THIS STANDARD IS: STD NO : 31-93-13

Updated INDEX : 22.8

PERFORMANCE STANDARD DATE : 7 NOV 2006
OWNER : 8152
PAGE : 1 OF 94

SUBJECT : METAL TEMPERATURES - PROGRAM WIN 11012 - RELEASE 2.21

PURPOSE : To provide the User Manual and Validation Sheet for the Superheater and
Reheater Metal Temperature Program.

REMARKS: This Standard to be effective immediately.

NOTES: 1. See Page 2 for Versions.

PROGRAM MANAGER
REVIEWED BY: T. MISKELL STANDARDS ENGINEERING - 9390
MANAGER
APPROVED FOR CONTENT: R. KUNKEL PERFORMANCE DESIGN ENGINEERING - 8152
PROGRAM MANAGER
APPROVED FOR PUBLICATION: T. MISKELL STANDARDS ENGINEERING - 9390

This document contains proprietary data and shall not be

reproduced or disclosed without permission of ALSTOM Power Inc.
 SUBJECT: Metal Temperature - Program WIN 11012
UNITS: „ ENGLISH; † METRIC; † BOTH;
PRODUCT LINES: CHECK THE PRODUCT LINES THAT THE STANDARD IS APPLICABLE TO
† ALL; „ A = CONTROLLED CIRC. BOILERS
„ B = SUPERCRITICAL BOILERS
„ C = VU40 AND VU60 BOILERS
„ E = FLUIDIZED BED BOILERS (CFB)
„ F = NATURAL CIRC. BOILERS (UTILITY)
Ver. 0 - First Issue
Ver. 1 - Added text to Standard; added Table of
Contents. Updated Validation Form to Release
2.07.
Ver. 2 - Updated Validation Form to Release
2.08; updated Table of Contents; revised Pages
38 and 79 to reflect additional codes; revised
Page 8 to reflect current ASME Addenda.
Ver. 3 - Updated ASME Stresses to 1995 Edition,
1996 Addenda; added T1a material; T91
oxidation limit increased from 1175o F to
1200o F; updated Input Sheets 1, 2, 3 and 4;
updated Validation to Release 2.10.
Added external update feature for tubing costs
and show cost ID on cost summary. Provided
new fields for future Analysis Letter Interface. If
new Item Nos. fields are utilized, program
provides cost sub-totals for assemblies, loose
tubes and nipples.
For Supercritical Units, plots now include two
extra points (mwt, ost) to account for design
allowance. Services Engineering does not plan
to use this feature and can bypass it using a plot
code of “5” in lieu of “3”.
Swing calculation output now includes load
number and input bulb SL.
Corrected Sample Calculation Appendix G.
STD NO : 31-93-13
INDEX : 22.8
DATE : 7 NOV 2006
OWNER : 8152
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† NONE
† H = HEAT RECOVERY STEAM GENERATORS (HRSG)
† P = PULVERIZERS – MILLING SYSTEM
† R = CHEMICAL RECOVERY BOILERS
„ S = SERVICES (AFTER MARKET USE)
Versions
Ver. 4 - Updated Validation to Release 2.11;
revised Columns 66-68, Sheet 1 (Page 35.0),
Sheet 3 (Page 37.0) and Metal Plot Instructions
(Paragraph 2). Updated ASME Stresses to 1995
Edition, 1997 Addenda and Code Case 2284.
Corrected tube sequence number for alarm
temperatures. Supercritical design allowance, if
input, is calculated only when inlet header
pressure is supercritical.
Ver. 5 - Updated ASME Stresses to 1998 Edition,
1998 Addenda and 1999 Addenda; changed
Alarm temperature report to tabular format.
Ver. 6 - Updated T23 material per Code Case
2199-1; all of the last Paragraph, (1), now
appears on Page 14.0.
Ver. 7 - Name change to ALSTOM Power Inc.;
updated to Release 2.14; revised Pages 8.0, 9.0,
10.0, 13.0, 13.1, 14.0, 15.1, 16.0, 17.0, 18.0,
19.0, 20.0, 24.0, 26.0, 28.0, 35.0, 36.0, 43.0,
47.0, 48.0, 51.0, 52.0, 66.0, 68.0, 72.0, 80.0
and 82.0.
Ver. 8 - Updated release to 2.15; added Code
E01 to Columns 66-68-Page 8.0; revised Design
Pressure in Columns 10-13, 15-18, 20-23, 25-
29, 31-35-Page 9, Columns 17-21, 23-27-Page
13, Columns 39-42, 44-47-Page 13.1, revised
Figure 4-Page 38.
SUBJECT: Metal Temperature - Program WIN 11012 STD NO : 31-93-13
INDEX : 22.8
DATE : 7 NOV 2006
OWNER : 8152
PAGE : 3 of 94

Ver. 9 - Updated to Release 2.17; added

Permissible “Double Bifurcate” Arrangements -
Page 69; deleted Issue Date from Table of
Contents; revised Sheet 1-Figure 1 and Sheet 2-
Figure 2; made changes on the following pages -
13, 15, 17, 31, 34, 36, 37, 42, 44, 46, 48, 49,
53, 69, 88 and 89.

Ver. 10- - Updated to Release 2.19; Revised

Pages 5, 13; Corrected typo on Page 82
Paragraph 9(b), Diagram Code was missing;
Corrected Table Appendix F, Page 90, Corrected
Table Page 93; Editorial Changes, Converted
Table of Contents Pages 6 and 7 to a Table,
converted Pages 18 & 19, 22 through 24, 29, 54
to Tables; Converted Figures 7, 8, & D-1,
Appendix E, Pages 55, 56, 86 & 87 to an Excel
Graphs

Ver. 11- Corrected Reference in Ver. 10 above

from Page 42 to 82; Corrected IW dimension
line for Double Loop with Wrapper Sketch on
Page 42.

Ver. 12- Revised Release Version to 2.20, Page

1, Validation Sheet Page 5 and added 2005
Addenda to Page 13.

Ver. 13- Revised Release Version to 2.21;

Validation Sheet Page 5; Pages 6,13, 14 and 48.
 SUBJECT: Metal Temperature - Program WIN 11012 STD NO : 31-93-13
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OWNER : 8152
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1.0 Purpose

The purpose of this standard is to:

1.1 Provide documentation on the

validation status of Program WIN 11012.

1.2 Provide the Revision Index (current

dates of each sheet) as listed in the Table of
Contents.

2.0 Use of Standard and Revisions

This standard controls the revisions (dates)

of all pages listed in Sections 1, 2 and 3. Each
time any sheet(s) is revised, the sheet(s) will have
a new date(s) and the standard will be revised.
SUBJECT: Metal Temperature - Program WIN 11012 STD NO : 31-93-13
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DATE : 7 NOV 2006
OWNER : 8152
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Form EPVR-1
Engineering Program Validation

The release of this program has been determined by the signatures below to be in
accordance with Standard No. 7-87, Index 15.13.6 and substantially meet the program
requirements and that the results from the program have been verified and deemed good.
Information required to maintain and control the program resides in a database under
Engineering Automation control.

Program Name: Metal Temperatures Type: 1

Version: 2.21 Release Date: November 7, 2006

Program Description:
Metal Temperatures for Superheaters and Reheaters

Scope of changes and enhancements in this version:

- Updated allowable stress labels per ASME 2006 Addenda (No change in stress values).
- Updated Thickness calculations to include ASME A-317 (user controlled option).
- Corrected Allowable Stresses for T92 per ASME Code Case
2179-5 (proposed reduced stress levels, Std 3-2006-01).
- Corrected Allowable Stresses for T122 per ASME Code Case 2180-4 (proposed reduced stress levels,
Std 3-2006-01).
- Updated revision designations for Code Cases 2115-2, 2179-5, 2180-4.
- 2159-2 is no longer a Code Case, and is now designated SA 213 TP347HFG.

AUTHORIZATION:

Owner: ____________________________________________________ Date: ___________________

Robert Kunkel

Program Reviewer: ________________________________________ Date: ___________________

Gregory Calkin

Developer: ________________________________________________ Date: ___________________

Chung Hsu
SUBJECT: Metal Temperature - Program WIN 11012 STD NO : 31-93-13
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Table of Contents

Page No.
Summary 8

Program Description

A. General Information 9-10

B. General Input Information and Instructions 11,12

C. Input Instructions for Long Form
Card Type 1 - Problem Identification 12,13,14
Card Type 2 - Problem Thermal Data 14,15
Card Type 3 - Section Thermal Data 15,16,17
A. Fluid and Metal Unbalance Factors 17
B. Gas and Steam Side Unbalance Factors 17
Input Instructions for Card Type 1A 18
Input Instructions for Card Type 1B 19
Card Type 4 - Section Thermal Data 20,21
Input Requirements for Defining Swing Calculations for Card Type 4 22,23,24
Swing Calculation Feature 25-29
Card Type 5 - Cavity Thermal Data 30
Card Type 6 - Slice Thermal Data 31

Sheet 2 - General Arrangement Data (Fig. 3) 32,33,34

Sheet 3 - Cavity Arrangement Data 34,35,36
Sheet 4 - Selection Data (Fig. 4) 37,38,39

D. Input Instructions for Short Form 40-47

Note: The standard was previously identified as Performance Standard 83-001.

SUBJECT: Metal Temperature - Program WIN 11012 STD NO : 31-93-13
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Table of Contents (Cont.)

Page No.
Figures

1 Input Sheet 1 Problem Thermal Data (Fig. 1) 48

2 Input Sheet 2 Section Thermal Data (Fig. 2) 49
3 Input Sheet 3 General Arrangement (Fig. 3) 50
4 Input Sheet 4 Selection Data (Fig. 4) 51
5 Input Sheet 3 General Arrangement (Fig. 5) 52
6 Metal Plot Instruction 53,54
7 Round-The-Bend Factor for Platens Only (Fig. 7) 55
8 Toe Factor for Spaced Sections Only (Fig. 8) 56

Appendices

Appendix A Basic Equations and Calculation Procedures 57-68

Appendix B Element Numbering & Flow Linkage Examples 69-77

Appendix C Short Form Program Procedures 78-84

Appendix D SH Division Panel Short Form Input Calculation Procedures for Unit 85,86
With Coal firing

Appendix E Design Allowance Method for Supercritical Pressure Units 87,88,89

Appendix F Application of Performance Standards in Program 90-93

Appendix G Correction of RCand RN for Cavity Radiation (Sample Calculation) 94

Note: This standard was previously identified as Performance Standard 83-001.

 SUBJECT: Metal Temperature - Program WIN 11012 STD NO : 31-93-13
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DATE : 7 NOV 2006
OWNER : 8152
PAGE : 8 of 94

The output results of the program are

Superheater and Reheater Metal
Temperature Calculation Procedure
for Utility Type Units
Computer Program WIN 11012
Summary
presented in tabulated format with two optional
plotted formats that can be requested for one or
more elements. In addition to steam and metal
temperatures, the program also develops cost
analysis results for economic considerations.
Alarm steam temperature and pendant swing
calculations are also available as options.

The Superheater and Reheater Metal

Temperature Program WIN 11012 was originally
developed and put into operation in 1966-67.
Since then this program has undergone many
revisions and modifications to improve and
expand its use. During this time there was never
a formal user manual written to document and
describe the complete program. Instead, the
written information includes a series of
memorandums, letters and lecture notes. All of
this available background information was
carefully reviewed in the development of this
program manual. The program includes a
considerable number of the performance design
standards that are programmed into subroutines.
All of these subroutines were reviewed and
updated as needed to agree to the current
standards. A cross-reference index of these
standards is included in the manual to aid in
future updating of the program.

In general, this program has the capability

for a given superheater and reheater
arrangement, material selection and heat
balance to calculate the steam and metal
temperatures at selected points along any tube.
The program achieves this by its inherent
flexibility to handle a wide variety of different
types of sections and combinations of up to three
sections. The computational methods included in
the program have also been made flexible so
that many options and alternatives are available
to the engineer. In this way he/she maintains
control over the program to get the best and
most applicable selection for a given set of input
conditions.
 SUBJECT: Metal Temperature - Program WIN 11012
Program Description
A. General Information
1. Objectives and Scope
For a given superheater or reheater
arrangement, material selection and heat
balance, the program has the capability to
compute the steam and metal temperatures at
selected points along any tube. The program
achieves this objective by its ability to handle a
wide variety of different types of sections. The
following sections lie within the scope of the
program for both subcritical and supercritical
pressure units:
(1) Spaced Pendant
(2) Platens
(3) Panels
(4) Horizontal Sections With and Without
Hangers
(5) Combination Horizontal and Pendant
Sections
(6) Combination Platen-Pendant Sections
2. Program Flexibility
The computational method that is
developed into this program has been made
flexible enough so that many options and
alternatives are available to the Engineer. Thus,
he maintains control over the program to get the
best and most applicable results for a given set
of input conditions. The following variations are
permitted:
(1) Variation in tube diameter, material and
wall thickness along any tube and from tube-to-
tube.
(2) Bifurcation between any tubes and at any
point within a section.
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(3) For those sections that are continuous,
having no intermediate header, changes in
intermesh can take place between sections.
(4) For a given section, variation in geometric
layout and intermesh can take place. However,
for a given section, whatever ST and SL is given
as representative, it is constant for all assemblies
of that section. Furthermore, for any given
assembly, the sum of all tubes that lie in a plane
normal to that assembly must equal or be less
than the total number of assemblies for that
section.
(5) For sections absorbing direct radiation,
variation of the total presented radiation along
the presented plane can take place.
(6) Cavity radiation for both external and
internal cavities can be accounted for.
(7) Variation of the total transfer rate Rt = (Rc
+ Rn) for both steam and metal temperatures
along any tube and from tube-to-tube is
permitted.
(8) Linear distribution of the gas temperature
drop across a section can be handled. In fact, if
a particular gas temperature at a point is
desired, it too can be handled.
(9) Provisions for unbalance carryover,
desuperheater allowance, and in the case of
supercritical pressure units, the design allowance,
have been included.
(10) Provision has been made to allow the
engineer to determine at what points and for
what tubes the metal temperatures are to be
calculated.
(11) The program will automatically correct the
flow ratio for variations in the average specific
volumes between tubes.
 SUBJECT: Metal Temperature - Program WIN 11012
(12) Provision has been made to submit any
number of load and fuel combinations with a
single arrangement and selection.
(13) Tubing cost summaries are used in
conjunction with performance data to assist in
optimizing a section. The metals program
normally solves from header to header, with
tubing “sections” spanning multiple boiler
components including loose tubes and header
nipples.
While performance is not influenced by
ignoring component boundaries, costs and
interfaces with other systems are affected. New
features now allow the user to specify component
boundaries, create component based cost
summaries and support component data export
to other systems. If you omit the new component
codes you will not benefit from some of the new
features, but the program will continue to
operate as it did in the past.
3. Output Results
The output results have been set up to
permit the rapid layout of metal temperature
diagrams. For a given section and at a point
where the metal temperature was requested
(provided the point is gas touched), the output
data includes the following:
(1) The identification of that section, tube and
point.
(2) The material and thickness at the point.
(3) The balanced and unbalanced steam
temperature. If only the steam temperatures are
desired, these will be given. The unbalanced
steam temperature includes the given unbalance
carryover.
STD NO : 31-93-13
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(4) The unbalanced mid-wall and outside
surface temperatures. These temperatures
include all prorated allowances and unbalances
where applicable. Provision has been made so
that the program checks the front and rear side
of a tube to see which is hottest. If the rear face
temperature exceeds the front face then both
temperatures are given. For supercritical
pressure units, the program first computes a
metal temperature by the normal method, and
secondly by the design allowance method. The
results of both methods for metal and outside
surface temperature are given.
(5) Along with the calculated metal temperature
at a given point, the allowable metal temperature
and oxidation limit for the material at that point
is given. Should the calculated metal or outside
surface temperature exceed either or both the
allowable metal temperature and oxidation limit,
a printed statement so stating this is given.
(6) The prorated temperature differentials for
desuperheater and design allowance.
(7) The total heated length (ineffective
excluded) from the point it first becomes gas
touched to the point where the metal temperature
is calculated.
(8) The total pressure drop.
(9) The specific volume corrected flows.
(10) The total tubing cost for commercial
thickness.
4. Basic Calculation Procedures
The calculation procedure followed by
the program is very similar to that previously
used in hand calculations. Appendix A
summarizes the basic equations incorporated in
the program.
 SUBJECT: Metal Temperature - Program WIN 11012
B. General Input Information and
Instructions
The input data sheets for both the long and
short forms are divided into three groups as
follows:
(1) Thermal Data Sheets 1 and 2
(2) Arrangement Data Sheet 3
(3) Selection Data Sheet 4
The complete detailed instructions for the
long form are included in Part C. Input
information and instructions for platens and
panels using the short form are included in Part
D. Copies of all input sheets are included in
Section II.
In general, the Thermal Data Sheets include
information for problem identification and an
itemized listing of the required heat balance,
cavity and slice information including direct
radiation quantities and design allowances. The
Arrangement Data Sheet deals with the
description and correlation between section
geometry and the absorption of heat. Finally, the
Selection Data Sheet deals with the preliminary
selection of tube diameter, wall thickness, alloy
and the number and type of resistance bends for
all tubes listed on the Arrangement Data Sheet.
A section is defined in this program in the
same sense that sections are defined in the
Steam Generator Program, i.e., a quantity of
heating surfaces having a representative ST, SL,
and fixed number of assemblies. Furthermore, it
considers an assembly as being some grouping
of tubes that are essentially coplanar. Each tube
of an assembly is called an element. To be
precise, an element is any given length of a
circuit whose internal steam flow bears a fixed
relationship with other circuits by virtue of its
internal resistance relative to the total section
resistance.
STD NO : 31-93-13
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Each element is unique and has an
identifying number relative to the section it is part
of, i.e., section 1, element 1, element 2, and so
forth. If an element undergoes bifurcation, two
new elements are formed. If two elements join in
bifurcation, they produce a new element. The
O. D. tube wall thickness and material may vary
along the length of an element.
Elements are further subdivided into length
portions called legs. The legs of an element are
sequentially numbered 1, 2, 3, 4, 5, and so
forth. The reasons for dividing an element into
legs are:
(1) Whenever the outside diameter changes.
(2) Whenever an element commences to or
ceases to be gas touched surface or any portion
that becomes ineffective surface.
(3) Whenever it is desired to subject certain
portions of an element to localized heat
absorption effects.
(4) Whenever it is desired to calculate either the
steam or metal temperature.
The program will calculate (upon request) the
steam and metal temperature at the end of a leg
but not at any other point along the leg.
Each leg is further identified in terms of its
location and direction. The leg of an element
which is ineffective tubing has a code
identification letter I (ineffective). For those legs
which are gas touched, the code identification
letters are: U, D, R or L (up, down, right or left,
respectively). The up and down directions are
normal to the gas flow whereas the right and left
directions are parallel to the gas flow. The gas
touched hanger tube portion of an element has a
code identification letter H (hanger).
 SUBJECT: Metal Temperature - Program WIN 11012
For a given arrangement, an element may
actually change direction several times. It is not
necessary to define a new leg every time a
change in direction takes place. Hence, the leg
of an element may be defined as being U, D, R,
L, or H for its entire length, when in reality
several changes in direction have taken place.
Until the program user develops a complete
understanding of the mechanics of the program
with reference to how it treats direct radiation, it
is recommended that he closely follow the
physical layout of his arrangement drawing.
When a spaced section absorbs direct radiation
only the U and D legs can absorb this form of
heat for the steam temperature analysis. For the
metal temperature analysis it makes no
difference. On platens, it is mandatory that all R
and L legs be specified. On superheater panels,
the proportioning of the elements into legs
should be in accordance with the physical layout,
i.e., I, D, R, U, and L.
A hanger or H tube, if called for in the
program, cannot be subjected to direct radiation.
The steam temperature analysis of a hanger tube
is still the same as if it were a U, D, R, or L tube.
However, the metal temperature analysis of a
hanger tube does not recognize the existence of
internal non-luminous radiation, but instead
substitutes and applies a cavity radiation rate
against a Distribution B metal temperature
contribution for spaced elements (Sheet No.
882). This is a means of treating single row
hanger tubes as spaced interior tubes.
STD NO : 31-93-13
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C. Input Instructions for Long Form
Sheet 1 - Problem Identification and Thermal
Data (Figure 1)
Card Type 1: Problem Identification
Columns 3-8: Contract Number or Repeat Loads
If additional thermal loads are desired for the
same arrangement (Sheet 3) and selection (Sheet
4), they can be combined into one program run
by entering the word REPEAT in Columns 3-8 of
Sheet 1. Then for each set of thermal conditions
(Sheets 1 and 2) that follows a complete set of
input, the program will be rerun with the same
arrangement and selection data.
Columns 10-18: Job Name - Up to 9 Spaces
Recommended to insert contract number when
REPEAT is used in Columns 3-8.
Columns 19-21: Load
MCR, CL, 20, 50, etc.
Columns 23-39: Section Description Sequence
Up to 17 Spaces
Recommended to enter abbreviated problem
description by section sequence i.e., SH-PLAT-
PEND-PEND, RH-PLAT-PEND, RH-PEND-PEND.
Columns 40-42: Section Type Sequence
For each section by sequence enter either I to
designate it as an intermediate section, or F as a
finishing section i.e., I, F, II, IF, III or IIF. This
field is for information only. It is not required by
the program.
Columns 44-51: Date
Month/day/year i.e., 02/27/81.
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Columns 70-73: Hottest Element for TC Alarm

Columns 53-64: Engineer's Name - Up to 12
Spaces If it is desired to have the program select the
hottest tube for the thermocouple alarm
Column 65: Final Plot (See Page 40) temperature calculation, leave these spaces
blank, otherwise enter the section and element
Columns 66-68: ASME Code Stress Standard number desired. For a multi-section
problem, the program uses the tube
These spaces must be filled in to correctly index numbering sequence from the first
one of the ASME Code Addenda that is included section. Therefore, if an element is to be
in the program, or your job will be ended. In specified from either Section 2 or 3, it
Column 66 enter A to specify the addenda. In must be indicated by its flow linked tube
Columns 67 and 68 enter the year of the number in the first section (Columns 72-
required ASME Code. For example: A94, A97, 73). This also means that the section number to
284 (designates ASME Code Case 2284). Check be entered in Column 71 is always 1.
code requirements for your project. Available
ASME Codes: Columns 74-77: Tube Cost ID Override
(Optional)
S77 S84 A96
W77 W84 A97 If left blank the program will default to the latest
S78 S85 284 (Code available cost and show its Cost ID on the output.
If you want to use costs other than the default,
W78 W85 Case 2284)
enter the corresponding cost ID in this field.
S79 E86 A98
W79 A87 A99 Costs may now be updated by the Procurement
S80 A88 A00 Department (with Engineering approval) at any
W80 E89 E01 time without requiring release of a new program
S81 A90 A02 version.
W81 A91 A03
S82 E92 E04 If you input additional component information for
nipples and loose tubes defined within a metals
W82 A93 A05
section, the metals cost summary will include
S83 A94 A06 itemized costs, sorted by component.
W83 E95
Existing tubing that is not being replaced, but is
Column 69: Alarm Temperature part of a metals section, show zero cost if an E is
placed in Column 55 of the selection data. This
Enter a 1 in Column 69 if alarm temperatures feature will primarily be used by ALSTOM Power
are to be calculated by the program; otherwise Performance Projects.
leave this space blank. If a 1 is entered, then for
each element for which a print plot is requested Column 78: PG-27.2.1
by entering a 1 in Column 67 of Sheet 3, an
alarm temperature will be calculated. Thus, if no This column is only applicable to A06 or later.
print plots are requested, then no alarm Enter 1 if PG-27.2.1 calculation method is
temperatures will be calculated, even though a 1 required, otherwise the A-317 method will be
is entered in Column 69 of Sheet 1. calculated.
 SUBJECT: Metal Temperature - Program WIN 11012
Column 80: Intermediate Results Code
This column is used for printing out intermediate
results when checking the program. This column
should be left blank for all contract calculations.
Card Type 2: Problem Thermal Data
Column 3: Number of Continuous Sections
Enter either 1, 2, 3, 4 or 5 as the program can
handle up to 5 continuous sections with no
intermediate headers. A change in intermesh
can occur between sections.
Columns 5-6: Fuel Code
Enter one of the 14 different fuel codes as listed
on Sheet 1.
Column 7: Metal Conductivity Standard
Leave blank to use ASME conductivity (default).
Enter 9 to use the old “CE” standard.
Column 8: Y Value Equation
This column must be left blank and is being
reserved for future use in case the ASME
allowable stress equation is ever revised. Current
equation used goes back to the winter 1963
Addenda.
Columns 10-13: Design Pressure,
50 to 8000 psig
Columns 15-18: Inlet Header Pressure,
50 to 8000 psig
Columns 20-23: Outlet Header Pressure,
50 to 5000 psig
This is the outlet pressure of the last section. The
inlet header pressure must exceed the outlet
header pressure. The transition from a
supercritical inlet header pressure to a subcritical
outlet header pressure will not be computed.
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Columns 25-29: Inlet Header Temperature,
200 to 1500o F
For subcritical pressure units, the combination of
inlet temperature and pressure must be equal to
or exceed that of saturated steam. If the inlet
header temperature equals the saturation
temperature, enter 9999.9 instead of the
temperature.
Columns 31-35: Outlet Header Temperature,
200 to 1500o F
The outlet header temperature must be greater
than the inlet header temperature. This is the
outlet temperature of the last section.
Columns 37-44: Steam Flow, 25,000 to
10,000,000 lbs/hr
For superheater panels deduct the estimated total
flow through the steam cooled spacers from the
total flow to the panels. Usually steam cooled
spacer flow is estimated as 2 times the number of
horizontal SCS tubes times 10,000 lb/hr at MCR,
and prorated at lower loads.
Columns 46-47: Design Allowance, ΔTS at
Inlet Header, 0 to 99o F
To be applied against supercritical pressure units
only (reference Appendix E).
Columns 49-50: Design Allowance, ΔTS at
Outlet Header, 0 to 99o F
To be applied against supercritical pressure units
only (reference Appendix E).
 SUBJECT: Metal Temperature - Program WIN 11012
Columns 52-53: Unbalance Carryover, ΔTS
0 to 990 F
This is the unbalance in steam temperature from
the previous section that is considered constant
for all legs. Note that this unbalance carryover
may be reduced or eliminated depending on
configuration of the section inlet links. If there is
only one inlet link or two/four which crossover,
unbalance carryover is reduced to zero. If there
are only two inlet links that do not crossover,
reduce the unbalance carryover by half.
Desuperheater Allowance - Subcritical
Pressure Units Only
All of the following items must be entered if
the desuperheater allowance is to be applicable
at a load point.
Columns 55-58: Saturation Pressure at Drum
50 to 3206 psig
Columns 60-63: Desuperheater Inlet Pressure,
50 to 3206 psig
Columns 65-69: Temperature at
Desuperheater Inlet,
0
200 to 1100 F
Columns 71-74: Pressure at Superheater
Outlet, 50 to 3206 psig
Columns 76-80: Temperature at Superheater
Outlet, 200 to 1100o F
The program obtains an equivalent Δh (enthalpy
difference) by adding 75o F to the superheater
outlet temperature and applies this Δh as a
constant at the desuperheater inlet. For all
sections upstream of the desuperheater, the
program linearly interpolates from the steam
drum to the desuperheater inlet on the basis of
enthalpy to obtain the equivalent Δh at both the
inlet of the first section to the outlet of the last
section.
STD NO : 31-93-13
INDEX : 22.8
DATE : 7 NOV 2006
OWNER : 8152
PAGE : 15 of 94
Sheet 2 - Section Thermal Data (Figure 2)
Card Type 3: Section Thermal Data
Column 3: Section Number
Enter a 1, 2, 3, 4, or 5 for the particular section
being input. For a “short form” run, enter 9.
For a multi-section problem, the data for each
section as given by Sheets 2, 3 and 4 must be
inputted in numerical order. For each REPEAT
load that is indicated on Sheet 1, a Thermal Data
Sheet 2 for each section must follow, arranged in
numerical order. For example, for a two section
problem to be run at MCR and CL (control Load),
the complete input would include the following
data sheets inputted in the order shown:
(1) Sheet 1 - Problem Thermal Data, MCR
(2) Sheet 2 - Section 1 Thermal Data, MCR
(3) Sheet 3 - Section 1 Arrangement Data
(4) Sheet 4 - Section 1 Selection Data
(5) Sheet 2 - Section 2 Thermal Data, MCR
(6) Sheet 3 - Section 2 Arrangement Data
(7) Sheet 4 - Section 2 Selection Data
(8) Sheet 1 - Problem Thermal Data, CL
(REPEAT, Cols. 3-8)
(9) Sheet 2 - Section 1 Thermal Data, CL
(10) Sheet 2 - Section 2 Thermal Data, CL
Column 5: Section Type
Enter 1 through 6 to describe the particular
section. The list of the six possible section types
by number is given on Sheet 2. In general, a
section that is classified as a platen (Types 3 or 6)
or as an upper furnace division panel (Type 4)
has an SL/D ratio of 1.2 or less. For both
platens and panels, the open space between
tubes that has been used is generally 3/8". For
spaced sections (Types 1, 2 or 5) the general rule
is that SL/D ratio should equal 2.0 but in no case
should it be less than 1.8.
 SUBJECT: Metal Temperature - Program WIN 11012 STD NO : 31-93-13
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DATE : 7 NOV 2006
OWNER : 8152
PAGE : 16 of 94

Columns 7-8: Number of Cavities-Maximum of Columns 17-21: Entering Steam

o
20 Temperature, 200 to 1500
F
Cavities can be either external or internal to a
particular section. A Type 5 card must be This is the inlet steam temperature for the section
included with the input for each cavity. involved. For inlet saturation temperature enter
9999.9.
Columns 10-11: Number of Slices-Maximum of
10 Columns 23-27: Leaving Steam Temperature,
0
200 to 1500 F
Presented plane of direct radiation can be sliced
up into a maximum of 10 slices and each slice This is the outlet steam temperature for the
need not be of equal length. A Type 6 card must section involved. It must be higher than the inlet
be included with the input for each slice. steam temperature to the section.

Columns 13-15: Number of Transverse Tubes
per Assembly (Platens and
Panels Only)
For platens insert the total number of vertical
tubes across one platen including both the up
and down legs. For panels insert the total
number of horizontal tubes up from the lower
horizontal tube, as shown below:
For Platens:
Columns 29-32: Entering Gas Temperature,
o
5000 to 3500 F
Enter the gas temperature to the nearest degree.
Columns 34-37: Leaving Gas Temperature,
o o
500 to 3500 F
This gas temperature may be used by the
program according to the gas temperature
priority to establish the gas temperature at a
point for platens and panels. It must be less than
the entering gas temperature.

Columns 39-42: Section Inlet Pressure,

50 to 8000 psig

For subcritical pressure units, the combination of

No. of Tubes inlet temperature and pressure must be equal to
(12 Shown) or exceed the properties of saturated steam.
For Panels:
Columns 44-47: Section Outlet Pressure,
50 to 8000 psig

The section inlet pressure must be greater than

the section outlet pressure.

No. of Tubes
(6 Shown)
 SUBJECT: Metal Temperature - Program WIN 11012 STD NO : 31-93-13
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DATE : 7 NOV 2006
OWNER : 8152
PAGE : 17 of 94

Columns 49-52: Convection Transfer Rate B. Gas and Steam Side Unbalance
o
(Rc), Btu/ft2-hr- F Factors

Applicable to all section types (1-6) as given on
Card Type 3, Column 5. The input value in these
columns must be greater than zero. See
Appendix G for correction factor.
Columns 54-57: Internal Non-Luminous
Transfer Rate
o
(Rn), Btu/ft2-hr- F
Same comment as for Rc (reference Columns
49-52). See Appendix G for correction factor.
A. Fluid and Metal Unbalance Factors
In general, fluid and metal unbalance factors
should be the same.
Columns 58-61: Fluid (Steam) Unbalance
Factor
If left blank, program will use 0.12. (Column 59
requires decimal point, if input is provided.)
Columns 62-65: Metal Unbalance Factor
The following input options are primarily
used by ALSTOM Power - Performance Projects.
(B1) Adjustment Index: Column 79 of Card 1
Card 1A: Gas Side Unbalance Card
Card 1B: Steam Side Unbalance Card
(B2) Sequence of Inputs:
Card 1
Card 1A (optional)
Card 1B (optional)
Card 2
(B3) Input Instructions for the Adjustment
Factors
Adjustment Index
= 7 RT Adjustment Factor (Gas Side
Unbalance Adjustment)
= 8 Resistance Adjustment Factor
(Steam Side Unbalance Adjustment)
= 9 Both the Gas Side and the Steam
Side Unbalance Adjustment

If left blank, program will use 0.12. (Column 63

requires decimal point, if input is provided.)

(A1) If unbalance factors are provided by

the Engineer, they should only be inputted for the
first section, and the program will use those
values for all sections and repeat loads. The
program does allow the user to input different
values for different sections, but the user should
be aware that the last input value will be the
value used for the rest of the sections and loads.
SUBJECT: Metal Temperature - Program WIN 11012 STD NO : 31-93-13
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OWNER : 8152
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(B4) Input Instructions for Card Type 1A

Item Field
No. Name Description Column Type

*1 Card Type Enter 1A 1-2 A

2 Section No. Enter the Section No. of the 3 I

current element

3 Beginning The first element number of 4-5(N=1) 52-53(N=8)

element of the Nth group 11-12(N=2)
number for 18-19(N=3) (I)
Group N 25-26(N=4)

(N=1, 10) Example: 32-33(N=5) 60-61(N=9)

01 39-40(N=6) 67-68(N=10)
18 46-47(N=7)

4 End element The last element number of 6-7(N=1) 55-56(N=8)

number for Nth group 13-14(N=2) 62-63(N=9)
Group N 20-21(N=3) 69-70(N=10)

(N=1, 10 Example: 27-28(N=4)

03 34-35(N=5)
25 41-42(N=6) (I)
48-49(N=7)

**5 Extra RT Enter the percentage of 8-10(N=1) 50-52(N=7)

adjustment the extra RT adjustment 15-17(N=2) 57-59(N=8)
for Group N factor for the Nth group 22-24(N=3) 64-68(N=9)
29-31(N=4) 71-73(N=10)
36-38(N=5)
43-45(N=6)
(N=1, 10) Example: (I)
-08
+23
006

6 Continuation Enter 1 if the next card will 80 (I)

Index be the card type 1A. Leave
blank if the next card will not
be the card type 1A
* If, and only if, the adjustment factor is 7 or 9, then the card type 1A should be an input card.
** The extra RT adjustment factor is applied to every leg ends in the gas touched area of any
tubes in the group which the steam temperature calculation is requested.
SUBJECT: Metal Temperature - Program WIN 11012 STD NO : 31-93-13
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OWNER : 8152
PAGE : 19 of 94

(B4) Input Instructions for the Card 1B

Item Field
No. Name Description Column Type

*1 Card Type Enter 1B 1-2 A (I)

2 Beginning The first element number of 3-4(N=1) 52-53(N=8)

element of the Nth group 10-11(N=2)
for Group N 17-18(N=3)
24-25(N=4)
(N=1, 11) Example: 31-32(N=5) 59-60(N=9)
01 38-39(N=6) 66-67(N=10)
18 45-46(N=7) 73-74(N=11)

(I)
3 End element The last element number of 5-6(N=1) 54-55(N=8)
number for the Nth group 12-13(N=2) 61-62(N=9)
Group N 19-20(N=3) 68-69(N=10)
26-27(N=4) 75-76(N=11)
(N=1, 11) Example: 33-34(N=5)
03 40-41(N=6)
25 47-48(N=7)
(I)
**4 Extra Enter the extra resistance 7-9(N=1) 49-51(N=7)
Resistance for the Nth group 14-16(N=2) 56-58(N=8)
for Group N 21-23(N=3) 63-65(N=9)
28-30(N=4) 70-72(N=10)
(N=1, 11) Example: 35-37(N=5) 77-79(N=11)
-08 42-44(N=6)
+23
006

* If, and only if, the adjustment factor is 8 or 9, then the card 1B should be an input card.

** The extra resistance is applied only to the first leg of all the elements in the group.
 SUBJECT: Metal Temperature - Program WIN 11012
Card Type 4: Section Thermal Data
Columns 3-5: Number of Assemblies -
Up to 999 per Section
Applicable to all section types (1-6) as given on
Card Type 3, Column 5. The input value in these
columns must be greater than zero and should
equal the number of actual assemblies. For a
superheater panel section, use the number of
panelettes. In a multi-section problem the
number of assemblies as inputted in these
columns is independent of the flow linkage to
and from the other sections.
Columns 7-11: Transverse Spacing of
Assemblies (ST), Up to 999.99"
The input value in these columns must be greater
than zero. Even though several spacings may be
used within one section, only one representative
value can be entered.
Columns 13-17: Longitudinal Spacing of Tubes
(SL), Up to 999.99"
This is the longitudinal spacing of tubes within an
assembly and as for the transverse spacing, only
one value can be entered. The input value in
these columns must be greater than zero.
Columns 19-22: Length Facing Furnace, ft
This is the average length of the section facing
the furnace. For sections absorbing direct
radiation this is the length of the presented direct
radiation plane. The input value in these
columns must be greater than zero.
Columns 24-27: Horizontal Length, ft
This is the length facing the furnace at the bottom
of a non-sliced platen. It is used only for non-
sliced platens where the input value must be
greater than zero. For platens over arch floor
use 0.1 ft.
STD NO : 31-93-13
INDEX : 22.8
DATE : 7 NOV 2006
OWNER : 8152
PAGE : 20 of 94
Columns 29-31: Toe or Round-the-Bend Factor
0 to 1.00
For platens (over the furnace only) insert the
applicable round-the-bend factor as obtained
from Figure 7. For spaced pendants insert the
applicable toe factor as obtained from Figure 8.
These are adjusted angle view factors that
proportion the amount of direct radiation (Sheet
No. 708A) that is used for metal temperature
calculations at these particular locations.
Note: It is not possible to make a toe factor
calculation for a platen. If a factor is entered for
a platen it will always make a round-the-bend
calculation at the end of the leg.
Columns 33-36: Utility Gas Temperature,
o
Maximum 3000 F
A utility gas temperature is required to be
inputted at a value greater than zero for the
application of Sheet No. 708A heat absorption
rate to the following:
(1) Non-sliced platens (gas temperature at
bottom of platen).
(2) If toe or round-the-bend factor is entered in
Columns 29-31.
(3) Panels (gas temperature at bottom of
panel).
(4) When a Tube Class 6 or 7 (Sheet 3,
Column 25) metal temperature calculation
is required.
See Appendix D, Figure D-1 to get utility gas
temperature values.
Columns 38-43: Direct Radiation106 Btu/hr
Program Limits 0 to 109)
This quantity must be entered at a value greater
than zero when the vertical radiating plane is not
sliced. The use of this quantity in the program is
dependent upon whether the section type is
platen or spaced as follows:
 SUBJECT: Metal Temperature - Program WIN 11012 STD NO : 31-93-13
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OWNER : 8152
PAGE : 21 of 94

(1) If the section is a platen, this quantity is the
presented direct radiation along the vertical
length of the platen. For this type of section
the program will distribute that portion of
direct radiation that is absorbed to each
tube within an assembly according to the
distribution of radiation, see Sheet No. 65-
049. A portion of the direct radiation will
not be absorbed and will pass through to
the following section.
Column 46: Printer Plot Scale Factor
If this space is left blank or a zero is entered the
print plot will use a scale factor of 1000 F per
inch. If a 1 is entered then the scale factor will
be varied in order to fit the print plot onto a
single sheet in its most readable size. In most
cases 1000 F per inch is sufficient and will be
used. For a multi-section problem this entry is
only required for the first section.

(2) If the section is spaced, the direct radiation Columns 72-75: Assembly Component Item No.
absorbed should be the same quantity of
direct radiation as given to and used by the Enter the Analysis Letter Item No. for the
Steam Generator Module to obtain a heat superheater/reheater assembly that forms most
balance for the section. The program will of this section, (e.g.: R-09, S-12). This field is
distribute the direct radiation to each tube used to correctly itemize components on the cost
as before, and then for the steam summary and to export metals data to other
temperature analysis it will adjust the heat programs.
absorbed by each tube until all of the direct
radiation is absorbed. Note that a metals section may actually include
nipples or loose tubes that belong to other
Column 45: Printer Plot Interpolation Code components. Selection Data, Columns 56-60, is
used to specify the component to which such
If print plots are to be requested on the “stray” nipple or loose tube “DAGS” belong.
Arrangement Sheet 3, then the user can select
the format of the plots by either leaving this
space blank or by entering a 1. If the space is
left blank or a zero is entered, the printer will
only spot the calculated temperature points. If a
1 is entered the program will interpolate between
the spotted temperature points and connect the
points by dots. The print code for the spotted
temperatures is as follows:

1 Balanced Steam Temperature

2 Unbalanced Steam Temperature
3 Mid-wall Metal Temperature
4 Oxidation Surface Temperature
+ Allowable Code Metal Temperature (only
pluses are connected linearly by dashes)

For a multi-section problem this entry is only

required for the first section.
SUBJECT: Metal Temperature - Program WIN 11012 STD NO : 31-93-13
INDEX : 22.8
DATE : 7 NOV 2006
OWNER : 8152
PAGE : 22 of 94

(A) Input Requirements for Defining Swing Calculations for Card Type 4

Columns Field Description Type

Name

55 Swing Enter the type of method used to calculate Integer

Index the swings. This index should be given
only for the first section.
1 - Formula Set 1
Using the input width and SL to calculate the swings.
2 - Formula Set 2
Using the leg description, horizontal leg length,
pendant bottom angle to calculate the swings.
3 - Formula Set 3
Using the input width, SL, horizontal leg length, leg
description, pendant bottom angle to calculate the swings.

56-59 Outside Enter the width to the center line of the outside Implied
Width tube in feet. Enter the total width of the outside Decimal
tube if the current section is a double loop section.
Enter the width of the outside tube if the current
section is a single loop or half loop section.

60-63 Inner Enter the width to the center line of the inner Implied
Width tube in feet. This should be given only for a Decimal
double loop section. For a double loop problem
with two sections, it should be handled as two
separate single loop sections. See sketch of Double
Loop section on Page 15.7.

64-65 Bottom Enter the absolute pendant bottom angle in

Angle 1 Degrees of the first loop (Default = 0). Integer
66-67 Bottom Enter the absolute pendant bottom angle in Integer
Angle 2 Degrees of the second loop (Default = 0.).
This should be left blank for a single loop section.
This should be left blank for a double loop problem
handled as two separate single loop sections.

68-71 SL This is the longitudinal spacing in inches for the BULB design. Implied

The clearance distance between the tubes is Decimal

defaulted to 1/32” for the platen section. The
clearance distance between the tubes is defaulted
to 3/8” for the spaced section.

72-75 Item No. See previous page. Alpha

SUBJECT: Metal Temperature - Program WIN 11012 STD NO : 31-93-13
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(B) Width Calculation for the Swing Calculation

(1) Single Loop Section

(1A) Swing Code = 1

Width (Nth element) = Width-of-the-Outside-Tube

- 2 * (N - 1) * SL / 12

Where SL = SL from Columns 13-17 of Card Type 4 for the

regular swing calculation (1Aa)

= SL from Columns 68-71 of Card Type 4 (or defaulted

values) for the BULB (1Ab) swing calculation.

N = The tube sequence number.

* The tube sequence number is consistent with the sequence
number of the plots.
* The tube sequence number is consistent with the element
number for any short form sections.
* The tube sequence number is consistent with the
element number for any sections without the same
as code in the arrangement data or bifurcates.
* The tube sequence number will not be correct for any
arrangement data with the use of the same as code.

(1B) Swing Code = 2

For the regular swing calculation:
Width (Nth element) = Width-From-Leg-Description
* COS (Bottom-Angle) (1Ba)

For the BULB swing calculation:

Using the same equation as Case (1Ab)

(1C)Swing Code = 3
For the regular swing calculation:
Using the same equation as Case (1Ba)
For the BULB swing calculation:
Width = Width-of-the-Outside-Tube * (1 - SL(BULB) /SL)
+ Width-from-Arrangement-Data * COS (Bottom-Angle)
* SL(BULB) / SL (1Ca)
SUBJECT: Metal Temperature - Program WIN 11012 STD NO : 31-93-13
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(2) Double Loop Section

(2A) Swing Code = 1

Because the metal temperature program does not allow SL to be changed in

any section, the width of both loops are assumed to be the same.

Width (Nth element) = (Width-of-the-Outside-Tube

- Width-of-the-Inner-Tube) / 2
- 2 * (N - 1) * SL / 12

Where SL = SL from Columns 13-17 of Card Type 4

for the regular swing calculation (2Aa)

= SL from Columns 68-71 of Card Type 4 (or defaulted values) for the BULB
swing calculation. (2Ab)

N = The tube sequence number.

* (See Notes in (1A))

(2B) Swing Code = 2

For the regular swing calculation of any loop:

Width (Nth element) = Loop-Width-From-Leg-Description

* COS (Loop-Bottom-Angle)
for the BULB swing calculation using the same equation (2Ba)

(2C) Swing Code = 3

For the regular swing calculation:

Using the same equation as Case (2Ba)

For the BULB swing calculation:

Width = (Width-of-the-Outside-Tube

- Width-of-the Inner-Tube)
* (1 - SL(BULB) /SL) /2
+ Loop-Width-From-Arrangement-Data * COS (Bottom-Angle)

* SL(BULB) / SL (1Ca)
 SUBJECT: Metal Temperature - Program WIN 11012 STD NO : 31-93-13
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OWNER : 8152
PAGE : 25 of 94

Swing Calculation Feature of the
Metal Temperature Program
The swing calculation feature of the metal
temperature program is intended to calculate the
swing distance of every tube as well as the
average swing for all the tubes with minimum
extra inputs. This feature will also calculate the
BULB swing for all the tubes with the clearance
distance between the tubes specified by the user
or defaulted by the program. The program will
summarize all the results and add the tables to
the end of the metal temperature outputs.
temperatures of the legs or DAGs are used for
the thermal expansion coefficients of all the
points. The program can only handle those
tubes that the plots of the tubes requested. The
user should plot all the tubes in order to get the
proper values for the average swings of the
complete loop. The program has no restrictions
for all the short form sections.

The program can only handle single loop

section(s) or double loop section(s). The
program has to use the arrangement data to
calculate all the required geometries. The leg
description of the arrangement data has to be
consistent with the arrangement drawings.

The program cannot handle horizontal sections

or the horizontal units. When the number of
intermesh between the sections is changed and
the "same as" code is used in the arrangement
data, the element number from the metal
temperature program and the tube number from
the drawings is not consistent anymore. The user
should set the SWING INDEX to 3 for the swing
calculation in this situation. The program should
be able to handle the tubes with bifurcates for
most of the cases but the SWING INDEX should
also be set to 3 for the long form bifurcate
problem. For any short form sections, the
SWING INDEX should be set to 1.

The program calculates the thermal expansion of

all the DAG ends along the vertical tubes in the
gas touched area. The metal temperature of the
DAG ends is either calculated or interpolated in
the program. The program also calculates the
thermal expansion of all the legs in the gas
touched area which the metal temperature
calculation requested. The average metal
SUBJECT: Metal Temperature - Program WIN 11012 STD NO : 31-93-13
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(3) Double Loop in Two Sections

For any problem which handled the double loop as two separate single loop sections, the
program treats each section as a single loop section. The calculation follows the same rules as
the part (1) of the documentation.

(3C) Required Input Items: Swing Index, Outside Width

Input Items:

(1) Swing Index = 1

Single loop section(s): None
Double loop section: Inner Width

(2) Swing Index = 2

Single loop section(s): Bottom Angle 1
Double loop section: Bottom Angle 1, Bottom Angle 2

(3) Swing Index = 3

Single loop section(s): Bottom Angle(s) 1
Double loop section: Inner Width, Bottom Angle 1, Bottom Angle 2
SUBJECT: Metal Temperature - Program WIN 11012 STD NO : 31-93-13
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SUBJECT: Metal Temperature - Program WIN 11012 STD NO : 31-93-13
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PAGE : 28 of 94
 SUBJECT: Metal Temperature - Program WIN 11012 STD NO : 31-93-13
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DATE : 7 NOV 2006
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PAGE : 29 of 94

Example of Swing Calculation Output

Contract: XXXXXX
Heating Surface: SH Plate
THE INPUT DATA FOR THE SWING CALCULATION:

THE SECTION NO = 1 THE SECTION WIDTH = 3.90

Load Condition

SWING CALCULATION SUMMARY TABLE

1 2 3 4 5 6 7 8
BULB BULB --- FLOW LINKAGE ---
TUBE LOOP AVERAGE CIRCUIT CLEARANCE CIRCUIT TUBE S E S E S E
NO NO LENGTH WIDTH SWING WIDTH SWING EXPANSION E L E L E L
C M C M C M
(FT) (FT) (IN) (FT) (IN) IN OUT
(IN) (IN)
1 1 37.1 3.90 0.5 3.90 0.5 4.5 4.6 1 1
2 1 36.9 3.53 1.0 3.58 0.9 4.4 4.5 1 2
3 1 36.7 3.15 1.1 3.26 1.0 4.3 4.5 1 3
4 1 36.5 2.78 1.3 2.95 1.3 4.3 4.5 1 4
5 1 36.3 2.40 1.5 2.63 1.4 4.2 4.4 1 5
6 1 36.2 2.03 1.8 2.31 1.6 4.2 4.4 1 6
7 1 36.0 1.65 2.2 1.99 1.9 4.1 4.3 1 7
8 1 35.8 1.28 2.9 1.68 2.2 4.1 4.3 1 8
9 1 35.6 0.90 4.2 1.36 2.8 4.0 4.2 1 9
10 1 35.4 0.53 7.1 1.04 3.6 4.0 4.2 1 10
11 1 35.2 0.15 25.0 0.72 5.2 4.0 4.2 1 11

FOR THE CURRENT LOAD OF THE SINGLE LOOP PROBLEM

THE TOTAL NUMBER OF TUBES = 11
THE AVERAGE SWING = 4.4
THE AVERAGE SWING FOR BULB = 2.0

Column 5 = First Try Without Bulb

Column 7 = Final Results With Bulb
 SUBJECT: Metal Temperature - Program WIN 11012
Card Type 5: Cavity Thermal Data
For sections having cavities the program uses the
cavity thermal data as one means to obtain the
local gas temperature at the point where a metal
temperature calculation is requested. This is
done by linear interpolation by tube rows
between the upstream and downstream cavity
gas temperatures. The program also calculates
the non-luminous radiation from each cavity and
determines its contribution to each element leg
for both steam and metal temperature
calculations. Since cavities are not used for
superheater division panel steam or metal
temperature calculations, there should be no
Type 5 cards for a panel section.
Column 1: Card Type Number
Enter a number 5 for each cavity. The total
number of cavities or Type 5 cards for each
section must equal the number of cavities entered
on the Type 3 card (Columns 7-8) for the section
(maximum of 20).
Columns 2-3: Cavity Number
Each cavity of a particular section is assigned an
identification number from 1 to 20 that can be in
any order.
Columns 4-8: Average Steam Temperature,
o
400 to 1100 F
Enter the estimated average steam temperature
of the legs facing the cavity.
Columns 9-12: Average Gas Temperature,
o
700 to 2650 F
Enter the average gas temperature of the cavity
facing the section.
STD NO : 31-93-13
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DATE : 7 NOV 2006
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PAGE : 30 of 94
Columns 13-15: Radiant Beam Length, 0.1 to
20 ft
Enter the radiant beam length of each cavity.
Since this program uses the upstream and
downstream cavity gas temperatures to define
the gas temperature at any point, cavities with
small beam lengths may need to be inputted.
The radiant beam length of a cavity that does not
contain any screens or hangers is calculated by
the following customary formula:
RBL = 3.4 (V/A)
Where V and A refer to the total cavity volume
(ft3) and total cavity boundary surface (ft2)
including inlet and exit planes. To calculate the
radiant beam length for other types of cavities
refer to Appendix I of Coal Firing Procedure,
Standard No. 11-95, Index 24.1.
Columns 16-19: Average Length of Cavity,
0.1 to 999.9 ft
It is current practice to enter 999.9 for average
cavity length on all Type 5 cards. This will insure
that no incorrect cavity length, shorter than the
actual, is entered. The program is written to
automatically correct any increased cavity
radiation if an incorrect average cavity length,
greater than the actual, is entered. But if a cavity
length shorter than the actual is entered, the
reduced cavity radiation resulting from this error,
will not be corrected and will be used.
WARNING: If intermediate results are requested,
then the actual average cavity length must be
entered on all Type 5 cards.
 SUBJECT: Metal Temperature - Program WIN 11012
Card Type 6: Slice Thermal Data
In general, a section is sliced whenever it is
desired to vary either the gas temperature or the
direct radiation along the length of a section
facing the furnace. In the linear interpolation
routine for calculating the local gas temperatures
(reference Card Type 5), if the requested point is
located in a slice, then the program will use the
average gas temperature entering the slice as the
upstream gas temperature in preference to the
upstream cavity gas temperature.
Column 1: Card Type Number
Enter a number 6 for each slice. The total
number of slices or Type 6 cards for each section
must equal the number of slices entered on the
Type 3 card (Columns 10-11) for the section
(maximum of 10).
Columns 2-3: Slice Number
Each slice of a particular section is assigned an
identification number from 1 to 10. Slices must
be numbered from top to bottom in sequential
order starting with Number 1.
Columns 4-7: Gas Temperature,
o
500 to 3500 F
Enter the average gas temperature entering each
slice. This applies to all sections except panels
(Section Type 4) where a gas temperature is to be
entered only for the last slice.
Columns 8-11: Length of Slice, >0 ft
Enter the length of each slice that must be
greater than zero feet. Slices need not be of
equal length.
Columns 12-17: Direct Radiation,
0 to 109 Btu/hr
Enter the direct radiation presented to each slice
in 106 Btu/hr.
STD NO : 31-93-13
INDEX : 22.8
DATE : 7 NOV 2006
OWNER : 8152
PAGE : 31 of 94
Note: For panels and spaced sections this
quantity is absorbed direct radiation whereas for
platens it is the presented direct radiation. Also
for vertical platens the presented direct radiation
along the horizontal length at the bottom is to be
entered in the last slice. *
Note: When the total radiation to the bottom of
the platens is inputted directly from the output of
the Upper Furnace Program PUF-IIIA, then the
length of the last slice to be inputted in Columns
8-11 must be the distance from the panels ** to
the furnace nose as shown in Figure 2 of the
Coal Firing Procedure, Standard No. 11-95,
Index 24.1. If the horizontal length of the platen
bottom is inputted as the length of the last slice,
then the total radiation to the bottom of the
platens, as taken from the output of the Upper
Furnace Program PUF-IIIA, must be reduced
proportionally.
* If the platen is above the nose and sliced, add
a dummy slice 0.1 ft long, getting 0.1 x 109
Btu/hr.
** If an open upper furnace, distance is from first
platen tube to furnace nose.
 SUBJECT: Metal Temperature - Program WIN 11012
Sheet 2: General Arrangement Data
(Figure 3)
This sheet includes the general arrangement data
needed for steam and metal temperature
calculations. Each section is described by
sequentially numbered tube elements and legs.
The user divides each tube element into a series
of sequentially numbered legs. The selected
number and length of the legs depends on the
type of tube (up, down, right, left or hanger), the
heat absorption and the locations where steam
and metal temperatures are to be calculated.
Steam and metal temperatures can only be
calculated at the downstream end of a leg.
Columns 1-3: Element Number-Maximum of
100 Elements per Inlet Header or
200 Elements per Section (see
Appendix B)
Starting with the first element of a section, enter a
number 1 in Column 3 for each leg of element
one. Number each succeeding element
sequentially up to the maximum number of
elements. Each new flow path must have a new
element number. Thus, if an element undergoes
bifurcation then two new elements are formed
and two new element numbers must be used. If
two elements join in bifurcation, then they
produce a new element and likewise a new
element number is needed. The O. D. tube wall
thickness, and material may vary along the
length of an element. After all elements and legs
are entered, the last entry in Columns 1-3 must
be 999. This tells the computer that the
arrangement data set is complete.
Columns 4-5: Leg Number
Each element is divided into a number of lengths
that are identified by leg numbers. The first leg
of each element must be number 1 and each
succeeding leg must be numbered sequentially
(2,3,4,5) in the order of steam flow.
STD NO : 31-93-13
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DATE : 7 NOV 2006
OWNER : 8152
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If an element or a portion of an element is the
"same as" a preceding element and the "same as"
Code in Column 6 is to be entered, then enter
the element number of which all or part is to be
duplicated.
Column 6: Tube Description, 7 Type Codes are
Permitted (I,U,D,R,L,H,S)
Enter in Column 6 the Type Code that describes
the particular leg as follows:
I (ineffective); U (up); D (down); R (right); L (left);
H (hanger - low temperature horizontal section
only); S (same as element named in Columns
4-5, starting with leg named in Columns 19-20,
and ending with leg named in Columns 22-23).
See Page 11, Item (4).
Columns 7-10: Tube Length, 0.1 to 999.9 - ft
For each leg enter the appropriate length.
Columns 11-14: Tube O. D. 1" to 5"
For each leg enter the tube outside diameter.
The general arrangement tube diameter is only
used for heat transfer surface calculations.
Columns 15-17: Heat Transfer (Rc + Rn)
Adjustment, -99% to +99%
Use these columns to adjust the average
convection and internal non-luminous heat
absorption as established by the program. Enter
the sign in Column 15 (either + or -) and the
percent factor in Columns 16 and 17. For
example, if +05 is entered, the actual factor
used in the program will be 1.05; if -05 is
entered, then the actual factor will be 0.95. This
factor can be used for all sections.
 SUBJECT: Metal Temperature - Program WIN 11012
For steam temperature calculations, the program
sums up the total direct radiation and the total
cavity radiation that is absorbed by each section.
It subtracts the sum of these radiations from the
total heat absorption (Q), as calculated from the
inlet and outlet steam conditions, and identifies
the remainder as convection and internal non-
luminous. The program distributes this quantity
of heat to each leg on an average basis using the
gas touched areas. If this average distribution is
not appropriate for certain legs, then an
adjustment factor can be entered to increase it or
reduce it accordingly.
For metal temperature calculations the program
also applies this adjustment factor to the
calculation of the convection and non-luminous
heat absorption rates at the selected points for
metal temperature calculation. The calculation
of convection and non-luminous rates uses the Rc
and Rn as inputted on Sheet 2 for the particular
section with the calculated gas and steam
temperatures.
Columns 18-20: Number of Coplanar Tubes,
1 to 999
Enter the number of coplanar tubes for only the
first leg of each numbered element. The number
of coplanar tubes is the number of similar
elements that are repeated across the section. In
a one-section problem it is equal to the number
of assemblies as shown on Sheet 2, Card Type 4.
In a multi-section problem it is dependent on the
numbering of elements and the flow linkage
between sections (see Appendix B for more
details.)
If the "same as" Code has been entered in
Column 6, then in Columns 19-20 enter the leg
number of the element where the coincidence
begins.
STD NO : 31-93-13
INDEX : 22.8
DATE : 7 NOV 2006
OWNER : 8152
PAGE : 33 of 94
Columns 21-23: Direct Radiation Tube Number
Enter the tube number counted from the direct
radiating source to the point (end of leg) where a
metal temperature calculation is requested. If
there is no direct radiation source inputted, either
presented or absorbed, then no direct radiation
number must be entered. If only a steam
temperature calculation is requested at the end
of a leg, then no direct radiation number is
needed.
For spaced or platen sections which are sliced
(slice identification is entered in Columns 26-27)
and for which a metal temperature calculation is
requested in Column 24, a direct radiation
number must be entered.
For panel sections that have 3 slices or more, no
direct radiation numbers are required for the
upper slices. Direct radiation numbers are only
required for those legs ending at or below the
inner most bend or leg of the last slice. The
reason for direct radiation numbers for panels is
to obtain a gas temperature drop and an
external radiation rate for metal temperature
calculations.
If the "same as" Code has been entered in
Column 6, then in Columns 22-23 enter the last
coincident leg number to be duplicated. No
further entries on this card with the "same as"
Code are needed.
Column 24: Calculation of Metal
Temperatures, Code No. 1 or 2
Enter a 1 if both steam and metal temperatures
are desired. Enter a 2 if only the steam
temperature is desired. Leaving this space blank
or entering a zero means that neither steam nor
metal temperatures are desired.
 SUBJECT: Metal Temperature - Program WIN 11012
Column 25: Tube Classification (at point of
metal temperature calculation),
Codes 1-7
Enter one of the following tube type codes if a 1
is entered in Column 24:
1 - Exterior Leading
2 - Exterior Trailing
3 - Interior
4 - Toe Calculation
5 - Around-the-Bend Calculation
6 - 708A Rate Applied against Interior Tube
7 - 708A Rate Applied against Exterior Tube
Note: For spaced or low temperature horizontal
sections, enter either 1, 2, 3, or 4. For platen
sections, enter either 1, 2, 3, 5, 6, or 7. For
Panel sections enter 1 or 3.
Columns 26-27: Slice Identification, 0 up to 10
Enter the slice number from the slice information
on Sheet 2 (Cards Type 6) for the slice which
includes the end of this leg.
Columns 28-31: Overriding Gas Temperature,
o
0 to 3500 F
In the calculation of metal temperatures the local
gas temperature is required in order to calculate
the convection and non-luminous heat
absorption rates for the desired point. Normally
this entry is left blank or zero, and thus the gas
temperature is obtained from an interpolation
routine using the upstream and downstream gas
temperatures. If instead a particular value for
the local gas temperature is desired, then it can
be entered as the overriding gas temperature.
CAUTION: Since this is the only thermal data
that is entered on Sheet 3, it will also apply to all
"REPEAT" loads (reference Sheet 1, Card 1,
Columns 3-8).
STD NO : 31-93-13
INDEX : 22.8
DATE : 7 NOV 2006
OWNER : 8152
PAGE : 34 of 94
Sheet 3 Cavity Arrangement Data for
Steam and Metal Temperature
Calculations, Maximum of 10 Sets
of Cavity Data (see Appendix C)
Columns 32-49: Cavity Sets A and B –
Upstream and Downstream
Cavities
For spaced, platen and low temperature sections
the upstream cavity (A) and the downstream
cavity (B), which are nearest the end of the leg
are used for gas temperature interpolation. If
either the length input for cavity A or the length
input for Cavity B is greater than zero, then the
respective cavity radiation will be used for the
steam temperature calculations. If a 1 is entered
in either Column 40 or 49, then the respective
cavity heat absorption rate will be used in the
metal temperature calculations.
For panels that cavity input locations for length
and cavity number are used to specify the actual
leg length exposed to a particular slice. If a leg
or portions of a leg were exposed to 3 slices,
then Cavity Set A would give the leg length in the
first slice (enter a 1 for slice 1 under the cavity
number), Cavity Set B would give the leg length
in the second slice (enter a 2 for slice 2 under the
cavity number), and Cavity Set C would give the
leg length in the third slice (enter a 3 for slice 3
under the cavity number).
Columns 32-35: Length, ft
For spaced, platen, and low-temperature
horizontal sections enter the leg length or portion
of the leg length that absorbs cavity radiation
from the upstream cavity (A) nearest to the end of
the leg. This length should be equal to or less
than the average cavity length (Sheet 2, Card 5,
Columns 16-19). The leg length or portion of
the leg length that is normal to the upstream
cavity should not be included. If the cavity
radiation rate should be included in the metal
temperature calculation at the end of a leg which
is completely normal to the cavity, then this
length can be zero.
 SUBJECT: Metal Temperature - Program WIN 11012
For panels enter the leg length that received
radiation from the particular slice as identified in
Columns 36-37.
Columns 36-37: Cavity Number
For spaced, platen, and low temperature sections
enter the upstream cavity number from Sheet 2,
Type 5 cards for the appropriate cavity. For
panels enter the slice number that the leg length,
as inputted in Columns 32-35, received radiation
from.
Columns 38-39: Tube Number
For spaced, platen and low temperature sections
enter the number of tubes in from the upstream
cavity (Columns 36-37) to the end of the leg.
For panels these columns should be left blank.
Column 40: * * * *
Enter a 1 if the upstream cavity radiation is to be
accounted for in the metal temperature
calculations, otherwise leave blank. For panels,
leave this column blank.
Columns 41-44: Length, ft
Same as Columns 32-35 except this length is
applicable to the downstream cavity (B) that is
nearest to the end of the leg.
Columns 45-46: Cavity Number
Same as Columns 36-37 except this is the
downstream cavity number.
Columns 47-48: Tube Number
Same as Columns 38-39 except this is the
number of tubes in from the downstream cavity
to the end of the leg.
STD NO : 31-93-13
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DATE : 7 NOV 2006
OWNER : 8152
PAGE : 35 of 94
Column 49: ****
Enter a 1 if the downstream cavity radiation is to
be accounted for in the metal temperature
calculation, otherwise leave blank. For panels
leave this column blank.
Columns 50-57: Cavity Set C
The input for these columns is basically the same
as for Columns 32-39 or Columns 41-48 except
it is immaterial whether Cavity C is upstream or
downstream. Cavity C is only used for heat
absorption as applicable to the steam
temperature calculations and cannot be used for
metal temperature calculations. For panels enter
only the leg length and slice number if leg
receives radiation from 3 slices.
Columns 58-65: Cavity Set D
The input for these columns is basically the same
as for Columns 32-39, 41-48 or 50-57 except
Cavity D is also like Cavity C in that it is only
used for heat absorption as applicable to the
steam temperature calculations and cannot be
used for metal temperature calculations. For
panels enter only the leg length and slice number
if leg receives radiation from 4 slices.
Column 66
Enter a number 1 if additional cavity data sets
are to be entered on the next input line as
follows:
Columns 32-39: Cavity Set E
Columns 41-48: Cavity Set F
Columns 50-57: Cavity Set G
Columns 58-65: Cavity Set H
 SUBJECT: Metal Temperature - Program WIN 11012
Column 66
Enter a number 1 if either Cavity Set I or Cavity
Set J are inputted on the next input line as
follows:
Columns 32-39: Cavity Set I
Columns 41-48: Cavity Set J
Note: Cavity Sets E through J are inputted like
Cavity Set C and are used only for heat
absorption as applicable to the steam
temperature calculations and cannot be used for
metal temperature calculations.
For panels, enter only the leg length and slice
number if leg receives radiation from additional
slices.
Column 67: Print Plots
Enter a 1 for the first leg of each element for
which a print plot of steam and metal
temperatures is desired. For a two or three
section problem this entry is required only for the
first leg of each element of the first section and
the resulting print plot automatically will include
temperature plots for the flow connected
elements of Section 2 and Section 3. Thus, if a
print plot is desired for a particular element of
either Section 2 or Section 3, then it must be
requested by using the flow connected element in
Section 1. No alarm temperatures will be
calculated for an element unless print plots are
requested (see Sheet 1, Card Type 1, Column
69).
If the "same as" Code is used in Column 6, then
no entry is needed in Column 67 and a print plot
will be returned if requested for the element
duplicated.
STD NO : 31-93-13
INDEX : 22.8
DATE : 7 NOV 2006
OWNER : 8152
PAGE : 36 of 94
"All Load" Plots: With multiple repeat loads, it
may be difficult to tell whether a selection is
optimized, especially if you look at plots for each
load individually. Any given point could appear
to have too much tolerance but actually be
governed by one of the other repeat loads.
To simplify multiple load analysis, the program
provides an additional set of plots called "All
Load" after it plots the last repeat load.
The program first looks for all loads that have the
same design pressure as the initial load. It then
examines this set of repeat loads and determines
the maximum temperatures at each point. Next
the program prepares a plot of these maximum
temperatures and labels it "All Load". The last
column in the table below the graph specifies the
load number that governed each point. You will
not receive "All Load" plots unless there is at least
one repeat load with the same design pressure
as the initial load.
Note: The location of the end point of each leg
or DAG is indicated just above the X-axis on the
print plot by one of the symbols defined below:
! Temperatures were calculated.
- Temperatures were determined by linear
interpolation.
Ι Temperatures are on ineffective leg and were
calculated.
+ Temperatures are on ineffective leg or
DAG and were set equal to unbalanced
steam temperature.
? Temperatures are at end of DAG and were
determined by linear interpolation.
 SUBJECT: Metal Temperature - Program WIN 11012
Sheet 4 - Selection Data (Figure 4)
In general, this sheet includes the user's selection
of tubing diameter, material, and thickness for
each element of the section. Each element is
entered as a series of length portions called
DAGs (Diameter - Alloy - Gauge). For each
DAG the flow linkage and equivalent resistances
are included for flow and pressure drop
calculations. The selection of DAGs does not
have to be related to the selection of legs, except
that the sum of the leg lengths, as entered on
Sheet 3, must be equal to within 1 ft. to the sum
of the DAG lengths. If this difference is more
than 1 ft, the program will not run. If this
difference is equal to or less than 1 ft, a warning
message will be printed out but the program
should run. If the resulting calculated metal
temperatures are not satisfactory, then the
selection data has to be modified by the user and
the program rerun. This program does not
iterate to obtain the final selection, the user
achieves this by changing his selection and
making a series of runs.
Columns 1-3: Element No.
Enter the element numbers sequentially starting
with number 1. The element numbers entered
on Sheet 4 must correspond to the element
numbers entered on Sheet 3. After all elements
and DAGs are entered, the last entry in Columns
1-3 must be 999. This tells the computer that the
selection data set is complete.
Columns 5-6: DAG Numbers
Each element as entered on Sheet 4 is divided
into a number of lengths that are identified by
DAG numbers. The first DAG of each element
must be number 1 and each succeeding DAG
must be numbered sequentially (2, 3, 4, 5, etc.)
in the order of steam flow. An element can be
entered as only one DAG. The number of DAGs
for any one element does not have to equal the
number of legs.
STD NO : 31-93-13
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DATE : 7 NOV 2006
OWNER : 8152
PAGE : 37 of 94
If this element or a portion of this element is the
"same as" or duplicates a preceding element,
and the "same as" Code or S is to be entered in
Column 34, then enter the element number of
which all or part is to be duplicated.
Columns 8-11: Length, 0.1 to 999.9 ft
For each DAG enter the appropriate length. The
sum of the DAG lengths for each element must
equal the sum of the leg lengths to within 1 ft.
Columns 13-16: Outside Diameter, 1" to 5" OD
For each DAG enter the tube outside diameter.
The selection tube diameter, as entered here, is
used for metal temperature calculations.
Columns 18-23: Material
For each DAG enter one of the material
identification codes as listed on Sheet 4.
Identification letters and numbers are entered
without any spaces and are left justified starting
in Column 18. Only the material codes listed
may be used.
Columns 25-27: Tube Wall Thickness,
0.133" to 0.563" MWT
The minimum tube wall thickness to be entered
here should be a tube thickness that is commonly
used for superheater or reheater elements. Index
22 of the Performance Standards includes a
listing of outside diameters and thickness in the
metal temperature section (Sheet No. 77-007).
Columns 29-34: Flow Linkage
These columns are used to indicate bifurcation
between elements, flow linkage of elements
between sections, and to indicate DAG numbers
when the "same as" Code is used. In addition to
the following input instructions for the individual
flow linkage entries, Appendix B includes several
examples to illustrate element numbering and
flow linkage procedures.
 SUBJECT: Metal Temperature - Program WIN 11012 STD NO : 31-93-13
INDEX : 22.8
DATE : 7 NOV 2006
OWNER : 8152
PAGE : 38 of 94

Column 29: Section No. Column 34: Bifurcate

This column is used when new elements are
formed or joined by bifurcation within a section
or when the elements of two sections are linked
together. When bifurcation is indicated within a
section, enter the section number of the
bifurcated tubes. When elements of one section
are linked to elements of a second section, enter
the section number of the second section.
Columns 30-31 or 32-33: Element No.
Four input uses of these columns are described
as follows:
(1) When two elements are joined by a bifurcate,
a new element is formed. For each of the two
elements that enter the bifurcate, the section
number of the new element is entered in Column
29, the new element number is entered in
Columns 30-31, and a "B" is entered in Column
34.
(2) When one element undergoes bifurcation
and two new elements are formed. For the one
element that enters the bifurcate, the section
number of the two new elements is entered in
Column 29, the two new element numbers are
entered in Columns 30-31 and Columns 32-33,
and a "B" is entered in Column 34.
(3) When an element of one section is flow
linked to an element of a second section, the
section number of the second section is entered
in Column 29, the element number in the second
section is entered in Columns 30-31, and
Columns 32-34 are left blank.
(4) When the "same as" Code is to be used for
an element or a portion of an element, enter the
DAG number in Columns 30-31 where the
duplication begins and enter the last DAG
number to be duplicated in Columns 32-33. For
this use an "S" has to be entered in Column 34.
Enter a "B" for the element or elements that enter
a bifurcate. Enter an "S" to indicate that this
element or a portion of this element is the "same
as" or duplicates the element named in Columns
5-6, starting with the DAG number in Columns
30-31, and ending with the DAG number in
Columns 32-33.
Columns 36-45: Equivalent Bends
These columns are used to input the physical
number of each standard type of flow resistance
that is included in each DAG. The program
evaluates the pressure drop of the flow
resistances using the standard number of
equivalent diameters as indicated below.
Columns 36-37: RB at 50
(Equivalent Diameters)
Enter the number of squeezed return bends
having a bend radius less than the tube outside
diameter.
WARNING: If the number of return bends is
equal to or greater than 15, the program will
assume you are entering the number of
equivalent diameters.
Columns 38-39: 180 at 30
(Equivalent Diameters)
o
Enter the number of 180 bends.
Columns 40-41: 90 at 25
(Equivalent Diameters)
o
Enter the number of 90 bends.
Columns 42-43: 45 at 15
(Equivalent Diameters)
o
Enter the number of 45 bends.
 SUBJECT: Metal Temperature - Program WIN 11012 STD NO : 31-93-13
INDEX : 22.8
DATE : 7 NOV 2006
OWNER : 8152
PAGE : 39 of 94

Columns 44-45: Entrance or Exit at 30

(Equivalent Diameters)

Enter the total number of entrances and exits.

Entrance and exit losses are applicable to the
junction between tubes and headers.

Column 55: Existing DAG

Services Engineering may enter E in this field to

indicate that this Existing tubing will not be
replaced and will not be included in the cost
summary.

Column 56: Loose Tube or Nipple

Enter L to indicate that this DAG is a loose tube

or N for a Nipple that belongs to another
component designated in Columns 57-62.

Columns 57-62: “Stray” Component Item No.

For DAGs that are not part of the main Assembly

described on card 4, Columns 72-75, enter the
component Item No. to which the DAG actually
belongs. For example, nipples are part of a
header component. Loose tubes are usually a
separate component and have their own item
number. See the following figure that shows how
components are typically separated at field welds
(FW):
 SUBJECT: Metal Temperature - Program WIN 11012 STD NO : 31-93-13
INDEX : 22.8
DATE : 7 NOV 2006
OWNER : 8152
PAGE : 40 of 94

D. Input Instructions for Short Form 2. Short Form Restrictions

1. General Information The following restrictions to the short form

The purpose of the short form input
procedure for WIN 11012 is to reduce to a
minimum the input arrangement data required to
describe platens and panels. The long form
arrangement data sheet (Input Sheet 3) is
replaced by one short form arrangement data
sheet which is much easier to complete. The
format of the other three Sheets (1, 2 and 4)
remains the same, except there are some
modifications in the instructions for completing
these input sheets.
The short form procedure is limited to
several commonly used pendant platen and
panel arrangements as listed below:
procedure apply:
(1) The problem must consist of a single
section.
(2) The variation of assemblies must be the
same for all elements. Variations in
arrangement between assemblies will not be
recognized.
(3) On double loop platens, ineffective lengths
are not permitted between the inner legs as
shown below.

(1) Single loop platens

(2) Double loop platens
(3) Double loop platens with wrapper tube
(4) Single loop panels
(5) Single loop panels with girdling tube
(6) Single loop platens with girdling tube

Arrangements of platens and panels which

do not conform to one of the above must be (4) The short form program is only applicable
solved using the long form of input. to parallel flow arrangements that locate the inlet
header adjacent to the upstream gas flow and
In the short form procedure the program the outlet header adjacent to the downstream
generates the general arrangement data set that gas flow.
would have been inputted using the long form.
In doing this to a programmed set of rules, the (5) Bifurcation, if present, must occur above the
user gives up some of the flexibility that is roof line. The following three types of bifurcates
available under the long form. Such items as the are allowed:
variation in heat absorption rates and the
number and location of points for metal
temperature calculations are subject to a fixed
routine. The short form programmed procedures
are described in Appendix C.
 SUBJECT: Metal Temperature - Program WIN 11012 STD NO : 31-93-13
INDEX : 22.8
DATE : 7 NOV 2006
OWNER : 8152
PAGE : 41 of 94

3. Short Form Input Instructions Card Type 3, Columns 49-57: Rc and Rn

Since Input Sheets 1, 2 and 4 are the same For panel units with coal firing see Appendix D of
for both the long and short form procedures, the this standard.
long form input instructions, as given in C,
should be generally followed. Only the required Card Type 4, Columns 29-31: Toe or Bend
modifications to the long form instructions will be Factor
included below. Since the Arrangement Data
Sheet 3 is completely changed, all the input For platens remember to enter the required
instructions for Short Form Input Sheet 3 are round-the-bend factor from Figure 7.
included below.
Card Type 4, Columns 33-36: Utility Gas
o
Sheet 1 - Problem Thermal Data (Figure 1) Temperature, F

Follow the long form input instructions except as
follows:
Card Type 2, Column 3: Number of Sections
Enter only a 1 since the short form procedure can
handle only one section.
Note: REPEAT can be used on Card Type 1,
Columns 3-8 with the short form procedure if
additional thermal loads are desired.
Sheet 2 - Section Thermal Data (Figure 2)
Follow the long form input instructions except as
follows:
Card Type 3, Column 3: Section Number
Enter a 9 to tell the program that this is the short
form input procedure.
For platens remember to enter the utility gas
temperature whether or not the platen is sliced.
For panel units with coal firing see Appendix D.
Card Type 6, Columns 4-7: Gas Temperature of
Slice
For panels enter only the gas temperature for the
ninth slice, leaving all other slices blank or zero.
For panel units with coal firing see procedure for
determining the Slice 9 gas temperature as given
in Appendix D.
Card Type 6, Columns 8-11: Length of Slice - ft
When dividing a section into slices, make sure
that the sum of the vertical slices adds up to at
least 0.1 ft greater than the length facing the
furnace (Card Type 4, Columns 19-22).

Card Type 3, Columns 10-11: No. of Slices

For panels, enter a number equal to the number

of slices either 3 or 9, since short form panels
must be divided into 3 or 9 slices. Current
practice is to use 9 slices.

Short form platens can be divided into a

maximum of 10 slices.
 SUBJECT: Metal Temperature - Program WIN 11012 STD NO : 31-93-13
INDEX : 22.8
DATE : 7 NOV 2006
OWNER : 8152
PAGE : 42 of 94

Card Type 6, Columns 12-17: Direct Radiation

The total direct radiation from the Steam
For panels enter the “absorbed” direct radiation Generator Module must be distributed per Table
in each slice by distributing the total direct A and list on Card Type 6, starting with Slice No.
radiation as taken from the output of the Steam 1, which is located near the roof.
Generator Module and multiplying by
percentages shown in Table A. Sheet 3 - Short Form General
Arrangement Data (Figure 5)
This Table assumes you have 9 slices of equal
length. A single simplified general arrangement
data sheet for the short form procedure replaces
For short form platens use “presented” direct the general arrangement data sheets (usually
radiation. more than 1 is required) for the long form
Table A procedure.
Distribution of Direct Radiation
Slice No. Percent of Total The following sketches show the location of
the lengths and dimensions that are needed for
completing the Short Form Arrangement Data
1 6.1
Sheet 3.
2 7.4
3 8.7
4 9.8
5 11.2
6 12.3
7 13.6
8 14.7
9 16.2
10 Total 100.0

II OI II OI
Roof
Line

S S

H
IH

IW
W W

Single Loop Double Loop with Wrapper

 SUBJECT: Metal Temperature - Program WIN 11012
Card Type 7: Short Form General
Arrangement Data
Columns 3-6: Inlet Ineffective Length, ft
Enter the ineffective length (II) at the inlet header
(use average value).
Columns 8-11: Outlet Ineffective Length, ft
Enter the ineffective length (OI) at the outlet
header (use average value).
Columns 13-16: Section Height, ft
Enter the gas touched vertical height (H) of the
section.
Column 33: Section Code Number
Enter one of the following codes:
0 or Blank - Single loop platen
1 - Double loop platen
2 - Double loop platen with
wrapper tube
3 - Single loop panel
4 - Single loop panel with girdling
tube
5 - Single loop platen with girdling
tube
STD NO : 31-93-13
INDEX : 22.8
DATE : 7 NOV 2006
OWNER : 8152
PAGE : 43 of 94
Columns 18-21: Section Width, ft
Enter the section width (W) as measured along
the lower horizontal edge of an assembly,
centerline to centerline of one panelette or
platen.
Columns 23-27: Spacing, inches
Enter the spacing (S) between tubes within an
assembly.
Columns 29-31: No. of Element Below Roof
Enter the number of elements that exists below
the roof line. As stated before, bifurcates must
be located above the roof.
Columns 35-38: Inner Height, ft
For a double loop platen (Code No. 1 or 2),
enter the inner height (IH) of the inner loop. If
single loop section, leave blank.
Columns 40-44: Inner Width, ft
For a double loop platen (Code No. 1 or 2),
enter the inner width (IW) of the inner loop. If
single loop section, leave blank.
Column 46: Print Plots
Enter a 1 if print plots of steam and metal
temperatures are required. A print plot will be
generated for each tube for which steam and
metal temperature calculations are requested on
Card No. 8.
 SUBJECT: Metal Temperature - Program WIN 11012
Card Type 8: Short Form Tube Sequence
Numbers for Which
Calculations are Required
A maximum of 14 tube sequence numbers can
be entered on this card to designate which tubes
require steam and metal temperature
calculations. The tube sequence numbers are a
sequential numbering of the tubes that are below
the roof (Cad 7, Columns 29-31). If bifurcates
are used above the roof, then the tube sequence
numbers will not coincide with the element
numbers used on the Selection Data Sheet 4.
See example below.
STD NO : 31-93-13
INDEX : 22.8
DATE : 7 NOV 2006
OWNER : 8152
PAGE : 44 of 94
Columns 3-5: 1st Calculation
Enter the 1st tube sequence number for which
steam and metal temperature calculations are
required. Enter a 999 if calculations are
required for all elements.
Columns 7-5, 11-13, 15-17...55-57:
2nd Calculation to 14th Calculation
Including the first calculation (Columns 3-5) enter
up to a maximum of 14 tube sequence numbers
for which stem and metal temperature
calculations are required. If a 999 is entered in
Columns 3-5, leave these columns blank.
For example, it is desired to have steam and
metal temperatures calculated for the 1st, 2nd,
4th, 9th, 15th and 30th tubes for a platen in
which there are 30 tubes or elements below the
roof. For this case enter a 1 in Column 5, a 2 in
Column 9, a 4 in Column 13, a 9 in Column 17,
a 15 in Columns 20-21 and a 30 in Columns
24-25 and leave the rest of the card blank.
 SUBJECT: Metal Temperature - Program WIN 11012 STD NO : 31-93-13
INDEX : 22.8
DATE : 7 NOV 2006
OWNER : 8152
PAGE : 45 of 94

The pertinent input data for Sheet 4 would be entered as follows:

Element No. DAG No. Material Thickness (inch)

**
(Columns 1-3) (Columns 5-6) (Columns 18-23) (Columns 25-27)
1 1 TP304 .200
1 2 TP304 .240
1 3 TP304 .280
1 4 TP304 .300
2 1 T11 .240
2 2 T11 .260
2 3 T11 .280
2 4 T11 .300
5 1 T11 .240
5 2 T11 .260
5 3 T11 .280
5 4 T11 .300
999
 SUBJECT: Metal Temperature - Program WIN 11012 STD NO : 31-93-13
INDEX : 22.8
DATE : 7 NOV 2006
OWNER : 8152
PAGE : 46 of 94

simply the procedure for obtaining such

Sheet 4 Short Form Selection Data agreement the following formulas were
(Figure 4) developed and can be used to calculate the total
element length that the short form program will
Follow the long form input instructions, generate.
except that the "same as" Code cannot be used
(Column 34). (1) Single loop platen or single loop panel:

To overcome this drawback, a short form

L = II + OI + 2H + W - (TN-1) ⎛⎜ 4S ⎞⎟
feature was developed to reduce the Sheet 4 ⎝ 12 ⎠
input data required. Tubes that have a uniform
distribution of materials can be grouped, so that (2) Double loop platen:
only the first and last element of each group
needs to be defined. The program will create the
input data for the intermediate elements by L = II + OI + 2H + W + 2IH - (TN-1) ⎛⎜ 4S ⎞⎟
⎝ 12 ⎠
determining the breakpoints in the material
selections by linear interpolation. All elements (3) Double loop platen with wrapper tube:
which are connected to bifurcates above the roof
must be individually defined on Sheet 4 and Use formula for double loop platen for all
cannot be part of or exist within one of these tubes except wrapper tube.
groupings.
L for wrapper tube = II + OI + 2H + W
The example on the previous page of a 5
element single loop section illustrates the method (4) Single loop platen or single loop panel with
to be used for grouping elements which have a girdling tube:
uniform distribution of materials. Only a partial
listing of the input sheet items is included. Use formula for single loop platen or panel
for all tubes except girdling tube.
The other input items such as length, OD,
flow linkage and equivalent bends for each of L for girdling tube = II + OI + 2H + W –
the above DAGs would still be required. No
input entries are needed for elements 3 and 4 (TN-1) ⎛⎜ 2S ⎞⎟
⎝ 12 ⎠
that will be created by the program. It should be
obvious that for a platen or panel whose material
selection is to be in groups of tubes with the where: L = total element length to be
breakpoints following along straight line cuts that calculated, ft
the amount of selection input data or number of II = ineffective length at inlet header,
DAGs to be defined will be greatly reduced. ft
OI = ineffective length at outlet
In defining the DAG lengths on Sheet 4 it is header, ft
most important that the total element length as H = height of section, ft
obtained from the sum of the DAG lengths W = width of section, ft
equals within one foot the element length that is IH = inner height of section, ft
generated by the short form program. If the S = spacing, inches
difference in element lengths is greater than one TN = tube number below roof line
foot, then the program will not run. In order to
 SUBJECT: Metal Temperature - Program WIN 11012 STD NO : 31-93-13
INDEX : 22.8
DATE : 7 NOV 2006
OWNER : 8152
PAGE : 47 of 94

In addition to obtaining agreement

between the total selection length and the total
arrangement length of an element that the short
form program generates, it is also important that
the user define his selection lengths so that a
material break does not occur along the
horizontal length of a pendant platen or panel
section. If a material break is selected and
inputted so that it occurs along the horizontal
length including the corners, then an error will be
printed out and the short form program will not
run.

F. Output for Program Win 11012

Refer to Part A - General Information, for a

description of the data which are printed out and
returned.
SUBJECT: Metal Temperature - Program WIN 11012 STD NO : 31-93-13
INDEX : 22.8
DATE : 7 NOV 2006
OWNER : 8152
PAGE : 48 of 94

SH and RH Metal Temperature Program WIN 11012 Page ____ of ____

Sheet 1 (Problem Thermal Data) Figure 1

Sect.

ASME Code

Standard
Type

Plotter

Stress
Contract No.
or Job Name Load Section Description Sequence Seq Date
Engineer's Name
Repeat Load
1 2 3
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68

Intermediate Results
Unbal. Adjust. Index
PG-27.2.1
Alarm Tube
Temp Cost ID
Override

SEC ELM
69 70 71 72 73 74 75 76 77 78 79 80

Supercritical Only
Steam Function°°°°
Metal Cond. Std°°°

Outlet Header (°F)

Y Value Equation
No. Contin. Sect.

Inlet Header (°F)

Carryover (°F)
Design Allow.

Design Allow.
Inlet Outlet Inlet Outlet

Unbalance
Fuel Code

Design Header Header Header Header

°°

Pressure Pressure Pressure Temp. Temp. Steam Flow

(psig) (psig) (psig) (°F) (°F) (lb/hr)

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53

2
* *
°° Fuel Code °°° Metal Conductivity Std. °°°° Steam Function
01 Gas - Blast Furnace Blank - ASME Blank - IAPWS-IF97 (1997 ASME) Subcritical Pressure Units Only
02 Gas - Natural Avg. 9 - Old "CE" 1 - Steam Table Desuperheater Allowance
03 Gas - Coke Oven 2 - 1967 ASME Steam Functions
04 Oil - Bunker Satur. Deshtr. Temp. at Press Temp.
05 Coal - Coke By Prod. Press. at Inlet Deshtr. at at
06 Coal - Penn. Drum Pressure Inlet SH Outlet SH Outlet
07 Coal - East L.V. (psig) (psig) (°F) (psig) (psig)
08 Coal - East H. V.
09 Coal - Midwest
54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80
10 Coal - Wyoming
11 Coal - North Dakota * *
12 Wood - 30% Moist.
13 Wood - 50% Moist.
14 Bagasse - 50% Moist.
SUBJECT: Metal Temperature - Program WIN 11012 STD NO : 31-93-13
INDEX : 22.8
DATE : 7 NOV 2006
OWNER : 8152
PAGE : 49 of 94

SH and RH Metal Temperature Program WIN 11012 Page _____of _____

Sheet 2 (Problem Thermal Data) - Figure 2

C o n v e c t. In te rn a l

Transverse Tubes
Section Type *

Per Assembly
T ra n s fe r N o n -L u m . F l u id
Section No.

Number of

Number of

Number of
Cavities

E n te rin g L e a v in g E n te rin g L e a v in g S e c tio n S e c t io n R a te R a te (S te a m )

Slices

M e ta l
S te a m S te a m G as G as I n le t O u tle t [R c ] [R n ] U nbal U nbal
Tem p. Tem p. Tem p. Tem p. P re s s u re P re s s u re (B tu /h r- (B tu /h r- F a c to r F a c to r
(°F ) (° F ) (°F ) (°F ) ( p s ig ) ( p s ig ) ft2-° F ) ft2-° F )

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65

3 * * * *

Print Plot Code

Toe or

Scale Factor
Assemblies

T ra n s v e rs e L o n g it u d i n a l L e n g th R ound U t ili t y D ir e c t * S e c tio n T y p e :

Number

S p a c in g S p a c in g F a c in g H o riz . th e G as R a d ia t io n 1. S H P endant S paced

of

ST SL F u rn a c e L e n g th Bend Tem p. 2 . S H o r R H H o riz o n ta l S p a c e d

( in ) (in ) (ft) (ft) F a c to r (°F ) (M B T U ) 3 . S H o r R H P e n d a n t P la t e n
4. SH Pendant Panel
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46
5. R H P endant S paced
4 * * * * * * 6 . S H o r R H H o riz o n ta l P la te n

C a v ity T h e r m a l D a ta S lic e T h e r m a l D a ta C a r d T y p e 4 - C o n t in u e d
A v e ra g e A v e ra g e A v e ra g e L e n g th D ir e c t
Beam Length

Swing Index

Bot. Angle 1

Bot. Angle 2

Component
Assembly
(degrees)

(degrees)

Item No.
Number

Number
Radiant

S te a m G as L e n g th G as of R a d ia t io n B u lb

Outside
Enter 5

Enter 6
Cavity

Width

Width
Inner
Slice
(ft)

(ft)

(ft)
Tem p. Tem p. o f C a v ity Tem p. S l ic e SL
(° F ) (° F ) (° F ) (°F ) (ft) (M B T U /h r) (in )

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75

* *
* *
* *
* *
* *
* *
* *
* *
* *
* *
* *
* *
* *
* *
* *
* *
* *
* *
* *
* *
* *
* *
* *
* *
* *
*
*
*
* * * *
*
* P r in t e r P lo t I n t e r p o la t io n C o d e
* 0 o r B la n k - S p o t T e m p e r a t u r e P o in t s o n ly
* 1 - C o n n e c t T e m p e r a t u r e P o in t s w it h D o t s
*
*
* S c a le F a c t o r
* 0 o r B la n k - U s e S c a le f a c t o r o f 1 0 0 ° F / in c h
* 1 - U s e V a r ia b le S c a le F a c t o r
*
SUBJECT: Metal Temperature - Program WIN 11012 STD NO : 31-93-13
INDEX : 22.8
DATE : 7 NOV 2006
OWNER : 8152
PAGE : 50 of 94

SH and RH Metal Temperature Program WIN 11012 Page _____of _____ Sheet 3 (General Arrangement) - Figure 3

M e t a l I*n f o . I f * C *a v it ie s t o D e* s c r ib e G *a s T e m p e r a*t u r e
P o in t t o b e C a lc . C a v it y S e t A C a v it y S e t B C a v it y S e t C C a v it y S e t D

Calc Metal Temp**

Rc+Rn Adjustment
Tube Description*

More Cavities?
Tube Class ***
Heat Transfer

Tube Number

Identification

Gas Temp.
Overriding

Print Plots
Radiation
Coplanar
Element
Number

Number

Length

Length

Length

Length

Length
Tubes

Cavity

Cavity

Cavity

Cavity
No. of

Direct
Tube

Tube

Tube

Tube

Tube
Slice
O.D.

(°F)
Leg

Leg

(%)

****

****
No.

No.

No.

No.

No.

No.

No.

No.
(in)
(ft)

(ft)

(ft)

(ft)

(ft)
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67

* * * * * *
* * * * * *
* * * * * *
* * * * * *
* * * * * *
* * * * * *
* * * * * *
* * * * * *
* * * * * *
* * * * * *
* * * * * *
* * * * * *
* * * * * *
* * * * * *
* * * * * *
* * * * * *
* * * * * *
* * * * * *

* L e g D e s c rip to n ** C a lc . M e ta l ** * T u b e C la s s **** P rin t P lo ts

I - I n e f f e c t iv e 1 - E x t e r io r L e a d in g 1 - I f C a v it y is t o b e a c c o u n t e d
U - U p Tube 1 - C a lc . M e t a l T e m p a t e n d 2 - E x t e r io r T r a ilin g f o r in t h e m e t a l t e m p . 1 - P lo t w a n t e d f o r
D - D ow n Tube o f L e g , O t h e w is e le a v e 3 - I n t e r io r c a lc u la t io n . O t h e w is e e le m e n t s t a r t in g w it h
R - R ig h t T u b e le a v e b la n k . 4 - T o e C a lc . le a v e b la n k . t h is L e g . O t h e r w is e
L - L e ft T u b e 5 - A r o u n d B e n d C a lc . le a v e b la n k .
H - H anger Tube 2 - P r in t s t e a m t e m p e r a t u r e 6 - 7 0 8 A ( I n t e r io r ) M o r e C a v itie s ?
S - S a m e a s E le m # ( C o l. 4 - 5 ) o n ly 7 - 7 0 8 A ( E x t e r io r ) 1 - I f E le m e n t & L e g is t o b e
f r o m L e g # ( C o l. 1 9 - 2 0 ) c o n t in u e d t o d e s c r ib e
t o L e g # ( C o l. 2 2 - 2 3 ) m a x im u m o f 1 0 c a v it ie s .
O t h e r w is e le a v e b la n k .
SUBJECT: Metal Temperature - Program WIN 11012 STD NO : 31-93-13
INDEX : 22.8
DATE : 7 NOV 2006
OWNER : 8152
PAGE : 51 of 94

SH and RH Metal Temperature Program WIN 11012 Page _____of_____ Sheet 4 (Selection Data) - Figure 4

F lo w L in k a g e E q u iv a le n t B e n d s D a ta E x p o rt / C o s t

Nipple / Loose Tube

Entrance or Exit
Min. Wall Thk.

Existing DAG
180° Bends
Section No.

90° Bends

45° Bends
Bifurcate *
Element

Element

Element
Number

Return
O u ts id e

Tube
DAG

@50

@30

@25

@15

@30
" S tra y "
No.

No.

No.
(in)
L e n g th D ia m e te r M a te r ia l * *
C om ponent
(ft) ( in )
Ite m N o .

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62

* * *
* * *
* * *
* * *
* * *
* * *
* * *
* * *
* * *
* * *
* * *
* * *
* * *
* * *
* * *
* * *
* * *
* * *
* * *
* * *
* * U s e t h e f o llo w in g C o d e s le f t ju s t if ie d f o r * (C o l 3 4 )
M a t e r ia l I d e n t if ic a t io n B - B ifu r c a te
S - E le m e n t is s a m e a s E L M # ( C o l 5 - 6 )
SA178A T 2 T92
fro m D A G # (C o l 3 0 -3 1 )
SA178C T 5 T122
to D A G # (C o l 3 2 -3 3 )
SA178D T 9 HR3C
SA192 T 11 S304H
B la n k - N o n e o f t h e A b o v e
S A 2 1 0 *** T 12 TP304H
SA210C T 21 TP310
T1 T 22 TP321H
T1A T 23 TP316H
T 91 TP347H
347H FG

* * * S A 2 1 0 D e s ig n a te s S A 2 1 0 A - 1
SUBJECT: Metal Temperature - Program WIN 11012 STD NO : 31-93-13
INDEX : 22.8
DATE : 7 NOV 2006
OWNER : 8152
PAGE : 52 of 94

SH and RH Metal Temperature Program WIN 11012 Page _____of_____ Platen Short Form
Sheet 3 (General Arrangement) - Figure 5

Used for Double Loop

Platen O nly

Below Roof
Card Type

Ineffective

Ineffective

Print Plots
Elements
Spacing
Section

Section

Code *
Length

Length

Height

Height
No. of
Outlet

Width

Width
Inner

Inner
Inlet

(in)
(ft)

(ft)

(ft)

(ft)

(ft)

(ft)
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46

7 *
* * * * * *
* Code
B lank - S ingle Loop
1 - Double Loop
2 - Double Loop with W rapper Tube
3 - Panels without G irdling Tube
4 - P anels with G irdling Tube
5 - S ingle Loop P laten with G irdling Tube

E nter Tube S equence Num bers for which Calculations are Required
Card Type

Calc.

Calc.

Calc.

Calc.

Calc.

Calc.

Calc.

Calc.

Calc.

Calc.

Calc.

Calc.

Calc.

Calc.
10th

11th

12th

13th

14th
2nd

3rd

4th

5th

6th

7th

8th

9th
1st

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57

8
 SUBJECT: Metal Temperature - Program WIN 11012 STD NO : 31-93-13
INDEX : 22.8
DATE : 7 NOV 2006
OWNER : 8152
PAGE : 53 of 94

Metal Plot Instructions

1. Run WIN 11012 Production version with a 3

in Column 65 of Card 1. ALSTOM Power –
Performance Projects uses a different plot format
and must enter a 5 in Column 65, especially for
supercritical units. These plots do not include the
two extra points (mwt, ost) for supercritical design
allowance. A plot file (e.g.
G:\OUTPUT\11012PRODB00.718) will return to
your output directory along with the normal
metals output file. Rename the file to DOS format
with no more than 8 characters with 3 character
extension e.g. 11012B00.718.

2. To run the METPLOT PC program go to your

output directory containing the plot file and from
DOS type METPLOT3. Enter the plot file name
(e.g. 11012B00.718) at the program prompt.
The program will ask if you want to plot all tubes,
or specific tubes. (You can also control the tubes
plotted from within the metals program and
specify plot all tubes in the plotting program.)

A typical example of the METPLOT output is

shown on Page 54.
SUBJECT: Metal Temperature - Program WIN 11012 STD NO : 31-93-13
INDEX : 22.8
DATE : 7 NOV 2006
OWNER : 8152
PAGE : 54 of 94

CONTRACT NO JOB NAME JOB DESCRIPTION ENGINEER DATE

RH PEND & FINISHING
PRINT PLOT OF CIRCUIT STARTING WITH ELEMENT NUMBER 2

A M
SEC ELEM DAG DIAM ALLOY GAGE DAG DEVEL. ALLOW MIDW MIDW OXID
LENGTH LENGTH METAL CLOS. METAL CLOS.
TEMP. TEMP. TEMP. TEMP.
1 2 1 2.500 SA21 0 0.100 4.90 4.90 898 184 714 136
1 2 2 2.500 T12 0.133 55.10 60.00 999 37 962 57
1 2 3 2.250 T1 0.133 8.10 68.10 976 137 839 61
2 9 1 2.000 T1 0.133 7.20 75.30 988 150 838 61
2 9 2 2.750 T12 0.180 26.50 101.80 1028 17 1011 8
2 9 3 2.750 TP304H 0.150 22.20 124.00 1170 101 1069 325
2 9 4 2.750 TP304H 0.150 28.00 152.00 1170 45 1125 269
2 9 5 2.000 T22 0.198 8.90 160.90 1110 86 1024 77
SUBJECT: Metal Temperature - Program WIN 11012 STD NO : 31-93-13
INDEX : 22.8
DATE : 7 NOV 2006
OWNER : 8152
PAGE : 55 of 94

Round-The-Bend Factor for Platens Only – Figure 7

1 + Cos 2φ
Factor F =
4
⎛1⎞
where φ = arctan ⎜ ⎟
⎝L⎠
0.5
Round the Bend Factor, dimensionless

0.4

0.3

0.2

0.1

0
0.1 1 10
Length, ft
 SUBJECT: Metal Temperature - Program WIN 11012 STD NO : 31-93-13
INDEX : 22.8
DATE : 7 NOV 2006
OWNER : 8152
PAGE : 56 of 94

Toe Factor for Spaced Sections Only - Figure 8

1.0 φ =90°
Adjusted View Factor - FV , dimensionless

0.9

0.8 φ =60°

0.7
φ =45°
0.6

0.5
φ =30°
0.4

0.3

0.2
φ =10°
0.1

0.0
0 5 10 15 20 25 30 35 40 45

θ/2 Degrees
 SUBJECT: Metal Temperature - Program WIN 11012 STD NO : 31-93-13
INDEX : 22.8
DATE : 7 NOV 2006
OWNER : 8152
PAGE : 57 of 94

Appendix A 1. Total heat absorbed by steam within a

section (QT):
Basic Equations and Calculation Procedures
QT = Ws (hout - hin)
The calculation procedures included in WIN
11012 can be divided into four major areas: where: Ws = total steam flow, lb/hr

heat absorption calculations, flow and
pressure drop calculations, steam
temperature calculations, and metal
temperature calculations.
Even though the flow calculations and steam
temperature calculations are interdependent, they
are described separately. Not every procedure
and option included in the program is described.
This was done to keep the procedures straight
forward and easier to understand.
A. Heat Absorption Calculations
hin = inlet steam enthalpy, Btu/lb
hout = outlet steam enthalpy, Btu/lb
2. Total heat absorbed by a section (QT):
QT = QADR + QACR + QC+NL
where: QADR = direct radiation absorbed by
section, Btu/hr
QACR = cavity radiation absorbed by
section, Btu/hr

This program uses the heat balance data as QC+NL = convection plus internal
inputted (obtained from the output of the Steam non-luminous radiation
Generator Program) and in no case does this absorbed by section, Btu/hr
program attempt to re-compute the heat balance
for any section. Even though the total heat pickup 3. Distribution and summation of direct
is fixed for each section, this program does radiation absorbed by a section
calculate, for platens and spaced sections, the
presented radiation from each cavity and the (QADR):
distribution of the absorbed radiation throughout ⎛ Lleg ⎞ ⎛ Ncopt ⎞
each section. By overall difference, the program Q'ADR = QPDR (% Abs) ⎜ ⎟⎜ ⎟
⎜ L furn ⎟ ⎜ Nassy ⎟
determines the total heat absorbed by convection ⎝ ⎠⎝ ⎠
and internal non-luminous radiation and Q ADR = ∑ Q'
ADR
distributes this quantity of heat uniformly on the
basis of gas touched or heated surface. This
uniform distribution can be altered by the user where: Q' = direct radiation absorbed by leg
ADR
through inputted adjustment factors. For panels, Btu/hr
the heat absorption calculations do not follow the QPDR = presented direct radiation,
described procedures. Panels are always sliced inputted value on Sheet 2, Btu/hr
and cavities are not considered. The heat %Abs = % heat absorption per tube
absorbed in each slice is an inputted value on row per superheater Sheet No.
Sheet 2 and is uniformly distributed in all but the 65-049, Standard No. 5-96,
last slice. Index 21.7
 SUBJECT: Metal Temperature - Program WIN 11012 STD NO : 31-93-13
INDEX : 22.8
DATE : 7 NOV 2006
OWNER : 8152
PAGE : 58 of 94

Lleg = Tube or leg length facing direct
radiation source, ft
Lfurn = length facing furnace or length of
direct radiation plane,
inputted value on Sheet 2, ft
Ncopt = number of coplanar tubes,
inputted value on long form
Sheet 3, Columns 18-20
Nassy = number of assemblies across the
furnace width
Note: For spaced sections, the presented direct
radiation is considered to be 100% absorbed and
none passes through. To accomplish this in the
calculations, the % absorption for the individual
tube legs are adjusted upwards until the total of all
% absorption equals 100%.
4. Distribution and summation of cavity
radiation absorbed by a section (QACR):
Note: This program obtains the cavity non-
luminous radiation rate from a routine based on
superheater Sheet No. 705. This standard
includes a fuel correction factor that is correlated
to the 14 standard fuel codes. Although the
standard includes provisions for using the actual
fuel analysis, this program only has provisions for
using the standard fuel codes (Input Sheet 1).
Since the overall heat pickup per section is fixed to
the steam generator program, any deviations in
the cavity radiation rate due to the fuel analysis
would only have a small affect on the intermediate
steam temperatures and only a negligible affect on
metal temperatures.
5. Total heat absorbed by a section from
convection and internal non-luminous
radiation (QC+NL):
QC+NL = QT - QADR - QACR

S
QPCR = (RN )cav (L cavNassy T ) ( Tg - t s ) 6. Distribution of convection and internal
12 non-luminous radiation:
⎛L ⎞ ⎛⎜ Ncopt ⎞
Q'ACR = QPCR (% Abs) ⎜ act ⎟⎜ ⎟
⎝ L cav ⎠ ⎝ Nassy ⎟ ( GTS)leg
⎠ Q' = Q C+NL (1 + % R T Adj )
C + NL ∑ GTS
Q ACR = ∑ Q'
ACR
where: Q' = convection and non-luminous
C + NL
where: Q' = cavity radiation absorbed by radiation absorbed by each
ACR
each leg, Btu/hr leg, Btu/hr
QPCR = presented cavity radiation, as ∑ GTS = total running sum of gas
calculated for each cavity, touched surface, ft2
Btu/hr ( GTS )leg =
(FAC )DoL
, gas touched
(RN)cav = cavity non-luminous radiation 12
rate, Btu/hr-ft2-o F surface per leg, ft2
(FAC) = 2 for platen or panel sections
Lcav = average length of cavity, ft
Lact = actual element length exposed (FAC) = π for spaced sections
to cavity, ft Do = outside tube diameter, inches
ST = transverse spacing between L = length of leg, ft
assemblies, inches % RT Adj = convection and non-luminous
Tg = average gas temperature of radiation adjustment, inputted
cavity, o F on long form Sheet 3,
ts = average steam temperature of Columns 15-17
leg length facing cavity, o F
 SUBJECT: Metal Temperature - Program WIN 11012 STD NO : 31-93-13
INDEX : 22.8
DATE : 7 NOV 2006
OWNER : 8152
PAGE : 59 of 94

B. Flow and Pressure Drop Calculations For supercritical pressures:

C = (0.8) (3.36 x 10-6)f where f =
By applying the general pressure drop Moody's friction factor
equation for superheaters and reheaters to a (reference Sheet No. 77-013)
parallel flow arrangement of elements, the flow α = 2.0
through each element can be directly solved for. β = 5
To do this, the procedure uses two other known
facts; one, that the total flow through the section 2. Calculation of the flow through each element:
equals the sum of all the individual element flows;
and two, that the overall pressure drop across To describe the procedure that is used by the
each flow path is equal. Since the pressure drop is program to calculate the flow through each
dependent upon the specific volume, the first set of element, the basic equations are show for a simple
flow calculations are made by setting the average three element pendant section operating at
specific volume for each element equal to the subcritical pressure:
overall average specific volume for the section. As
part of the first steam temperature calculations, the FT = total flow, lb/hr
average specific volume for each element also is
calculated. Using these calculated average F1,F2,F3 = flow through each element, lb/hr
specific volumes, the element flows and pressure
drops are recalculated. ΔPT = total section pressure drop, psi

1. Calculation of superheater and reheater

pressure drop:
(reference Sheet No. 77-011)
α (TEL)
ΔP = C ⎛⎜ F ⎞⎟ v
⎝ N ⎠ (D)β
Where:
F = element flow, lb/hr
N = number of tubes per element
(TEL) = developed element length plus
total equivalent length of bends,
etc., ft
D = average length weighted inside
diameter, inches
v = average specific volume for each
element, ft3/lb

For subcritical pressures:

C = 2.1099x10-7 (f), where, F=1.0
α = 1.85
β = 4.97
 SUBJECT: Metal Temperature - Program WIN 11012 STD NO : 31-93-13
INDEX : 22.8
DATE : 7 NOV 2006
OWNER : 8152
PAGE : 60 of 94

For nomenclature of the following, see Item 1 N = N1 + N2 + N3

where: ∑ R
under B. R 0.54 R10.54 R 20.54 R 30.54
F2 FT
FT = F1 + F2 + F3 also, =
N2 R 0.54 ∑ N
2
R 0.54
ΔPT = ΔP1 = ΔP2 = ΔP3
F3 FT
=
N3 R 0.54 ∑ N
1.85 (TEL) v 3
⎛F ⎞
ΔP1= C ⎜ 1 ⎟ R1 ; R1= 1 1 R 0.54
N
⎝ 1⎠ D1 4.97

1.85 (TEL) v Using this basic method, the program can

⎛F ⎞ 2 2
ΔP2 = C ⎜ 2 ⎟ R2 ; R2 = calculate the flows for up to 100 elements per inlet
N
⎝ 2⎠ D2 4.97 header. It also can handle the more complex
1.85 (TEL) arrangements that arise from using bifurcates.
⎛F ⎞
ΔP3 = C ⎜ 3 ⎟ R3 ; R3 = 3 v3
N 4.97 Although the procedure basically is the same, the
⎝ 3⎠ D3 equations and programming become much more
complex. The maximum number of elements that
Solve for F2 and F3 in terms of F1 as follows: the program can handle currently within any one
section is limited to 200.
ΔP2 = ΔP1
⎛N ⎞ ⎛ R ⎞
0.54 C. Steam Temperature Calculations
F2 = F1 ⎜ 2 ⎟ ⎜ 1 ⎟
⎝ N1 ⎠ ⎝ R 2 ⎠
This part of the program calculates the enthalpy
ΔP3 = ΔP1
and pressure at the end of each leg, and then
0.54
⎛N ⎞ ⎛ R ⎞ from the steam tables determines the steam
F3 = F1 ⎜ 3 ⎟ ⎜ 1 ⎟
⎜ N1 ⎟ ⎜ R ⎟ temperature and specific volume. The steam
⎝ ⎠⎝ 3 ⎠
temperatures are printed as output for only those
legs for which either a metal temperature
By substitution solve for F1 in terms of FT as
calculation or a steam temperature is requested.
follows:
The average specific volume for each element
0.54 0.54
⎛N ⎞ ⎛ R ⎞ ⎛N ⎞ ⎛ R ⎞ which is used for the second flow calculation is the
FT = F1+ F1 ⎜ 2 ⎟ ⎜ 1 ⎟ + F1 ⎜ 3 ⎟ ⎜ 1 ⎟
⎝ N1 ⎠ ⎝ R 2 ⎠ N R
⎝ 1⎠⎝ 3 ⎠ average of the inlet specific volume of the first leg
or and the outlet specific volume of the last leg.

FT
F1=
0.54 0.54
⎛N ⎞ ⎛ R ⎞ ⎛N ⎞ ⎛ R ⎞
1+ ⎜ 2 ⎟ ⎜ 1 ⎟ + ⎜ 3 ⎟⎜ 1⎟
⎝ N1 ⎠ ⎝ R 2 ⎠ ⎝ N1 ⎠ ⎝ R 3 ⎠

The flow per tube becomes:

F1 FT
=
N1 (R )0.54 ∑ N
1
(R )0.54
 SUBJECT: Metal Temperature - Program WIN 11012 STD NO : 31-93-13
INDEX : 22.8
DATE : 7 NOV 2006
OWNER : 8152
PAGE : 61 of 94

Neither the flow calculations, as described in B,
nor the steam temperature calculations can be
solved independently. The flow calculations
require the average specific volume, whereas the
steam temperature calculations require the flow.
To obtain a solution, the program includes a
simple two-step iterative procedure in which each
calculation is repeated only once. For the first flow
calculation, the average specific volume for each
element is set equal to the overall average specific
volume of the section. Using the resulting flows
and pressure drops, the first steam temperature
calculation is made. Using only the inlet and
outlet specific volume as determined for each
element, an average specific volume is calculated
which is used to recalculate the element flows and
pressure drops. The recalculated flows and
pressure drops then are used to calculate the final
steam temperatures to complete the procedure.
1. Heat absorbed by each element leg, Q' :
T
Q' = Q ' + Q' + Q'
T ADR ACR C+NL
Note: Heat absorption quantities are defined in
A; prime quantities, as used here, are for element
legs. For panels the heat absorbed by each
element leg is determined directly from the heat
absorption that is inputted for each slice.
3. Pressure at the outlet of each leg, P:
P = Pi - L ΔPT
LT
where: Pi = pressure at inlet to leg, psi
L = Length of leg, ft
LT = total length of element (sum of all
leg lengths), ft
ΔPT = total element pressure drop, psi
4. Balanced steam temperature, ts:
Obtained from steam tables using pressure
(P) and enthalpy (h), as evaluated at the end of
each leg.
5. Unbalanced steam temperature, (ts)UB:
a. Obtained from steam tables using
pressure (P) and the following unbalanced
enthalpy (h)UB.
b. For subcritical pressures the unbalanced
enthalpy at the end of each leg is calculated as
follows (assuming 12% unbalance):
(h)UB = hi + 1.12 Σ(Δh) + (Δh)CO + (Δh)DSP

2. Steam enthalpy at the outlet of each leg, h:

h = hi + Δh
QT
h = hi +
F
where: hi = enthalpy at the inlet to leg, Btu/lb
F = flow per element, lb/hr
SUBJECT: Metal Temperature - Program WIN 11012
where:
1.12 Σ(Δh) = summation of balanced Δh from
inlet header increased by 12%,
Btu/lb
(Δh)CO = enthalpy change equivalent to the
inputted to the inputted steam
temperature unbalance carryover
(reference Sheet 1, Card 2,
Columns 52-53); evaluated by the
program at the inlet temperature
and pressure to the first section
and assumed constant for all legs,
Btu/lb
(Δh)DSP = desuperheater unbalance
allowance, Btu/lb, for sections
upstream of the desuperheater;
evaluated along the element
length as follows:
Pi − P
( Δh )DSP = ( Δh)E + ( Δh)L - ( Δh)E
( ΔP ) T
(Δh)E = equivalent desuperheater enthalpy
change at entrance to first section
(inlet header), But/lb
(Δh)L = equivalent desuperheater enthalpy
change leaving last section (outlet
header), Btu/lb
(ΔP)T = total header to header pressure
loss, psi
STD NO : 31-93-13
INDEX : 22.8
DATE : 7 NOV 2006
OWNER : 8152
PAGE : 62 of 94
Note: The program obtains an equivalent
o
enthalpy change (Δh) by adding 75 F to the
superheater outlet temperature and applies this
equivalent enthalpy change, as a constant, at the
inlet to the desuperheater. For all sections
upstream of the desuperheater, the program
linearly interpolates on the basis of enthalpy from
the steam drum to the inlet of the desuperheater in
order to obtain (Δh)E at the entrance to the first
section and (Δh)L at the outlet to the last section.
c. For supercritical pressures, the
unbalanced enthalpy is calculated using the same
procedure, except the desuperheater allowance
(Δh)DSP is not used and becomes zero. For
supercritical pressures there is an alternate
provision to input a design allowance temperature
difference at the inlet header and also, at the
outlet header (Sheet 1, Card 2, Columns 46-50).
These inputted temperature differences are not
used in the calculation of the unbalanced steam
temperatures but are prorated at the end of each
leg and included in the calculation of the design
allowance mid-wall metal temperature (reference
Part D).
D. Metal Temperature Calculations
In this part of the program, the tube mid-wall and
surface metal temperatures are calculated at the
end of each leg for which a metal temperature
calculation is requested (reference Input Sheet 3,
Column 24). Complete metal temperature
calculations are made only at the requested points.
The maximum allowable tube mid-wall metal
temperatures corresponding to the ASME Code
allowable stress values and the allowable
oxidation temperature limits per ALSTOM Power
standards also are determined at the requested
points.
 SUBJECT: Metal Temperature - Program WIN 11012 STD NO : 31-93-13
INDEX : 22.8
DATE : 7 NOV 2006
OWNER : 8152
PAGE : 63 of 94

If print plots of the steam and metal temperatures
are requested, then intermediate points, to be
plotted as dots, also can be requested. The plotted
dots along an effective leg are linearly interpolated
from calculated points. The numbered points, as
plotted, are either calculated, if at the end of a leg,
or linearly interpolated between calculated points,
if at the end of a DAG or effective leg for which no
metal temperature calculations were requested.
For each ineffective leg or end of a DAG the metal
temperatures, if not calculated, are set equal to the
unbalanced steam temperature.
If print plots are requested, then in addition to the
plotted results, the minimum closure temperature
difference along each DAG is determined and
printed out. The closure temperature difference is
the ASME Code allowable mid-wall metal
temperature minus the calculated or interpolated
mid-wall metal temperature. It is evaluated at the
end of each leg and also at the end of each DAG.
Some caution should be exercised when using
these minimum closure values. The minimum
value could be in error if it occurs at the end of a
DAG where the tube material and thickness
change and if the mid-wall metal temperature is
an interpolated rather than a calculated value.
1. Evaluation of the tube metal thermal
conductivity, k:
The thermal conductivity of the tube metal is
used for the evaluation of the various tube metal
temperature contributions that are combined in the
calculation of the mid-wall metal temperature.
Since the thermal conductivity varies with the metal
temperature, it should be evaluated at the mid-
wall metal temperature. To initiate the metal
temperature calculations, the program includes a
procedure that estimates the mid-wall metal
temperature so that the thermal conductivity can
be initially evaluated. After the initial metal
temperature calculations are completed, the
calculated mid-wall metal temperature is
compared to the estimated mid-wall metal
temperature. If the difference is greater than
5o F, then a new thermal conductivity is evaluated
using the calculated mid-wall metal temperature.
The metal temperatures then are once
recalculated.
a. Procedure used to estimate mid-wall
If Q'T = 0, as for ineffective leg,
(Tm)EST = ts + 75
where: ts = balanced steam temperature at the
requested point, oF
If Q' > 0, as for heated leg,
T
.04 Q '
( Tm )EST = t s + T
(FAC )DoL
where: Q' = heat absorbed by leg, Btu/hr
T
L = length of leg, ft
Do = outside tube diameter, inches
(FAC) = 2 for platen or panel sections
(FAC) = π for spaced sections
b. The thermal conductivity, k, is evaluated
per Metal Temperature Sheet No. 848 using either
the estimated or calculated mid-wall metal
temperature.
2. Evaluation of the inside film conductance,
Hc:
The inside film conductance, Hc, is evaluated
using Metal Temperature Sheet Nos. 64-008 and
82-005, Standard No. 48-88, pages 9 and 10.
The input parameters required for these standards
are: flow per tube (F), inside diameter (Di),
pressure (P), and the balanced steam temperature
(ts), all of which are at the requested point for the
metal temperature calculations.
 SUBJECT: Metal Temperature - Program WIN 11012 STD NO : 31-93-13
INDEX : 22.8
DATE : 7 NOV 2006
OWNER : 8152
PAGE : 64 of 94

3. Evaluation of the local gas temperature at
requested point for metal temperature
calculations, (Tg)PT:
In general, the metal temperature program
includes routines for calculating the local gas
temperature at the end of a leg for which metal
temperature calculations are requested by using
the available input data according to the following
rules:
a. Overriding Gas Temperature
If the user wants to override the
programmed gas temperature calculations for a
specific leg when using the long form, then an
overriding gas temperature can be entered on
Input Sheet 3, Columns 28-31, (reference Figure
3). Then all metal temperature calculations
for this point will use the overriding gas
temperature.
b. Local Gas Temperature Within
Spaced Sections
In general, the local gas temperature at
the requested point within a spaced section is
determined by the program, using a linear
interpolation routine between the upstream and
downstream cavity gas temperatures. Further, if
the spaced section is sliced, then the gas
temperature entering the slice, which includes the
requested point, will be used in preference to the
upstream cavity gas temperature. For accurate
gas temperature calculations within spaced
sections, it is important to define all cavities,
regardless of size.
c. Local Gas Temperature Within
Platen Sections
direct radiation number to get the local gas
temperature at the requested point. The main
difference between spaced and platen sections is
that cavity gas temperatures, if inputted, are not
used for platens.
If the platen is not sliced, then both the upstream
gas temperature and the downstream gas
temperature are determined by linear interpolation
from the temperature at the bottom of the platen
to the roof. For this interpolation, the utility gas
temperature is assumed located at the bottom of
the platen and the overall entering and leaving
gas temperatures are located at the midpoint
between the bottom of the platen and the roof.
Thus, for an unsliced platen, the utility gas
temperature must be entered on Sheet 2 and the
gas temperature leaving the platen must be less
than the gas temperature entering. If the platen is
sliced, then the upstream gas temperature is set
equal to the gas temperature entering the slice in
which the requested point is located. The
corresponding downstream gas temperature is
calculated using the upstream or slice gas
temperature less an overall temperature gradient
across the slice, which is calculated as follows:
( ΔTg )slice = Ef ( Tg )slice - ( ts )E
( Tg )E - ( Tg )L
where: Ef =
( Tg )E - ( ts )E
(Tg)E = gas temperature entering
o
platen, F
(Tg)L = gas temperature leaving
o
platen, F
o
(Tg)slice = gas temperature of slice, F
(ts)E = steam temperature entering
o
platen, F

In general, the program calculates an

upstream gas temperature and a downstream gas
temperature corresponding to the requested point,
and then makes a linear interpolation using the
number of transverse tubes and the
 SUBJECT: Metal Temperature - Program WIN 11012 STD NO : 31-93-13
INDEX : 22.8
DATE : 7 NOV 2006
OWNER : 8152
PAGE : 65 of 94

The local gas temperature at the requested point
then is prorated linearly as before using the direct
radiation number and the following temperature
gradient per tube row:
( ΔTg )slice
( ΔTg ) tube =
NT
where: NT = number of transverse tubes across
platen (reference Input Sheet 2,
Card Type 3, Columns 13-15)
d. Local Gas Temperature Within
Superheater Panels
Gas temperature calculations for panels
are completely different than for spaced or for
platen sections because panels do not consider
cavities and panels are always sliced. Because the
heat absorption in the upper slices is considered
uniform, no local gas temperatures are required
and thus, the slice gas temperatures are left blank
on Input Sheet 2.
For the last slice, the slice gas temperature and the
utility gas temperature must be entered on Input
Sheet 2. Thus, if the requested point is located in
the last slice and no direct radiation number is
given, then the local gas temperature at the point
is set equal to the slice gas temperature.
Otherwise, if a direct radiation number is given,
then the local gas temperature is linearly prorated
between the utility gas temperature and the
inputted slice gas temperature.
4. Local heat absorption rates required for the
evaluation of the metal temperature
contributions at the requested point:
a. Direct radiation heat absorption rate,
Btu/hr-ft2
where: QPDR = presented direct radiation, Input
Sheet 2, Btu/hr
% Abs = % heat absorption per tube row,
superheater Sheet No. 65-049
Nassy = number of assemblies across
furnace width
Ltube = length of slice or tubes facing
direct radiating plane, ft
Note: For either the last slice of a panel, an
unsliced platen, or a sliced platen having a Tube
Class 6 or 7 metal temperature calculation
specified in Column 25 of Input Sheet 3, the direct
radiation heat absorption rate, (Q/A)DR, is
obtained from the Sheet No. 708A rate, the
percent heat absorption per tube row and the
transverse tube spacing ratio as follows:
S
( Q / A )DR = ( Q / A )708 A (% Abs ) ( T )
2Do
b. Convection heat absorption rate,
Btu/hr-ft2
( Q / A )CONV = Rc ( Tg )PT − t s (1 + % R T Adj )
where: Rc = overall convection heat transfer
rate for section, Input Sheet 2,
But/hr-ft2-o F
(Tg)PT = local gas temperature at
requested point (reference 3),
oF
ts = balanced steam temperature at
requested point, o F
% RT Adj = convection and non-luminous
radiation adjustment, inputted
on long form Sheet 3,
Columns 15-17

Q
( Q / A )DR = PDR (% Abs )
(FAC ) (Do / 12 ) L tube Nassy
 SUBJECT: Metal Temperature - Program WIN 11012 STD NO : 31-93-13
INDEX : 22.8
DATE : 7 NOV 2006
OWNER : 8152
PAGE : 66 of 94

c. Internal non-luminous radiation heat (Tg)DC = downstream cavity gas

o
absorption rate, Btu/hr-ft2 temperature, F

( Q / A )INL = R N ( Tg )PT − t s (1+ % R T Adj )
where: Rn = overall non-luminous radiation
heat transfer rate for section, Input
o
Sheet 2, Btu/hr-ft2- F
d. Upstream cavity radiation heat
absorption rate, Btu/hr-ft2
ST
( Q / A )UCAV = (RN )UC ( Tg )U - t s
(FAC )Do
where: (Rn)UC = non-luminous radiation heat
transfer rate for upstream cavity,
o
Sheet No.705, Btu/hr-ft2- F
(Tg)U = upstream gas temperature,
either slice gas temperature or
upstream cavity gas
temperature for spaced
section, o F
ST = transverse spacing between
assemblies, inches
Note: This contribution to the metal temperature
is included only if the upstream cavity is requested
to be included in the metal temperature
calculations (long form Sheet 3, Column 40).
e. Downstream cavity radiation heat
absorption rate, Btu/hr-ft2
( Q / A )DCAV = (RN )DC ( Tg )DC - t s
ST
(FAC )Do
where: (Rn)DC = non-luminous radiation heat
transfer rate for downstream
cavity Sheet No. 705,
o
Btu/hr-ft2- F
Note: This contribution to the metal temperature is
included only if the downstream cavity is requested
to be included in the metal temperature
calculations (long form Sheet 3, Column 49).
5. Evaluation of mid-wall metal
temperature distributions
( ΔT ' , ΔT ' , ΔT ' ):
A B C
(% Abs )
a. Metal temperature standards (reference
Sheet No. 74-011) are based on the
following two dimensionless parameters:
HcDi D
and o
k Di
o
where: Hc = film conductance, Btu/hr-ft2- F
k = metal thermal conductivity,
o
Btu-in/hr-ft2- F
b. Metal temperature distributions for
platen and panel sections:
ΔT ' , Sheet No. 875, All Contributions -
A
Tube Class 3 (see Sheet 3 long
form, Column 25)
'
ΔT , Sheet No. 876, Convection and Ext.
B
Upstream Radiation - Class 1;
Convection and Ext. Downstream
(% Abs ) Radiation - Class 2
'
ΔT , Sheet No. 877, Internal Radiation
C
& Ext. Downstream Radiation -
Class 1; Internal Radiation & Ext.
Upstream Radiation - Class 2
 SUBJECT: Metal Temperature - Program WIN 11012 STD NO : 31-93-13
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Note: The following typical example shows the

c. Metal temperature distributions for
spaced sections:
ΔT ' , Sheet No. 881, Convection & Ext.
A
Upstream Radiation - Class 1, 2,
3; Internal Radiation - Class 2
'
ΔT , Sheet No. 882, Internal Radiation
B
- Class 3
ΔT ' , Sheet No. 883, Ext. Downstream
C b.
Radiation - Class 1, 2, 3; Internal
Radiation - Class 1
6. Evaluation of the unbalanced mid-wall metal
temperature, Tm:
a. For subcritical pressure, P < 3206.7
Tm = ( ts )UB + 1.12 ( ΔTA + ΔTB + ΔTC )
where: (ts)UB = unbalanced steam temperature
at requested point (reference
o
Page 47, C-5), F
procedure used by the program to make the
summation of the heat absorption contributions for
an exterior leading tube, (Class 1) of a spaced
section:
' ⎛ Do ⎞[(Q / A)
ΔTA = ΔTA ⎜ ⎟ DR + (Q / A)CONV + (Q / A)UCAV ]
⎝ 100k ⎠
ΔTB = 0
' ⎛⎜ D o ⎞⎟[(Q / A)
ΔTC = ΔTC INL + (Q / A)DCAV ]
⎝ 100k ⎠
For supercritical pressures using
Normal Method, P > 3206.7
Use same procedure as given for
subcritical pressure, except that in the calculation
of the unbalanced steam temperature, (ts)UB, the
desuperheater allowance, (Δh)DSP, is equal to
zero.
c. For supercritical pressures using
Design Allowance Method
(Appendix E), P > 3206.7:
Tm = ( ts )UB + 1. 12 (FC) ( ΔTA + ΔTB + ΔTC ) + DA

' ⎛ Do ⎞
ΔTA = ΔTA ⎜ ⎟ (Q/A), where: FC = metal temperature adjustment
⎝ 100 k ⎠ factor for design allowance method
summation of the heat absorption FC = 0.80 for platens and panels
contributions applicable to metal FC = 0.85 for spaced sections
o
temperature distribution A, as DA = Design Allowance Δt, F
obtained from the applicable metal
temperature standards. Note: The design allowance Δt is prorated from
the inlet and outlet design allowance temperature
' ⎛ D ⎞ differentials, as inputted on Sheet 1. It is prorated
ΔTB = ΔTB ⎜ o ⎟ (Q/A), on the basis of the pressure drop ratio along the
⎝ 100 k ⎠
length of an element (this is approximately the
same for metal temperature same as using the length ratio) as follows:
distribution B.

' ⎛ Do ⎞
ΔTC = ΔTC ⎜ ⎟ (Q/A),
⎝ 100 k ⎠
same for metal temperature
distribution C.
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P −P 8. Evaluation of the maximum allowable

DA = DA i + i ( DA o − DAi ) mid-wall metal temperature (Tm)A:
ΔPT
where: DAi, DAo = design allowance Δt's as
inputted on Sheet 1 a. From the inputted design pressure and
Pi = pressure at inlet to leg, psi tube geometry, the program calculates the
P = pressure at outlet of leg, psi appropriate "Y" value and the allowable ASME
ΔPT = total element pressure drop Code stress (reference Sheet No. 78-029).
for section, psi
b. From the inputted material identification
d. Evaluation of the unbalanced mid-wall code and the ASME Code identification, the
metal temperature at the backside of the program converts the allowable stress value into a
tube, (Tm)BS: maximum allowable mid-wall metal temperature
(reference applicable Metal Temperature
For subcritical pressures: Standards for Allowable Stress - Pressure Part
Materials).
⎡ ΔTC' ΔTA' ⎤
(Tm )BS = ( t s )UB + 1.12⎢ ΔTA + ΔTB + ΔTC ⎥ 9. Evaluation of the allowable oxidation
⎢ Δ ' Δ ' ⎥ surface temperature, (To)A:
⎣ T A TC ⎦

Note: This is same basic equation as for the front Using the inputted material identification
side tube distributions except that the A and C code, the program determines the applicable
temperature distributions, as obtained from the ALSTOM Power oxidation temperature limit for the
standards (reference 4), are reversed. The particular material (reference Sheet No.
supercritical pressure equation for the backside 64-007).
mid-wall temperature would have the same
changes as included in the bracketed term. 10. Comparison of the calculated metal
temperatures to the allowable metal
7. Evaluation of the unbalanced surface temperatures:
metal temperature, To:
The program compares each calculated
The following equation from Sheet No. metal temperature (both mid-wall and surface) to
63-044-1 is used for all surface temperature the corresponding allowable metal temperature. If
calculations: any one of the calculated metal temperatures
exceeds the corresponding allowable metal
[Tm − (ts )UB ] ln ⎛⎜ D2D+oD
⎞
⎟ temperature, a warning message is printed out.
To = Tm + ⎝ o i⎠
2k + ln ⎛⎜ Do + Di ⎞⎟
HcDi ⎝ 2Di ⎠
where: Tm = unbalanced mid-wall metal
temperature that corresponds to
the desired surface metal
o
temperature, F
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Appendix B In other words, for the Metals Program to run with

this arrangement,
Element Numbering and
Flow Linkage Examples

A. Programmed Circuitry

Any combination of the following

arrangements of elements is permissible between
headers:

Must be modified for Metals

Flow it must be modeled as follows:

The program is limited to a maximum number of

100 elements that can emerge from the inlet
header. The program also is limited to 200
elements that can be specified for any one section.
A different element number must be assigned to Acceptable for Metals
each leg or tube that enters or leaves a bifurcate.

Permissible “Double Bifurcate” Arrangements

The preferred method is to modify the flow linkage
The Metals Program cannot handle certain for the inlet bifurcates, which in most cases, should
common double bifurcate arrangements without have a negligible affect on flow distribution.
modifying their true flow linkage. The program
can only handle “double bifurcates” when the
second bifurcate converges flows diverged by the
first bifurcate.

A typical non-conforming example is the “double

bifurcated” Low Temperature Superheater (LTSH)
used on many utility boilers. With this
arrangement, bifurcates are used at the rear wall
inlet header to reduce the rows of inlet header
nipples. Each bifurcate feeds two tubes within the
same horizontal assembly. Flow from adjacent
horizontal assemblies are then re-combined prior
to entering a pendant assembly.
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begins at the inlet header and proceeds in the

B. One-Section Problems
The following examples illustrate the element
numbering procedure and flow linkage of one-
section problems applicable to both the "long" and
"short" forms of the program. In all cases, the
procedure for numbering elements
direction of flow towards the outlet header, as
shown in the following examples. The flow linkage
between elements, when bifurcates are used, is
specified on the Selection Data Sheet 4. The
applicable portion of this sheet is included for each
of the following examples:

Example 1:

Flow In Selection Data Sheet 4

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Note: This example is unique in that elements are crossing over each other through the use of offsets. The flow
linkage, as specified above, is only concerned with the connection between elements and not their relative
position to one another. The inter-tube distribution of heat for steam and metal temperature calculations is
taken care of by the direct radiation and cavity tube numbers as specified on the Arrangement Data Sheet 3.
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C. 2-Section Problems section in a 2-section problem basically is the

The following examples illustrate the
numbering procedure and flow linkage for two-
section problems that are applicable to only the
"long" form of the program. The "short" form of
the program can be used only for 1-section
problems. No examples are included to illustrate
3-section problems since adding the second
same as adding the third section in a 3-section
problem.
In a 2-section problem, each section has its own
heat balance, arrangement data, and selection
data. The element numbering system for the
second section begins at the boundary line
between the 2 sections.
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Example 8: To Illustrate Change of Intermesh For Sections No. 1 and 2, No. of Coplanar Tubes
= 1/2 No. of assemblies in Section No.1.
 SUBJECT: Metal Temperature - Program WIN 11012
D. Problems with Special Assemblies
The following examples illustrate the
element numbering procedure and flow linkage
for superheat or reheat sections that have both
regular and special assemblies. Special
assemblies are used where not all the assemblies
across the width of a boiler have the same
arrangement data and/or intermesh.
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In order for the program to correctly
calculate the flow in each element and the
header to header pressure drop, all assemblies
must be included in the same program run. The
metal temperatures program can be set up
through the use of additional element numbers
and by varying the number of coplanar tubes so
that both regular and special assemblies can be
run together. The maximum number of 100
elements leaving the inlet header and 200
elements per section must not be exceeded.
Also, only one value for the transverse tube
spacing and only one value for the longitudinal
spacing can be entered as input. If several
spacings are used, then only the most
representative spacing should be entered.
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Example 10: Two Section Problem

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E. Definition of Number of Coplanar Tubes must include both the regular assemblies and the
special assemblies.
a. The number of assemblies described
for each section is always the number of actual b. The best way to describe how to
assemblies in the section. Even when a section determine the number of coplanar tubes is by
has special assemblies, the number of way of the following examples.
assemblies
2 to 1 Ratio

No. of Assem. 6 3

No. of
Coplanar Tubes 3 3

3 to 1 Ratio

No. of Assem. 12 4

No. of 4 4
Coplanar Tubes
3 to 2 Ratio
6 4
No. of Assem.

No. of
Coplanar Tubes 2 2
 SUBJECT: Metal Temperature - Program WIN 11012
Appendix C
Short Form Program Procedures
The short form input program is limited to six
commonly used platen and panel arrangements
as defined in Section I, Part D. Also, the short
form input program is applicable only to parallel
flow arrangements that locate the inlet header
adjacent to the upstream gas flow and the outlet
header adjacent to the downstream gas flow. All
other section types and header arrangements
must be solved using the long form input
procedure.
Note: Short form platens can be divided into a maximum of 10 slices.
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The short form input program generates the
detailed arrangement data required by Sheet 3 of
the long form input procedure. The elements are
prescribed and numbered by the user on the
Selection Data Sheet 4. The short form program
then divides each element into legs according to
the following illustrated procedures:
Ο Indicates the end of a leg where also a
metal temperature calculation is requested.
X Indicates the end of a leg where no metal
temperature calculation is requested.
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Note: Short form panels must be divided into 3 or 9 slices. For each leg, the short form program generates the
required long form data of Sheet 3 according to the following rules:

1. Element Number
The element numbers are defined from inlet header to outlet header. Where tube bifurcates are used above the
roof, element numbers are continued sequentially as shown below:

Note: When the use fills out the Selection Data Sheet 4, the element structure should follow the above
Procedure without variation.
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2. Leg Number

Leg numbers will start with 1 at the

beginning of each element and increase
sequentially in the direction of flow.

3. Leg Description

The proper identification will be assigned to

each leg depending upon its direction. Those
currently used are I (ineffective), D (down), R
(right), and U (up).

4. Length

The length of the particular leg in feet.

5. Outside Diameter

The outside diameter to be used for each leg

is determined from the Selection Data Sheet 4.

6. RTAdjustment

Platens: +5% or +0.05 will be prorated

from the leading exterior vertical tube to the
center tube, -5% or -0.05 will be prorated from
the trailing exterior vertical tube to the center
tube and +10% or +0.10 will be prorated from
the leading exterior horizontal tube to the center
tube as shown below:
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Panels: A constant +5% will be used for all legs in the third or ninth slice as shown below:
if 9 slice 3 slice

7. Number of Coplanar Tubes

Since the short input program can be used for only a one-section problem, the number of coplanar
tubes will equal the number of assemblies. The number of assemblies from the section data will be
inserted in the appropriate spaces of the arrangement data for the first leg of each element.

8. Direct Radiation Number

Platens: The tube location for platens is carried out throughout the whole unit from both the vertical
and horizontal inlet radiating planes as shown below:
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Panels: The tube location for panels is determined only for those legs below the innermost leg. The direct
radiation number for panels is used only to obtain a gas temperature drop and percent radiation for metal
temperature calculations at the requested points.

9. Metal Temperature Information

In dividing the elements into legs, the short form program has selected most of the leg lengths according
to the points where the metal temperature calculations are required. For each of these legs, the metal
temperature information for Sheet 3 will be provided according to the following rules:

a. Calculate Metal Temperature Code

For all legs that require a metal calculation, a 1 will be inserted.

b. Tube Classification

For the point at the end of each leg where the metal temperature calculation is to be made, one of the
following seven tube classification codes will be entered according to the following diagrams:

Tube Classification Diagram Code

1 - Exterior Leading ------------------

2 - Exterior Trailing
3 - Interior
5 - Around the Bend Calculation
6 - 708A Interior O O
7 - 708A Exterior X X

Note: For platens, all legs which end in the heated gas pass are set up for a metal temperature calculation. For those
legs which end at or along the horizontal tube portions at the bottom, the tube classification is set up to be 6 for the
interior tubes and 7 for the exterior tube. This means that the direct radiation by Sheet No. 708A of the superheater
section will be used for the metal temperature calculations at these points, whether or not the platen is sliced.
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c. Slice Identification b. Panel

For each leg for which a metal
temperature calculation is required, the short form
program will determine the slice in which the end
point of the leg falls.
d. Overriding Gas Temperature
The overriding gas temperature is not
used with the short form program and will be left
blank of Sheet 3.
For panels, the cavity input locations for
length and cavity number are used to specify the
actual leg length exposed to a particular slice.
The short form program will break down the
length of each leg and distribute it according to
the slices in which it lies. Since the short form
panel must have either 3 or 9 slices, the program
will fill in the leg lengths and slice numbers under
Cavity Sets A, B, and C, as required.

10. Cavity Sets A, B, and C

a. Platen

Cavity Sets A and C will not be used for

short form platens and will be left blank on Sheet
3. If the user specifies cavity information on Sheet
2, it will be considered a downstream cavity and
will be used to set up the following information
under Cavity Set B for those legs designated as D
(down) or U (up).

Length - length of this leg

Cavity Number - a 1 will be entered
Tube Number - the tube location from the
downstream cavity will be
entered as shown below
**** - since cavity will be used in
metal temperature
calculations, a 1 will be
entered
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Appendix D where: (Tg)A = Utility gas temperature

Superheater Division Panel Short Form Input (ΔTg)A-B = the gas temperature drop
Calculation Procedure for Unites With Coal Firing across the division panels
as calculated by the upper
The short form input program for superheat furnace program, PUF III-A
division panels requires input data that are not
readily available from the Steam Generator 3. Heat Transfer Rates, Rc and Rn
Program output. These input data include the
utility gas temperature, the Slice 9 gas a. Convection Rate, Rc
temperature, and the heat transfer rates, Rc and
Rn. The following calculation procedures were Use 85% of the rate obtained from Sheet
developed so that each of these items can be No. 707 with the following input values:
readily determined:
Wg
GMV =
1. Utility Gas Temperature FGA

In most cases, the FOT (Furnace Outlet where: Wg = total gas flow rate, lb/hr
Temperature) as obtained from the heat transfer FGA = Dn x (Furnace Width) @ Panel
performance calculation procedure for Bottom, ft2
Tangentially Coal Fired Panel Type Utility Designs ( ΔTg ) A − B
MGT = ( Tg )A −
Sheet No. 79-008, Figures 5, 6, and 7) is 3
artificially high to obtain the correct upper furnace FA = 1.0
performance and gas temperature entering the
platens. Figure D-1 should be used to correct the b. Non-Luminous Radiation Rate, Rn
FOT as obtained from Sheet No. 79-008 to an
actual predicted gas temperature at the bottom of Use 85% of the rate obtained from Sheet
the division panels. This corrected gas No. 705 with the following input values:
temperature at the bottom of the division panels,
3.4 (DP x HP x SMAX )
(Tg)A, will be entered on Sheet 2 as the utility gas RBL =
2(DPHP + HP SMAX + DP SMAX )
temperature.

2. Slice 9 Gas Temperature where: SMAX = Maximum distance between

panels, ft
For calculation of metal temperatures in Slice ( ΔTg ) A − B
MGT = ( Tg )A −
9 of the division panels, the short form program 2
requires the Slice 9 gas temperature to be entered Arith. Avg. Steam. Temp. = Avg.
on Sheet 2. The Slice 9 gas temperature can be Steam Temperature in Panels
determined as follows:

( ΔTg ) A− B
(Tg ) Slice9 = (Tg ) A −
18
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Utility Gas Temperature for SH Division Panels with Coal Firing - Figure D-1

2800

2700
Utility Gas Temperature °F (Corrected FOT)

2600

2500

2400

2300

2200

2100

2000
2000 2100 2200 2300 2400 2500 2600 2700 2800 2900
FOT by Performance Design Procedure, Std 79-008 °F
 SUBJECT: Metal Temperature - Program WIN 11012
Appendix E
Design Allowance Method for
Supercritical Pressure Units
This appendix describes the alternate design
allowance method used to calculate superheater
metal temperatures in supercritical pressure units.
Included is a section by section illustration and
description which shows how to calculate the
steam temperature design allowances and
unbalance carryover which are required as input
for this method.
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It should be noted that the metal temperature
program does not actually calculate or print out
the unbalanced steam temperature for the
design allowance method as shown in the
diagram below. Since only the mid-wall and
surface metal temperatures for the design
allowance method are computed and printed
out, the programmed procedures were combined
so that the prorated steam temperature design
allowance is included directly in the mid-wall
metal temperature calculation. If the user wants
to determine the unbalanced design steam
temperature which corresponds to the design
allowance method, he can readily do so since the
printed output includes the prorated steam
temperature design allowance at the end of each
leg for which a metal temperature calculation
has been requested.
 SUBJECT: Metal Temperature - Program WIN 11012
1. The solid lines, A-B-C-D-E, represent the
balanced steam temperatures that correspond to
the normal heat balance as obtained from the
steam generator calculations with 4% spray.
2. The dashed lines, A'-B'-C'-D'-E, represent the
design steam temperatures for the design
allowance method. These are the calculated
steam temperatures that are required to produce
the normal superheater outlet temperature with
reduced section heat absorption (85% for
convective sections and 80% for radiant sections)
and with 2-1/2% spray. The temperature
differences between the design steam
temperatures (A'-B'-C'-D'-E) and the normal steam
temperatures (A-B-C-D-E) are the design
allowances.
3. The procedure for calculating the design
steam temperature begins with the superheater
outlet temperature, where the design allowance or
steam temperature difference is fixed at zero.
Then, by assuming that the spaced finishing
superheater section absorbs only 85% of the
normal heat absorption, the design steam
temperature (ts) entering the spaced finishing
superheater will be the steam temperature
equivalent to the enthalpy at D' as follows:
hD' = hE - .85(hE - hD)
Thus, the design allowances for the spaced
finishing superheater section to be entered on
Input Sheet 1, Card 2 in Columns 46-47 and 49-
50 (reference Figure 1) are as follows:
(DA)i = (ts)D' - (ts)D ; (DA)o = 0
At intermediate points within the spaced finishing
superheater section or at the end of each element
leg where a metal temperature calculation is
requested, the metal temperature program
prorates the design allowance from inlet to outlet
on the basis of pressure drops.
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4. The procedure for calculating the design
steam temperatures for the design allowance
method is carried back through the desuperheater
assuming 2-1/2% spray. By heat balance of the
desuperheater, the design enthalpy heaving the
platens can be calculated as follows.
1 ⎡ .025 ⎤
hC’ = ⎢hD ' − .040 (hD − .96 hC )⎥
.975 ⎣ ⎦
Further, by assuming 80% of the normal heat
absorption and correcting the normal steam flow
for 2-1/2% spray, the design enthalpy entering the
platens and panels can be calculated as follows:
hB' = hC’ - .80 ⎛⎜ .960 ⎞⎟(hC - hB )
⎝ .975 ⎠
h A’ = hB’ - .80 ⎛⎜ .960 ⎞⎟ (hB - hA )
⎝ .975 ⎠
From the equivalent steam temperatures at A', B',
and C', the inlet and outlet design allowances for
the panels and platens can readily be determined
and entered on Input Sheet 1. At the intermediate
points, the design allowance is again prorated by
the metal temperature program on the basis of
pressure drop from inlet to outlet.
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5. The normal steam temperature unbalance at ΔTm = normal difference between the mid-
any point within a section is the temperature wall metal temperature and the bulk
difference that is equivalent to 12% of the steam temperature as determined
cumulative increase in the normal steam enthalpy from summation of the metal
from the inlet header (reference Unbalanced temperature contributions as
Steam Temperature Calculations in Appendix A, described by Sheet No. 74-001 of
Paragraph C.5). For the design allowance the metal temperature section.
method, this normal steam temperature unbalance
is added to design steam temperatures, as
illustrated by temperature points A' to B" to C"' for
panels and platens and D' to E' for the spaced
finishing superheater section. Note that the
normal steam temperature unbalance at the outlet
of the panels is carried over to the platens. This is
the unbalance carryover that must be entered on
Input Sheet 1, Card 2 in Columns 52-53 and that
is considered constant for all legs.

6. The mid-wall metal temperature for the design

allowance method is calculated by the metal
temperature program as follows:

Tm = ( ts )UB + DA + 1. 12 ( FC )( ΔTm )

where:

(ts)UB = normal unbalanced steam

temperature for supercritical pressure
units, includes the carryover
allowance where applicable, but
does not include the design
allowance

DA = prorated steam temperature design

allowance at point of requested metal
temperature calculation

FC = 0.80 for platens and panels

FC = 0.85 for spaced sections
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Appendix F 2. Distribution of External Radiation to

Application of Performance Standards in
Program
A. Areas of Program Which Utilize Equations
or Values Taken from Standards
Tube Banks
The following subroutines include tables of
values to duplicate the applicable performance
standards as listed below:

1. Radiant Heat Transfer at Furnace

Outlet

Subroutines Sheet No. 708A and FOUT

include a table of values which duplicates Sheet
No. 708-A and also include extrapolated values
o
for furnace temperatures up to 3000 F.

Subroutines Fuel SL/D Sheet Nos.

BLOCK A Coal & Oil 1.0 65-023, 65-024
BLOCK A Coal & Oil 1.188 65-025, 65-026
BLOCK A Coal & Oil 1.3 65-027
BLOCK A Coal & Oil 2.0 65-028
BLOCK A Coal & Oil 2.5 65-029
BLOCK A Coal & Oil 3.0 65-030
LOAD Gas 1.0 65-046
LOAD Gas 1.188 65-046
LOAD Gas 1.3 65-047
LOAD 2 Gas 2.0 65-047
LOAD 2 Gas 3.0 65-047
 SUBJECT: Metal Temperature - Program WIN 11012
3. Cavity Non-Luminous Radiation Rate
Subroutine RSUBN includes the same
series of equations as the Steam Generator
Program which are based on Sheet No. 705. This
standard includes a fuel correction factor that is
correlated to the 14 standard fuel codes or the
actual fuel analysis. The program has provision
for use of the 14 standard fuel codes only.
4. Superheater Element Pressure Drop
for Establishing Flow Distribution
Subroutine PDROP includes both the
subcritical and supercritical pressure drop
equations as given by Sheet No. 77-011-A. For
the supercritical pressure drop, this subroutine
also includes a curve fit of the Moody friction
factor curves as given on Sheet No. 77-013. The
program also determines the total equivalent tube
length using loss factors given on Sheet No.
77-011-B.
Superheater Element Type &
Heat Transfer Contribution Sheet Nos.
Interior Platen Elements 875
Exterior Platen Elements – 876
Convection & External Radiation
Exterior Platen Elements – 877
Internal Radiation
Spaced Elements - Distribution A 881
Spaced Elements - Distribution B 882
Spaced Elements - Distribution C 883
STD NO : 31-93-13
INDEX : 22.8
DATE : 7 NOV 2006
OWNER : 8152
PAGE : 91 of 94
5. Thermal Conductance of Tube Wall
Metal
Subroutine THERC includes an equivalent
straight line equation indexed by constants to the
list of materials which duplicates Sheet No. 848.
6. Inside Film Coefficient for Superheated
Steam Flow
Subroutine FILMC includes a curve fit of
Sheet No. 64-008 that gives the uncorrected film
coefficient. This subroutine also includes a table
of values for the physical property correction
factors as given on Sheet Nos. 82-005-A and
82-005-B.
7. Superheater Mid-wall Tube Metal
Temperatures
Subroutine MTDST includes tables of
values which duplicate the following listed
standards and also includes extrapolated values
for Do/Do ratios of 2.5 and 3.0.
 SUBJECT: Metal Temperature - Program WIN 11012 STD NO : 31-93-13
INDEX : 22.8
DATE : 7 NOV 2006
OWNER : 8152
PAGE : 92 of 94

8. Superheater Outside (Hot Face) Tube 12. Standard Tube Diameters and Thickness
Surface Temperature
Subroutine THKCHK includes standard
Subroutine SURFT includes the tube metal outside diameters and thickness for checking the
temperature equation as given on Sheet No. selection data entered on Input Sheet 4. The
63-044. standard outside diameters and thickness are
based on the tabulations of geometric properties
9. ASME Code - Tube Stress Formula - Y of tubes as indexed on Sheet No. 77-007.
Value Equation
13. Steam Properties
Subroutines YVAL and YVAL9 include both
the present Y value equation, as given on Sheet Subroutine STEAM contains a steam table
No. 75-001, and the previous 1962 equation. lookup routine for obtaining the saturation and
superheated steam properties including pressure,
10. ASME Code - Allowable Stress Values and temperature, enthalpy, and specific volume. The
Mid-Wall Temperatures actual steam property values are stored on a
tape that is named TAPE 12. The property values
Subroutines ATEMP, ATEMP9, and ATEMP8 are stored in 52 pressure bands; 19 pressures
include tables of values for the following tubing are in the supercritical region and 33 pressures
materials as given in Standard No. 48-88, Index
6 are in the subcritical region. Each pressure bank
21.8. has a capacity to store up to 216 values that
include the pressure value plus 71 values of
Materials Materials temperature, enthalpy, and specific volume. For
SA192 T91 most of the pressure banks, the actual values
SA210A T2 stored are less than 36 for each property. From
the operating steam pressures inputted for a
T1 T21
specific problem, subroutine RDPRS reads 10
T11 T5 pressure bands into the active steam table from
T22 TP316H which subroutine STEAM obtains the property
T9 TP310H values that are used in the steam and metal
TP304H SA210C temperature calculations.
TP321H SA178C
TP347H HR3C
T12 T23
T92 T122

11. ALSTOM Power Allowable Oxidation

Surface Temperature for Heat Absorbing
Tubing

Subroutines OXID and OXID9 include the

tabulated values as given on Sheet No.
64-007.
 SUBJECT: Metal Temperature - Program WIN 11012 STD NO : 31-93-13
INDEX : 22.8
DATE : 7 NOV 2006
OWNER : 8152
PAGE : 93 of 94

B. Cross Reference Index Between Sheet Nos. and Program Subroutines

Sheet Nos. Program Subroutine Names

705 RSUBN
708-A S708A, FOUT
848 THERC
875 MTDST
876 MTDST
877 MTDST
881 MTDST
882 MTDST
883 MTDST
63-044 SURFT
64-007 OXID, OXID9
64-008 FILMC
64-020* ATEMP, ATEMP9, ATEMP8
65-016-A & 65-016-B * ATEMP, ATEMP9, ATEMP8
65-023 BLOCK A
65-024 BLOCK A
65-025 BLOCK A
65-026 BLOCK A
65-027 BLOCK A
65-028 BLOCK A
65-029 BLOCK A
65-030 BLOCK A
65-046 LOAD
65-047 LOAD, LOAD2
75-001 YVAL, YVAL9
75-005* ATEMP, ATEMP9, ATEMP8
77-011-A & 77-011-B PDROP
77-013 PDROP
78-012* ATEMP, ATEMP9, ATEMP8
78-013* ATEMP, ATEMP9, ATEMP8
78-020 THKCHK
78-021 THKCHK
78-022 THKCHK
78-023 THKCHK
78-024 THKCHK
78-025 THKCHK
81-008 THKCHK
81-009 THKCHK
82-005-A & 82-005-B FILMC
* Not in current Standards.
 SUBJECT: Metal Temperature - Program WIN 11012 STD NO : 31-93-13
INDEX : 22.8
DATE : 7 NOV 2006
OWNER : 8152
PAGE : 94 of 94

Appendix G

Correction of RC and RN for Cavity Radiation (Sample Calculation)

Cavity A Cavity B General Data

Fuel-Midwest Bit. Coal

No. of Assemblies - 38
45' RBL Cavity A = 3.6 Tg = 2030o F ts = 950o F
S T=20"
52' RBL Cavity B = 7.4 tg = 1770o F ts = 830o F

Transfer Rate from Steam Generator Program

o
RC = 5.68 Btu/hr ft2- F
RN = 6.12 Btu/hr ft2 - 0F

Radiation from Cavity A

Projected surface = length facing cavity x ST x No. Assemblies = 52 x 20 x38 = 3293 ft2
12
2 o
RN from Sheet No. 705: -1 = 9 x 1.04 = 9.36 Btu/hr ft F RN = Q
S x Δt
Qcav = 9.36 x 3293 x (2030 - 950) = 33.3 x106 Btu/hr Q = (RN) (S) (Δt)

Radiation From Cavity B

Projected surface = 45 x 20 x38 = 2850 ft2
12
RN = 9.9 x 1.04 = 10.3 Btu/hr ft2 oF
Qcav = 10.3 x 2850 x (1770 - 830) = 27.6 x 106 Btu/hr

Total Cavity Radiation = 33.3 x 106 + 27.6 x 106 = 60.9 x 106 Btu/hr

Note: For small sections, correct cavity radiation by the percent absorbed by the section (Sheet Nos. 73-023 to
73-030), Standard No. 5-96, Index 21.7.
7H 8H

Note: For small sections, correct cavity radiation by the percent absorbed by the section (Sheet Nos. 73-023 to
73-030), Standard No. 5-96, Index 21.7.
9H 10H

Correction Factor
Total Heat Absorbed by Section = 435 x 106 Btu/hr
Direct Radiation = - 29 x 106 Btu/hr
Q (Cavity Radiation, Convection and N.L. Radiation) = 406 x 106 Btu/hr
Cavity Radiation = - 60.9 x 106 Btu/hr
Convection and N. L. Radiation = 345.1 x 106 Btu/hr
Correction Factor to Total RT = 345.1 / 406 = 0.85

Adjusted RC and RN for cavity radiation effect: RC = (0.85) (5.68) = 4.83 RN = (0.85) (6.12) = 5.2

Note: RC and RN must also be multiplied by any SEF used in the Steam Generator Module.