ASME PTC 4-2013
(Revision of ASME PTC 4-2008)
Fired Steam
Generators
Performance Test Codes
A N A M E R I C A N N AT I O N A L STA N DA R D
ASME PTC 4-2013
(Revision of ASME PTC 4-2008)
Fired Steam
Generators
Performance Test Codes
AN AMERICAN NATIONAL STANDARD
Two Park AvYork, A
Date of Issuance: February 7, 2014
This Code will be revised when the Society approves the issuance of a new edition.
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Copyright ¤2014 by
THE AMERICAN SOCIETY OF MECHANICAL ENGINEERS
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CONTENTS
Notice ....................................................................................................................................................................................
Foreword ..............................................................................................................................................................................
Committee Roster ................................................................................................................................................................
Correspondence With the PTC Committee .....................................................................................................................
vi
vii
ix
x
Section 1
1-1
1-2
1-3
1-4
Object and Scope ....................................................................................................................................
Object ...............................................................................................................................................................
Scope ................................................................................................................................................................
Typical Uncertainty for Efficiency ...............................................................................................................
Steam Generator Boundaries .......................................................................................................................
1
1
1
2
3
Section 2
2-1
2-2
2-3
Definitions and Description of Terms ......................................................................................................
Definitions ......................................................................................................................................................
Abbreviations .................................................................................................................................................
Units and Conversions ..................................................................................................................................
12
12
15
15
Section 3
3-1
3-2
3-3
3-4
Guiding Principles ...................................................................................................................................
Introduction ....................................................................................................................................................
Performance Test Procedures .......................................................................................................................
References to Other Codes and Standards .................................................................................................
Tolerances and Test Uncertainties ...............................................................................................................
17
17
20
27
28
Section 4
4-1
4-2
4-3
4-4
4-5
4-6
4-7
4-8
4-9
4-10
4-11
4-12
4-13
4-14
4-15
4-16
Instruments and Methods of Measurement ............................................................................................
Guiding Principles .........................................................................................................................................
Data Required ................................................................................................................................................
General Measurement Requirements .........................................................................................................
Temperature Measurement ..........................................................................................................................
Pressure Measurement ..................................................................................................................................
Velocity Traverse ............................................................................................................................................
Flow Measurement ........................................................................................................................................
Solid Fuel and Sorbent Sampling ................................................................................................................
Liquid and Gaseous Fuel Sampling ............................................................................................................
Sampling of Flue Gas ....................................................................................................................................
Residue Sampling ..........................................................................................................................................
Fuel, Sorbent, and Residue Analysis ...........................................................................................................
Flue Gas Analysis ..........................................................................................................................................
Electric Power .................................................................................................................................................
Humidity ........................................................................................................................................................
Measurements for Surface Radiation and Convection Loss ....................................................................
29
29
29
32
49
53
54
54
57
62
62
63
64
64
65
66
66
Section 5
5-1
5-2
5-3
5-4
5-5
5-6
5-7
5-8
5-9
5-10
5-11
5-12
Computation of Results ...........................................................................................................................
Introduction ....................................................................................................................................................
Measurement Data Reduction .....................................................................................................................
Capacity ..........................................................................................................................................................
Output (QrO), Btu/hr (W) ...........................................................................................................................
Input ................................................................................................................................................................
Energy Balance ...............................................................................................................................................
Efficiency .........................................................................................................................................................
Fuel Properties ...............................................................................................................................................
Sorbent and Other Additive Properties ......................................................................................................
Residue Properties .........................................................................................................................................
Combustion Air Properties ..........................................................................................................................
Flue Gas Products ..........................................................................................................................................
68
68
68
71
71
72
72
73
74
76
78
80
84
iii
5-13
5-14
5-15
5-16
5-17
5-18
5-19
86
88
95
96
99
100
5-20
Air and Flue Gas Temperature ....................................................................................................................
Losses ..............................................................................................................................................................
Credits .............................................................................................................................................................
Uncertainty .....................................................................................................................................................
Other Operating Parameters ........................................................................................................................
Corrections to Standard or Design Conditions .........................................................................................
Enthalpy of Air, Flue Gas, and Other Substances Commonly Required for
Energy Balance Calculations ....................................................................................................................
Calculation Acronyms ...................................................................................................................................
Section 6
6-1
6-2
Report of Test Results .............................................................................................................................
Introduction ....................................................................................................................................................
Report Contents .............................................................................................................................................
132
132
132
Section 7
7-1
7-2
7-3
7-4
Uncertainty Analysis ...............................................................................................................................
Introduction ....................................................................................................................................................
Fundamental Concepts .................................................................................................................................
Pretest Uncertainty Analysis and Test Planning .......................................................................................
Equations and Procedures for Determining the Standard Deviation
for the Estimate of Random Error ...........................................................................................................
Equations and Guidance for Determining Systematic Uncertainty .......................................................
Uncertainty of Test Results ..........................................................................................................................
134
134
134
140
5
6
7
8
9
10
11
18
21
4-4.3.1-1
4-4.3.1-2
4-8.2.1-1
4-8.2.1-2
5-19.12-1
5-19.12-2
5-19.12-3
5-19.12-4
7-2.2-1
7-2.2-2
7-2.3-1
7-5.2.1-1
Typical Oil- and Gas-Fired Steam Generator .............................................................................................
Typical Pulverized-Coal-Fired Steam Generator, Alternative 1: Single Air Heater .............................
Typical Pulverized-Coal-Fired Steam Generator, Alternative 2: Bisector Air Heater ..........................
Typical Pulverized-Coal-Fired Steam Generator, Alternative 3: Trisector Air Heater .........................
Typical Circulation Bed Steam Generator ..................................................................................................
Typical Stoker-Coal-Fired Steam Generator ..............................................................................................
Typical Bubbling Bed Steam Generator ......................................................................................................
Steam Generator Energy Balance ................................................................................................................
Repeatability of Runs ....................................................................................................................................
Illustration of Short-Term (Peak to Valley) Fluctuation and Deviation
From Long-Term (Run) Average .............................................................................................................
Sampling Grids: Rectangular Ducts ............................................................................................................
Sampling Grids: Circular Ducts ..................................................................................................................
Full Stream Cut Solid Sampling Process ....................................................................................................
Typical “Thief” Probe for Solids Sampling in a Solids Stream ...............................................................
Mean Specific Heat of Dry Air Versus Temperature ................................................................................
Mean Specific Heat of Water Vapor Versus Temperature ........................................................................
Mean Specific Heat of Dry Flue Gas Versus Temperature .......................................................................
Mean Specific Heat of Dry Residue Versus Temperature ........................................................................
Types of Errors in Measurements ................................................................................................................
Time Dependence of Errors ..........................................................................................................................
Constant Value and Continuous Variable Models ....................................................................................
Generic Calibration Curve ...........................................................................................................................
25
51
52
58
59
117
118
120
121
136
136
138
147
Tables
1-3-1
2-3-1
3-1.3-1
3-2.3-1
3-2.6.2-1
4-2-1(a)
4-2-1(b)
4-2-2
4-2-3
4-2-4
Typical Code Test Uncertainties for Efficiency ...........................................................................................
Units and Conversions ...................................................................................................................................
Comparison of Efficiency Determination ...................................................................................................
Operating Parameter Deviations .................................................................................................................
Minimum Test-Run Duration .......................................................................................................................
Parameters Required for Efficiency Determination by Energy Balance Method: Energy Losses .......
Parameters Required for Efficiency Determination by Energy Balance Method: Energy Credits .....
Parameters Required for Efficiency Determination by Input–Output Method .....................................
Parameters Required for Capacity Determination ...................................................................................
Parameters Required for Steam Temperature/Control Range Determination ....................................
3
16
20
23
26
30
33
34
35
36
7-5
7-6
Figures
1-4-1
1-4-2
1-4-3
1-4-4
1-4-5
1-4-6
1-4-7
3-1.1-1
3-2.2.1-1
3-2.6.1-1
iv
111
122
141
145
150
4-2-5
4-2-6
4-2-7
4-2-8
4-2-9
4-2-10
4-2-11
4-2-12
4-3.6-1
4-3.6-2
4-3.6-3
4-3.6-4
4-3.6-5
4-8.4.2-1
5-16.5-1
5-20.2-1
5-20.2-2
Parameters Required for Exit Flue Gas and Air Entering Temperature Determinations ...................
Parameters Required for Excess Air Determination ..................................................................................
Parameters Required for Water/Steam Pressure Drop Determinations ...............................................
Parameters Required for Air/Flue Gas Pressure Drop Determinations .................................................
Parameters Required for Air Infiltration Determination .........................................................................
Parameters Required for Sulfur Capture/Retention Determination .....................................................
Parameters Required for Calcium-to-Sulfur Molar Ratio Determination .............................................
Parameters Required for Fuel, Air, and Flue Gas Flow Rate Determinations ......................................
Potential Instrumentation Systematic Uncertainty ...................................................................................
Potential Systematic Uncertainty for Coal Properties ..............................................................................
Potential Systematic Uncertainty for Limestone Properties ....................................................................
Potential Systematic Uncertainty for Fuel Oil Properties .........................................................................
Potential Systematic Uncertainty for Natural Gas Properties ..................................................................
F Distribution .................................................................................................................................................
Two-Tailed Student’s t Table for the 95% Confidence Level ...................................................................
Acronyms ........................................................................................................................................................
Measurement and Uncertainty Acronyms ..................................................................................................
Nonmandatory Appendices
A
Calculation Forms ..........................................................................................................................................
B
Sample Calculations ......................................................................................................................................
C
Derivations ......................................................................................................................................................
D
Gross Efficiency: Energy Balance and Input–Output Method; LHV Efficiency:
Energy Balance Method ............................................................................................................................
E
The Probable Effects of Coal and Sorbent Properties ...............................................................................
F
References .......................................................................................................................................................
v
37
38
39
40
41
42
42
43
45
47
47
48
48
61
99
124
131
151
185
254
258
261
272