPECIFICHEAT OF DRY RESIDUE VERSUS

TEMPERATURE
130

Dry residue (77OF reference)
0.269
0.267
".
U
0.265
.
E 0.263
3
g 0.261
0.259
$ 0.257
I
.-o
k
0.255
0.253
5
m
0.251
S
0.247
0 . 2 4 5 1 1 1 1 1 1 1 1 1 1 1 1 , 1 1 , 1 , 1 1 1
1000 1100 1200 1300
1400
1500
1600
1700
1800
1900
2000
Temperature, "F
FIG. 5.19-4 MEANSPECIFICHEAT OF DRY RESIDUE VERSUS

TEMPERATURE (CONT'D)
131

TC = 2 T - 77, "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
CALCULATION
ACRONYMS 5.20.1.2 FunctionSymbols
Ad Additional
5.20.1 Basis for Section 5 Acronyms. The acronyms Di Difference (Delta)
usedthroughoutthis Section (except for uncertainty)
Fr Fractional
are built from symbols from the following groups and Mn Mean
arrangedin 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
HHVV 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 c02 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
D Percent fuel input energy F0 Fuel oil
Qr Heat transfer rate G Gaseous fuel
R Universal gas constant Gr Gross
Ra Radiation Hc Hydrocarbons, dry basis
R h Relative humidity I Input
Rs Required In Inerts
Se Stack effect L Loss
st? Specific gravity Lg Leakage
132

~~ ~
-STD.ASME PTC 4-ENGL L998

0759b70
Ob15073
T58
MC Magnesium carbonate To Total

Mh Magnesium hydroxide Ub Unburned
N2 Nitrogen W Water
N2Q Atmospheric nitrogen Wv Water vapor
NO, Nitrous oxides X Auxiliary
O output Xp Percent excess
o
2 Oxygen X-ratio Xr
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
Recycle j Fuel, sorbent component
RY k Fuel, sorbent constituent
S Sulfur
Lv Outlet, exit, or leaving
Sb Sorbent
Sulfur capture Re Reference
SC
Sh Superheat Z Location (refer to Figs. 1.4-1 through 1.4-7
for specific locations)
SV 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 AcronymsUsed
Th Theoretical See Tables 5.20.2-1 and 5.20.2-2.
133

STD-ASME PTC 4-ENGL 1998 m 0759670 06L5074 994
TABLE 5.20.2-1
ACRONYMS
~ ~ ~~ ~~ ~~~ ~~
Acronyms Description Units

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

DnA Fg Density of wet air or flue gas Ibm/ft3 (kg/m3)
DnFg Density of wet flue gas Ibm/ft3 (kg/m3)
DnGF Density of gaseous fuel Ibm/ft3 (kg/m3)
DnSt Density of steam/water Ibm/ft3 (kg/m3)
D VpCO 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
efficiency ECrn Combustion %

efficiency €F Fuel %O
€Gr Gross efficiency %O
EX Combined efficiency
auxiliary
of 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 (J/kg)
HA L 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 (J/kg)
HDA En 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 1eakag.e 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 (J/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 (J/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)
HH VPr Higher heating value of pulverizer rejects Btu/lbm (J/kg)
Hk Enthalpy of constituent k Btdlbrn (J/kg)

Hkz Enthalpy of constituent k a t location z Btu/lbm (Jlkg)
HL v Enthalpy leaving, general Btu/lbm (Jlkg)
134

TABLE 5.20.2-1
ACRONYMS
Acronyms
HMnA Average enthalpy of wet air Btu/lbm (Jlkg)

HMnFg Average enthalpy of wet gas Btullbm (J/kg)
HMnFgL vCr Average enthalpy of wet gas at TMnLvCr Btu/lbm (Jlkg)
HPr Enthalpy of pulverizer rejects leaving pulverizer Btullbm (Jlkg)
Hraz Radiation heat transfer coefficient for location z Btu/ft2h . 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)
HRsEn Enthalpy of residue entering Btdlbm (Jlkg)
HrSlf Heat generated due to sulfation Btu/lbm (Jlkg)
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 Btu/lbm (Jlkg)
HStL vCr Enthalpy of steam (based on ASME Steam Tables), at Btu/lbrn (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 ft (m)
H V& Heat of reaction for calcination or hydration of constituent k Btullbm (J/kg)

H Vrni Enthalpy of volatile matter, i, where i is 1 or 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) Btu/lbrn (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 r, design conditions Btu/lbm (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)
MFrSO, 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 m 0759670 Obl1507b 7b7
TABLE 5.20.2-1
ACRONYMS
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 (kgkg)
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 "F
(Jlkg K)
MnCpFg Mean specific heat of wet flue gas Btullbm "F
(Jlkg K)
MnCpk Mean specific heat of constituent k Btullbm OF
(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 moleslmass fuel
MoFrCaS Calcium to sulfur molar ratio moleslmole
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 moleslmass fuel
Mo ThACr Moles of theoretical air required (corrected) molesJmass fuel
Mo ThA Pcu Theoretical air required for gasified fuel products molesJmass fuel
Mo WA Moles of moisture in air moledmass air
Mo WPc MoDPc plus moles H20 from tuel, sorbent and any additional moleslmass 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 V. 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 O/O mass
MpCRs Percent free carbon in residue O%. mass
MpFk Percent fuel constituent k Y O 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

~~~ ~~ ~
~ ~~~
STD-ASME PTC 4-ENGL L998 0759b70 Ob15077 bT3 m
TABLE 5.20.2-1
ACRONYMS
Units Acronyms Description
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 Ib d B t u (kg/J 1
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 )
Mq Rsz Mass of residue collected at location I IbmfBtu (kg/J)
MqSb Mass of sorbent on input from fuel basis lbm/Btu (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 lbm/Btu (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 Ibm/Btu ( k g N )
Mq WSb Water from sorbent on input from fuel basis Ibm/Btu ( kg/J 1
Mq WvF Water from H,O vapor in fuel Ibm/Btu (kg/J)
MrA Fg 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 lbmlh (kg/s)
MrCwz Mass flow rate of cooling water at location z Ibmfh (kg/s)
MrDA Mass flow rate of dry air Ib m k ( kg/s)
MrF Mass flow rate of fuel Ibm/h (kg/s)
MrFg.? 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)
MrRs.? Mass flow rate of residue at location z Ib d h (kg/s)
Mr RyFg Mass flow rate of recycled flue gas l b m h (kg/s)
MrRyRs Mass flow rate of recycled residue l b m k (kg/s)
MrSb Mass flow rate of sorbent lbmk (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 lbmlh (kg/s)
MrStzd Mass flow rate of steam at location z, design value Ibm/h (kg/s)
M r WSb Mass flow rate water in sorbent I b d h (kg/s)
Mr W.? 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 graindft3 (g/m3)
MwA Molecular weight of wet air masdmole

MwCak Molecular weight of sorbent calcium compound k masdmole
MWCC Molecular weight of calcium carbonate rnasdmole
MwCo Molecular weight of carbon monoxide, CO mass/mole
M wCO~ Molecular weight of carbon dioxide, CO2 masshole
137

~
~ ~~
STD.ASME PTC 4-ENGL L998 m 0759b70 ObL5078 S3T m
ASME PTC 4-1998 FIRED S T E A M GENERATORS
TABLE 5.20.2-1
ACRONYMS
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 N O masdmole
MwS Molecular weight of sulfur masdmole
Pa Barometric pressure psia (Pa)

PAZ Static pressure of air at point I in. wg (Pa)
PDiA Fg 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 O
h 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 (CD)in flue gas % fuel input
QpLDFg Loss due to dry gas O+& fuel input
QPLHz F Loss due to water formed from combustion of H, in fuel % fuel input
QPLY R5 Loss due to unburned hydrogen in residue Y' fuel input
QpLk Loss due to constituent k % fuel input
QpL NOx 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
QpLUbHc Loss due to unburned hydrocarbons in flue gas Y' fuel input
QPL WA Loss due to moisture in air %O fuel input
QPL WF 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 )
QrAP W Energy increase in ash pit water B t d h (W 1
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 )
QrB WAd Credit due to energy supplied by additional moisture Btuh ( W1
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) Btuh (W)
QrIGr Energy input gross, energy input from fuel plus credits Btulh ( W )
I38

~ ______~
STD-ASME PTC 4-ENGL 1998 m 0759b70 Ob15079 476 D
TABLE 5.20.2-1
ACRONYMS
Acronyms
QrL Losses calculated on an energy basis, general Btu/h (W)

QrLAc Loss due to air preheater coil supplied from the steam Btuh (W)
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 Btuk W1
QrLk Loss due to constituent k Btulh (W)
QrLRu Loss from recycled streams Btuh (W)
QrL RVFS 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 (W1
QrL WSb Loss due to water in sorbent Btuk (W)
QrO Total heat output Btuh (W)
QrRhCr Corrected reheat absorption for contract conditions Btuh (W)
QrRsWL v Sensible heat in residudwater leaving the ash pit .
Btu/ft2 ( W/m2 )
QrShCr Superheater absorption corrected for design conditions Btu/h (W)
QSh Superheat absorption Btuk (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 ft/R (J kg/K)
RqQrRhd Required reheater absorption, design Btu/h (W 1
RqQrShd Required superheater absorption, design Btuk (W)
Se Stack effect in. wg (Pa)

SS 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 "F ("C)

TAEnd Design entering air temperature "F ( O C )
TA fz Average surface temperature of area z 'F ("C)
TAz Temperature of wet air at location z O F ("C)
TC Temperature on X-axis of enthalpy figures "F ("C)
TDAz Temperature of dry air at location z "F ("C)

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

TFgEn Temperature of flue gas entering component "F ("C)
TFgEnCrd Gas temperature entering air heater corrected to design "F ("C)
conditions
TFgL v Temperature of flue gas leaving "F ("C)
TFgLvCr Corrected gas outlet temperature (excluding leakage) OF ("C)
TFgL vCrd Exit gas temperature corrected to design conditions 'F ("C)
Thfz Hot face (wall) temperature at location z "F ("C)

TK Temperature in K O F ("C)
Tkz Temperature of constituent k a t location z "F ("C)

TL vk Temperature of constituent k leaving the steam O F ("C)
TMnAEn Average entering air temperature "F ("C)
139

ASME FTC 4-1998 FIRJ3D STEAM GENERATORS
TABLE 5.20.2-1
ACRONYMS
Acronyms
TMnA fCrz Average surface temperature corrected to design at location I "F ("C)
TMnAfz Average surface temperature at location z "F ("C)
TMnARe Reference surrounding air temperature "F ("C)
TMnAz Average surrounding air temperature "F ("C)
TMnFgLvCr Average corrected gas outlet temperature "F ("C)
TRe Reference temperature "F ("C)
TStz Temperature of steam at location z O F ("C)
Twb Wet-bulb temperature 'F ("C)
VA2 Average velocity of air ftlsec (&S)
VPCG Percent of COz in flue gas, wet basis YO volume
vpcoz Percent CO in flue gas at location 4 wet basis YO volume
VPGj Gaseous fuel component j Btu/ftz (J/mz )
VpH20 Percent water in flue gas, wet basis Yo volume
Vp Hc 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

TABLE 5.20.2-2
MEASUREMENT AND UNCERTAINTY
ACRONYMS
Description
Acronyms
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
PCHGPAR 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 TDDE V Standard deviation of the sample
STDDEVMN 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
2 Time averaged value of the measured parameter
4 Pitch angle
9 Yaw angle
141

SECTION 6 - REPORT OF TESTRESULTS
6.1 INTRODUCTION - dates of the test

0 Summary. This Section briefly describes the objec-
The performancetest report documentsthe 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.,
beenmetand to describe the testproceduresand on the unit to be tested.
pertinent results. This Section presents guidance on both 0 Objectives andAgreements. This sectionaddresses
content and format of information typically included in the objectives of the test, required test uncertainty,
thisreport guarantees, operating conditions, and any other stipu-
lations.
0 Test Descriptions and Procedures. This sectionin-
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-
testreportsmayvary somewhat, the contents will eters
typicallybe organized and include theinformation as - a list of the equipment and auxiliaries being tested,
describedbelow: including nameplate data
- a list and description of the testinstruments 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 3pproved ment andsampling, 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 specifiedcondi-
0 General Information. This portion of the report gives tions. Test uncertainty is also stated in the results.
the reader information neededto 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 0 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 majorfluctuationsand 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
is Blank
SECTION 7 - UNCERTAINTYANALYSIS
UCTION 7.1 T temperature
f Student’s t-statistic
Uncertainty analysis is a procedurebywhich the
U uncertainty
accuracy of test results can be quantified. Because it
U any parameter
is requiredthat 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 meaningfulperformancetest.
X any parameter
PTC 19.1, Measurement Uncertainty, is theprimary
Y any parameter
reference for uncertainty calculations andanyuncer-
Z any parameter
tainty analysis methodthat 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 thisCode. This Section addresses
R =max)
V degrees of freedom
the following:
Cr population standard deviation (c? is the popula-
0 determining precision uncertainties tion variance)
0
0
estimating bias uncertainties
propagating the precision and bias uncertainties x
a
b
()i sum of ()¡ from i = a to i = b
0 obtaining the test uncertainty 7 time
Additional information on uncertainty is available in 7.1.1.1
Subscripts
PTC19.1,Measurement Uncertainty. B bias
7.1.1GeneralList of Symbols for Section7. The I instrument, instrumentation
following symbols are generally used throughoutSection 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
o 2 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 precisionindex, standard deviation of themean following facts about uncertainty:
S sample standard deviation (s2 is the sample
variance) Uncertainty analysis
bestis the procedure to estimate
SDI spatial distribution index the error limit in a set of measurements or results.
test
145
Previous Page
is Blank
~ ~
STDmASHE PTC 4-ENGL L998 0759670 OhL5084 833 m
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 bythe measured value
tainty includes the true value. plus or minus theuncertainty for 95% of the measure-
The uncertainty of a test result is a measure of the ments. The concept of coverage is necessaryin uncer-
quality of the test. tainty analysis since the uncertainty is only an esti-
Uncertainty analysis performed after atest is run mated error limit.
allows the testengineer to determine those parameters
and measurements that were thegreatest contributors The calculated average value of a parameter plus or
to testing error. minustheuncertainty thus definesaband in which
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 anduncertainty are similar inmany respects.
measurement problems andpermits designing a cost- There are many types and sources of error, butwhen
effective test. a number is assigned to error, it becomes an uncertainty.
A performance test code based on a specified uncer- Accuracy is usedinterchangeably 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 lowuncertainty.
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 measurementisthesumofafixed bias error anda
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 (energybalance or input/output) for evaluat- respectively. The characteristics of these two types of
ing steam generator efficiency. Uncertainty analysis error are quite different.
helpsthe parties to the testmakethese choices. Precision is manifested by the fact that repeated
7.2.2 UncertaintyAnalysisPrinciples. This Section measurements of the same quantity by the same measur-
reviewsfundamental concepts ofuncertaintyanalysis. ingsystem operated by the same personnel do not
It is anaccepted principle that all measurements yield identical values.Precision is arandom 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, resultingnot only fromthe errors inthe data Bias is a characteristic ofthe 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 aspecific instrument system and data reductionand
the basic measurements and data reduction procedures calculation procedures.
and then to propagate those uncertainties into the uncer- Whenthemagnitudeand sign of a bias isknown,
tainty of the result. it mustbehandled as a correction to themeasured
Notethefollowingdefinitions: valuewiththe corrected valueused to calculate test
result. Bias estimates considered in uncertainty analysis
0 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 aflue gas analyzer, thebias resulting fromusing
test results could be based on the true value, not the anuncalibratedflowmeter,the bias arising from the
measured or calculated value. deteriorated condition ofapreviously calibrated flow
Uncerruinty is the estimated error limit of a measure- meter, errors resulting from calculation procedure ap-
ment or result.' proximations, and the potentialerrors made in estimating
Coveruge 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 thanthe 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 overthe course of a test.such
performance. as calibration drift of an instrument.
146

~
STD. ASME PTC 4-ENGL 1798 m 0759670 Lib15085 77T m
True population
average ( p l
Parameter x
L Measured
value (X&
FIG. 7.2-1 TYPES OF ERRORS I N MEASUREMENTS
areassociatedwithvariability 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 flowingfluidmust be zero at
duct) hasbeentreated 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 usuallynot zero.
a potential source ofbias. In a performance test, engineers sample several points
A complete uncertainty analysis requires determining in space andtimeandthenuse averages of the data
values for both precision and bias in the basic measure- to calculate testresults. 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 uncertaintyofthe average value of a parameter and its instantaneous and/
results. Uncertainty analysis can be performedbefore or localvalues are used to estimate the error in the
a test is run (pretest analysis) and/or after a test is measurements and in any results calculated from them.
run (post-test analysis). The method of calculating the average and the method
of calculating theuncertainty in the averagedepend
7.23 AveragingandModels 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 “constantvalue”model,
such as temperature and concentration of certain constit- inwhich 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 parameteronly at a single inwhich it is assumed thattheparameter has some
point or within a limited region of space and at discrete continuous variationin time and/or space (refer to
instants or over limited “windows” of time. It is well Subsection 5.2.3.1).
knownthat 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 L798 W 0757b70 ObL508b b o b m
ASME pIy3 4-1998 FIRED STEAM GENERATORS
measured
Mean
error
Total 6= ß + E
value of
parameter
Obvious error - outlier
AL
Precision
A A A
Frequency
distribution
error Bias of
measurement
L True valueof
parameter
I Time during which the parameter

I
is assumed to be constant
t
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 becausethe laws of physics dictate that andfor area variation it is
it must be otherwise. Figure 7.2-3 illustrates these
concepts. All of thevariabilityinthe actual data for
a constant valuemodelparameter is taken as error;
however, only the scatter about the continuous variation
shouldbe considered error for a continuous-variable
model. Because data are obtained only at discrete points in
The proper average value for a constant value model space andor 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 themidpoints of
equal time or area increments, the integrated average
-
x =-
l
N i = L
xN xi (7.2-1) may be calculated with Eq. (7.2-1); however, the preci-
sionindex is not calculated by Eq. (7.2-2)becausea
~~
constant value model is inappropriate. It must also be

and the standard deviation Of the mean Or emphasized that alternative, more accurate, numerical
its estimate, the sample standard deviation of themean integration schemes can be developed that do not use
Eq. (7.2-1) to calculate theaverage.
The experimental error in an integrated average is
(xi - X’)] (7.2-2)
due totwosources: error inthepointvalues ofthe
data, and error due to thenumericalintegration. The
is the proper index of the precision error. firsttype is the “ordinary” experimental error due to
The proper average for a continuous-variable model processvariations, instrument errors, etc. The second
parameter is an integrated average. For time variation, type results fromthe 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 m
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 theresults. The following discussion of
these methods is based on theassumptionthatthe
reader has an understanding of elementary statistics.
Statistical concepts for performance test code work are
discussed in PTC 19.1 andBenedictandWyler [4].
Notall methods advocated in these references have
beenadoptedinthisCode.
- Analysis of precision errors is based on the assump
r tionthatthey follow aGaussian (normal) probability
Constant Value Model distribution. One important result of this assumption is
theroot-sum-squaremethod 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 boththe gas temperatureandthe
oxygen content of the gas. Any error intemperature
is unconnected with oxygen content; the two are inde-
Improper
error Continuous
pendent. On the other hand, the results of a fuel analysis
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
r
of one component, (e.g., carbon), islowerthanthe
r percentage of another component (e.g.. ash), the percent-
age of another component(s) must be higher.
Continuous Variable Model
Measurementerrors can also beindependent or
dependent. The independence or dependence of errors
can be different from the independence or dependence
FIG. 7.2-3 CONSTANT VALUE AND of themeasuredparameters. If all constituents ofa
CONTINUOUS VARIABLE MODELS fuel sample are determined independently from different
procedures applied to different subsamples, thenthe
errors are independent, eventhoughthe 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, thenthe error ofthat constituent is obviously
error isprecision. Special equations mustbeused 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 istaken as bias. dependent, this dependence mustbeaccounted 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 withparameterand error dependence can
for steam generator test results are given in Sections be minimizedby reducing measurementsand 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

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 althoughthe actual biases are notrandomvariables,
dependentparameters and dependent errors. estimates of bias are randomvariables.
The degrees of freedom of a set of data is a measure Bias estimates must be basedon experience and
of the amount of independent information in the data. good judgment. PTC 19.1 provides few a general
A set of 10 temperature readings begins with 10 degrees guidelines for estimating bias. Obviously, the person
offreedom. The numberof degrees of freedom of a inthebestposition 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 - .)z] ‘/z
(7.2-3)
since thetest data fromwhich to calculate them do
not yet exist. In some cases, it is not feasible to obtain
N- 1 i=l
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 testthat are basedon estimates rather thanon
A somewhat cumbersome formula is needed to deter- measurements. Likewise, it is sometimes more cost-
minethe resulting degrees of freedom whena result effective to assign reasonable values to certain parame-
depends on several parameters, each witha 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 havea large number of degrees of freedom, between various hoppers or the amount of heat radiated
the effects of degrees offreedom disappear fromthe 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.Inthis Code, uncertainties in estimated
can dominate the degrees of freedom of the result. parameters are generally treated as bias.
The precisionuncertaintyofa result is theproduct 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’sr-statistic. The Student’s t-statistic is based uncertainty in any results calculated from the data. This
on thedegreesoffreedom of the precision indexof process is called propagation of uncertainties. Because
theresult andtheprobabilitylevel selected (95% in precisionand 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 thefinal 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 ofall ward, if somewhattedious.Assumethataresult (R)
theparametersthat affect the result according to the is calculated by
equationsgiven in Section 7.4.
Bias is “frozen” in the measurement system and/or
the data reductionand result calculation processand
cannot be revealed by analysis of the data. For a given R = f(xl, . . ., X M )
~ 2 ,
set of measurements using a given measurement system,

the bias is fixedand is notarandomvariable. Bias
errors are thosefixed errors that remain even after where
instrument calibration (bias e m r canbe 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, thebasicpropagation
for bias. Most often, however,it is necessary toestimate equationis
150

STD-ASME PTC 4-ENGL 1998 0759b70 Ob15089 315 m
FIRED PTC 4-1998
where u is the degrees of freedom of the result, and

+. the bias uncertainty is
where u, = u, (7.2-8)
e = theprecisionindex (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= thenumberof independent measured quantities (Student’s r-timesprecision index) into thetotaluncer-
The root-sum-squareadditionof errors istheoreticallytainty. This Code adopts theroot-sum-squarecombina-
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 = (U:, + u p (7.2-9)
following dimensionless form:
[il[ “)r”)J ’1
‘12
7.3 PRETESTUNCERTAINTYANALYSIS
= (2 (7.2-5)
R ax;R xi ANDTESTPLANNING
A pretest uncertainty analysis is an excellent aid in
testplanning. The parties to a testcanuse a pretest
where e,¡ is theuncertainty (precision or bias)in xi. uncertainty analysis toassist in reachingmany of the
The coefficients
agreements
required in Section 3. Decisions regarding
number and types of instruments, number of readings,
number of sampling pointsin a grid, andnumber of
fuel andor sorbent samples can be madebasedon
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 theminimumnecessaryto achieve the
partial derivatives. These derivatives are usually esti- targetuncertaintyand by revealingwhen it isnot
mated by a numericalperturbation technique necessary or cost-effective tomake certain measure-
ments. For example, it may be possible to achieve the
af agreedupon target testuncertainty by using a nine
”I
(7.2-6) pointflue gas sampling grid rather than a 16 point
axi
grid or by using historical data rather than multiple
f(x1. . . ., x ; + 6 x;. . . ., x”) -Ax¡, . . .. x;. . . ., XM) laboratory analyses for fueland sorbent properties.
6X; The methodology of a pretestuncertainty analysis
isformally identical tothat 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 withtheperturbedparameterreplacing estimated ratherthan 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 (processvariations,
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
manytimes (one recalculation for each independent persons. Values obtained from similar tests are often
parameter), anautomated calculation procedure is highly a good starting point.
desirable. A complete pretest uncertainty analysis may require
The precisionuncertainty 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 mostcost-effective manner. Computer
support isessentialto 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 andtest 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:
7.4EQUATIONSANDPROCEDURESFOR multiple measurements made over time at a single
DETERMININGPRECISIONINDEX 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 requiredpost- multiple measurements made at several locations in a
testuncertainty 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 usespredicted values for the parameter averages the sumof averaged measurements, e.g., totalcoal
andprecisionindexes. The equations and procedures flow rate when multiple weigh feeders are used
ofthis Section areaimedat 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
steampressure) naturally exhibit perturbations about to determine the average flow rates, e.g., solid residue
theirtrue (or average) values. These perturbations are flow rates
the realvariations 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
7.4.1.1MultipleMeasurements 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;'= 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
thereproducibility of the instrument. Reproducibility
includes hysteresis, deadband, andrepeatability [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. V, =N- 1 (7.4-4)
For a post-test uncertainty analysis, the instrumenta-
tionvariances are not specijìcallyrequired, 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- weightedAverages). 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 therealvariance 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 thevalue of
ignored. If the instrumentation variance is less than the parameter at thepoint:
152

RRED STEAM GENERATORS ASME PTC 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 thenumber of readings over time and i in two steps:
identifies the point in the grid. For unweighted averages
x is the measuredparameter,such as temperature or %k = (7.4-10)
oxygen. "I
The sample standard deviations, sample standard
deviations ofthe mean, and degrees of freedom are
calculated at each grid point as if the parameter exhib-
j=O
[8::k l6%j+I,k
R3j+l.k +I- g1*3j+2,k
R3j+2.k
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 (64 ~ 4 ) ~
ter depends on the averaging ruleused. v, = (7.4-11)
4
"I
For multiplemidpointruleaverages, theprecision
indexis:
(7.4-6)
For the composite midpoint rule average,the precision
The associated degrees of freedom is indexis
where
v=
5 [A]
i= I
PI4
(7.4-7)
The associated degrees of freedom is

I (7.4-12)
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 whichis 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:
P 81s%j,k+-+-
AJ. = - I6%j+l,k 81$3j+2,k (7.4-14)
x [9:k 1-
" I
S;k =
3
4Si3j+I.k 9%j+Z.k R3j+l.kR3j.k R3j+2,k
~
+ (7.4-8)
j=O '3j+ I .k r3j+2.k
7.4.1.3 Integrated
Average
Parameters
(WeightedAverages). Parameters such as flue gas
temperature or oxygen are sometimes calculated as
weighted averages. The weighting factor is the fluid
velocityfraction 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
S,,,,= the sample standard deviation ofthe kth set distribution.
of measurements Velocity measured simultaneously with the parameter,
the sample standard deviation with respect to with several complete traverses.The number ofreadings
time at point j , k [from h.(7.4-3)] at each point in the grid must be large enough to
rj,,= the number of readings at j , k assure statistical significance.Generallysix or more
153

STDOASME PTC 4-ENGL L998 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-
x,,¡ beingtheweightedvalue. For temperature, for sition ofthe streams. These streams may be gaseous
example, (such as flue gas) or solid (such as coal, sorbent,
andresidue). Usually, these samples are obtained in
Xj,¡ = (+)
v.’
l j i (7.4-15)
increments; thatfinite
is a sample
intervals. The sample locations may
taken
is
be
at periodic
separated in
space, as in sampling multiple coal feeders or multiple
pointsinaflue gas duct cross section, as well as in
where v isthespace-andtime-averaged velocity.
time.It should benotedthatinthis Code, solids
Velocity Measured Simultaneously With the Parame-
composition is treated as a constant value parameter
terwitha Small Number of CompleteTraverses. 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 isthatthe
must be provided tosimultaneously measure the velocity
gaseous samples are usually analyzed “online” during
and the parameterata single fixed point. The point
should be selected so that theexpected values of velocity thetestwhile solid samples areusually analyzed in a
and the parameter are approximately the average values. laboratoryata later time.
Data should be recorded with a frequency comparable There are two alternative means for determining
tothat for other data. the average properties ofmaterial samples taken in
The instantaneous values from the pointare multiplied increments; therefore, there are two means for determin-
to give avariable xj: ing the precision index. The first methodfor 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 beusedin the performance calculations)
is then determined as the mean of all of the individual
sample results. Inthesecondmethod,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 theremaybe replicated analyses of the composite
standard deviation for the integrated average parameter sample, there is still only one sample for analysis.
following themethod described in Subsection 7.4.1.4 Often, a combination of both methods is themost
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
firescoal from a single seam, themoisture and ash
can be highlyvariablewhile 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 precision indexes, should be determined from
FW= the weighted average analysis of several individual samples, while theaverage
U W = the unweighted average values for the other constituents (on amoisture-and-
P = the parameter (temperature or oxygen) ash-free basis) can be determined from a single analysis
Plw is calculated as described in Subsection 7.4.1.2. ofamixed 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, anddividedsepa-
able, the precision index of velocity is estimated from rately, the average value ofa constituent is the mean
multiple readings at a single point, together withthe 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 PTC 4-1998
IncrementsMixedPriortoAnalysis. If the sample popularion standard deviation(dby assuming that sH

increments are mixedprior to analysis, thevarious isthesmaller of (sH,cr).The precisionindexcan be
increments aremechanically 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 ofthe analysis
of themixed 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 andmust mixed. The degrees of freedom for this estimate can
therefore be e~timated.~ Itis often possible to obtain be taken as infinite. Refer to Subsection 4.8.2 for
accurate estimates using historical data or, sometimes, additional requirements whenusingthismethod to
limited measurements, for determining precision. estimate coal-constituent precision.
EstimatesfromHistorical Data. Cases wherethis 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 typicallytaken
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 aretheindividualpoint 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 thesame 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 aretakenfrom each
0: Moisture-and-ash-free constituents for coalmined grid point,theprocessmost closely matchesmultiple
from a single seamshould satisfy this condition so midpoint averaging. The point-to-point variation in Oz,
thathistorical data fromthe same seam can beused althoughnotrevealedby the composite sample, is
to estimate theprecision for the test data. considered a bias due to numericalintegration by
If a numberofmeasurementsaremadefrom the thisCode.
same population, it is unlikely that the sample standard Even though the point-to-point variation is not consid-
deviations willbe 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 basedon nH on thisvariationisrevealedonlyinthe composite
observations andhave sample standard deviation sw sample. Itisassumedthat 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 theparameter(e.g., spatially averagedoxygen
concentration) were a constant value parameter:
7.4.1.5 A Single Measurement or the Sum of
Single Measurements. For parameters determinedby
where ,,,S and sminare the larger and smaller values a single measurement or the sum of single measure-
of (sH,s)and Fnmax-l,nmin-l,Sa is theupper 5% point ments,theprecision 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- l. that it can be neglected. The spatial and time variations
Now suppose thatthenumberof readings in the ofsuch parameters shouldbeconsidered as biases,
second set is very large ( n + m). We can generate withappropriate estimates made for theirmagnitude.
an estimate of the probable maximumvalue of the The problem of uncertainty ofsingle measurements was
considered extensively by Kline andMcClintock [5].
)It should be noted that rnulriple analyses of the same gross sample
can give the precision index of the
analytical
instruments
and
procedures but give no information abouttherealvariationinthe 4While it may be arguedthattheprecisionindex and degrees of
materialproperties or the samplingvariation. In most cases, these freedom arebetterthan thosecalculatedby Eqs. (7.4-2) and (7.4-
lattertwosources of variabilitydominatetheprecision of material 4) because several points are sampled, it is impossible to determine
properties. these“better”valuesafterthesamplesaremixed.
155

7.4.2PrecisionIndexand Degrees of Freedomfor z = cüv

Intermediate Results. Frequently, a parameter used as
if it weremeasured data is actually calculated from and uses the “propagation of error” formula. The sensi
moreprimarymeasurements. Two examples are fluid tivity coefficients are
flow rate,whichis often determined from differential
pressuremeasurements,and enthalpy, whichis deter-
C,@) =C and (z@v) = CU (7.4-21)
mined from temperature (and sometimes, pressure) mea-
surements. There aretwo possibilities for calculating
The precision index is
theprecisionindex 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 Pì = [(CF S,,)’ + (CiïSis,)2]1’2 (7.4-22)
result to theprimarymeasurements. This isnot 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
the precision indexof the result.The following describes
specific cases.
7.4.2.1Parametersofthe Form z = C 4. The
measurements, x;, should first be converted to zi.Then
7.4.2.4 Flow Rates UsingWeigh Bins or Tanks.
the average andthe sample varianceof z can be Weighbins or tanks are used as integrating devices
calculated from the z;. Differential pressure flow meters
to smooth out variances inthe flow rate. The desired
exhibit thistype of parameter relationship.
flow rate generally is one occurring upstreamofa
componentwith storage capacity. For example, the
7.4.2.2Parameters of the Form z = ao + alF +
ug2+ . . . + u p n . Equation (7.2-4)
is applicable to catchofabaghouse can be determined by aweigh
bin on the disposal line fromthebaghouse hoppers.
functions of one variable; inthis case thevariableis
X. The sensitivity coefficient for Z is
If weight and time readings are taken at the beginning
andtheendof the test period,the average flowrate,
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 precisionindex is where

u ] , u2= the initial andfinalweightreadings,respec-
tively
PI = (z @x) (S,’> (7.4-20) T], = the initial and final time readings, respectively
As multiple measurements are nottypicallymadeof
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 precisionindexis:
The. most commonoccurrence of this form of equation
in steam generator performance testing is an enthalpy-
temperaturerelationship.
7.433 Parameters of theForm z = C ï i V.

Generally,themagnitudeofthe 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 (ui,vi)
The instrumentation biases are likely to be significant.
into theintermediate result (2;) andthen average the
valuesof the intermediate result and calculate their 7.43 Precision Index and Degrees of Freedom of
precisionindexand degrees offreedom. Test Results. If the test result is a measured parameter,
The second alternative calculates z from the averages such as the temperature oftheflue gas exiting the
of u and v steam generator, then the precision index and degrees
156

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~
STD.ASME PTC 4-ENGL 1798 0757b70 Ob15075 b 1 9 m
of freedom ofthe result are just the values for the methodsusingacomputer. If a computer program is
parameter itself. If the test result must be computed available to calculate thetest resultant, R, fromthe
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, byasmall amount (h;), keeping the value
the individual parameters. of the other parameters constant and evaluating the
change in the calculated value of the test resultant, M.
7.43.1 CombiningPrecisionIndexes. 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 (R@> = (?) =
SR
-
hi
(7.4-30)
] ”’ (7.4-26) hi is a small value such as xi/100 or xi/l,OOO.

For a pretest uncertainty analysis, predicted perform-
ance data are used for theaveragevalues. The actual
where
average values ofthemeasured parameters areused
Rexi=(dR/dxi) =the sensitivity coefficient of parame-
ter xi on result R and k is the total for apost-test analysis.
number of parameters that are used
to calculate R
7.5EQUATIONSANDGUIDANCE FOR
7.43.2 CombiningDegrees 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 all reasonable
attempts to eliminate it (such as calibrating instruments)
YR =
i (Rex;
(7.4-27) havebeenmade.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 SensitivityCoefficients. The sensitivityco- but they remain estimates nevertheless. A second essen-
efficients are thepartial derivatives of the result with tial fact concerning bias is that its value(s) is unique
respect to the parameter: to themeasurement system employed in aspecific
test and to the process and ambient conditions during
thetest.
(7.4-28)
This Section gives certain mandatory rules for making
bias estimates and for mathematicalmanipulationof
in accordance with E q . (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 anymodels for
bias set forth in this Section, provided that the parties
to thetest agree to do so and thattheyagreeonan
(7.4-29) appropriate substitute.
7.5.1
General Rules
The relative sensitivity coefficient is useful in a Bias limits usedinthis 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 uponby the parties to the test
of thetestresult.
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 physicalprocess so suggests and the parties to the
157

~ ~~
STDSASME PTC 4-ENGL L998 m 0759670 0615096 555
test agree that such estimates are the best available. The maximum positive or negative deviation from
If nonsymmetrical 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 inanymeasurement or from reference accuracy do not include the effects of
result is afixedvalue, an esrimafe 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 permittedifboth parties to the test agree. as the root-sum-square of the precision indexofthe
calibration curve (the Standard Error of Estimate of
7.5.2 Biases in Measured Parameters Due to Instru- thefitted curve) andthe bias limitofthe reference
mentation instrument. Refer to PTC 19.1, Measurement Uncer-
There areanumber of sources of instrumentation tainty, for further information.
bias in any measurement; among thoseare:primary
7.5.2.2CombiningBiasesFromSeveralCompo-
element, primary sensor, transducer,amplifier, analog/
digital converter, recording device, and environmental nents. If an instrument system has several components
and each hasa separate bias limit, thecombinedbias
effects. ISA Standard ANSVISAS5 l . 1 may beconsulted
for general information about instrumentation bias [7]. limitofthe measurement is
Section 4 gives guidance for estimating bias limits
due to specific instrumentation systems. This section B = (B: + B: + . . . . + B y 2 (7.5- 1)
providesgeneral guidelines and rules for combining
these elemental biases. where subscripts 1, 2 . . . m represent thevarious
If separate components of aninstrumentation 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 thetest data, the than one-fifth of the largest in a specific loop maybe
biases shall be excluded from the uncertainty analysis. ignored in calculating the biasof the parameter.
Estimatedbiases resulting from drift in calibration,
ambient effects, etc., are included in theuncertainty 7.5.2.3 Multiple Measurements With a Single In-
analysis. strument. For multiple measurements at a single loca-
tionwitha single instrument (such as measuringthe
7.5.2.1BiasDue to a SingleComponent. Ifa temperature at several points in aflue 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 mentationbiasofthe average value of theparameter
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, = B,¡ (7.5-2)
The deviation is expressed in anumberofways:
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 SeveralLocations. The mostcommon
been made. The width of the envelope, A, is a measure example is theuseofafixed&id of thermocouples
of the precisionof the device and is sometimes called the to measure (average) flue gas temperature. Two different
reproducibilityofthe 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

~~
~
STD-ASME PTC 4-ENGL L998 m O759'b7O Ob35097 491 m
FIREDSTEAM GENERATORS ASME WC 4-1998
--"-T v
10 30
FIG. 7.5-1 GENERIC CALIBRATION CURVE
tutes one loop) are judged to have the same bias. This 7.53 Bias in Spatially Nonuniform Parameters.
wouldtypically occur when all thermocouples are of Certain parameters in a steam generator performance
the same typeand quality andall 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 fluegas composition,
bias in the average parameter (temperature) isequal should be evaluated as flow weightedintegrated average
to the instrument bias for any one oftheloops: values [8] (refer to Subsections 4.3.4 and 7.2.3).
In practice, integrated averages are approximated by
B, = B,¡ (any i ) (7.5-3A) sampling at afinitenumber of points and usinga
numerical approximation to thenecessaryintegral. In
The second situation is when different loops are addition to this approximation, the parties to the test
judged to havedifferentbiases. 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
varietyof other reasons.Inthis case, theinstrument 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.
B, = - BXi (7.5-3B) If measurements are made at onlya few points
NX=I
(sometimes as few as one or two),thenthemethods
where suggested below for estimating these biases cannot be
N = the number of different instrument loops used. Likewise, these methods cannot be used for
L?,,=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

estimatedand assigned by agreement between parties
to thetest. Experience and data fromprevious tests
= I;.([ OS SDI
(7.5-5)
on similar unitscan serve as the basis for amodel. MultipleMidpoint Rule

Bias estimates must be large enough to account for
theindeterminate errors present in small samples.
7.53.1 SpatialDistributionIndex. It is possible
to make mathematically elegant estimates of numerical
= I[(-. ‘’O SDI
(7.5-6)
integration error; however, these estimates require where m is thenumber 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 usuallynot available, a heuristic model is selected by the Code committee to reflect the relative
proposedfornumerical integration bias. The model magnitude of the biases and the dependence of the
assumes thatnumerical integration errors are propor- bias on thenumber of grid points but have no other
tionaltothe following spatialdistributionindex: theoretical basis.Inthe case ofa single stream (e.g.,
flue gas) divided between two or more separate ducts,
themodelisapplied to each duct. If historical or
preliminarytraverse 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 T is the integrated average value of z. Since SDI 7.53.3 Bias Associated with Flow Weighting. Al-
is itself an integral, it must be calculated by a numerical thoughthetheoretically proper averages for somepa-
integration method. While it is probably advantageous rameters such as flue gas temperature andoxygen
to use the same integration rule that is used to calculate content areflow-weighted, it is often not advisable to
z for the performance calculations, the value calculated useflowweightingina performance test because the
bythe multiple midpoint rule is satisfactory: errors associated withvelocity determination may be
greater thanthe error madebynot flow weighting.
There are, therefore, two different types of bias error
associated withflow weighting:
If flow weighting is used in the performance calcula-
where m is the number of points in the measurement tions, then there is a bias error due to the bias in the
grid. Inthe case ofa single stream (e.g..flue gas) velocity data used for weighting.
dividedbetween two or more separate ducts, SDI is If flow weighting is not used the in performance calcu-
calculated for each duct. It should be noted thatalthough 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 betweenthe (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 isnot). This Code treats either type
this data. as flow weightingbias.
7.53.2 BiasDue to NumericalIntegration. Sub- Flow Weighting Bias When Flow Weighting Is Used.
section 5.2.3.3 describes threenumerical integration There aretwo options in this case: (1) thevelocity
schemes (averaging rules). The recommended bias limits used for flow weighting. is measured simultaneously
for eachmethodare: with the parameter beingweighted (temperature or
Triple Midpoint Rule oxygen content); and (2) the velocityused for flow
weighting is measuredin 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 regardinguse of
Composite Midpoint Rule velocity data for flow weighting).
160

STD*ASME PTC 4-ENGL 1998 0759670
Ob15099 2b4 m
FIREDSTEAMGENERATORS ASME F’TC 4-1998
For the jrsr option, where the velocity is measured

simultaneously with the parameter being averaged, the (7.5- 11)
flowweightingbias estimate is:
For the second oprion, wherepreliminaryvelocity
- - Bv data are available, but not used to calculate a weighted
BFW = (PUW - PFW) = (7.5-7)
average, the recommended bias modelis:
V
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 oftheweighted average, Pm
FW= weighted averages
7.53.4 CombinedBias for IntegratedAverages.
- biaslimitforvelocity
B”=
The combined bias for integrated average values is
V = average velocity
For the secondoption, 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-
- tion7.5.2.
- Bv
BFW = 2(pUW - PFW) (7.5-8)
V 7.5.4 Bias Due to Assumed Values for Unmeasured
Parameters. The midpoint betweenreasonable“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 WeightingBiasWhen 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 flowratewastaken
the difference between the weightedandunweighted
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) preliminaryvelocity
parameter. It would be the midpoint between the “lim-
traverse data exist, but the parameters are nevertheless
iting”values set, of course, by judgment andagreed
not flow weighted.
to by theparties to thetest.
For the firstoption, 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
anash 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
- 1 m si true value can be lower than the measurement but not
TF, = -X -Ti (7.5-9) higher).
m i=l B
7.5.5 BiasLimit for TestResults. The total bias
where limit for a result calculated fromthemeasuredand
m = number of points in the traverse plane assumed parameters is
B= absolute temperature ( B = T OF + 459.7)
[
The bias estimate is: k ‘12
BR = &J2] (7.5-14)
i= I
BTJW = 2CTuw - TFW) (7.5-10)

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@xi)(BxJdetermines the classification as positive or
temperature bias: negative.
161

~~
STDOASME PTC 4-ENGL L998 D 0759670 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 freedomanda 95%

The precision index and the bias limit of a test result confidence limit and is taken from Table 5.16-
arecombined into thetestuncertaintyaccordingto: 1 or Eq. (5.16-7). In addition to thevalue for
UR, thetestreportshall also statethevalues
of PI,, 3,and B,
where
fuo.025 = the percentile point of Student’s t-distribution
162

STD-ASME PTC 4-ENGL 1998 m 0759b70 O b L 5 L O L 742 m
ASME PTC 4-1998
NONMANDATORYAPPENDIXA
CALCULATIONFORMS
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. Evenwhen a computer program is used, it is SHEET. Usedto average each data point with respect
suggested thatthefirst-timeuserperform 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 themain text, Sections 4, 5, and 7. on this form.
Due to thewidevarietyofthe types of unitsand BIAS -BIAS DATA REDUCTION WORK SHEET.
fuels addressed by this Code, several calculation forms Used to account for and calculate the bias limit for
havebeendeveloped for specific requirements. The each measurement device, including all the compo-
purpose of each form is described brieflybelow: nents of the measurement.
O EFF- EFFICIENCYCALCULATIONS.Used to o UNCERTa - UNCERTAINTY WORKSHEET 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 requiredfor 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
should be used for spatially nonuniform parameters
excess air, dry gas weight, etc.
O GAS - GASEOUS FUELS. Usedto convert the ulti-
first. Separate forms are included for output and effi-
ciency.
mate analysis of gaseous fuels from a percent volume
UNCERTb -UNCERTAINTY WORKSHEET NO.
basis to a percent massbasis. 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 - UNBURNEDCARBON 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. Whensorbent is used, such as fuel flow, calciudsulfur ratio, etc.
this form is used tocalculate the weighted average of INTAVG -UNCERTAINTY WORKSHEET INTE-
carbon andcarbon 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. Usedin conjunc- both space and time, such as flue gas temperature in
tion with the unburnedcarbon 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 associatedwith A.2 SYSTEM OF UNITS
sorbent and sulfur capture are also calculated.
O OUTPUT -OUTPUT. Used to calculate unit output. Fuelefficiency is a function of thepercentinput
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 NONMANDATORYAPPENDIXA
the fuel, such as airflow, use units of l b d b m 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 ofunitsbecause, in effect, it isa normalized This item requires that the combustion calculations
result. For example, 10% ash in the fuel has a meaning be completed first andis mentioned here only because
only when fuels with similar higher heatingvalues 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 totalinput 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, theunitsused on the forms compared to the calculated result when the efficiency
areabbreviatedand are some multiple of the basic results are completed and the calculations reiterated
mass/mass or masdunit of heat input. Some ofthe if the difference is greater than 1%. Refer to Subsec-
more frequently usedabbreviations are described below: tion 5.7.3.
multiple fuels - calculate a composite fuel analysis
l b d b m - pound mass of one constituent per pound
and weightedaverage HHV based onthe 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 themajor input by the difference
pound mass ofanother 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 OrderofCalculationsfor LowAsh Fuels
fuel. These are convenient units to use for the combus-
(OilandGas)
tion calculations.
0 lb/lOKB - 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 theunit configuration or fuelrequired
estimating total input as described in Section A.3 above,
A.3 ORDER OFCALCULATIONS
repeat the calculations until convergence is obtained.
The calculation sequence is described below for three
A.3.2Order of Calculations for FuelswithAsh
levelsofcomplexity, depending upon fuel type. Prior
to these calculations, the user will have to complete (Coal) - NoSorbent
thefollowingpreliminary calculations:
Step 1. 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 testcondi- 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 unitconfiguration or fuelrequired
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 massflow
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 secondaryair heaters, the weighted aver- unmeasuredlocation. (Refer to instructions for RES.)
164

STD=ASME PTC Y-ENGL 1998 m 0759b70 Ob15103 515 m
NONMANDATORY APPENDIX A ASME PTC 4-1998
Srep 1. Complete Items [ l ] through [lo], Form RES. than one source of air, such as primary
Srep 2. Complete the calculations on Forms SRBa and secondaryair, enters at different tem-
and SRBb. The calculations are iterative untilconver- 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 1and 2 until convergence is differentsources. Refer to Items [35]
obtainedforthemass rate of residue. through [ U ] below.
Srep 4. Complete the remaining items on Form RES. Item
Average
3 Exit Gas Temperature (Exclud-
Srep 5. Complete the calculations on the combustion ing Leakage). Enterthe 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. Comparethe 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.4EFFICIENCYCALCULATIONS - (excluding leakage if leaving air heater).
Refer to Items [45] through [51] below.
INSTRUCTIONSFOREFFFORMS
Item 4 FuelTemperature. Enter the temperature
The efficiency calculation forms are used to calculate of the fuel entering the steam generator
efficiencyastested as well as efficiencycorrected envelope. This item is required to calcu-
to standard or contract conditions. The combustion late theenthalpyoffuel. 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 HotAir
Quality Control Equipment.
form. The usershouldrefer to Section 5 for details These items refer to equipment such as
regardingthedefinition and calculation of individual hot precipitators where there is a com-
losses and credits. bined efficiencyloss due to surface radia-
tion and convection, and air infiltration.
A.4.1FormEFFa. This form contains theinput 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 ResultsFrom Combustion Calculation
if applicable, and so noted under the specific efficiency Form CMBSTN. These items are calcu-
loss or credititems. lated on the combustioncalculation forms
and the item number fromthose forms is
Items 1-6 Temperatures, "F. These items require indicated in brackets.
that the user enter the temperature and Item 10 Dry Gas Weight[77]. Enter thedry gas
determine an enthalpy for certain constit- weight leavingthe boiler, economizer, or
uents. Calculation of enthalpy for wet air entering the air heater (no hotAQC
and wet flue gas requires data from the equipment). This is normally the boiler
combustion calculation form (Items [ 101 operating controlpoint 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, hotAQC
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 withsep-
steam generator envelope. Where more arate air heaters.
165

STDOASME PTC 4-ENGL 1998 W 0759670 Ob15104 451 m
ASME PTC 4-1998 NONMANDATORY APPENDIX A
Item 11 Dry Air Weight [69]. Enter the dry air Item 35A Primary Air Temperature Entering, "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 weightedvalue 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, IbAb DA [7]. This item Item 36A PrimaryAir Temperature Leaving Air
is required to calculate the enthalpy of Heater, "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 fuelbasis units. Refer to Item [38A].
corresponding to the same location as Item 36B Calculate the enthalpy of wet air. Refer
Item [ 101 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, "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 temperingairflow 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; calcufate the 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 fromauxiliaryequipment in peringairflowmay also behelpful in
units of million Btuper 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 AirTemperature Entering, "F.
here. Refer to Section 5. Note thatenergy Enter value from Form CMBSTNa, Item
added to the envelope is credited; the [16A].
power to the driving equipment must be Item 40 PrimaryAirflow (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 andCon- 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 temperingair-
flow byenergy balance as indicated. Note
that thecalculations assume thatthe mea-
The calculations of Items [35] through [M] 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,Klbh. Enter the calculated
maryand secondary air streams andpulverizedcoal value from Form CMBSTNc, Item [96],
fired units with atmospheric tempering air are examples based on the excess air leaving the pres-
ofunitsthatrequire these calculations. sure part boundary.
166

STDeASME PTC 4-ENGL L998 m 0759670 ObL5L05 398 m
Item 43 Secondary Airflow, Klbh. Calculate the result in Column B, %. For losses or credits calculated
secondary airflow by difference. on inputbasis, enter the results in Column A,MKB
Item 44 Average Entering Air Temperature, O F . (million BtUn). Upon completion of the inputfrom
Calculate the weighted average entering fuel calculation, Item [loll, those items calculated on
air temperature. aninputbasis can be converted to a percentfuel
efficiencybasisby dividing the result by theinput
The calculations of Items [45] through [51] are
from fuelandmultiplying by 100. Eachsection 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 fromFormEFFc.
Item 45A Flue Gas Temperature Entering Primary The calculationof losses and credits is generally
Air Heater, “F. Enter measured flue gas self-explanatory with the aid of the instructions for the
temperature from CMBSTNb Item [50]. input form, EFFa.Refer to Section 5 for definitions
Item 45B Calculate theenthalpyof wetflue gas and explanations.
based on the fluegas moisture and solids
content determined on FormCMBSTNc, Item 75 Surface Radiation and Convection Loss.
Items [78] and [81]. This is the one itemonthisform 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 airheaterleakage from Form through [33D] from EFFa forrequired
CMBSTNc, Item [88]. measured parameters. If a test has been
Item 46B Calculate the enthalpy ofwet 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 FuelEfficiency, %. 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 Inputfrom Fuel, MKB. Calculate the in-
Item 49 FlueGasFlowEnteringPrimaryAir 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 FlowEntering 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, anestimated mass flow rate of fuel
culate the weightedaverage exit gas tem- (input) isrequired 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 assumedandthen 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 wherefuel 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 thosethat
can be conveniently calculated on a percent input from more than one source of entering air temperature, not
fuel basis and those thatcanbecalculatedon a Btu/ all sources measured (use calculated total airflow to
h basis (units of millionBtuperhour are used). The calculate weighted average)
efficiency is then calculated directly in accordance with more than one source of exiting gas temperature, not
the equation for Item [ l m ] . 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

~_______~ ~
STDmASME PTC 4-ENGL L998 0759670 ObL510b 224
0 residue massflow rate measured atsome locations and A.5.1 Form CMBSTNa. This form contains mostof
calculated result used to determine total theinputrequired to complete the threecombustion
0 sorbent used calculationforms. Some of the general inputandim-
multiple fuel firing pacting combustiodefficiency 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 theuser. Refer
the results of losses and credits that are not universally to Section 5 of the Code if more in-depth explanation
applicable toallfossilfiredsteam generators andare
is required.
usually minor. Refer to Section 5 for the definition of
thelosses. For anyunittobe tested, if the losses/
credits are applicable, itshould be indicated whether
theyweretested or estimated. The calculated or esti- Item 1 HHV - Higher Heating Value of
Fuel,
matedresultshouldbe entered' where appropriate. It Btuflbm As Fired. This item must becon-
isnotedthat it is not possible to identify all potential sistent with the fuelanalysis in Item [30].
lossedcredits in changing
a 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. basedon percent mass flow rate from
each fuel. (Refer to Section 5 . )
Item 2 UBC -Unburned Carbon, lbd100 lbm
fuel from RES or SRBb Form. Also enter
A S COMBUSTIONCALCULATIONS - in Item [30B].
INSTRUCTIONS FOR CMBSTN FORMS For gaseous and liquid fuels, this item
is normally.zero. For solid fuels with ash
The combustion calculationforms 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
powerplantperformancemonitoring calculations and required if UBC is tested.
for efficiency calculations. Users will find this calcula- For general combustion and excess air
tionformreadily adaptable toa 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
0 excess air for Oz. wet or dry basis when residue mass flow rates are mea-
0 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 isestimated.
0 conversion of Oz, 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
dry gas weight, used for efficiency calculations obtained.
wet gas weight, used for energy balance calculations For the first estimate, the user may use
0 dry and/or wet air weight measured fuel flow, Item [4a], or calcu-
determination of air infiltration lated fuel flow, Item[4b], from measured
0 calculation ofcorrected air heater exit gas temperature output and estimated efficiency.If the
(temperature excluding air heater leakage) operating characteristics of aunit are
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-
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, Klbmh. Refer to
used) Item [3].
fuel, residue, flue gas, and air mass flow rate when Item 4b Calculated Fuel Flow, Klbm/h. Refer to
input is known Item [3]. Calculated result, Option 4b,
fuel analysis check based on theoretical air. This is a and usedfor subsequent efficiency calcu-
check on whether the fuel analysis is reasonable. Refer lation iterations when fuel flow is re-
to Section 5. quired.

~
STD=ASME P T C 4-ENGL L998
Item 5 Output, MKBtu/h. Required to calculate type are usually averaged for efficiency
fuel flow, Option4b, and used for subse- calculations but may be calculated indi-
quentefficiency 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, andused for subsequent efficiency separate air heaters withdifferent flow
calculation iterations when fuel flow is rates.
required. Item 16 Air Temperature Entering Air Heater,"F,
Item 7 Moisture in Air, lbrdlbm Dry Air. This Primary/Secondary or Main. Referabove
item is required for the general gas and for multiple air heaters. Enterair 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 [l 11. If used to calculate the corrected gas tem-
moisture in air is not measured, a standard perature leavingthe 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 requiredto calculate air based on the expected air togas leak-
moisture in air. Moisture in air may be age splits for each entering air stream
determined from relative humidityand supplied by themanufacturer (refer to
dry-bulb temperature and/or wet-and Item [ 18C] below).
dry-bulb temperature. Refer to Section 5 Item17 O2Entering Air Heater, Primary/Second-
for calculation procedure. ary or Main. Enter the measured oxygen
Item 12 SummationAdditional Moisture Mea- content entering each air heater.
sure, Klbm/h. Enter any moisture intro- Item 18 O2Leaving Air Heater, Primary/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 theweighted average air to flue
period. gas leakage split. This would normally
Item 13 Additional Moisture, lbm/100 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 theonly source of spond to theHHV in Item [ 11. For multi-
additionalmoisture, this value is fre- ple fuel firing, this is composite
the analy-
quentlymeasured and/or agreedupon sis. Refer to Item [l].
prior to a teston a lbm H20/100Ibm Item19 Mass Ash, IbndlOKbtu. The mass frac-
fuel basis, in which case this agreed upon tion of totalresidue is required at specific
value would be entered here. locationsto determine the enthalpy of flue
Item 14 Additional Moisture, Ibm/lOKEitu. Con- gas. For low ash fuels when sorbent is
vert additional moisture above to Ibm/ not used, the sensible heat of ash in flue
lOKBtu basis. gas can be ignored when the enthalpy of
Item 15 Gas Temperature Leaving Air Heater, "F; 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 O. 15 IbndlOKBtu, enter zero for Item [79]
no leakage (excluding leakage). If there for each column where O2 is entered.
is noair heater, this item may be ignored. If the result of Item [ 191 is greater than
If applicable, enter the measuredgas tem- O. 15 lbm/lOKBtu 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 respectto the totalresidue 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 07’7 m
ASME PTC 4-1998 APPENDIX NONMANDATORY A
Item [79] for each columnwhere O2 is weight for efficiency corrected to contract conditions. If
entered. This normally can be calculated excess air is known, proceed to Item [m]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 thereis 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@).
notedthatany addition of solids other Item 52 Enter theflue gas O2entering andleaving
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 (Sm) calculation [17B], [18A], and [18B].
sheets must be completed and the results Item 53 Moisture in air. If O2 at locationisona
entered for these items. dry basis, enter zero. If O2 at location is
onawet 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 undertheItem 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 56-58 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, lb/ 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 onCMBSTNb
A.5.2.1Corrections for SorbentReactionsand 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 61-68 These items areused 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, IbdlOKE3. This is may be skipped.
the mass of gaseous combustion products If the stoichiometric O,, CO2, andSO2
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 basisand 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 , CO,, SO2, air, and gas weights when since the orsat C02 sorbent also ab-
excess air is known, such as when calculating dry gas sorbs SOz.
170

~
STD-ASME PTC Y-ENGL 1978 m 0759b70 Ob15109 T 3 3 W
NONMANDATORY APPENDIXA ASME PTC 4-1998
A.5.3.1 Flue Gas Products, IbndlOKBtu Item 85 Enter the enthalpy of wet air basedon
the temperature of the gas leaving theair
heater (in Item [83]) and the moisture in
Items 69-74 The mass of the products that make up air (in Item [7]).
wetflue gas onan lbdlOKBtu 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
theproducts inthewet flue gas onan in fluegas entering the air heater (in Item
lbm/lOKBtu basis. [78E]), andresidue 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 themeasured gas temperature,usethe
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 theenthalpyof 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, Klbm/h.
leaving the steam generator envelope.
These items are calculated after the efficiency calcula-
Refer to Item [ 191.
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 onan 1bdlOKBtu
combustioncalculations.
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 theinput 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, residuerate,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 weightedaverage 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 shpped if using theexcess air leaving the boiler will
there is no air heater or temperature is be higher thanthe actual flow through the
not measured. forced draft fan(s). For air resistance and/
Item 83 Enter (from Item [ 151) themeasured 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 wetairflowbasedon
of the air entering the air heater. the excess air in Item [95].
171

STD.ASME PTC 4-ENGL L998 m 0759b70 O b L S L L O 755
A.6GASEOUS 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 gaseousfuel analysis from a percentvolume basis
Item 18 Density at 60°F and 30 in. Hg, lbdft’.
to a percentmassbasis. The ultimate analysis of a
Calculation of the density is based on the
gaseousfuel is reported in termsoftheas-firedfuel
sum of Column 4.
components (such as CH4, C2H6) on a percent volume
Item 19 Higher Heating Value, Btdft3. Calculate
basis. The higherheatingvalueof 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 thisCoderequire an elemental fuel analysis on a
by 100.
percentmassbasisand a higherheatingvalue on a
Item 20 Higher
Heating Value, Btdlbm. The
mass or Btu/lbm 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.7UNBURNEDCARBONAND 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,thisform
(15.6OC) and 30 in. Hg (762 mm) in ac-
is used to calculate theweighted average ofcarbon
cordance with the standardreferencetem-
and carbon dioxide in the residue. These results are
perature for reporting the higher heating
usedin 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 valueof each constit-
are furnace bottomash (bed drains), economizer or
uent is provided. Refer to Item [3].
boiler hoppers, andmulticlone rejects and fly ash leaving
Item 6 Higher Heating Value of Gas. Multiply
theunit.
Columns 2 and 5 to obtain the HHV of
It is necessary to know the quantities of ash leaving
each constituent.
theunit 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
unitswith sorbent) inthe 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 constituentin the fuel The mass of residue leaving each location maybe
component. Notethatwater, HZOv, is measured, in whichcase the measured values foreach
considered to be in the vapor state. location would be entered in Column 5.
Item 14 MW, Ibdmole. The molecular weight of The residue at one or more locations may be measured
each elemental constituent isgiven 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 each for 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, Nb&. Not re- A.7.1 Units WithoutSorbent
quired if residue split is measured or mea-
Item11 Unburned Carbon, lbd100 Ibm Fuel.
sured at all locations. When residueis
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 ashin 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 WithSorbent
the efficiency result converges. For effi- Enterthe 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, K l b d . 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,
residueismeasuredat 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- thetotal residue calculated onForm
tal residue (from Item [21]) under Item SRBb, Item [50].
[5F]. Estimate thetotalresidue,Item
[5F], initially from the sum of the sorbent A.73 Total Residue
flow rate plus Item [l] x Item [3]/100.
Item 21 Total Residue, Klbm/h. Calculate the to-
For locations where residue mass flow
tal residue in Klbm/h. Compare Item[21]
ratewasnot 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 thedifferencebetween the total resi-
ble) untilItem [5F] andItem [21] are
due mass flow rate, Item [5F], and the
within 2%.
sumofthemeasured mass flow rates
Item 22 Total Residue, IbdlOKBtu. Convert res-
times theestimated 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 SensibleHeatResidue 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 residuefor each tem-
Item 7 CO2 in Residue, %. Required onlyfor 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

A.8SORBENTCALCULATIONSHEET - results. Refer to Section A.3 or Subsec-

MEASUREDCAND CO, INRESIDUE 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),massflow
+Item 3 Sorbenfluel Ratio. The sorbent-to-fuel
rate of spent sorbent and residue, and the calcium-to-
ratio (lbm sorbentnbm fuel) is used to
sulfur molar ratio. These two forms are used in conjunc-
convert the sorbent mass flow rate to a
tionwiththeunburnedcarbonand residue calculation
fuel rate or input from fuel basis which
form for units with sorbent, RES. Sorbent Form SRBc
is usedfor all calculations related to input
isused 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 [l].
sorbent chemical reactions and sulfur capture. The
Item 4 Carbonin 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 arebaseduponmeasuringCin
envelope. Enter the result calculated for
the residue to determine unburned carbon, and carbon
Item [9F] on Form RES. For general per-
dioxide (CO2)inthe residue to determine percent
formance calculations when theCand
calcination ofthe Caco3 inthesorbent.Asa 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 [ 15B],
Item 5 C02 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 willbe 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
are estimated initially and results are reiterated using performance calculations when the C and
the last calculatedvalues. CO2in the residue are not measured,enter
Items marked with a plus sign (+) are the calculatioh zero to indicate not measured.
Item 6 Moisture in Air, l b d b m Dry Air. Enter
results thatmust be recalculated after each iteration.
The results of this form are also required for general the moisture in air from CMBSTNa, Item
[7]. This item is not requiredif the 4 and
combustiodefficiency calculations, such as for correc-
tions to contract conditions or performance monitoring. SO2analyses are measured on a dry basis.
Items 7, 8 Sulfur capture is calculated from O2 and
For general combustion/efficiencycalculations when the
C and CO2 in residue are not measured, enter typical S 0 2 measured at the same location. The
values for unburned carbon, Item [lSB], and calcination, method ofmeasurement should be on the
Item[23A]. Typical values for sulfur capture may be same basis, i.e., wetor dry. Although this
used, or calculations of sulfur capture maybebased is not described, if they are not on the
on measured SO2 and O2 anda typical fuel analysis. same basis, the conversion ratio from wet
For corrections to contract conditions, refer to Section 5. to dry maybeassumedto convert the
constituent measured on a wet basis to a
A.8.1 Form
SRBa dry basis and the calculations reiterated
until the assumed wet-to-dry conversion
A.8.1.1 Data Required ratio agrees with the calculated ratio.
Item 7 SO2 Flue Gas. Enter the measured value
*Item 1 Fuel Rate, Klbh. Initially enter themea- 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 SO2, %. Enter the
essary to recalculate the residue and sor- measured value of 0, measured at the
bent using theRES and SRB forms after same location as the SO2 above.
completion of the efficiency calculations Item 9 S02 and O2 Basis Wet or Dry. Enter
untilthe 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 L998 m 0759670 Ob15113 4b4 m
NONMANDATORYAPPENDIXA ASME PTC 4-1998
Item 10 Additional Moisture, lb/100 lb Fuel.En- A.8.2

Form
SRBb
terthetotal additional moisture from
A.8.2.1SulfurCapture Based onGasAnalysis
CMBSTNa, Item [ 131. This item is not
required if Items [7] and [8] are measured
on a dry basis. Items 30-45 Calculate sulfur capture basedon S 0 2
and 0, in the fluegas. 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.Forgeneral
Item15UltimateAnalysis, % Mass. Enter theul- 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 [30] through [M].
is measured, it will be necessaryto repeat Items 3&33If O2 and SO2 aremeasured on a dry
the calculations untiltheassumedun- basis, enter thevaluesindicated in the
burned carbon is within 2% of the esti- ‘‘Dry’’ column. If measured on a wet ba-
mated value. sis, perform thecalculations in the “Wet”
Items 16-18 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 [31] through [33] OtherSorbent/ResidueCalculations
from Form CMBSTNb. Refer to instruc-
tions for CMBSTNb for more details. +Item 47 SO3Formed, lb/l 00 lb Fuel. Calculate the
SO3 formed in the calcium oxide (Ca0 +
A.8.1.3 SorbentProducts 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 MW. Molecularweightofthesorbent 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 MoYlOO lb. 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 NONMANDATORY APPENDIX A
tionsof Item [15] through [51] markedwitha plus Item 80 Credit Due to Sulfation, % fuel input.
sign (+) until estimate is within2% of the calculated Calculate credit due to sulfation and enter
result. result on Form EFFb, Item [66], in Col-
Refer tothe instructions for Form RES. Enter the umn B (%).
results of Item[50] above underItem [20] onForm 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 within2%of Item [5F]. A (MD).
If not,repeatthe residue calculations, RES Items [5]
through [lo], revise Items [4]and [5] on SRBa, and
repeat thesorbent form calculations for the items marked A.9 OUTPUT - INSTRUCTIONSFOR FORM
witha plus sign (+) until convergence is obtained. OUTPUT
A.8.3 Sorbent CalculationForm SRBc -Efficiency This form is used to calculate unit output. The form
Calculations consists oftwo parts. The first portion deals withthe
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
onthisform. The sensible heat loss from residue, secondportionofthe form deals withthe calculation
whichincludes 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-
CMBSTNathroughCMBSTNc, be completed first.It 2 flow is calculated by subtracting the reheat-2 extraction
is suggested that this formbe completed after completing andturbine seal flow and shaft leakage fromthe sum
theinput for the efficiency calculation forms. of the cold reheat-1 flow plus reheat-1 spray water flow.
Enter all applicable measuredflows, temperatures
Item 61 Sorbent Temperature, "F. Enter the tem- and pressures in the lightly shaded blocks. Determine
perature of the sorbent. Calculate the 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 inthe 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- 1Item 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 fromSorbent Loss, MKBtuh. Cal- [l] should not include SH spray water
culate water from sorbent loss and enter flow.
result on Form EFFb, Item [59], in Col- Item2 SH Spray Water. When SH spray water is
umn A (MKB). supplied from feedwater, enter the flow,
Items 71-77 Losses
from Calcinatiofihydration, 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 [a]. Note that when
enter the sum under Item [77] andon the spray water temperature is lower than
Form E m , Item [%I, 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 0757670Ob15115237 M
NONMANDATORYAPPENDIXA ASME PTC 4-1998
tive. This item is not applicable to units flow, temperature, and pressure, andcal-
wherethespraywateris from a sweet culate the enthalpy. It is recommended
water condenser internal to the steam theflow be measuredratherthan cal-
generator envelope. culated by energy balance due to the dif-
Items 3-8 These items are used to calculate SH ficultyof obtaining a representative
spraywaterby 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 providedto calculate main steamflow heater extraction flow(s) and turbineseal
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.
theflows are required to calculate output. Item 24 Turbine Seal Flowand Shaft Leakage.
Provision for entering temperatureand This item is normallyestimated 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.
Items these 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 thatare 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 [ 181. extraction flowis calculated by energy
Item 18 Main Steam. When feedwater flow is balance in Item [29].
measured,main steam flow is the sumof Items 30-34 F W Heater No. 2. Applicable for units
the feedwater flow and SH spray water where the second point heater extraction
flow less the blowdown flow, internalex- is from thecold 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, internalextrac- thalpy. The steam extraction flow is cal-
tionflows, miscellaneous auxiliary ex- culated by energy balance in Item [34].
tractions, and energy added to thesuper-Item 35 Cold Reheat Flow. The cold reheat flow
heater spray water.Notethat 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 anyother miscellaneous extrac-
tion flows.
Item 36 Reheat Output. The reheat output is the
A.9.2 Units with Reheat
sum of theenergy 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

ASME PTC 4- I998 NONMANDATORY APPENDIX A
A.10DATAREDUCTIONWORKSHEETS - a percent of the reading or in the same

INSTRUCTIONSFORDATAFORMS 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-
WorkSheet
sured parameter. For spatially nonuni-
This form is used to average each data pointwith form parameters, enter the result of the
respect to timeand calculate the standard deviation spatial distribution index, Item [43], on
for usein determining theprecision component of Form INTAVG.
uncertainty. This form is also usedto average each Items2A,2B, Calculate the total positive andnega-
data pointwithin a sampling grid beforethe 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.11UNCERTAINTYCALCULATIONS -
INSTRUCTIONSFORUNCERTAINTY
analog value or a digital value, such as
WORK SHEETFORMS
millivolts. If the value in Column 1 is a
digital value, convert it to an analog value The uncertainty worksheet forms are used to calculate
in Column 2. If the instrumenthas a cali- overall testuncertainty. These forms can beused 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 formsshould
in Column 4. becompletedbeforetheuncertainty 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 ontheuncertainty 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 andbias errors
deviation. for measuredparameters.
A.ll.l Form
UNCERTa - Uncertainty
Work
A.10.2Form BIAS - Bias DataReduction SheetNo.1
Work Sheet Two similar work sheets havebeen provided, one
This data sheet is used to account for and calculate for output and one for efficiency. Eachworksheet
the bias limit for each measurement device, which form contains the input information for data reduction
includes all the instrument components required for the and information required for determination of the preci-
measurement. Therefore, if pressures arereadbytwo sion component of uncertainty. As noted on the form,
different qualities of pressure transducers or some ther- this work sheet is set up for spatially uniform parame-
mocouples are readwith 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-
one data sheet would be required for both pressure form parameters to obtain input for thisform.
and temperature. Refer to Section 4 for suggestions on
whatshould be considered andtypicalvalues. 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/orestimated 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 finitecoverage of each measured parameter from Form
of the grid. PREC,Item[2], or FormINTAVG,
Items 2, 3 Enter agreedupon values for bothposi- 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

~~
STD-ASME PTC ‘4-ENGL L998
BIAS Sheet Enter the BIASSheet Number. The same Item 10 Recalculated Efficiency. Enter the recal-
Number BIAS data can often be usedfor 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
plicablepositive bias information from from Item [7]. The average value of all
the BIAS work sheet. other measured parameters shouldnot
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 indexfor each late the relative sensitivity coefficient in
measured parameter in accordance with accordance with the equation.
the equation. If Form INTAVG was used, Item 13 PrecisionIndex 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 wasused, 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 percentchange equation shown. This converts the per-
in the average value of each measured centage bias numbers to the measured
parameter. The recommendedpercent 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 biaslimit 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 themeasured
the average value of the measured param- units for each measured parameter.
eter is zero, enter any small incremental Item 20 BaseOutput or Efficiency. Enter Item
change. It is important that the incremen- [37] from Form OUTPUT or Item [80]
tal change bein the same units as the fromForm EFFb, calculated withthe
average value. averagevalue of all measuredparam-
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.
theinformationrequiredto calculate totaluncertainty. Item 23 Student’s ?-Value. Enter the Student’s r-
The nomenclature used on these work sheets refers to value determined from Table 5.16-1in
output and efficiency; however, the sheet can beused the Code.
for any calculated itemsuch as fuelflow, calcium/ Item 24 Precision Component of Uncertainty.
sulfur ratio, etc. Calculate the precisioncomponent 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 withthe
measured and/orestimated 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 L998 m 0759b70 O.bl15LL8 Tllb
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 indexin accordance with the
well as theinformationrequired 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 whichvarieswithboth 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 maybemorethan one flue or precision index of the grid in accordance
duct, such as two or more air heater gas outlets. This with the calculation.
sheetshould be filledout for each flue or duct and Item 42 Degrees of Freedom for Grid. Calculate
theaverage result of each flue or ductthen averaged the degrees of freedom for the grid in
together. Refer to Section 5.13 for considerationsregard- accordance with the equation.
ingaveraging multiple ducts. This form is set up for Item 43 Spatial Distribution Index for Grid. Cal-
averagingusing the multiple midpointruleforthe 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 onForm
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 ofPoints 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 agreedupon 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 theesti-
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 [M]
with respect to time for each grid point through [471.
from Form PREC. After this form is completed, Items [40] through
Item 36 StandardDeviation. Enter the standard [42] and [48] shouldbe entered on Form UNCERTa,
deviation with respect to time for each Items [l], [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 measuredparameter, 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 EFFaEFFICIENCY CALCULATIONS

Data Required
Average Entering Air Temp
47 Flue Gas Temp

Lvg Sec
AH, CMBSTNc
F C8811 I 48 I Total Gas EntAir Htrs, Klb/hr
CMBSTNc C931 I
49 Flue Gas FlowEntPr¡Air Htr, Klb/hr C401 X (C3781 - 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
Initial
flow
AH Estimate I I Calculated I I
NAME OF PLANT ASME PTC 4 MASTER FORM UNIT NO.
TEST NO. DATE I LOAD
(TIME START: END: JCALCBY I
IDATE
ISHEET OF I
181

ASME FTC 4-1998 NONMANDATORY APPENDIX A
FORM EFFb EFFICIENCY CALCULATIONS

LOSSES, YO Enter Calculated Result in YOColumn C61 A( MK8 B( Oh
60 Dry
C101Gas x C3Al I 100
X I100
Waterfrom H2Fuel C121 x (C361 - ClAl) I 100

x ( - 45) 1 1 0 0
Water from H20 Fuel C131 x (C381 - ClAl) 1100
x ( - 45) 1 1 0 0
Water from
H20v Fuel C141 x C3C1 1100
X I 100
641 Moisture in Air C161 x
X
C3Cl 1100
1100
65 UnburnedCarbon in Ref C181 x 14500 I C191 = x 14500 I
66 Sensible Heat of Refuse - fromForm RES
67 Hot AQC Equip (C201 X (CSAI - C6AI) - (C221 - C2011 X (C6B1 - C6C1)) 1 1 0 0
-
( x ( - I-( - ) x ( - ))I100
I 68 lother Losses. %Item
Basis
EFFcForm - from C1101 I I I
I 69 lSummation of Losses. % Basis I I I
I MKB LOSSES.
in Enter
MKBtu/hr Column CAI I ~~~~
~ ~~~
r~I
.~~~ ~
75 SurfaceRadiation andConvection - fromFormEFFaItem C321

76 SorbentCalcination/Dehydration - fromFormSR8cItem C771
77 Water
from Sorbent - from
Form SRBc Item C651
78
79
80 Other Losses, MKBtu/hr Basis - fromForm EFFc Item C1111
81 Summation of Losses, MKBtu/hr Basis
CREDITS, YO EnterCalculationResult in % Column C61
C111 x C2A1/ 100
x 1100
Moisture in Air C161 x C281 I 1 0 0
x 1100 I I
% (100 - C691 + C901 1 x C301 I ( C301 + C811 - C981 )

+ +
1 I
NAME OF PLANTASME PTC 4 MASTER FORM UNIT NO.
TEST NO. DATE LOAD
TIME START: END: CALC BY
DATE
SHEET OF
182

~~
~~
STD.ASME PTC 4-ENGL L798 m 0759b70 ObL5LZL 530 m
ANONMANDATORY APPENDIX PTC 4-1998
FORM EFFc EFFICIENCY CALCULATIONS

OtherLossesandCredits
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.
~~~ ~ ~
!Summation of Credits. YO Basis I I

CREDITS. MKBtuhr
Result Enter
MKB in Column CAI I
113A I I Heat
(external
in
Moisture
Additional to envelooe) I l I
~~~~

TEST NO. DATE ILOAD
END:
TIME START: CALC BY
DATE
SHEET OF
183

ASME PTC 4-1998 NONMANDATORY APPENDIXA
FORM CMBSTNa COMBUSTION CALCULATIONS

I DATA REQUIRED I
I 1 IHHV - Higher
Heating Value of Fuel, Btu/lbm as fired I I
~~~
I
SORBENT DATA (Enter O if Sorbent not Used)
20 ]Sorbent
. ~ . Rate.
~~... .Klhm/hr
.. - .. . .. I
21 C02 from Sorbent,lbm1100 Ibm Sorb from SRBa Item C2511
22 H20 from Sorbent, lbmf100 Ibm Sorb from SRBa Item C2611
23 Sulfur Capture, Ibmflbm
Sulfur from SRBb Item C451
24 Spent
Sorbent, l b d 1 0 0 Ibm fuel from SRBb Item C481
25 ISorWFuel Ratio, Ibm SorWlbmFuel IC201 / C31

TEST NO. DATE LOAD
DATE
SHEET OF
184

NONMANDATORY APPENDIX A
FORM CMBSTNb COMBUSTION CALCULATIONS

COMBUSTIONPRODUCTS
5
0
J Ultimate 2fl Theo Air F 4 Dry Prod F 4 Prod
Wet F 3 H 2 0 Fuel
Analysis lbm/100 Ibm Fuel Moll100 Ibm Fuel Mo1/100 Ibm Fuel IbdlOKB
Yo Mass C301 x K C301 / K C301 / K C301 x WK11/1001
35 /Total The0 Air Fuel Check, Ib/lOKB I (C31M1 + C3081 x 11.51) / (C11 / l o o ) I
CORRECTIONS FOR SORBENT REACTIONS AND SULFUR CAPTURE
From EFFa Items C17A1,C17B1,C18A1, and C1881

FLUE GAS ANALYSIS, Mol/lOO lb Fuel Dry Wet
53 I Moisture in Air O C71 x 1.608
1
54 Dry/Wet Products Comb C431 C441
Moisture 155 /Additional O 1C131/18.0151 I ! I
56 C471 x (0.7905 + C533
57 Summation C541 + C551 + C561
58 20.95 - C501 X (1 + C5331
1
~~~
60 Excess Air, 100 x C501 x C571 / C471 I C581 I

NAME OF PLANT
ASME PTC 4 MASTER FORM I UNIT NO.
TEST NO. D A IE LOAD
TIME START: END: CALCBY
DATE
SHEET OF
185

FORM CMBSTNc GENERAL COMBUSTIONCALCULATIONS
91 FuelRate, Klbkr 1000 x C9OI/C11

92 ResidueRate, Klbkr C801 x C901/10 I I I
93 WetFlue Gas, Klb/hr C751 x C901/10
95 ]ExcessAirLvgBlr, % I As Applicablefrom C601

96 ITotal Air to Bk, Klbmkr I (1 + C951/100) x (1 + C711 x C481 x C901/10
TEST NO. DATE LOAD
186

STD-ASME PTC 4-ENGL L978 m 0759b70 ObLSL25 L B b
A
NONMANDATORY APPENDIX PTC 4-1998
FORM GAS GASEOUS FUELS

1 I Fuel Type
I
14 MW, Ibdrnole 2.0161
32.00)
28.02 I 32.061 18.02 12.01
I
15 Mass, l b d 1 0 0 moles C131 x C141 I I
1
16 Summation Line C161
17 IAnalysis, O/O Mass xC15l/Cl6l
100 I I
18 I Density at 60°F and 30 in. Hs Ibm/cu f t C41/100 I
1
19 Higher Heating Value, Btu/cu f t C61/100
I
20 Higher Heating Value, Btu/lbm C181/C191

TEST NO. DATE LOAD
END:T I M E START: CALCBY
DATE
SHEET OF
187

ASME PTC 4-1998
FORMRES UNBURNED CARBON & RESIDUE CALCULATIONS

I DATA REQUIRED FOR RESIDUE SPLIT
1 1 Ash in Fuel, Yo CMBSTNb
Form
from C3OJ1 I 12 H H V Fuel, Btu/lb as fired
3 lFuel Mass Flow Rate, Klbm/hrfromFormCMBSTNa C4bl from Form CMBSTNa C11
a Item C31 - Use measured or estimated value initially. (See CMBSTNa)
Recalculate after boiler efficiency has been calculated until estimated value is within 1%of calculated value
b Residue splits estimated - Enter value in Col C81 and calculate Col C51
Residue rate measured - Enter measured mass flow rates in Col C51. When residue not measured at all locations,
estimate split and flow for measured locations. Reiterate until estimated total residue is withn 2% of calculated.
c Enter the % free carbon in Col C61 (total carbon correcter for C02). Units with sorbent - Enter the Yo CO2 in Col C71.
3 Residue Mass Flow 4 c 1J c02 4 Residue Split % c 24 c02
Input Calculated in Residue in Residue Calculated Wtd Ave O h Wtd Ave Yo
Location Klbm/hr Klbmkr Yo % Input 100 x C5llC5FI C61 x C81/100 C71 x C81/000
I
A Furnace
UNITS WITHOUT SORBENT

I
11 Unburned Carbon, l b d 1 0 0 Ibm Fuel IC11 x C9F1/(100 - C9Fl) I O.OO(
20 ITotal Residue, l b d 1 0 0 Ibm Fuel IC11 + c111 I 0.00
UNITS WITH SORBENT

d Enter average C and C 0 2 in residue, C9Fl & C1OF1 above or SRBa (Items C41 & CS]) and complete Sorbent Calculation Forms,
1
11 Unburned Carbon, l b d 1 0 0 Ibm Fuel Formlfrom SRBb Item C491 I
I
20 Total Residue, l b d 1 0 0 Ibm Fuel Form
/from SRBb Item C501
TOTAL RESIDUE
21 I Total
Residue, Klbdhr C201 x C31/100
e When all residue collection locations are measured, the measured residue split is used for calculations. Ifa portion
of the residue mass is estimated, repeat calculation above until Col C5Fl and Item C211 agree within 2%.
22 /Total Residue, I b d l O K B t u 100 x c201/c21
I
23 SENSIBLE HEAT RESIDUE LOSS, %
Location
4 Residue
Temp [BI,
YO
x C221,
Ibm/lOKBtu
Btu/lbm
x H Residue, / l o 0 0 Loss
Yo
A Furnace X X /10000
B Econ X X /10000
C Precipitator X X /10000
D X X /10000
E X X /10000
H residue = 0.16 x T + 1.09E - 4 x TA2 - 2.843E - 8 x T*3 - 12.95

TEST NO. DATE LOAD
DATE
SHEET OF
188

~~
STD-ASME PTC 4-ENGL L99e m 0759b70 ObLSb27 T59
FORM SRBaSORBENTCALCULATION SHEET

Measured C 'and C02 inResidue
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.
* EstimateUnburnedCarbon C1581, and Calcination C23Al initially.
Reiterate until estimated value is within 2 % of calculated value.
+ Items that must be recalculated for each iteration.
COMBUSTION PRODUCTS
4
Analysis Unimate F Dry Prod
% Mass IbmllOO Ibm Fuel Fuel Ibm
MoV100 Moll100 Ibm Fuel
SORBENTPRODUCTS
H20
lbl100 lb Sorb
v
I I I
H I
I TOTALlbCa, Moll100 Sorb TOTAL +
I
TEST NO. DATE LOAD
TIME
EN START: D: CALC BY
DATE
I I
~~
I SHEET OF
189

ASME ITC 4- 1998 NONMANDATORY APPENDIXA
FORM SRBbSORBENT CALCULATION SHEET

MeasuredCand C02 in Residue
SULFUR CAPTURE BASED ON GAS ANALYSIS
I Select Column wr Item C91
30 MoistureAirin MOS
IM
I OI DA
Wet Drv
0.0 C61 x 1.608
DrY I
31 Additional Moisture 0.0 [101/18.015
3 2 Products Combustion Fuel C17Ml C17Ml + C18M1 +
I
33 H20 Sorb C31 x C2611/18.016 0.0 I Calc I
34 IC02 Sorb +
135 I (0.7905 + C303 x Cl6M1/28.963 I+ I
I
36 Summation C311 thru C351 +
I
- 37 . 1.0 - (1.0 + C301) x C81120.95 1
138 I (0.7905 + C303 x 2.387 - 1.0 I I
39 I C7Bl x C361/C17DI/C371 +
40 I C381 x [7BI/C371 I
45 I Sulfur Caoture.
Sulfur Ib/lb (100- C391)/(100 + C4011 + I
UNBURNED CARBON, CALCINATION AND OTHER SORBENT/RESIDUE CALCULATIONS
1
47 S03 Formed, lWl00 lb Fuel C451 x C17D1 x 80.064 +
4 8 ISwnt Sorbent. lWl00 lb Fuel C471 + (100- C2511 - C26Il) X C31 I+
4 9 Unburned Carbon, lb/100
lb (C481
Fuel + C15J1) X C41/(100 - C411 +
5 0 Residue
Rate, lb
lb/100 Fuel C491 + C481 + C15J1 +
51 Calcination,
Ib/lb CaC03 1 - C501 X C51 X 0.0227/C2OAI/C31 +
I 5 2 1 CdS Molar Ratio. CalMol
Mols S C31 x L2211 x 32.0646/C15Dl I I
Compare the following, reiterate if initial estimate not within 2% calculated
Initial Est Calculated
Unburned Carbon, lb/lOO lb Fuel ICl5Bl IC491
I C23Al
Calcination,
C02/Mol Mol CaC03 (c511
I
I
Enter result of Item C501 on Form RES, Item C201.
I f residue mass
notflow rate measured
all at recalculate
locations,
II
I SRBa
RES and and SRBb
refuse
until converaence
on 2%. of rate I
~ _ _ _ ~
NAME OF PLANT
ASME PTC 4 MASTER
FORM I UNIT
-~ NO.
TEST NO. DATE LOAD
END:
TIME START: CALC BY
DATE
I ISHEET OF I
190

APPENDlX NONMANDATORY ASME PTC 4-1998
FORM SRBc SORBENT CALCULATION SHEET

Efficiency
DATA REQUIRED
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 MKBtulhr
Water
from
Sorbent C21 X C2611 X (C62Al - C60A1)/100000
X x ( - )/100000
CalcinatiodDehydration
L ICaC03 ICZOAI x C23Al x C21 x 0.00766 = 0.00 x 0.00 x 0.00 x 0.00766
2 Ca(OH12C2OBl x 1.0 x C21 x 0.00636 = 0.00 x 1.0 x 0.00 x 0.00636
3 MgC03 [2OC1 X 1.0 x C21 x 0.00652 = 0.00 X 1.0 X 0.00 X 0.00652
4 Mq(OH)2C20Dl x 1.0 x C21 x 0.00625 = 0.00 x 1.0 x 0.00 x 0.00625
5 I
5
7 Summation
of Losses
Due CalcinatiodDehydration
to SUM C711 - C761
CREDITS, %
4 Sulfation
6733 x C451 x Cl5Dl I C631
CREDITS, MKBtuhr
5
J Sensible
Heat from Sorbent C21 x [ L I A I / 1000
X / 1000
Enthalpy of Limestone - See text for other sorbents

HCAC03 = C611 X (0.179 + 0.1128E -3 X C6111 - 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) / 100
JAME OF PLANT ASME UNIT

PTC FORM
4 MASTER NO.
-EST NO. DATE LOAD
YME START: END: CALC BY
DATE
SHEET OF
191

~~~ ~
STD.ASME PTC 4-ENGL 3998 m 0759b70Ob35330 S43 m
ASME PTC 4-1998 NONMANDATORYAPPENDIX A
192

~
STD-ASME PTC 4-ENGL 1998 m 0759b70 Ob15131 4 8 T D
NONMANDATORYAPPENDIXA ASME 4-1998
FORMPREC PRECISION DATA REDUCTION WORKSHEET

I Measured Parameter: I
W
X
Y
z
i
- ~~ ~
2 Average
Value (Clal + Clbl + Clcl + . . . Clz1)lz
-3 StandardDeviation
( ( l / ( z - 1)) x ((Clal - C21)"2 + (Clbl - C 2 P 2 + . . . + (Cl21 - C21)*2))41/2)

TEST NO. DATE LOAD
DATE
SHEET OF
193

STD.ASME PTC 4-ENGL L998 M 0759670 ffblt5lt32 3Lb M
FORM BIASBIAS DATA REDUCTION WORKSHEET
* This is a percent of reading
NAME OF PLANTASME PTC 4 MASTERFORM UNIT NO.

TEST NO. DATE LOAD
TIME
DATE
SHEET OF
194

STD.ASME PTC 4-ENGL L998 m 0759670 0615133 252
195

STDOASME PTC Y-ENGL L998 m 0759b70 ObL5L311 399 m
ASME €'TC 4-1998 NONMANDATORY APPENDIX A
196

STD-ASME PTC U-ENGL 1998 W 075qb70Ob15135025
ASME PTC 4- 1N a
NONMANDATORY APPENDIX A
197

ASME F"C 4-1998
NONMANDATORY APPEIWIX A
-,
i L
U
W
.-
r
O
.-VI
.-
r
P
Tm
V
al
E
LC
'c
O
VI
al
Em
u
al
m
m
U
O

198
! tL
b

ASME PTC 4-1998

NONMANDATORYAPPENDIXA
"
7 "
1 "
" "
"
"
". ".
" "
"
C
O
""
" - "
a
5
"- "
"- " "- -
I
C
"
" ".
I)
199
-
X
STDmASME PTC Y-ENGL L998 D 0759b70 Ob15138834
ASME FTC 4-1998 APPENDIX NONMANDATORY A
FORM INTAVGUNCERTAINTY WORK SHEET

integratedAverageValueParameters
Grid Location:
30 [No. of Points Wide
No. of Points High
No. of Total
Points C301 x C311
133 I No. of Readinss Per Point
Y
2
40 Average
Value of Grid (C35al + C35bl + ....)/C321
Precision
Index Grid
of ((C37al%! + C37bIW + ....)Al/Z)/C321
Degrees of Freedom
Grid
C41lA4/(C38al
of + C38bl + ....
Soatial
~~~ ~~
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 (C4414 + C45IA2 + C46IA2 + C47IA2.)A1/2

TEST NO. DATE LOAD
END:
TIME START: CALC BY
DATE
SHEET OF
200

~~ ~
STDmASFlE PTC 4-ENGL L998 m 0759670 ObL5L39 770 m
ASME PTC 4-1998
NONMANDATORYAPPENDIX B
SAMPLE CALCULATIONS
This Appendix presents examples which demonstrate The bias error for this measurementisdetermined
the calculation methods outlined or recommended in by evaluating the measurement system shown on Figure
this Code. The calculations in thisAppendixfocus B.l-l. Subsection 4.4.2 ofthe Code wasreviewed 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 - CalculationForms. This Appendix
includes thefollowing 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 o 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 threesections
illustrate temperature, pressure, and flow measurements
Section 4 ofthis Code providesadditional bias
for feedwater to the steam generator.
errors whichcouldbe 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 usedin
be applicable for a particular temperature measurement.
the following examples do not always agreewiththe
As this example illustrates, most ofthe above bias
potential valueslistedin Section 4.
errors are verysmallandcan be ignored.
The Bias Data Reduction Work Sheet provided with
this Code can be used to summarizethe bias errors
and calculate the overall bias error for this measurement.
B.l TEMPERATURE
MEASUREMENT
A completed Bias DataReductionWork Sheet for
This example illustrates how feedwater temperature water temperature isshown in Table B.l-2.
can be measured and the uncertainty determined. Figure The feedwater temperature wasmeasuredwith a
B.l-1 shows the temperature measuring system. The standard grade Type E thermocouple. This thermocouple
following temperatures wererecorded during thetest: has a bias error of 23°F. This valueisdetermined
44OoF, 440"F, 439"F, 439"F,440"F,and439°F. from published manufacturers' accuracy data. The bias
The average valueand standard deviation for these error for the lead wire is assumed to be 5 1.O"F based
six measurements were439.5"Fand 0.55"F, respec- on engineering judgment and experience from similar
tively. The Precision Data Reduction Work Sheet pro- measurement systems. Depending onthelocationand
videdwiththis Code can be used to performthis fluidstratificationwhere the temperature is measured,
calculation or theprocedurespresented in Section 5 there can be a biaserror. 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 wereassumed 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 of0.1"F wasassumed.
20 1

ASME PTC 4-1998 NONMANDATORYAPPENDIX B
1439.301
Intermediate
junction box
Junction fi Temperature
display
Feedwater pipe
FIG. 6.1-1TEMPERATUREMEASUREMENT
Based on the above bias errors, the overall bias error ambient conditions at transmitter
of the feedwater temperaturewas calculated to be ambient conditions at junctions
f3.16"F. 0 electrical noise
It shouldbenotedthatthere are anumber of ways drift
to reduce the bias error ofthis 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 maybe
not applicable
"
for a particular pressure measurement. As this example

This example illustrates how feedwater pressure can
illustrates, several of the above bias errors arevery
be measured and the uncertaintydetermined. Figure B.2-
small and could be ignored.
1 shows the pressure measuring system. The following
The Bias Data Reduction Work Sheet, provided with
pressureswererecordedduringthetest: 1,672; 1,674;
this Code, can be used to summarize the bias errors
1,668; 1,678; and1,691psig.
The average value and standard deviation for these
A completed Bias DataReduction Work Sheet for
five measurements were 1,676.6 and 8.82 psig, respec-
feedwater pressure is shownin Table B.2-2.
tively. The Precision Data Reduction Work Sheet pro-
The feedwater pressure was measured with astandard
videdwith this Code can be used to perform this
transmitter. This transmitter has a span of 800 to 2,400
calculation or theprocedurespresentedin 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 transmitterwas 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 inSection 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 oftheCodewasreviewed to
negligible.
determine possible bias errors. The following individual
Published manufacturers' data were also used to
bias errors wereevaluated for thisexample:
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 noisewas as-
0 location sumed to have a negligible effect. The transmitter was
202

STD-ASME PTC II-ENGL 1998 W 0359b30 ObL514L 329 m
APPENDIX NONMANDATORY B ASME PTC 4-1998
TABLE B.1-1
FEEDWATER TEMPERATURE PRECISION DATAREDUCTION WORK SHEET
Parameter:
Measured FEEDWATER
TEMPERATURE,
F
I
2 Value
Average (Clal + Clbl + C l c l + . . . Clz1)lz ! 439.50
Standard Deviation I 0.5477
~~ ~~
UAME OF PLANT
ASME PTC 4 Example
Problems B . l AND B.5 IUNIT NO.
rEST NO. DATE I LOAD I
r I M E START: END: CALC BY
DATE
SHEET OF
203

ASME PTC 4-1998 NONMANDATORYAPPENDIX B
TABLE B.l-2
FEEDWATER TEMPERATURE BIAS DATAREDUCTION WORK SHEET
~ ~ _ _ _
Temperature,
Water
Parameter:
Measured F Work Sheet No: 1D
Estimate of Bias Limit
TotalBias Limit
( a 4 + bA2 + cA2 + . . .I A (1/2) 0.00 3.16 0.00 3.16
&ME OF PLANT ASME PTC 4 EXAMPLE PROBLEMS B.l A N D B.5 UNIT NO.
!ST NO. DATE. LOAD
CALC M E START: END: BY
I DATE
SHEET OF
204

STD*ASME PTC 4-ENGL 1998 H 0759670 Ob15143 I T 1 H
NONMANDATORY APPENDIX B ASME PTC 4-1998
0 calibration of primary element

Junction stratification
box I-Ø I 1 0 temperature bias
Pressure
I 1 0 pressure bias
0 installation
Pressure transmitter
disdav
. . conditionnozzle
of
0 nozzle thermal expansion
O pressure correction (density effect)
0 temperature correction (density effect)
0 Reynolds number correction
0 measurement location
u Feedwater pipe
Section 4 of this Code provides additional bias errors
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 andcan be ignored.
The Bias Data Reduction Work Sheet, provided with
this Code, can be used to summarize thebias errors
not recalibrated after the test so a drift of 2 psi, based A completed Bias DataReduction Work Sheet for
on 0.25% of maximum scale per 6 months, was used. feedwater flow is shownin 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 2 1 % flow nozzle withpipetaps. The nozzlewasinspected
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 reducethe bias error of this example, including number similar to thelaboratorycalibration results;
usingamore 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 wasnotinspected after the test, so abias
error of 50.5% was assigned. The differential pressure
This example illustrates how feedwater flow can be
transmitter bias is 20.12% based on anaccuracy of
measuredandtheuncertainty determined. FigureB.3-
20.25%. The feedwater pressure bias was determined
1 shows theflowmeasuringsystem. The following
to be 9.81 psi, but has a negligible impact on feedwater
flowswererecorded 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 havea bias of 23.16'F,whichhasanimpact of
426.93,430.3,424.6,435.2,431.48,425.9,438.7,427.5, 20.27% on feedwater density for anuncertainty
434.43, and 441.7 Klbh.
20.14% 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
providedwiththis 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 Precision Data Reduction to reducethe bias error of this example, includinga
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 OUTPUTCALCULATION
by evaluating the measurement system shown on Figure
B.3-1. Subsection 4.7.2 of the Code wasreviewed to The purposeofthis example isto 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 determined. This Code recommendsthat
205

ASME PTC 4-1998 NONMANDATORY APPENDIX B
TABLE 6.2-1
FEEDWATERPRESSUREPRECISION DATA REDUCTION WORK SHEET
Parameter:
Measured PRESSURE,
FEEDWATER
Conversion to
psig
Correction Calibrated
1
Measured Data EnglishUnits Factor Data
C 1668.00 I I 1
k
I
m
U 1
, Y
z
I
2 Average
Value (Clal + Clbl + Clcl f . . . Clzl)/z 1676.60
3(Standard Deviation 8.8204
( ( l / ( z - 1)) x ((Clal - C21P2 + (Clbl - C2W2 f . . . + ( C l z l - C21)A2))"(1/2)
NAME OF PLANT
ASME PTC 4 EXAMPLE PROBLEMS 8.2 AND B.5 UNIT NO.
TEST NO. DATE LOAD
TIME START: EN D: CALC BY

STD-ASME PTC 4-ENGL L778 O757670 ObL5L45 T74 m
APPENDIX NONMANDATORY B ASME FTC 4-1998
TABLE B.2-2
FEEDWATER PRESSURE BIAS DATAREDUCTION WORK SHEET
Parameter:
Measured psig
Pressure,
Feedwater Sheet Work No: 2A
Estimate of Bias Limit
TotalBias Limit
(a" + 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
T I M E START: END: CALC BY
DATE
SHEET OF
207

ASME PTC 4- 1998 NONMANDAMRY APPENDIX B
Differential
pressure Flow
display
.transmitter I
i
transmitter ,,,ure
Prneel
Junction
box
4 4 Thermocouple
""L
\
.--I
,---I
I
Flow
nozzle
V
"" ' I
Feedwater pipe
FIG. B.3-1 FLOW MEASUREMENT
the uncertainty of steam generator output be calculated The steam generator output was calculated to be
independentofefficiency for several reasons: 558.22 Btuh using the output calculation form shown
in Table B.4-1. The useof this calculation formis
The output is typically a calculated parameter that is discussed inAppendix A. Sections B.l through B.3
guaranteed or determined independentlyof efficiency. show how the feedwater measurements and uncertainty
o 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 ina 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 theuncertainty
tors that use sorbent. for the output measurements. The completed Output
0 Determining output uncertainty simplifies thecalcula- Uncertainty Work Sheets are included in Tables B.4-
tions required for efficiency uncertainty. 2 andB.4-3. The average value, standard deviation,
number of readings, and positive andnegativebias
Figure B.4-1 shows a schematic of the steam genera- limit for each ofthe measurements is required to
tor and the measurements recorded to determine output. complete the calculations.
The followingmeasurementswererecorded: The output totaluncertaintywas 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 andabiaslimit of +7.73and -
0 feedwater temperature 7.73Btu/h.
feedwater pressure
0 main steam spray flow
0 main steam spray temperature
B.5 COAL FIRED STEAMGENERATOR
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 torandthe 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 L498 m 0759b70. ObL5L47
NONMANDATORYAPPENDIX B ASME PTC 4-1998
TABLE B.3-1
FEEDWATER FLOW PRECISION DATA REDUCTION WORK SHEET
Measured
Parameter: FEEDWATER FLOW, l b k r x 1,000
I
J
l Conversion to Correction Calibrated
MeasuredData English Units Data Factor
a 437000
b 437100
C 433960
d 428700
e 461900
f 428300
a 434800
438280 I I I
I I 430300 1
m 424600 I
X
I
Y
z
~~ ~~ ~
I
2 ValueAverage (Clal + Clbl+ C l c l + . . . ClzI)/z I 433774.00
3 Standard 8191.3905
( ( l / ( z - 1 ) ) x ((Clal - C2W2 + (Clbl - C21)Q + . . . + (Cl21 - C2l)A2)lA(112)
I I
~
NAME OF PLANT
ASME PTC 4 EXAMPLE PROBLEMS 8 . 3 AND 8.5 IUNIT NO.
TEST NO. DATE LOAD
. -F
n A.T
-.
I ISHEET OF I

STD-ASME PTC 4-ENGL 1998 m 0759b70 OblSL48 783 9
ASME Pn: 4-1998 NONMANDATORY APPENDIX B
TABLE 8.3-2
FEEDWATER FLOW BIAS DATAREDUCTION WORK SHEET
Parameter:
Measured Flow, Feedwater lWhr Work Sheet No: 3C I
I J
l
Estimate of Bias Limit I
Measured Parameter 2
J Positive 3
J Negative
Individual Biases of Bias Limit Percent* SourceUnit of Meas Percent* Unit of Meas
a (Calibration of primary element Calibration 0.40 0.40
Stratification I b I Nealiaible I 0.00 I I 0.001 I
Ic (DP Transmitter lcalculation I 0.12 I I 0.12 I I
nstallation Id INealiaible I 0.00 I I 0.001 I
e Condition of nozzleororifice Engineering judgment 0.50 0.50
f I Pressure correction lcalculation I 0.00 I 0.00 I
Total Bias Limit

(aA2 + bA2 + ch2 + . . .) * W 2 ) 0.68 0.00 0.68 0.00
cent This is a of readins I
~~
NAME OF PLANT ASME PTC 4 EXAMPLE PROBLEMS B.3 AND 6.5 UNIT NO.
TEST NO. DATE LOAD
END:
TIME START: CALC BY
DATE
r
SHEET OF
210

NONMANDATORY APPENDIX B ASME FTC 4-1998
I
- stream ) Main spray
I Main steam
Hot reheat
I 1
1
i-
Reheater
uperheater
Reheater -
A
? Cold reheat
Economizer - r' Feedwater
1
I
Air I heater
I
FIG. B.4-1 OUTPUT SCHEMATIC
O fuel higher heating value 0 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
e 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
111 I Sootblowing Steam I 0.0001 0.0 I 0.0 I 0.00 I 0.00 I

112 I
Steam SH 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
AUXILIARY EXTRACTION FLOWS
115
Steam 1 Aux 1 0.000 I 0.0 1 0.0 I 0.00 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
18 1 MAIN
STEAM I 1005.4
460.2051 I 1517.2 1 1492.31 I 493.72
I 1 9 I H I G H PRESS STEAM OUTPUT I Pl8 + Q2 + Q9
Q17through 490.19
1 2 9 l F W HEATER NO. 1 FLOW 1 O.OOOlW25 x (H26 - H25)/(H27 - H281 I
X [(H31 - H301 - W29 X (H28 - H33)1/(H32 - H33)

34 I F W HEATER NO.FLOW
35 ICOLD
2 0.0001W30
REHEAT FLOW
36IREHEATOUTPUT
I
IW35 x
363.745 IW18 - W23 - W24 - W29 - W34
(H20 - H21) + W22 x ( H 2 0 - H221 I 68.02
I
37 /TOTAL OUTPUT IQ19 + 436 558.22
NAME OF PLANT
ASME PTC 4 EXAMPLE PROBLEMS 8.4 AND B.5 IUNIT NO.
TEST NO. DATE LOAD
T I M E START: EN D: CALC BY
DATE
SHEET OF

NONMANDATORY APPENDIX B ASME F1y3 4-1998
213

0759b70Ob15L52104 D
214

STD-ASME PTC 4-ENGL 1998 W 0759b70 ObL5L53 040 m
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
- HHV
Fuel - -
J
Flow Furnace
' I
9 Carbon
9 Sulfur
Hydrogen
Moisture
Nitrogen
Economizer Ash
6 I heater
Air 1 @@
Oxygen
Ash Flow
Temperature
Carbon
Furnace Ash
Flow
Temperature
Carbon
FIG. B.5-1 EFFICIENCY SCHEMATIC
were determined in amanner similar to themethods energy balance method. The uncertainty of the efficiency
described in Sections B.l throughB.4. is also calculated for each method in order to evaluate
The EfficiencyUncertainty 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 efficiencymeasurements. The completedEffi- used for the coal fired steam generator in Section B.5
ciency Uncertainty Work Sheets are included at the end areused except for the following differences which
of this section. The average value, standard deviation, arerelated to the fuel:
number of readings, andpositiveand negative bias
0 fuel properties
limit for each of themeasurements 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 Efficiencyby the Input-Output Method. The
Also included at theend of thissectionare 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 higherheatingvalue.
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
mixedand one sample analyzed. The average higher
heating value for the test was determined to be 17,880
B.6 OIL FIRED STEAMGENERATOR
BtuAbm. The biases for the higher heating value were
Inthis example, theefficiency ofan oil firedunit considered to consist oftheASTMreproducibility
is determined by both the input-output method and the interval (89 BtuAbrn per ASTM D4809) anda 0.5%
215

STDmASME PTC ‘4-ENGL L998 0757b70 Ob35354 T87
EFFICIENCY CALCULATIONS
Data Required
I TEMPERATURES. F
216

STDOASME PTC 4-ENGL 1998 m 0759b70 ObL5L55 913 m
NONMANDATORY APPENDIX B ASME PM3 4-1998
LOSSES, 9'0 EnterCalculatedResultin YOColumn C61 Al MKB 61 %O
C101 x C3Al 1100

X 1100 5.08
Waterfrom H Z Fuel L121 x (C3Bl - ClAl) I 100
x ( - 45) I100 3.87
Waterfrom H20 Fuel C131 x (C3Bl - ClAl) 1 1 0 0
x ( - 45) I100 1.01
63 (Water from HZOv Fuel C141 x (C3Cl I 100
Moisture in Air C161 x C3C1 I 100
-~
79
80 Other Losses, MKBtuIhr Basis - fromForm EFFc Item C1111 0.000
81 Summationof Losses, MKBtuhr Basis 0.000
r
CREDITS, YO EnterCalculationResult in % Column C61

C111 x CZAl/ 100
x 1100 0.19
C161 x CZBI I100
x I 100 0.00
87 ]SensibleHeatinFuel 100 x C4Al I C191
Fuel Eff, o/o (100 - C691 + C901 ) x C301 / ( C301 + C811 - C981 )
217

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.
km T or E LOSSES, % EnterCalculatedResult in YOColumn [BI Al MKB BI %

llOA CO in Flue Gas O.Of
llOB Formation of NOx O.O(
ll0C Pulverizer Rejects 0.0'
llOD Air Infiltration O.O(
llOE Unburned Hydrocarbons in Flue Gas O.O(
llOF Radiation Loss to Hopper 0.11
llOG O.O(
110 Summation of Other Losses. YO Basis 0.2E
(Summation of Credits, 'Yo Basis I 0.00
CREDITS, MKBtuhr EnterResult in MKB Column CAI

113A Heat in Additional Moisture (external to envelope) 0.000
1138 0.000
113 Summation of Credits, M K B t u k r Basis 0.000
NAME OF PLANT
ASME PTC 4 EXAMPLE
PROBLEM 6.5 I U NIT
. ~
NO.
~-
TEST NO. DATE LOAD

- ,
I ]SHEET OF
218

EFFICIENCY UNCERTAINTY WORK SHEET NO. 16
lJ 2J 3 Total Positive 4 Total Negative 5 6J 7J 8J

Average
Bias Limit Bias Limit Degrees
Value Standard No. of
(Item C23 on (Item C21on Readings Precision of Incremental
Measured (Item C21 Deviation Bias
Form BIAS) Form BIAS) Index Freedom Percent Change*
Parameter on Form (Item C31 on Sheet (Item Cl1 on
lfvnm
~,.“... nATA
-...,.r PRFC)
.._“. Fnrm
_.... PRFC)
..--. No. % I Unit % 1 Unit Form PREC) ((C21*2)/C51)*1/2 C57 - 1 Change 181x ~l~/lOO
a Output 558.22 4.28 I 4.28 2.32 19.5 1.00 5.58
b Fuel HHV 11447.55 0.0707 bA 2.00 107.oc 2.00 107.00 2 0.0500 1 1.00 114.48
c Fuel Flow 61901.30 655.8452 3A 5.10 0.00 5.10 0.00 20 146.6515 19 l.OC 619.01
I& Barometric Pressure 29.50 0.0361 48 0.00 0.32 0.00 0.32 3 0.02 2 l.OC 0.30
___ __^ I _^^
“.
0.001 1.17 1 I “._”
“~rln I ----,
l.lZ I AI
Y,
” 4771. .”
I 51 -._
LOU 0.83
e Amb Dry Bulb Temp I 83.171 1.16901 1A 1
“A AnI nn,T”“l “1 I

50.“” “.OT+Lt nnn, n7- II 0.001 0.711 AI 0 371 51 1.01 i 0.38
f Relative Humidity I
WH , ^^^
V.““, “^_
“.l-, - --I 3.27 I “.“.
0.091 , 92.51 1.00 2.76
g Flue Gas Temp Lvg Pri P ,H 1 27b.01 1c 1 o.uui 5.LI) V.“”
It3
_- 1 u.lJu
^ ..^I 1 *L.L;I
^“I 1 A ne
u.uu, 1.23 0.101 8D.5) 1.00 0.85
h Comb Air Temp Ent Pri Air Htr( 84.81s
G Ent Set Air Htr 1 3.88 SA- 1 0.001 O.ld 0.04
,” l--l n-: I:_- Ul” I * cl, 4A I V.“”
n nnl “.”
r-l,,, ., II“.““, 1#%#1 II-.- 1-1 , I “.““, . ,.“, -.-- 0.04

0.00 0.141 o.nnl 0.141 n nc,l
"."" m-.7 I
--.- 1.00
-.. O.Ob
G Lvg Set Air Htr I 5.591 1 5B 1 I "."" ---
_ -. .. ‘.‘* 5.511 1 58 1 0.00 O.ld41 0.00 0.14 0.05 80.2 1.01j 0.06
I^ ,^ m--r-r, ,n I 3.21 O.OC,
nl 3.21 0.00 2 0.05 1 l.O( j 0.64
, rut, bar”“,I I “,.““I “.“I”, “.
n IFuel Sulfur 2.931 0.00711 bC 1 2.01 0.001 2.t 11 . 0.00 7 I
0.00 1 l.O( j 0.03
1 - __-- .-
o JFuel Hydrogen I 4.32) 0.00711 bU I 7.01
-._- 0.00 I 2.011 0.001 71 0.01 I II 1.00 0.04
-
p Fuel Moisture 10.05 0“.“. n7n7l
“. hE I 2.09 0.001 2.t 0.10
q Fuel Nitrogen 1.24 n.no711
_.__. -, 60 I 2.01 0.01 0 0.01
r Fuel Oxygen 732 0.0071 ii 2.01 0.01 0 0.07
s Fuel Ash 10.48 0.0071 bF 10.00 1 o.oc,n E 0.10
t FG Temp Ent Pri Air Htr 658.50 1H 0.00 3.231 -o.olit 6.59
_ _- 5.11
u Comb AirTemp Lvg Pri Air Htr 511.22 1J O.UUI 5.21
_^ 01 0.t ,
v Furnace Residue Flc )W, ^’70 I 15 0.00 3F 0.001 lO.OL, nl ” nn
V.“” 2 0.15
w Economizer Residue Flow, % 1 10 0.00 INPUT 0.001 0.001 0.00 2 0.10
x Precipitator Residue I Flnw..-.., %.- I, 75 0.00 36 0.00 I7n nnl
““.“” n-001 2 0.75
y Fuel Volumetric Matter I lO.OOl “.“”
n lnlTNPllTl
,-... ” ., -.--
m-m 1 o.ool OIOOI I=
-4 -.__ 0.10
II 4r;
-.a.““,nnl 1" . n~iTNPllTl
" " -. . " , O-00
_ __ I 0.00 I 0.c 10 0.00 3 0.58 2 1.00 0.45
”7 FIIPI
. -“, ,FiYPrl
._.“” C;““.erhon
--..
a.2
“_ I
c-_ a,, I “.“A LOII I ,P I nnnl
Y.““, ‘a37
_I.- 0.00 3.27 0.09 92.527 1.00
tb I Flue Gas Temp Lvg 3~ +W I LO”.OOI I I
85.881 1 ;i 1 0.001 1.2: 3 0.00 1.23 0.10 80.515 1.00
SC I Comb Air Temp Ent Set Air H tr I
-. . , , , .I- - __ .__‘““^
This worlc sheet IS set up for constant value paramrrcra.
See Section 5.2 of the Code for calculation of average value, degrees of freedom, and precision index for integrated average value parameters.
* The value used for incremental change can be any increment of the average value. The recommended increment iS 1.0% (0.01 times the average value).
If the average value of the measured parameter is zero, use any small incremental change. It is important to note that the incremental change must be in the same units as the average value.
‘IAME OF PLANT ASME PTC 4 EXAMPLE PROBLEM 8.5 UNIT NO.

‘EST NO. DATE LOAD
‘IME START: END: CALC BY
DATE
SHEET OF
EFFICIENCY UNCERTAINTY WORK SHEET NO. 2B
t
loJ 111 Absolute 12 Relative 13 Precision 14 Overall g Positive Bias 16 Negative Bias
3
Recalc Sensitivity Sensitivity Index of Result Deg of Freedom Limit of Result Limit of Result 0
Measured Efficiency Coefficient Coefficient Calculation Contribution ((Cl1 x C3AYlOO)“Z ((cl1 x C4Al/lOOP'2 L
Parameter * ([101- [201)/C91 Cl11 x Cll/E201 cl11 X kl /(cl11 X C61)"4/C71 + [38+'2P'1/2 x Cl11 + C481"2)"1/2 x Cl11 8
I n~nnnn I a7Ftl
1 -0.00091
-.---- -o.n008 “.“UU” 1.12 1.12
0.0000 0.71 0.71
003 0.0000 3.27 3.27
003 0.0000 1.23 1.23
-0.03251 -0.0014) -0.0005 0.0000 0.14 0.14

“.““““I 0.0000 ____ “._
n 141 , ld
n".L7
-0.0123 0.0000 [ 0.141 0.14
o.nnnn
------ I c-l 1At
“._. n“.L’,A
0.0000 I 7.nsl 7 ,-‘,A

_.__ __ -.---. -.wJOl 1.05)
-0.0001l -0.0005l -0.0000) 0.0000l 3.231
n nnnn I 2 ?,?I
-.---_
nnnnnl n“.“” nnl nnnl
V.“”
0.0000 20.00 20.00

100 0.0000 0.00 0.00
301 0.0000 0.00 0.00
I
ab 1Flue Gas----
Temn
--..r Lvg Set AH I 88.98211 -0.0237 -0.07461 -0.0020 3.27
0.0000 3.27
ac 1 Comb Air Temp Ent Set Air Htr I 89.0667 I 0.0212 0.0204\ 0.0021 0.0000 1.23 1.23
* This uncertainty work sheet is set up for calculating the uncertainty effect on efficiency; however,
this sheet can be used for any caklated item such as output, fuel flow, calcium/sulfur ratio, etc..
20 * Base Efficiency from Item C371 Output Form 1
21 Precision Index of Result (C13a-- .I”2 + C13b1”2
- ~~ + .... ..Pl/ 2 0.0002
22 Overall Degrees of Freedom r-_ -*
uurx4/K14al + C14bl + ...... . I o.oocIO
?!t Student t Value from Table 5.16-l in Code I
24 Precision Component of Uncertainty c211 x c231
25 Positive Bias Limit of Result . .- .-
Kl5alA2 + C15bq*- J"2 + . . . . ..PlIZ I 0,14061 a
26 Negative Bias Limit of Result (Clbal"2 + C16b1"2 + . . . . ..V'l/Z 0.1406
I
27 Positive Total Uncertainty ([241"2 + C251"2Pl/2
28 Negative Total Uncertainty ,r9n-m, I r?Llh?>Al I?
NAME OF PLANT ASME PTC 4 EXAMPLE PROBLEM B.5
TEST NO. DATE: ILOAD
TIME START: END: ICAI
- - I-Y
_ -RY I
[DATE
I~~II=FT nc
EFFICIENCY UNCERTAINTY WORK SHEET NO. 1C
lJ 2J 3 Total Positive 4 Total Negative 5 6J
Bias Limit Bias Limit
Average Standard No. of
(Item C21 on (Item C21 on
Measured Value Deviation Bias Readings Precision
Form BIAS Form BIAS)
Parameter (Item C21 on (Item C31 on Sheet (Item Cl1 on Index
(fram_. DATA) L1 Form PREC) 1 Form PREC) 1 No. 1 % I Unit I % 1 Unit 1 Form PREC) I ((C2YWIC5W1b -.-
a Furn Residue Carbon Content 0.1 0.00 7A 0.00 -0.40 0.001 0.401 2) 0.00 ,
b Econ Residue Carbon Content 4.8 0.45 7A 0.00 0.40 A ,vt' n An' LI R --
U.“” V.-t” J.lY
c Precip Residue Carbon Content 6.8 0.51 7A 0.00 0.40 0.00 0.40 6” 0.21
.d Furnace Residue Temp 2000.0 100.00 INPUT 0.00 50.00 0.00 50.00 3 5.77
e ,r~ ._...
1tconomlzer n..t.l..-
~_. ~(esmuc .r____
I emp I ,r.
D3D.t5,P. a-,*
‘+.f‘), .D
LD , ,.nc.
“.““I ..-.T
>.LI , 0.00 3.27 4 2.39

f 1Precipitator Residue Temp ( 276.5 1 1.291 1B 1 0.001 3.271 0.00 3.27 4 0.65
g IFuel Temp ! 84.01 l.O( 1F J 0.001 3.161 0.00 3.16 3 0.58
h I I I
i Avg Air Temp Ent Pulverizer 511.4 0.84 1J 0.00 3.20 0.00 3.201 10 0.27
1 Avg Pulv Tempering Air Temp

84.9 0.49 1A 0.00 1.12 0.00 1.121 10 0.15
k Pri Air Flow (Ent Pulverizer) 83.2 0.79 3H 5.39 0.00 5.39 0.00 1 10 0.25
I
I 1 I I I I I I I I I
m I FG Temp Ent Set Air Htr 660.0 1 ( ltt ( 0.001 3.231 0.001 3.231 0.39
n 1Comb Air Temp Lvg Set Air Htr I 493.9 1 1 1J I 0.001 3.20) 0.00 1 3.201 ! 0.29
I I
I I I
I I
I nls worK sneet Is set up ror consranr value parameters.
See Section 5.2 of the Code for calculation of average value, degrees of freedom, and precision index for integrated average value parameters.
I
l The value used for incremental change can be any increment of the average value.
The recommended increment is 1.0% (0.01 times the average value).
If the average value of the measured parameter is zero, use any small incremental change.
It is important to note that the incremental change must be in the same units as the average value.
NAME OF PLANT ASME PTC 4 EXAMPLE PROBLEM 8.5 UNIT NO.

TEST NO. DATE: LOAD : 2
f
DATE
SHEET OF E
EFFICIENCY UNCERTAINTY WORK SHEET NO. 2C
loJ llJ 12( 13( 14 Overall 15( l6J
Absolute Relative Precision Deg of Freedom Positive Bias Negative Bias
Recalc Sensitivity Sensitivity Index of Result Contribution Limit of Result Limit of Result
Measured Efficiency Coefficient Coefficient Calculation (Cl11 x C61)“4/ ((Cl1 x C3Al/lOOV’2 UC11 x C4Al/100)“2
c71 + C3l 31”2P’1/2 x Cl11 1 + [481”2P’l/Z x Cl11
0.0000 0.40 1 0.40
0.0000 n dn

from Item Cl001 on EFFb form 89.05
21 Precision Index of Result K13a1*2 + C13blA2 + .. . ...)A1/2 0.0154
22 Overall Degrees of Freedom C211”4/(C14aI + C14bl + . . . ...) 33.9763
23 Student t Value from Table 5.16-l in Code 2.0313
24 Precision Component of Uncertainty [221 x C231 0.0312
25 Positive Bias Limit of Result K15al*2 + C15b1*2 + . . . . ..)Ai/Z 0.3752
26 Negative Bias Limit of Result (C16alA2 + ClbbF2 + . . . ...)*1/2 0.3752
27 Positive Total Uncertainty ([241”2 + C251”2)“1/2 0.3765
28 Negative Total Uncertainty (C241"2 + C261A2P'1/2 0.3765
NAME OF PLANT ASME PTC 4 EXAMPLE PROBLEM B.s UNIT NO.
TEST NO. DATE: LOAD
/TIME START: END: CALC BY
STD-ASME PTC 4-ENGL 1998 m 0759b70 ObL51bl 117 m
INPUT DATA SHEET 1
- COMBUSTION CALCULATIONS - FORM CMBSTNa

1 1 of HHV - Hisher
Value
Heatins 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. KIb m h r 0.0
COMBUSTION CALCULATIONS - FORM CMBSTNb

30 I Fuel Ultimate Analysis, Y Mass I
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
for (Vapor G I 1 Moisture gaseous fuel) I 0.00
H I I Nitrogen
I I I Oxygen
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
NAME OF PLANT
ASME PTC
EXAMPLE
4 PROBLEM B.5 UNIT NO.
TEST NO. DATE LOAD
1 DATE
SHEET 1 OF I
223

~~~~ ~
STD-ASME PTC rl-ENGL L998 m 0759b70 Ob15162 053 m
ASME PM: 4-1998 NONMANDATORY APPENDIX B
INPUT DATA SHEET 2
A Furnace 0.10
B Economizer 4.78
C Precipitator 6.75
D
I
7 Carbon Dioxide in Residue, %

A Furnace I 0.00
B I Economizer 0.00
I I
E l I
24 Temperature of Residue, F
A Furnace 2000.0
B Economizer 653.8
C Precipitator 276.5
D
E
SORBENT CALCULATION SHEET
MEASURED C AND C02 I N RESIDUE - FORM SRBa
7A SO2 in Flue Gas, ppm O
8 O2 in Flue Gas at location where SO2 is measured, % 0.00
9 SO2 & O2 Basis, Wet COI or Dry C11 O
I 20 I Sorbent Products, VD Mass
A CaC03 0.00
B Ca(OH12 0.00
C MgC03 0.00
D Mg(OH)2 0.00
E H20 0.00
Inert
F 0.00
Calcination Fraction 1.00
NAME OF PLANT ASME PTC 4 EXAMPLE PROBLEM

8.5 UNIT NO.
TEST NO. DATE LOAD
TIME START: EN D: CALC BY
IDATE
/SHEET z OF I
224

~~ ~
~~
STD.ASflE PTC 4-ENGL L998 0759670 Ob15163 T9T
INPUT DATA SHEET 3

- - . .- - . .. -. .- - -. . . .- .. - . .- - .
I MEASURED C AND C02 in RESIDUE - FORMSRBb 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
1 Air I 0.00
I
85E Unburned
Hydrocarbon in Flue Gas 0.00
Losses, M K B t u k r
I
86A Wet Ash Pit 0.000
866 Sensible Heat in Recycle Streams - Solid 0.000
86C Sensible Heat in Recycle Streams - Gas 0.000
86D AdditionalMoisture 0.000
86E Cooling Water 0.000
86F Air Preheat Coil (Supplied by Unit) 0.000
Credits, O
h
87A I I 0.00
Credits, M K B t u k
88A
(External
Heat I
Moisture
in Additional to Envelope) 0.000
NAME OF PLANT ASME PTC 4 EXAMPLE
PROBLEM 6.5 UNIT NO.
TEST NO. DATE LOAD
END:
T I M E START: CALC BY
DATE
I SHEET 3 OF
225

ASME PTC 4-1998 NONMANDATORY AF'PENDIX B
INPUT DATA SHEET 4
PARAMETER
W
FLOW
Klbm/hr
I T
TEMPERATURE
F
I P
PRESSURE
PSIG
I
1 FEEDWATER 433774 439.5 1676.6
2 SH SPRAY WATER 26431 312.5 2006.4
3 Ent SH-1 Attemp O 0.0 0.0
4 Lvg SH-1 Attemp O 0.0 0.0
6 Ent SH-2 Attemp O 0.0 0.0

7 Lvg SH-2 Attemp O 0.0 0.0
INTERNAL EXTRACTION FLOWS
15 Aux Steam 1 O 0.0 0.0

16 Aux Steam 2 O 0.0 0.0
17
18 MAIN STEAM 1005.4 1517.2
NAME OF PLANT
ASME PTC 4 EXAMPLE
PROBLEM 8.5 UNIT NO.
TEST NO. DATE LOAD
TIME
I DATE
SHEET 4 OF
226

of the measured value for sampling bias (89 Btdlbm) 0 discharge coefficient
for a combined bias of0.70%.
A unit output of 565,270 Btuh was determined in The bias for the discharge coefficientisthe only
accordance with the description in Section B.4. In that bias not considered above.Notethe 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 impactontheuncertainty of efficiency thelowReynoldsnumberandanuncalibratedorifice.
determined by the energy balance method (refer to the Items [27] and [28] on Work Sheet 2 reportthe
Efficiency Uncertainty Work Sheet 2B, Items [15a] and overall uncertainty of the measured oil flow. The result
[16a]), itis directly proportional to theuncertainty of is 2.05%, whichwasdeemedtobeunacceptablefor
efficiency determined by the input-output method.In an input-outputtest.
order to minimizetheuncertaintyof the output, a In order to reducetheuncertainty of themeasured .
calibrated andinspectedASME PTC 6 flow nozzle oilflow, a positivedisplacementflowmeterwaspur-
with a flow straightener waspurchased. 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 biaslimit of the resultusing the calibrated positive
O. 1% of range was used and an uncertainty of 0.1% displacement meter was determined to be 0.6% of the
wasassumed for system error. The total bias for measured flowbased on a meter uncertainty of OS%,
feedwater flowwasreduced to 0.38%. It was also anuncertainty 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 weretunedandmore 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 takingmorereadings. Thus, by improving the fuel
reduced thetotaluncertainty 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 plantoil flow measurement system utilized a The measured oil flow for the test was determined to
square edge orificewith D and D/2 taps. The orifice be 35,140 Ibm/h.
has a Betavalueof 0.734 and installed in a 2 in., The efficiency by the input-output method is calculated
schedule 40 pipe. The bias associated withtheorifice per the following equation.
was considered tobe 0.5%.
The bias of the transducer and calibration error were output
Efficiency = 100 x
considered tobe0.6%and 1.90% of the fullrange Fuel Flow x HHV
of thetransmitter respectively. The full range of the
transmitter was 60 in. wg, thus thecombinedbias is = 100 x 565’370’000 = 89,967,%
35.140 x 17880
0.6708in. wg.
The oil analysis included the specific gravity, which The Efficiency by Input-OutputUncertainty Work
was determined to have a bias of 0.33% based on the Sheets wereused to calculate theuncertaintyofthe
ASTMreproducibilitylimit. efficiencydetermined by theinput-outputmethod.
The following differential pressure readings across For this test, the overall uncertainty of the efficiency
the orificewererecorded during a pretestuncertainty result determined by
the
input-output
methodwas
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.6.2EfficiencybytheEnergyBalanceMethod.
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 UncertaintyWork Sheets). The steadwater side measurements requiredto deter-
On Sheet 1, the basic flow equation is provided and mineunit output foranefficiencytest by the energy
all parameters are defined. The parameters to be evalu- balance method are thesame as for the input-output
ated in thecalculation of the oil floware: method. However, as can be observed by the uncertainty
results below, the influence of the output is insignificant
0 differential pressure, in. water ontheefficiencydetermined by the energybalance
0 specific gravity method result. Thus, the accuracy of the instrumentation
0 orifice diameter required to determine output is less critical.
227

ASME PK 4-1998 NONMANDATORY APPENDIX B
Measuredfuel flow is notrequired.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 andflue gas measurements are the principle
measurementsrequiredin addition to those required
for the input-output method. The most common mea-
surements are defined in Section B.5.
The UncertaintyWork Sheets for the OIL FIRING
ExampleProblem 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 theuncertainty of the result for thetwo
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-
taintyof 0.41% for the energy balance methodtest
with reasonable quality instrumentation.
228

OIL FLOW UNCERTAINTY WORK SHEET NO. 1
lJ 2J 3 Total 4 Total 5 6J 7J 8J 9J
Average Standard Positive Negative No. of Degrees
Measured Vafue Deviation Bias Bias Limit Bias Limit Readings Precision of Incremental
Parameter (Item C21 on (Item C31 on Sheet (Item C21 on (Item C31 on (Item Cl1 on Index Freedom Percent Chance*
(from DATA) Form PRECI Form PREC) No. Form BIAS) Form BIAS) Form PREC) ((C21”2)/C51)“1/2 c51- 1 Change C81 x Cl%100
a Differential Press, in. Wg 46.80000 1.3681 0.6708 0.6708 12.0000 0.3949 11.0000 1.0000 0.4680
b Specific Gravity 0.93000 0.0000 0.0031 0.0031 0.0000 0.0000 0.0000 1.0000 0.0093
c Discharge Coefficient, C 0.68807 0.0000 0.0092 0.0092 0.0000 0.0000 0.0000 1.0000 0.0069
d Orifice Diameter, d 1.51718 0.0000 0.0076 0.0076 0.0000 0.0000 0.0000 1.0000 0.0152

It is important to note that the incremental change muit be in ihe same units as the average value.
NAME OF PLANT OIL FIRING EXAMPLE PROBLEM UNIT NO.
TEST NO. DATE LOAD
nA7-C
1-s L
~SHEET OF I
I
OIL FLOW UNCERTAINTY WORK SHEET NO. 2
loJ 11 Absolute 12 Relative 13 Precision 14 Overall l5J l6J

Recalc Sensitivity Sensitivity Index of Result Deg of Freedom Positive Bias Negative Bias
Measured output Coefficient Coefficient Calculation Contribution Limit of Result Limit of Result
I Parameter II * 1I (ClOl-
----
C201)/[91
----- ~~~
1I [111x
---~
[11/[201 tI cl11 x C61 ([111x C61)"4/[71 c31* Cl11 c41* Cl11
a I Differential Press. in. Wa I 9.810 I o.lo4nl 0.4988 I 2.5906E - 07 0.0698 0.0698
O.OOOOE + 00
1 d IOrifice Diameter, d ) 9.9581 12.9323 1 2.0100) 0.0000 1 o.ooooE + 001 0.0981 0.0981
9I I I I I I I I
hl
i I 1 I I I I I I

I I I I I I
:,
I I I I I I I I I I

r 1 I I I I I I
s 1
t I I I I I I I I I
u 1 I I I I I I
v)
WI I I I I I I I I
x 1 I I I I I I
Yl
2 I I I I I I I I I
I * This uncertainty work sheet is set up for calculating the uncertaintv effect on efficiencv: however, I
-..--. _-... _,
r
OIL FIRING EXAMPI E PRDBLFM
lUA1 t
t ISHEET OF I
EFFICIENCY BY INPUT-OUTPUT UNCERTAINTY WORK SHEET NO. 1
Parameter
(from DATA1

, degrees of freedom,
EFFICIENCY BY INPUT-OUTPUT UNCERTAINTY WORK SHEET NO. 2
Recalc Sensitivity Sensitivity Index of Result Deg of Freedom Positive Bias Negative Bias
Measured Efficiency Coefficient Coefficient Calculation Contribution Limit of Result Limit of Result
Parameter * (Cl01 - C2Ol)IC91 ClllX clllc2ol Cl11 x C61 (Cl11 x C63)"4/C73 c41* Cl11
c33* Cl11
a Output, lE6 Btu/hr 90.8674 0.1592 1.0000 0.0981 4.7016E - 06 0.5380 0.5380
b Fuel Flow, klbmkr 89.0769 -2.5349 -0.9901 -0.1782 3.3578E - 05 -0.5523 -0.5523
c2 Fuel Higher Healing Value 89.0769 -0.0050 -0.9901 0.0000 O.ooOOE + 00 -0.6235 -0.6235
a I
e
f

. .
X
Y
z
aa
IUAI t
I ISHEET OF
~~
STD-ASME PTC 4-ENGL L998 0759b70 Ob15172 Obb W
NONMANDATORY APPENDIX B ASME FTC 4-1998
UNCERTAINTY WORK SHEET NO. 1
IIAIR TEMP
AHENT
ENT
MEASURED
I
AVE
VAL
84.88 I
STD
PARAMETER
DEV
0.47 I
NO
RDGS
10 I 0.15 1
DEG PREC VD
FREE INDEX
9
CHANGE
1 1.00 I
INCR
CHANGE
0.85 I
GAS TEMP €NT AH 658.50 1.87 10 0.59 9 1.00 6.59
GAS TEMP LVG AH (MEAS) 0.28 276.16 10 0.09 9 1.00 2.76
RAD. & CONV.LOSS. 1E6 BT 1.77 SURF 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, % 0.13 3.90 1 0.04 9 1.00 0.04
0 2 LVG AH, % 5.50 0.44 1 0.14 9 1.00 0.06
PRESS. I N HG 29.50BAROMETRIC
0.00 20 0.01 19 1.00 0.30
(MASS FRACTION OF REFUSE ENT AH I 0.75 1 0.00 I 1.00 I 0.01 I
O
'/ OXYGEN IN FUEL 0.55 0.00 1 0.00 O 1.00 0.01
Oh NITROGEN IN FUEL 0.35 0.00 1 0.00 O 1.00 0.00
FUEL TEMPERATURE 200.00 2.83 8 1.00 7 1.00 2.00
INAME OF PLANT: I UNIT NO. 1 I
TEST NO: 1 05/29/96 DATE 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
OIL FIRING SHEET OF
233

UNCERTAINTY WORK SHEET NO. 2A

Efficiency
MEASURED
234

~
~~
STD*ASME PTC 4-ENGL 1998 W 0759b70Ob15173939
UNCERTAINTY WORK SHEET NO. 2B

Efficiency
ABS REL TOTAL PREC +BIAS -BIAS
MEASURED RECALC SENS SENS DEGFR INDEX LIMIT LIMIT
PARAMETER PARAM COEFF COEFF CONTR RESULT RESULT RES
AIR TEMP ENT ENT AH 0.02305 0.0000
0.02443 90.001 0.0985 0.0985 0
GAS TEMP ENT AH 89.980 0.00000 0.00000 0.0000 0.0000 0.0000 0.0000
GAS TEMP LVG AH (MEAS) -0.08267 0.0000
-0.02694 89.906 -0.2384 -0.2384
-0.0024
SURF RAD. & CONV.LOSS, 1E6 BT -0.00312 0.0000
-0.15840 0.0000
89.977 -0.0554 -0.0554
UNIT OUTPUT, 1E6 BTU/HR 0.00067 0.00419
89.984 0.0000 0.0016 0.0063 0.0064
02 ENTAH. Yo 0.00019 0.0000
0.00436 89.980 0.0009 0.0009
0.0002
O2 LVG AH, o
/' -0.01805 -0.29527
0.0000 89.964 -0.0723 -0.0723
BAROMETRIC PRESS, IN HG 89.981 0.00090 0.00275
0.0000 0.0000 0.0008 0.0009
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 -0.00265 -0.00245
89.978 0.0000 -0.0030 -0.0027
RELATIVE HUMIDITY, Oh -0.00089 0.0000
-0.00211 -0.0008
89.979 -0.0015 -0.0015
HIGHER HEATING VALUE. BTUlLBM 0.10560 0.0000
0.00053 0.0000
90.075 0.0914 0.0914
% CARBON IN FUEL 89.944 -0.03990 -0.04038
0.0000 0.0000 -0.1075 -0.1075
HYDROGEN IN FUEL -0.65750 -0.06723
89.920 0.0000 0.0000 -0.2063 -0.2063
Yo SULFUR IN FUEL -0.00016 0.0000
-0.01400 0.0000
89.980 -0.0014 -0.0014
1% OXYGEN
F UI N
EL I 89.980 I 0.01455 I 0.00009 I 0.0000 I 0.0000 I 0.0015 I 0.00151
Yo NITROGEN
FUEL
IN I 89.980 I 0.00000 I 0.00000 I 0.0000 I 0.0000 I 0.0000 I 0.0000
TEMPERATURE
FUEL 89.986
0.00273 I 0.00606 I 0.0000 0.0027 I 0.0234 1 0.0234
TOTAL UNCERTAINTYRESULTS
Efficiency
I DATE 10/08/96
ASME PROBLEM
PTC4 EXAMPLE
OIL I SHEET OF I
235

ASME PK 4-1998 NONMANDATORY APPENLXX B
COMBUSTIONCALCULATIONS
I IDATAREQUIRED I
1 HHV, BTU/LBM AS FIRED 17880.00000 9 DRY BULB TEMP, F 83.17000
2 UBC I N REFUSE, LB/lOO 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, KLBlHR 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
I
8 BAROMETRIC PRESS, in Hg 29.500001 15 IMASS ASH, LB/IOKBTU 0.00000
SORBENTDATA(ENTEROIFSORBENTN0TUSED)
~O~SORBEN
RATE,
T KLBIHR I 0.00000123
ISULFUR
CAPTURE,
LBlLB
SULFUR
FUEL 1 0.00000
21 IC02 FROM SORBENT, LB/100 L B SORB I 0.00000[24]SPENT SORBENT, LB/100
LB SORB 1 0.00000
I
22 H20 FROM SORBENT, LB/lOO L B SORB I o.ooooo125 JSORBIFUEL RATIO, LB SORBILB FUEL 0.00000
COMBUSTION PRODUCTS
35 ]TOTAL THEO AIR CHECK, LBDOKBTU

IC31Ml + C3061 x 11.51 + C3OLl x 34.29/ I 7.49805
I
CORRECTIONS FOR SORBENT REACTIONS AND SULFUR CAPTURE
40 C02 FROM SORB, LB/lOO LB FUEL C211 x C251 0.00000
41 H20 FROM SORB, LW100 LB FUEL C221 x C251 0.00000
42 S02 REDUCTION, MOVlOO LB FUEL C32131 x C231 0.00000
43 DRYPRODCOMB, MOUlOO LB FUEL C32M1 + C401 / 44.01 - C421 7.44585
44 WET PRODCOMB, MOUlOO LB FUEL C33M1+ C411 / 18.016 + C431 12.00934
~ ~-
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, LBllOKB (100- C3OJl- C3OBl- C3OLl- C30D1 X C23I)/(ClY100) 0.55928
NAME OF PLANT: UNIT NO. 1
TEST NO: 1 05/29/96
DATE LOAD 100%
TIME START: 13:OO END: 17:OO CALC BY tch
OIL FIRING SHEET OF
236

~~
~~
STD-ASME PTC 4-ENGL 1978 D 0757670 Ob35375 703

COMBUSTION CALCULATIONS
I
LOCATION
I
ENT AH
l II
LVG AH
2 l o l o l o l o
Il
~ 1 -
501 02, YO (BELOW m = MEASURED 1 = LOCATION 5.5000 0.0000

3.9000 0.0000 0.0000 0.0000
51 I CO. I LOC CORR Com x(20.95 - 021)I(20.95 - 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 614.0 C751xC901/10
95 EXCESS AIR LVG BLR, % 21.8 96 TOTALAIRTOBLR,KLB/HR 578.9 (C691+C721)x
NAME OF PLANT: UNIT ND. 1
TEST NO: 1 DATE 05/29/96 LOAD 100%
T I M E START: 13:OO END: 17:OO CALC BY tch
OIL FIRING DF SHEET
237

ASME FTC 4- 1998 NONMANDATORY APPENDIX B
FORM EffaEFFICIENCY CALCULATIONS

Data Required
TEMPERATURE, F
1 IREFERENCETEMPERATURE I 77.01 1 A 1 ENTH WATER (32 F REF) I 45.00
AAVE
ENT AIR TEMP I 84.9 DRY AIR 2A 1.89 ENTH
28 ENTH WATER VAPOR 3.51
AAVE
EXIT GAS T (EXCL LKG) I 293.4 3A DRY GAS 51.68 ENTH
3B ENTH STEAM @ 1 PSIA 1192.61
3C ENTH WATER VAPOR 97.51
4 [FUEL TEMPERATURE I 200.0 4A ENTH FUEL 56.68
HOT AIR QUALITY CONTROL EQUIPMENT

5 1 HAQC ENT GAS T E M P 0.0 5AI
WET
ENTH I GAS I 0.00
6 1 HACQ LVG GAS TEMP I 0.0 6A1
WETENTH 1 GAS 0.00
238

FORM EFFbEFFICIENCY CALCULATIONS

LOSSES
RESULTYo BASIS
(ENTER IN Y COL) I MKB~
140 I DRY
GAS I C101 x C3Al / 100 I 29.96 I 4.7698 I
41 WATER FROM H2 FUEL C121 X (C3B1 - ClAl) I 100 5.2772 33.15
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 I 100 0.52 0.0828
4 5 UNBURNED CARBON I N REF C181 x 14500 / C191 0.00 0.0000
46 SENSIBLE HEAT OF REF from Form REF or REFS 0.00 0.0000
47AQCHOT EQUIPMENT Irefer to text 0.00 0.0000
48 OTHER LOSSES,
Form Ifrom
Yo BASIS EFFc C851 0.00 0.0000
5 4 SUMMATION LOSSES, Yo BASIS 63.64 10.1298
LOSSES, MKBTUlHR BASIS (ENTER RESULT IN M K B COL) MK0 Oh
]SURF
55RADIATION & CONV I refertextto 1.77 0.2824
56 I BLOWDOWN IC351 x (C35Al - C32Al) I 1000 0.00 0.0000
157 ISOOTBLOWING S T E A M I C361 x (C3Bl - C32Al) I 1000 I 0.00 I 0.0000
58 SORBENT CALClDEHYD Form from SRBc C771 0.00 0.0000
59 WATER FROM SORBENT Form from SRBc C651 0.00 0.0000
60 OTHERLOSSES Form from EFFc C861 0.63 0.1003
62 I BASIS
S U M LOSSES, MKBTU I 2.401 0.3827
CREDITS, Yo BASIS (ENTER RESULT IN Yo COL) I MKBI yo

I63 1 ENTERING DRY AIR ICl11 x C2Al I 100 I 1.091 0.17281
64 I MOISTURE I N AIR
I64 ICl61
C161 x C2Bl
C261 I 100 I 0.02 1 0.0030l
0.0030
65 SENSIBLEHEAT INFUEL 100 x C 4 A l l C191 1.99 0.3170
66 I SULFATION
166 Ifrom Form SRBc
from Form C801 I 0.00 I 0.0000
0.0000l
67 IOTHER
167 OTHER CREDITS,
CREDITS. % BASIS
BASIS from Form EFFc
Form lfrom 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 IAUX
EQUIPMENT POWER Ic311 I 0.00 I 0.0000l
173
HEAT
ISENS SORB
FROM FormIfrom SRBc C851 I 0.00 I 0.0000
80 FUEL EFF. o
/' (100 - C541 + C7111 X C301 I (C301 + C621 - C75I) 89.9802
81 INPUT FROM FUEL, MKBTU 100 x C301 / C801 628.2102
82 FUEL KLB/HR
RATE. 1000 x C811 / C191 35.1348
I T I M E START: 13:OO END: 17:OO I CALC BY tch I
239

ASME PTC 4-1998 NONMANDATORY APPENDlX B
FORM EFFcEFFICIENCY CALCULATIONS

OtherLosses and Credits
TIE CREDITS, MKBTWHR BASIS (ENTER RESULT I N MKB COLUMN) MKB Oh
88A HEAT I N ADD MOIS (EXIT ENVI 0.00 0.0000

888 0.00 0.0000
88 0.00 0.0000
NAME OF PLANT: UNIT NO. 1

TEST NO: 1 DATE 05/29/96 LOAD 100%
TIME START: 13300 END: 17:OO CALC BY tch
OIL FIRING SHEET OF
240

STDOASME PTC 4-ENGL L998 m 0759b70 ObL5379 357 m
ASME E*Iy: 4-1998
NONMANDATORYAPPENDIX C
DERIVATIONS
C.l INTRODUCTION
The derivation equations utilize the same acronym format as used in Section 5. Section 5.20 shows the format,
definitionof letters or letter combinations, andasummaryof acronyms used.
C.2DERIVATION OF SULFURCAPTURElRETENTIONFROMMEASURED 0 2 AND SO1

The derivation below is shown for O2 and SOz measuredonawetbasis. 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 minimalsuchthatthey do not havea significant impactonthe result. Refer also to Section
CS for derivation with CO and NO,.
VFOZ = - -
“O2 ” moles 02/mole wetgas(measured) (C.2-1)
loo MOWG’
VSFOZ = (’ - moles
SOz/mole
wet
(measured
gas SO2) (C.2-2)
MOWG
where MFSC is the fraction of sulfur in fuel captured or retained.
MOS02 = -moles
maximum so2/mass
(C.2-3) fuel
3206.4’
MODPP - - + +
- MODGSB,
MPN2F +
(C.2-4)
3206.4
1201
2801.3
maximum moles of dry products from fuel and sorbent/mass fuel
MOWPP = MODPP + MPH2F

-+ -
MPWF ~ MFWADn + MOWSB,
(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

~~ ~~ ~
STD-ASME PTC 4-ENGL L998 0759670 ObLSL80 079
ASME PTC 4- 1998 NONMANDATORY APPFNDIX C
MOTHAC = MOTHAP + --molestheoretical O2 correctedforsulfurretentiodmassfuel (C.2-7)

2 0.2095
The corrected theoretical air requires one-halfmoleof O2 for everymole of sulfur captured to form SO3 in
the reaction C a 0 + SO, + Caso4.
The moles ofwet gas (MOWG) is the sum of the maximum moles of wet products from fuel and sorbent less
themoles of SO, captured plus the molesofnitrogenin the theoretical air plus the moles of water in the
theoretical air plus the molesofwetexcessair.
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)

VF02
+-- (0.7905 + MOWA) + MOWG -( 1 + MO WA)
2095 0.2095 2
Let K = (0.7905 + MOWA) -1 -

1
-1 = 2.387 f0.7905 + MOWA) - 1 (C.2-10)
2 0.2095
1 - (I
vFo
0.2095 1
+ MOWA) 2 = MOWPP + MOTHAP (0.7905 + MOWA) + K MFSC MOS02 (C.2-11)
MOWG =
MOWPP + MOTHAP
-
(0.7905 + MOWA) + K MFSC MOS02
- (C.2-12)
1 - ( 1 + MOWA) 2
vFo
0.2095 J
VFSOZ
VFSOZ
(MOS02 - MFSC MOSO2)
MOWPP -i
-i- 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)
1 - (1 + MOWA) -
vFo2
0.2095 I
B [MOWPP + MOTHAP (0.7905 + MOWA)] + B K MFSCMOS02 + MFSC MOS02 = MOS02 (C.2-15)
242

~
STD-ASME PTC 4-ENGL 1996 m 0757b70 Ob15181 T05 m
APPENDIX NONMANDATORY C ASME l'TC 4-1998
MFSCMOS02 ( 1 + B K) = MOS02 - B [ M O W P P + MOTHAP (0.7905 + MOWA)] (C.2- 16)
1 - [ V F S 0 2 [ M O W P P + MOTHAP (0.7905 + M O W A ) ] ]
MFSC =
L [ l - ( 1 + MOWA)VF02/0.2095]MOSO* J
, mass/mass (C.2-17)
.1 +. ..
Kr
VFSO2
L 1 - ( 1 + MOWA) VF02/0.2095J
1
(2.3 DERIVATION OF EXCESS AIRBASEDONMEASURED 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 belowisthe 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,.
VPO2 - -
VF02 = - M 0 0 2 moles 02/mole wet gas (measured) (C.3-1)
loo MOWG'
MODP = -+ ( 1
1201
- MFSC) -
2801.3 3206.4
+ -+ MODGSB, (C.3-2)
moles of dry products from fuel and sorbenthass fuel
MPWF MFWADn MOWSB,

MOWP = M O D P + MPH F -
+ + +
(C.3-3)
18.015
1801.5
201.6
moles of wet products from fuel and sorbentlmass fuel
MPSF
- - -+ (1 + 0.5 MFSC) -MPO2F
MOTHAC =
0.2095 [,,,
3206.4+ 403.2
3200 1201
-- (C.3-4)
moles of theoretical air corrected for sulfur capture/mass fuel
Moles ofwet gas (MOWG) is the sum of the moles ofwet products from fuel and sorbent plus the moles of
nitrogen in thetheoretical air plus the molesofwater in thetheoretical air plus themolesofwet excess air.
MOWG = M O W P + 0.7905 MOTHAC + MOWA

MOTHAC (C.3-5)
+ FXA MOTHAC (1 + M O W A ) , moles of wet gaslmass fuel
28.966
MOWG = MFWA - = 1.608 MFWA, moles watedmole dryair (C.3-6)
18.015
MOO2 = FXA 0.2095 MOTHAC, moles

excess
02/mass
(C.3-7)
fuel
FXA MOO2 0.2095 MOTHAC

V F 0 2 = -- (C.3-8)
MOWG MOWP + MOTHAC (0.7905 + MOWA) + FXA MOTHAC (1 + MOWA)
243

STD.ASME PTC 4-ENGL L998 D 0759b70 Ob35182 941 M
ASME PTC 4-1998 NONMANDATORY APPENDIX C
FXA 0.2095 MOTHAC - VFO;!FXA MOTHAC (1 + MOWA) = VF02 [MOWP + MOTHAC (0.7905 + MOWA)] (C.3-9)
VF02 [MOWP + MOTHAC (0.7905 + MOWA)]

FXA = , mass fraction of excess air (C.3-10)
MOTHAC [0.2095 - VFO2 ( 1 + MOWA)]
VP02 [MOWP + MOTHAC (0.7905 + MOWA)]

PXA = 100 , % excess air (C.3-11)
MOTHAC [20.95 - VP02 ( 1 + MOWA)]
C.4 DERIVATIONOF 0 2 CORRECTEDFORCOAND NO, FORDETERMININGEXCESSAIR

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 theflue gas and is also considered to have an
insignificant impact on calculated excess air.
In this paragraph, anoxygen content corrected for CO and NO, (VP02C) is derived thatcanbesubstituted
for VPO, inthe excess air equations presented previously.
Consider thefollowingreactions:
2 0,+ 2 C + 2 Complete Combustion (C.4-1 )
2 0,+ 2 C + CO + C02 + 112 N, + 112 Incomplete Combustion (C.4-2)
N2 + 0 2 + NO + 1/2 N2 + '/to2 (C.4-3)
When CO is present, there is one-halfmole more 0, present per moleof CO than there would beif allthe
gasified carbon, CB, wereoxidized to CO,. For simplicity, NO, will be considered in its mostabundant form,
NO. When NO is formed, there is one-halfmole less 0, than if there wereno NO; however, thetotalnumber
of moles of gas does not change.
Referring to Section C.3, theequation for MOO, [Eq. (C.3-7)] becomes:
MOO2 = FXA 0.2095 MOTHAC + MOCO

-- -
MONO,
, moles excess O,/lbm fuel ((2.4-4)
2 2
VP02 "= MOO2 FXA 0.2095 MOTHAC +"- 1 MOCO 1 MONO,

"
(C.4-5)
100 MOG MOG 2 MOG 2 MOG
VPCO"
- - MOCO or--1 MOCO = -
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 L998 m 0759b70 ObL5L83 888 m
NONMANDATORY APPENDIX C ASME €TC 4-1998
VP02Cl
VPOz
VPCO
- VPNo, -+--
Let - "
- FXA 0.2095 MOTHAC (C.4-8)
100 1o0 200 200 MOG
where MOG is the moles of gas ona wet or drybasis.

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
-I- (C.4-9)
2 200
(C.4-10)
L' - 2 0 0 1
then
MOG = = MOTHG MOGCF (C.4-11)

r,L - --VPCOl
200 1
Dividing Eq. (C.4-8) by the moles of gas correction factor (MOGCF) yields
VP02 Cl - FXA 0.2095 MOTHAC

VPO2C = - (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 V P 0 2 C for V P 0 2 in
the excess air equations in Sections 5 and C.3. V P 0 2 C becomes:
VPOp - -+ -
vpNOx] 1"
2 2
, I [: ; " O p corrected for CO and NO, (C.4- 13)
C S DERIVATIONOFSULFURCAPTURE/RETENTIONFROMMEASURED O2 AND S02

CONSIDERINGCOANDNO,IN THE FLUE GAS
(Later)
(2.6 FUELEFFICIENCY - MIXEDUNITSFORLOSSES AND CREDITS

Mostlossesand credits canbe calculated conveniently onan input from fuelbasis.However, some lossed
credits can only be calculated on an energyper unit of time basis such as radiation and convectionloss.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
basedon the calculated efficiency. The equationbelow allows solving for efficiencyusing losses and credits in
mixed units:
QRF + QRB = QRO + QRL (C.6-1)
Multiplying by 100/QRF:
245

~~
STDOASME PTC 4-ENGL 1998 0757b70 Ob15184 7.14
ASME PTC 4-1998 NONMANDATORY APPENDIX C
QRB = 100 -
100 + 100 - QRO +
(C.6-2)
QRF QRF QRF
By definition,
QRO %
PFE = 100 - (C.6-3)
QRF'
QPL = 100 -
QRL % ((2.6-4)
QRF'
QPB = 100-QRB % ((2.6-5)

QR F'
.p. PFE 100 - QPL + QPB, % (C.6-6)
Lossescalculatedonanenergyinputbasiscanbeconvertedtoapercentbasis:
QRL = QPL = -
100 - QRL PFE, % (C.6-7)
QRF QRO
As in Eq. (Ch-6), adding credits and losses:
PFE = 100 - QPL + QPB - PFE E+ PFE -

QRB % (C.6-8)
QRO QRO'
whichreduces to
PFE = (100 - QPL + QPB) QRo 1,

[QRO + QRL - QRB
% (C.6-9)
246

NONMANDATORYAPPENDIXD
GROSS EFFICIENCY
D.l INTRODUCTION D.2ENERGYBALANCEMETHOD

Efficiencyis the ratio of energy output to energy To calculate grossefficiency (EGr) by the energy
input, expressed as a percentage. This Code recognizes balancemethod,the fuel efficiency (EF) shouldbe
two definitions of steam generator efficiency: fuel effi- calculated first by the energy balance methodin accord-
ciency and gross efficiency. The output term (QrO) is ance with Section 5 . Gross efficiency may then be
the same for both definitions of efficiency andis defined calculated from one of thefollowingequations:
in Sections 2 and 5 as the heat absorbed by the working
fluid to produce useful energy. For fuel efficiency (EF),
the energy inputtothesystem is defined as the total
heat of combustion available from fuel or thefuel
EGr = 100 Qro
QrF + QrB
= 100 1 - [
100 + QpB
] (D.2-1)
input (QrF). For grossefficiency (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 (QrIGr). The gross input

isthesum of theinputfrom fuel (QrF) plus credits
(QrB) or theenergyadded to thesystemfrom other
sources with respect to the reference temperature, 77°F QrO
(25°C). Refer to Section 5 for a morecomplete definition QrF = 100 -
, Btu/h (W) (D.2-2)
EF
of credits.
where
EGr = 100 OUTPUT
GROSS INPUT
= 100
QrlGr
E,
% (D.1-1) QrB= summation of credits, Btu/h (W) basis. Items
that result inanegative 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 acredit. This is amatterof
definition adopted by the Code committee, but
The advantage of gross efficiencyversusfueleffi- it is interesting tonotethattheyhave no
ciency is that it is a measureof the total energy required impacton gross efficiencybecausetheinput
to produce agiven 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 atotal system andmaybeused 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.3INPUT-OUTPUTMETHOD
basis as the energy cost ofthe fuel, andshould be
(usually is) evaluated separately. If the cost of credits Efficiency calculated bytheinput-outputmethod is
is evaluated separately, gross efficiency is notappro- baseduponmeasuringthe fuel flowand 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

ASME PM= 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 thecalculation of credits that
fore,toobtainreliableresults, extreme care must be are notmeasureddirectly.
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
massßowrate of dry air. The mass ßowrate 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 andthe Combustion Calculation form,
Appendix B). For units that do not utilize sorbent for
QrF = MrF HHVF, Btulh (W) (D.3-2) reduction of sulfur emissions, it maybe necessary to
calculateunburned carbon inthe refuse (refer tothe
where Unburned Carbon and Refuse Calculation form, Appen-
MrF= measured mass flow rate of fuel, lb& (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= heatinputfrom fuel, Btuh (W) Calculation form, AppendixB). 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 whichis calculated above.Theuse
tion.For the credits calculated on a percent of sorbent also impacts the mass flow rate of dry air.
248

STDmASME PTC 4-ENGL L998 m 0759b70 Ob15187 423 W
ASME W C 4-1998
NONMANDATORYAPPENDIX E
THEPROBABLEEFFECTS OF COALPROPERTIES
ONPULVERIZEDCOALANDCOALANDSORBENT
PROPERTIESONFLUIDIZEDBEDSTEAM
GENERATORDESIGNANDPERFORMANCE
E.1
INTRODUCTION Slagging, fouling, and combustion indices must be
developed for the design coal and compared to the test
This Appendixaddresses the following:
coalbefore any performancetest is begun. The test
0 Probable effects of coal properties on pulverized coal coalmust 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, andcombustion indices in making this
E.2PULVERIZEDCOALFIREDSTEAM judgment, since no single index gives totally accurate
GENERATORS and indisputable results.
This Section givesgeneral guidance for identifying E.2.3CoalPropertiesDetermination

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 beinclusive but rathertoidentify 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 burnedbefore
and performance trends. undertaking steam generator performance testing. Major
coal property tests include thefollowing:
E.2.1CoalRanWEquipmentSize
Steam,ItsGenerationand Use [7]provides acom- o proximate analysis
plete discussion of coal rank. Coal characteristics, and 0 ultimate analysis
coalrank in particular, have a dramatic impact on 0 ash fusibility
furnace sizing. Tuppeny [8] compares the size ofa 0 hardgrove grindability index
furnace burning eastern bituminous, midwestern bitumi- o ash mineral analysis
nous/subbituminous, Texas lignite, and Northern Plains combustion characteristics
lignite coals. Table E.2-1 summarizes the relative fur-
nace sizes, coal quantities, andpulverizer sizes based These andmany other tests and indices are listed
uponthe assumptions made in the reference. and discussed in Reference [4].
E.2.2SlaggingandFouling E.2.4 Probable Effects of Coal Properties on Steam

Slagging andfouling, other than expected andac- GeneratorDesignandPerformance
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 thermalperformance, 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 4-ENGL L998 D 0759670 ObL5L88 3bT m
ASME PTC 4-1998 APPENDIX NONMANDATORY E
TABLE E.2-1
EFFECTS OFCOAL RANKS ON STEAM GENERATORS
Relative
Dimensions
Furnace Relative Relative
Coal Pulverizer
Depth Quantities Coal width
Sizes Height
Eastern 1 1 1 1 1
Bituminous
Subbituminous 1.43 1.O6 1.08 1.05 1.7
Texas Lignite 1.64 1.08 to 1.24 1.16 to 1.26 1.07 to 1.30 1.84
NorthernPlains 1.76 1.76 1.26 1.45 2.0
Lignite
GENERAL NOTE: From this Table it becomesobvious that a steam generator designed for one coal rank
will notoperate well or maybe totallyunsuitable for othertypes of coals.Thisemphasizestheneed 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 question:
in fuelthe
There are
three
main parameters for atmospheric e proximate
bed
fluidized 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 thesteam 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 pertinentto combustion in pulverized-
NO, generation rate - To determine these perform- coal and stoker fired boilers (References [9], [ IO], [ 1 11).
ance parameters in the field, the Test Engineer must The differences are a result of the distinct environment
be aware ofandunderstandallfactorswhichmay inAFBCboilers (lower temperature, longer residence
influence these parameters. These factors canbe inher- times,larger coal particles,andmechanical effects of
ent inthe 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 testsand
interrelationsbetweenthesefactorsandtheAFBC analyses (References [9] and [lo]). These testsare
performance parameter, thisSection 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 indicatesthe extentof breakage of attrition of the
for predicting the effect on steam generator design and new fuel with respect to the design fueldue to transport
performance whenthefuel and/or sorbent is changed throughthe coal feed system and feedpoint.High
fromthedesign coal and/orsorbent.Aswiththe attrition increases the fines content, which can reduce
previoussection,thissection is not intended tobe combustion efficiency and increase emissions.
inclusive but rather to identify many of the design and Combustion-Enhanced Mechanical Attrition Test -
performancetrends.Inthissection,standardtests for This test is important mainly for low reactivity fuels
coal andsorbent are identified.Examinationofthe and indicates the extent of attrition whichoccurs 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 L998 m 0759b70 ObL5389 2Tb D
ENONMANDATORY APPENDIX ASME PTC 4-1998
TABLE E.2-2
EFFECTS OFCOAL PROPERTIES ON STEAM GENERATOR DESIGN AND
PERFORMANCE
Property
Variable
Coal
Affected
Componentk)
Probable
Effect On
1.Heating
Storage
Coal
Value
Silo Coal Flow Rate
Feeders Equipment Capacity
Pulverizers Number of Components
Burners in Service
Emission Control Turndown Ratio
Equipment
Coal Handling System
2. Coal MoistureContent 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
TurndownRatio
3. Volatile Content Burners RequiredFineness

Furnace Burner Design
Pulverizers Flame Stability/Ignition
Ignitors Unburned Carbon Loss
Furnace Geometry
Firing Methods
Pulverizer lnerting Needs
Turndown Ratio
4. GrindabilityIndex Pulverizers Capacity

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

Pulverizer 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. NitrogenContent Burners Burner Design

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

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

Pulverizers Explosion Potential
lnerting System Unburned Carbon Loss
Ignitors Turndown Ratio
25 1

ASME PTC 4-1998 NONMANDATORY APPENDIX E
TABLE E.2-2(CONT’D)
EFFECTS OF COAL PROPERTIES ON STEAM GENERATOR DESIGN AND
PERFORMANCE
Property
Variable
Coal
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 Reliability
Soot Blowing Requirements
10. Ash Fusibility Furnace SlagginglFEGTISteam

Soot Blower Temperature
Water Lancing Fouling/Steam Temperature
NO, Emissions
Soot Blowing and Water
Lancing Operation
11. Coal AshAnalyses Steam Generator SlagginglFEGTISteam

Emission Control Temperature
Equipment FoulingISteam 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
C13 through C71. References L21 and L71 are texts used extensively in the industry.
yield resultingfrom the different combustionenviron- cause thestandard analyses arenotentirelyrelevant

ment), devolatilization rate, volatiles and char burnout to AFBC,comparing the standard analyses of the design
times, and activationenergy 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 shownin a coalselection study identifiedin
tential; ifa coalswells, agglomerationmay bea poten-
Reference [12]. 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 characterizationtestsrevealed
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 mostimportant 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 showtheperformance
flexibility required to accommodate the fuelsintothe anddesignvariationsthat could be expected from a
unit and auxiliary equipment. For a fuel not previously change incoal. The firstcolumn shows thespecific
considered, neglecting to run the AFBC characterization coal property tests.Inthe second column, the steam
tests risks performance and operational problems.Be- generator component or process parameter is identified
252

STDOASME PTC 4-ENGL 1998 m 0759670 Ob25292 954 m
NONMANDATORY APPEMllX 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 propertyfrom thecoal test. In thefourth column, analyses for the sorbent: calcium, magnesium, moisture,
consequences areidentifiedforthe effect if action is and silica.
not taken to rectify the problem created by the variation Inaddition, it is advisable to performan abrasion
inthecoalproperty.Inthe fifth andsixth columns, testforthesorbentand a particle size distribution.
general corrective actionsare identified that could allevi- Ifthe geological classificationforthenew 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. 0 thermogravimetric analysis (TGA)
grain size
0 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)
morethan one recognized testforthe same property.
The purpose of this Appendix is to suggest sorbent E3.4 TheEffect of Sorbent Properties on Steam
tests for guidance in characterizing sorbent forusein Generator Designand Performance
steam generator designandperformance. Tables E.3-5 through E.3-7 showthe performance
Tables E.3-5 through E.3-7 showthe performance anddesignvariationsthatwouldbe expected froma
anddesignvariationsthatwouldbe expected from a change insorbent. These tables have the same format
change in sorbent. These tables have the same format as thepreviously described tables for coal. Review
as thepreviously described tables for coal. References [13] and [14] for more information.
253

STD-ASME PTC 4-ENGL 1998 W 075qb70 Ob15L92 890 m
ASME FTC 4-1998 ENONMANDATORY APPENDIX
TABLE E.3-1
PROXIMATE ANALYSIS FOR COAL
Corrective Action
Approximate Componentl
Analysis Effect
Process Parameter Consequences Equipment Process
Moisture feed
Underbed 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
combustion
carbon
fixed split fixed carbon or tion efficiency,
adjust level.
bed 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 (bub-

bling bed)
Adjust solids loading

(circulating bed)
Furnace tempera- Vary

particle size Install crusher with
ture profile range wider
distribution
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 sorbentre-
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-
overload cle, andlor
multiclone
Ash coolers Higher ash content Load reduction Upgrade ash coolen
could exceed ash
cooler capabilities
254

NONMANDATORY APPENDIX E ASME PTC 4-1998
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
Highersulfur
emis-
Increase
sorbent Upgrade sorbent
rate. sul-feed sions
would increase In- feed system. Up-
fur emissions crease recycle grade limestone
(bubbling
system
feed
bed)
Coal Ash Analysis
Sulfur retention A decrease in Higher

sulfur
emis-
Increase
sorbent Upgrade sorbent
system feed feed either
sions Mg0 con-
tent and/or Ca0
content would in-
crease sulfur ernis-
sions
Na,O Ash fusion

temper-
lower
A Na20 con- Lower
heat
transfer Require
repeated
could
tent
ature be indi- to freeboard outages to remove
lower
cator
of ash waterwall
and slag
fusion
tempera-
lower
boiler effi-
ture. I f freeboard ciency.
Decreased
temperature
loadex-
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 agglorner-
agglomeration in bed compartment
ation.
bed
Na20 Fly ash resistivity

An increase in Na,O Higher
solids emis- Decrease backend Upgrade ESP de-
W and K,O could in- sions temperature ifsign.
pos- Install am-
injection, monia crease
sible fly ash re-
and sistivity de- injection water
crease ESP system for ESP
efficiency
255

ASME E*Tc 4-1998 N O N M N A T O R Y APPENDIX E
TABLE E.3-3
SPECIAL TESTS AND SIZE ANALYSIS FOR COAL
Corrective Action
Special/ Component/
Process Tests Standard Effect
Parameter Consequences Equipment
Process
Higher heating value Fuel feed rate

Lower HHV requires Load reduction Increase firing
rate Upgrade
coal reed
(HHV) 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- I f 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
freeboard
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- pro-
wash
flexibility
tocoal
mesh) in higher free- Higher rectly. 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 L998 0759b70 ObL5195 5 T T m
NONMANDATORY APPENDIX E ASME PTC 4-1998
TABLE E.3-4
SPECIAL AFBC TESTS FORCOAL
Corrective Action
Special AFBC Component/
Process Tests Effect Parameter Consequences Equipment Process
Feedline attrition co- Feedlines Feedline attrition More carbon elutri- Adjusttransport ve- Adjust crusher. In-
efficients Combustion split causes increase in ated from combus-
with stall locity 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 depthUpgrade
fuel feed
Combustion split freeboard heat heat and evapora- (bubbling
system
bed).
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 bedtemper- Lower efficiencypos- 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
rate
cle
from certain com- combustion effi-
bustion models. ciency
Fragmentation index Fragmentation Lignite and subbi- Without this infor- Is 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 L998 M 0759b70 0,bLSlSb 436
TABLE E.3-5
CHEMICAL ANALYSIS OF SORBENT
Corrective Action
Chemical Componed
Analysis Effect
Process Parameter Consequences Process Equipment
Calcium Sorbent flow rate Decrease calcium

in 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 occurrenceof 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 feedlines dex below
Ii mestone feed-
Iines
Abrasion
Abrasion
Feedlines
index 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 L798 M 0757670 Ob15197 372
NONMANDATORY APPENDIX E ASME FI'C 4-1998
TABLE E.3-6
SIZE ANDTGA ANALYSIS AND GEOLOGICAL CLASSIFICATION OF SORBENT
Corrective Action
Particle Size Component/
Distribution Process
Effect Parameter 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- creaseESP
low optimum for capacity
process per-
formance
Sulfur
capture
Smaller
particles Less sulfur capture
could blow out of and less calcium
bed and have utilization
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)
captureSulfur
Reactivity 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
estimate
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.ASHE PTC 4-ENGL 1996 m 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
ln-bed attrition Limestone with
high Lower sulfur cap- Adjust velocity Install transport
attrition constant ture and calcium fans with flexible
Sulfur
capture attrite
into
will 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 m 0759b70 ObLSL99 145
ASME FT
' C 4-1998
NONMANDATORYAPPENDIX F
REFERENCES
Section 1 Section 6
None. None.
Section 7
Section 2
[ l ] Gerhart,P.M.,and R. Jorgensen.Uncertainty
[ l ] ASME SI-I, OrientationandGuide for Use of
Analysis:WhatPlaceinPerformance TestCodes?
SI(Metric)Units(ANSI2210.1).
ASMEPaper84-JPG-PTC-9,1984.
[2] ASME SI-9, Guide for Metrication of Codes and
[2]ASME PTC19.1, MeasurementUncertainty,
Standards SI (Metric)Units.
AmericanSociety of MechanicalEngineers,1985.
[3] ASME PTC 11, Fans, American Society of Me-
Section 3
chanical Engineers,1984.
[ l ] 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
PTC-5,1984.
Test Code Work.ASMEPaper78-WA-PTC-2,1978.
[2] Entwistle, J. Definition and Computationof Steam
[5] Kline,S.J.,andF. W. McClintock.Estimating
Generator Efficiency.ASMEPaper84-JPGC-PTC-6,
Uncertainties in Single Sample Experiments. Mechani-
1984.
calEngineering, January1953.
[3] Entwistle, J., T. C.Heil, and G.E.Hoffman.
[6] Sotelo, E. AtmosphericFluidizedBedCombus-
SteamGeneratorEfficiency Revisited. ASMEPaper
tionPerformanceGuidelines.EPRIReport CS-7164,
88-JPGC-PTC-3,1988.
1991.
[4] Davidson,P., E. Sotelo, and P. Gerhart.Uncer-
[7] ISA Standard ANSUISA S51 . l .
taintyAnalysisandSteamGenerator Testing. ASME
[8] 90-JPGCPTC8, Effects of SpatialDistributions
Paper 86-JPGC-PTC-1, 1986.
for PerformanceTesting
Section 4 Appendix A
None. None.
Appendix B
Section 5
None.
[ l ] Jones, F. E. The AirDensityEquation 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-October 1978.
Appendix D
[2] NBSTechnicalNotes270-3 to 270-8 as cited
None.
in CRC Handbook of ChemistryandPhysics, 65th
edition. CRC Press, BocaRaton, Florida. Appendix E
[3] JANAF Thermochemical Tables, Second Edition. [ l ] Burbach, H. E., and A. Bogot. Design Considera-
NSRDS-NBS 37. tions for Coal-Fired Steam Generators. Association of
[4] United States NationalAeronauticsand Space RuralElectricGeneratingCooperatives,1976.
Administration(NASA)PublicationSP-273. [2] Combustion, Fossil Power Systems. Combustion
[5] Kirov, N. Y. Chemistry of Coal Utilization, Sec- Engineering, Inc., 1981.
ondSupplementaryVolume.M.A. Elliott, ed. John [3] Durrant, O. W. Pulverized Coal - New Require-
WileyandSons,NewYork,1981. mentsandChallenges.
[6] Could, D. W. TheScience of Petroleum, 1938, [4]EPRICS-4283,EffectsofCoalQualityand
as citedinASMEPTC4.1-1964. Power Plant Performance and Costs, Volume 3, 1986.
26 1

STD-ASME PTC 4-ENGL L998 m 0759b70 Ob15200 797 m
ASME PTC 4-1998 NONMANDATORY APPENDIX F
[ 5 ] Gray, R.J., and G. F. Moore. Burning the Sub- [l 11 Characterization of Coals for FluidizedBed
Bituminous Coals ofMontanaand 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. [ 131 Fee, D.C., et al. Sulfur Control in Fluidized
[7] Steam, Its Generation and Use.Babcockand Bed Combustor: Methodology for Predictingthe 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 AFEE’S. Ninth International Con-
[9] EPRX Fuels Characterization Project Facilities
ference on Fluidized Bed Combustion, May 3-7, 1987,
andProcedures.Babcockand 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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COPYRIGHT American Society of Mechanical Engineers

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COPYRIGHT American Society of Mechanical Engineers

Date of Issuance: December 31, 1999

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No part of this document may be reproduced in any form,

The American Society of Mechanical Engineers

COPYRIGHT American Society of Mechanical Engineers

STD.ASME PTC 4-ENGL L998 W 0759b70 0634938 IT4 W

COPYRIGHT American Society of Mechanical Engineers

STD-ASME PTC 4-ENGL 3998 m 0759470 Ob34939 030 m

COPYRIGHT American Society of Mechanical Engineers

PERSONNEL OF PERFORMANCETESTCODESCOMMITTEE NO. 4

COPYRIGHT American Society of Mechanical Engineers

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

COPYRIGHT American Society of Mechanical Engineers

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

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

COPYRIGHT American Society of Mechanical Engineers

5.13 Airand Flue Gas Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

COPYRIGHT American Society of Mechanical Engineers

COPYRIGHT American Society of Mechanical Engineers

SECTION 1 - OBJECT AND SCOPE

1.1 OBJECT 0 comparing performance when firing an alternate fuel

sampling and analysis of coal, oil, or gas.

COPYRIGHT American Society of Mechanical Engineers

ASME PTC 4-1998 FIREDSTEAMGENERATORS

COPYRIGHT American Society of Mechanical Engineers

FIRED STEAM GENERATORS ASME PTC 4-1998

7.Thesteam generator boundariesshownon these 1.4.3

o 6 - FD Fan Inlet o 22 - Entering Gas Recirculation Fan

COPYRIGHT American Society of Mechanical Engineers

Main Spray Sway

Sootblowing Secondary Reheater

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FIG. 1.4-l TYPICAL OIL AND GAS FIRED STEAM GENERATOR

Main Spray Spray Cold

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COPYRIGHT American Society of Mechanical Engineers

FIG. 1.4-2 TYPICAL PULVERIZED COAL FIRED STEAM GENERATOR

\46 !V Secondary Reheater

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COPYRIGHT American Society of Mechanical Engineers

Ash Ash Ash 4 Condensate

FIG. 1.4-3 TYPICAL PULVERIZED COAL FIRED STEAM GENERATOR

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COPYRIGHT American Society of Mechanical Engineers

FIG. 1.4-4 TYPICAL PULVERIZED COAL FIRED STEAM GENERATOR

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FIG. 1.4-5 TYPICAL CIRCULATING BED STEAM GENERATOR

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tieat from Heat frcI!I 55 Stack

kWh Jnde:re air 1

FIG. 1.4-6 TYPICAL STOKER-COAL FIRED STEAM GENERATOR

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FIG. 1.4-7 TYPICAL BUBBLING BED STEAM GENERATOR

FIREDSTEAMGENERATORS ASME PTC 4-1998

31B - Leaving 1st Stage SH Desuperheater 1.4.5 Miscellaneous