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Techni

Note
TN GMSCD0


























ical
0903-01E
Yokoga
Marex
Tel.: +4
I
awa Marex Limited
House, 34 Medina
44 (0)1983 296011
Exaqu
Instrume

Road, Cowes, Isle
Fax: +44 (0)1983
uantum/P
ntation R
e of Wight, PO31 7D
291776

PPC Plan
Requirem
DA, England

t
ents
TN GMSCD090
Copyright R2.70 Is
23rd Octobe

03-01E
ssue 2
r 2012
TN GMSCD0903-01E Exaquantum/PPC Instrumentation Requirements: Technical Note
1

DOCUMENT REVISION RECORD


Date Issue No Revised Sections Description of Change
13thJuly 2011 1 First Issue First Issue
23
rd
October 2012 2 Second Issue Second Issue



1. INTRODUCTION ......................................................................................................................................... 2
2. BOILER PERFORMANCE CALCULATIONS ............................................................................................... 3
2.1. ASME Standard: Fired Steam Generators PTC 4 2008 ...................................................................... 3
2.2. PTC 4 Part One: Efficiency calculation by Direct Method ................................................................... 3
2.2.1. Instrumentation Required for Efficiency Calculation by Direct Method ............................................ 4
2.2.2. Other Information Required for Efficiency Calculation by Direct Method ......................................... 5
2.2.3. Additional Instrumentation required for more complex systems ...................................................... 5
2.3. PTC 4 Part Two: Efficiency calculation by Indirect (Heat Loss) Method ............................................. 7
2.3.1. Instrumentation Required for Efficiency Calculation by Indirect Method .......................................... 8
2.3.2. Other Information Required for Efficiency Calculation by Indirect Method ...................................... 9
2.4. Enhanced PPC Boiler Calculations ....................................................................................................... 9
2.5. ASME Standard: Gas Turbine Heat Recovery Steam Generators PTC 4.4 2008 ............................. 10
2.5.1. Instrumentation Required for HRSG Efficiency Calculation .......................................................... 11
2.5.2. Other Information Required for HRSG Efficiency Calculation ....................................................... 13
3. STEAM TURBINE PERFORMANCE CALCULATIONS ............................................................................. 14
3.1. Theoretical Turbine Efficiency ............................................................................................................. 14
3.1.1. Instrumentation Required for Turbine Efficiency Calculation ......................................................... 14
3.1.2. Other Information Required for Turbine Efficiency Calculation ...................................................... 15
3.2. ASME Standard: Steam Turbines PTC 6 1996 ................................................................................ 15
3.2.1. Instrumentation Required for Turbine Efficiency Calculation ......................................................... 16
3.2.2. Other Information Required for Turbine Efficiency Calculation ...................................................... 16
4. GAS TURBINE PERFORMANCE CALCULATIONS .................................................................................. 17
4.1. ASME Standard: Gas Turbines PTC 22 1997 .................................................................................. 17
4.1.1. Instrumentation Required for Gas Turbine Efficiency Calculation ................................................. 18
4.1.2. Other Information Required for Gas Turbine Efficiency Calculation .............................................. 18
5. UNIT HEAT RATE PERFORMANCE CALCULATIONS ............................................................................ 19
5.1. ASME Standard: Overall Plant Performance PTC 46 1996 ............................................................. 19
5.1.1. Instrumentation Required for Plant Performance Calculation........................................................ 19
5.1.2. Other Information Required for Plant Performance Calculation .................................................... 19
6. UNIT DEVIATION COST CALCULATIONS ............................................................................................... 21
6.1.1. Other Information Required for Unit Deviation Cost Calculation ................................................... 21
7. CONDENSER PERFORMANCE CALCULATIONS ................................................................................... 22
7.1. ASME Standard: Steam Surface Condensers PTC 12.2 1998 ......................................................... 22
7.1.1. Instrumentation Required for Condenser Efficiency Calculation ................................................... 22
7.1.2. Other Information Required for Condenser Efficiency Calculation ................................................ 23
8. FEEDWATER HEATER PERFORMANCE CALCULATIONS .................................................................... 25
8.1.1. Instrumentation Required for Feedwater Heater Performance Calculation ................................... 25
8.1.2. Other Information Required for Feedwater Heater Performance Calculation ................................ 25
9. AIR HEATER PERFORMANCE CALCULATIONS .................................................................................... 26
9.1.1. Instrumentation Required for Air Heater Performance Calculation ................................................ 26
9.1.2. Other Information Required for Air Heater Performance Calculation ............................................ 26
10. OTHER INFORMATION .......................................................................................................................... 27



TN GMSCD0903-01E Exaquantum/PPC Instrumentation Requirements: Technical Note
2

1. INTRODUCTION
The aim of this document is to allow a customer to assess whether they have sufficient instrumentation to
satisfy the requirements of the Exaquantum/PPC (Power Performance Calculations) application.

Exaquantum/PPC is an ASME compliant performance calculation package used in power generation
plants to determine the efficiency of plant equipment.

In general Exaquantum/PPC will determine the online performance and efficiency of plant equipment and
compare it with design values or norms. These design values can come from regression analysis of
existing plant data, expert knowledge of the plant, or in most cases from equipment manufacturers
datasheets. This document will also indicate what design values are required.

Simply fill in the details of what instrumentation and design values are available, and your local Yokogawa
sales office will be able to give you advice regarding the application of Power Performance Calculations
to your plant.

Your local Yokogawa sales office will also be pleased to provide a quotation for customizing the
Exaquantum/PPC Power Performance Calculations to suit your plant/requirements and/or advice
regarding additional instrumentation.
TN GMSCD0903-01E Exaquantum/PPC Instrumentation Requirements: Technical Note
3

2. BOILER PERFORMANCE CALCULATIONS
Performance and efficiency of a boiler reduces with time for a number of reasons, including:
- Poor combustion
- Heat Exchanger fouling
- Poor maintenance
- Poor operation

Exaquantum/PPC will allow energy efficiency improvements to be made by tracking variation from design
values. It can also assign a cost to these variations so that expensive, but easily correctable situations
can be prioritized and remedied.
2.1. ASME Standard: Fired Steam Generators PTC 4 2008
There are two parts to the ASME Standard which Exaquantum/PPC employs: -
o Part One: Direct method (also known as the Input-Output method)
o Part Two: Indirect method (more commonly known as the Boiler Efficiency by Heat Loss method,
or simply Heat Loss method)

Exaquantum/PPC uses the rules and instructions described by the standard for conducting performance
evaluation of fuel fired steam generators. These include coal, oil, and gas fired steam generators as well
as steam generators fired by other hydrocarbon fuels.
2.2. PTC 4 Part One: Efficiency calculation by Direct Method
The direct method used by Exaquantum/PPC has the following advantages over the Heat Loss Method: -
1. Easier to implement
2. Requires fewer parameters for calculation
3. Needs fewer instruments

This method for determining the efficiency of a boiler is also known as the Input-Output method because
it only requires the heat input from the fuel and the heat output as steam for its calculations.


Figure 2-1 Direct Boiler Efficiency Calculation


TN GMSCD0903-01E Exaquantum/PPC Instrumentation Requirements: Technical Note
4

loss water WL and blowdown BD feedwater, FW where
100
value calorific gross Fuel rate flow Fuel
enthalpy) feedwater - enthalpy (steam flow) WL - flow BD - flow (FW
e unavailabl is rate flow steam when form e alternativ Or
100
value calorific gross Fuel rate flow Fuel
enthalpy) feedwater - enthalpy (steam rate flow Steam
100
Fuel in heat Gross
Steam in Heat
100
Input Heat
Output Heat
Efficiency
= = =

=
=
=


2.2.1. Instrumentation Required for Efficiency Calculation by Direct Method

Measurement Notes
Available
in your
plant
Fuel flow rate Mass or Volume

Steam flow rate
Mass or Volume.
Can be replaced with feedwater flow rate if water losses can be
accounted for (e.g. blowdown)

Steam pressure For steam enthalpy calculation

Steam temperature For steam enthalpy calculation

Feedwater flow rate
Mass or Volume.
Only required if steam flow rate is unavailable.

Feedwater
Temperature
For feedwater enthalpy calculation.
Taken at boundary of boiler.

Blowdown flow rate
Mass or Volume.
Only required if steam flow rate is unavailable and Feedwater flow
rate is used.

Blowdown
Temperature
For feedwater enthalpy calculation.
Taken at boundary of boiler.
Only required if steam flow rate is unavailable and Feedwater flow
rate is used.

Other water loss flow
rates
Mass or Volume.
Only required if steam flow rate is unavailable and Feedwater flow
rate is used.

Other water loss
temperature
For water loss enthalpy calculation



TN GMSCD0903-01E Exaquantum/PPC Instrumentation Requirements: Technical Note
5

2.2.2. Other Information Required for Efficiency Calculation by Direct Method
In addition to the information previously defined, this function block requires the following design data:

Information Notes Available
Calorific value (Higher
Heating Value) of fuel
Constant, from Laboratory Analysis or as quoted by fuel supplier.

Boiler efficiency curve Typically quoted as a function of Steam Flow.


2.2.3. Additional Instrumentation required for more complex systems

Figure 2-2Complex Direct Efficiency Calculation

In a more complex system there may be multiple paths for the output steam flow, and more than one
input flow to be heated; for instance, multiple feed water paths or cold steam for reheat.
The following additional measurements may be required for your system.

Measurement Notes
Available
in your
plant
Superheated Steam
flow rate
Mass or Volume.


Superheated Steam
temperature
For steam enthalpy calculation

Superheated Steam
pressure
For steam enthalpy calculation

Hot Reheat Steam
flow rate
Mass or Volume.

Hot Reheat Steam
temperature
For steam enthalpy calculation

TN GMSCD0903-01E Exaquantum/PPC Instrumentation Requirements: Technical Note
6

Measurement Notes
Available
in your
plant
Hot Reheat Steam
pressure
For steam enthalpy calculation

Cold Reheat Steam
flow rate
Mass or Volume.

Cold Reheat Steam
temperature
For steam enthalpy calculation

Cold Reheat Steam
pressure
For steam enthalpy calculation

Superheat Spray
water flow rate
1
st
stage and 2
nd
stage.
Mass or Volume.

Reheat Spray water
flow rate
Mass or Volume.

Superheat Spray
water Temperature
For feedwater enthalpy calculation.
Only required if steam flow rate is unavailable and Feedwater flow
rate is used.

Reheat Spray water
Temperature
For feedwater enthalpy calculation.
Only required if steam flow rate is unavailable and Feedwater flow
rate is used.



Please indicate in the space below, any additional information that is relevant to your system:

Additional Information about your boiler
































TN GMSCD0903-01E Exaquantum/PPC Instrumentation Requirements: Technical Note
7

2.3. PTC 4 Part Two: Efficiency calculation by Indirect (Heat Loss) Method
The Indirect (Heat Loss) method provides the following benefits: -
1. Indicates why the efficiency of the system is lower
2. Assigns a cost to each Heat Loss
3. Allows finer tuning of Boiler design characteristics
4. Result is less affected by measurement errors

This method for determining the efficiency of a boiler works by subtracting all of the heat losses
associated with the boiler from 100. Thus if all the losses add up to 10%, then the boiler will be 90%
efficient. The advantage of this method is that an error in the measurements will have a smaller impact
than errors in the Direct Method measurements.

Compare:-
For Direct method a 1% error will lead to a calculation of 90% 1% = 89.1% to 90.9%
For Indirect method a 1% error will lead to calculation of 100% (10%1%) = 89.9% to 90.1%

S
T
E
A
M

O
U
T
P
U
T
FUELINPUT
AIR
BOILER
FLUEGAS
F
E
E
D
W
A
T
E
R
B
L
O
W
D
O
W
N
SOLIDFUELRESIDUE
L2.LossduetoHydrogeninFuel
L1.DryFlueGasLoss
L3.LossduetoMoistureinFuel
L4.LossduetoMoistureinAir
L5.LossduetoCarbonMonoxide
L6.SurfaceLoss
L8.BottomAshLoss
L7.UnburntlossinFlyAsh

Figure 2-3 Heat Loss Efficiency Calculation


Efficiency = 100 (LI+L2+L3+L4+L5+L6+L7+L8)

Where:
L6 = Loss due to surface radiation, convection and losses which are insignificant or difficult to measure.
Can be calculated if the surface area and surface temperature of the boiler are known, orcan be derived
from manufacturers data, else can be assumed as follows: -
o Industrial fire tube / packaged boiler = 1.5% to 2.5%
o Industrial watertube boiler = 2% to 3%
o Power station boiler = 0.4% to 1%

And:
L7 and L8 apply to solid fuel fired boilers only

TN GMSCD0903-01E Exaquantum/PPC Instrumentation Requirements: Technical Note
8

2.3.1. Instrumentation Required for Efficiency Calculation by Indirect Method
In addition to the instruments previously defined, this function block requires the following measurements:

Measurement Notes
Available
in your
plant
Flue Gas temperature For enthalpy calculation

Percentage of CO
2
or O
2
in flue
gas
From flue gas analysis. O
2
measurement preferred.

Percentage of COin flue gas From flue gas analysis

Steam flow rate
Mass or Volume.
Could be several instruments for instance Superheated
Steam flow + Reheated Steam flow.

Steam temperature
For enthalpy calculation.
Could be several instruments for instance Superheated
Steam temperature, Cold Reheated Steam temperature,
Hot Reheated steam temperature.

Steam pressure
For enthalpy calculation.
Could be several instruments for instance Superheated
Steam temperature and Reheated Steam temperature.

Condensate water flow rate Mass or Volume.

Condensate return temperature For enthalpy calculation

Combustion air flow rate Mass or Volume.

Combustion air temperature For enthalpy calculation

Combustion air pressure For enthalpy calculation, both primary and secondary

Makeup water temperature For enthalpy calculation

Fuel temperature For enthalpy calculation

Fuel pressure
For enthalpy calculation: not required for solid fuel fired
boilers.

Boiler surface temperature Optional: For calculation of L6

Ambient temperature Optional: For calculation of L6

Wind speed Optional: For calculation of L6

Draft pressure For enthalpy calculation

Atmospheric humidity For calculation of L4.

Boiler drum pressure For enthalpy calculation

Boiler drum temperature For enthalpy calculation


TN GMSCD0903-01E Exaquantum/PPC Instrumentation Requirements: Technical Note
9

2.3.2. Other Information Required for Efficiency Calculation by IndirectMethod
In addition to the information previously defined, this function block requires the following design data:

Information Notes Available
Calorific value (Higher
Heating Value) of fuel
From Laboratory Analysis or as quoted by fuel supplier.

% Carbon in fuel by
weight
From Laboratory Analysis of the fuel.

% Sulfur in fuel by
weight
From Laboratory Analysis of the fuel.

% Hydrogen in fuel by
weight
From Laboratory Analysis of the fuel.

% Nitrogen in fuel by
weight
From Laboratory Analysis of the fuel.

% Oxygen in fuel by
weight
From Laboratory Analysis of the fuel.

% Water in fuel by
weight
From Laboratory Analysis of the fuel.

% Ash in fuel by
weight
From Laboratory Analysis of the fuel. Solid fuels only

% Carbon in refuse by
weight
From Laboratory Analysis of the refuse. Solid fuels only

% Ash in refuse by
weight
From Laboratory Analysis of the refuse. Solid fuels only

Calorific value (Higher
Heating Value) of
carbon in refuse
From Laboratory Analysis of the refuse. Solid fuels only

Boiler efficiency curve
Design values (from manufacturer).
Typically quoted as a function of Steam Flow.

Boiler efficiency loss
due to radiation curve
Optional: For calculation of L6
Design values (from manufacturer).
Typically quoted as a function of Steam Flow.

2.4. Enhanced PPC Boiler Calculations
The ASME calculations described previously do not take into account the following losses: -
1. Blow down losses.
2. Auxiliary steam consumption; for instance Soot Blowers.

They also do not highlight the efficiency of individual components.
However, Exaquantum/PPC contains additional calculations to make use of any additional
measurements/information that might be available.

Measurement Notes
Available
in your
plant
Auxiliary Steam flow
Mass or Volume.
For Unit Heat rate and cost calculations

Auxiliary Steam pressure For Unit Heat rate and cost calculations

Reheat Steam temperature For Unit Heat rate and cost calculations

Reheat Spray flow
Mass or Volume.
For Unit Heat rate and cost calculations

Reheat Spray pressure For Unit Heat rate and cost calculations

Reheat Spray temperature For Unit Heat rate and cost calculations

TN GMSCD0903-01E Exaquantum/PPC Instrumentation Requirements: Technical Note
10

Measurement Notes
Available
in your
plant
Economizer Feedwater inlet
temperature
For Unit Heat rate and cost calculations

Percentage of SO2in flue gas From flue gas analysis

Percentage of NOXin flue gas From flue gas analysis


In addition to the information previously defined, this function block requires the following design data:

Information Notes Available
Expected Excess Air
curve
Design values.
Typically quoted as a function of Steam Flow.

Expected Steam
temperature curve
Design values.
Typically quoted as a function of Steam Flow.

Expected Hot Reheat
temperature curve
Design values.
Typically quoted as a function of Steam Flow.

Expected Economizer
Inlet Water
temperature curve
Design values.
Typically quoted as a function of Steam Flow.

Expected Blowdown
flow curve
Design values.
Typically quoted as a function of Steam Flow.


2.5. ASME Standard: Gas Turbine Heat Recovery Steam Generators PTC 4.4 2008
This standard is used by Exaquantum/PPC for evaluating the performance of Heat Recovery Steam
Generators (HRSGs) employed in combined cycle installations. A combined cycle shall be interpreted as
a gas turbine exhausting intoan HRSG.

There are two methodsto determine the efficiency of an HRSG as it is for boiler efficiency in PTC 4.

o Direct (Input-Output) method

streams steam and air, atomizing
air, augmenting fuel, ary supplement gas, exhaust the of each denotes stream" Each "
heaters. Water and LP, IP, Reheat, HP, the of each denotes water" steam, Each "
: Where
100
stream each for enthalpy)} Reference - enthalpy (Inlet rate flow Inlet {
water steam, each for enthalpy)} inlet - enthalpy (outlet rate flow {
100
credits heat fuel ary supplement in heat gas exhaust turbine gas in Heat
fluids by working absorbed Heat
100
(kJ/h) Input Heat
(kJ/h) Output Heat
(%) Efficiency

+ +
=
=



TN GMSCD0903-01E Exaquantum/PPC Instrumentation Requirements: Technical Note
11


o Indirect (Heat Loss) method
( )
velocity. and e temperatur the of functions are losses heat convection and Radiation
enthalpy gas exhaust Reference - enthalpy gas exhaust Outlet flow gas inlet
gas exhaust moist in loss Heat
loss heat convective loss heat radiation gas exhaust moist in loss heat losses Heat
100
input Heat
losses Heat
1 100
(kJ/h) Input Heat
(kJ/h) losses Heat - Input Heat
(%) Efficiency

=
+ + =
= =
|
.
|

\
|


2.5.1. Instrumentation Required for HRSG Efficiency Calculation

Measurement Notes
Available
in your
plant
Barometric pressure For calculation of exhaust gas enthalpy and heat input

Ambient relative
humidity
For calculation of exhaust gas enthalpy and heat input

Ambient dry bulb
temperature
For calculation of exhaust gas enthalpy and heat input

Inlet gas temperature For calculation of exhaust gas enthalpy and heat input

Outlet gas
temperature
For calculation of exhaust gas enthalpy and heat input

Inlet augmenting air
temperature
For calculation of total heat and flow rate with supplemental firing

Inlet fuel temperature For calculation of total heat and flow rate with supplemental firing

Inlet atomizing steam
temperature
For calculation of total heat and flow rate with supplemental firing

Fuel gas flow rate
Mass flow
For calculation of total heat and flow rate with supplemental firing

Atomizing steam flow
rate
Mass flow
For calculation of total heat and flow rate with supplemental firing

Augmenting air flow
rate
Mass flow
For calculation of total heat and flow rate with supplemental firing

Fuel gas flow rate
Mass flow
For calculation of total heat and flow rate with supplemental firing

HP steam temperature For calculation of heat output

HP steam pressure For calculation of heat output

HP steam flow rate Mass flow.-For calculation of heat output

Reheat outlet steam
temperature
For calculation of heat output

Reheat outlet steam
pressure
For calculation of heat output

Reheat outlet steam
flow rate
Mass flow, Calculation of heat output

Reheat inlet steam
temperature
Calculation of heat output

Reheat inlet steam
pressure
Calculation of heat output

Reheat inlet steam
flow rate
Mass flow.-For calculation of heat output

TN GMSCD0903-01E Exaquantum/PPC Instrumentation Requirements: Technical Note
12

IP steam temperature Calculation of heat output

IP steam pressure For calculation of heat output

IP steam flow rate Mass flow.-For calculation of heat output

LP steam SH outlet
temperature
For calculation of heat output

LP steam SH outlet
pressure
For calculation of heat output

LP steam SH outlet
flow rate
Mass flow.- Forcalculation of heat output

LP steam EV outlet
temperature
For calculation of heat output

LP steam EV outlet
pressure
For calculation of heat output

LP steam EV outlet
flow rate
Mass flow.-For calculation of heat output

Water heater inlet
water temperature
For calculation of heat output

Water heater inlet
water pressure
For calculation of heat output

Water heater inlet
water flow rate
Mass flow.- For calculation of heat output

Water heater outlet
water temperature
For calculation of heat output

Water heater outlet
water pressure
For calculation of heat output

Water heater outlet
water flow rate
Mass flow.-For calculation of heat output

LP Feed water
temperature
For calculation of heat output

LP Feed water
pressure
For calculation of heat output

LP Feed water flow
rate
Mass flow.- For calculation of heat output

HP Feed water
temperature
For calculation of heat output

HP Feed water
pressure
For calculation of heat output

HP Feed water flow
rate
Mass flow.- For calculation of heat output

IP Feed water
temperature
For calculation of heat output

IP Feed water
pressure
For calculation of heat output

IP Feed water flow
rate
Mass flow.- For calculation of heat output

Ambient temperature For calculation of heat loss

Surface temperature For calculation of heat loss

Forced convection air
velocity
For calculation of heat loss




TN GMSCD0903-01E Exaquantum/PPC Instrumentation Requirements: Technical Note
13

2.5.2. Other Information Required for HRSG Efficiency Calculation
In addition to the information previously defined, this function block requires the following design data:

Information Notes Available
Methane, ethane,
propane, iso-butane,
n-butane,and
nitrogen
Mole fractions of dry gas fuel compositions (from Section 4.1.2,
4.1.2. Other Information Required for Gas Turbine Efficiency
Calculation)

Carbon monoxide Mole fraction of dry gas fuel

Sulfur Mole fraction of dry gas fuel

Sulfur dioxide Mole fraction of dry gas fuel

Oxygen Mole fraction of dry gas fuel

Exhaust gas reference
temperature
For calculation of exhaust gas enthalpy and heat input

Weight ratio of steam
or water injection
For calculation of exhaust gas enthalpy and heat input

Fuel to gas ratio
Supplementary firing fuel-to-exhaust gas (gas turbine outlet) ratio.
For calculation of exhaust gas enthalpy

Fuel to air ratio
Gas turbine fuel-to-inlet air ratio (air entering evaporative coolers, if
utilized). For calculation of exhaust gas enthalpy

Mean specific heat of
fuel
For calculation of total heat and flow rate with supplemental firing

Lower heat value of
supplementary fuel
For calculation of total heat and flow rate with supplemental firing

Emissivity Radiation loss. Emissivitycalculation of heat loss

Area of surface factor
Area of surface though which heat loss occurs for radiation and
convection. For calculation of heat loss



TN GMSCD0903-01E Exaquantum/PPC Instrumentation Requirements: Technical Note
14

3. STEAM TURBINE PERFORMANCE CALCULATIONS
Exaquantum/PPC will allow energy efficiency improvements to be made by tracking Steam Turbine
operating variation from design values. It can also assign a cost to these variations so that expensive, but
easily correctable situations can be prioritized and remedied.
3.1. Theoretical Turbine Efficiency
The method that Exaquantum/PPC uses for calculation of Steam Turbine Efficiency employs the
Isentropic Enthalpy of the Exhaust Steam.

Figure 3-1 Steam Turbine efficiency calculations

100
turbine the across drop enthalpy al) (theoretic Isentropic
turbine the accros drop enthalpy Actual
Efficiency =

3.1.1. Instrumentation Required for Turbine Efficiency Calculation
In addition to the instruments previously defined, this function block requires the following measurements:

Measurement Notes
Available
in your
plant
Throttle Steam temperature (Main Steam Temperature)

Throttle Steam pressure (Main Steam Pressure)

HP Turbine Exhaust Steam
temperatures
(Cold Reheat Steam Temperature)

HP Turbine Exhaust Steam
pressures
(Cold Reheat Steam Pressure)

IP Turbine Inlet Steam
temperature
(Hot Reheat Steam Temperature)

IP Turbine Inlet Steam Pressure (Hot Reheat Steam Pressure)

IP Turbine Exhaust Steam
temperatures


IP Turbine Exhaust Steam
pressures


TN GMSCD0903-01E Exaquantum/PPC Instrumentation Requirements: Technical Note
15

Measurement Notes
Available
in your
plant
Crossover pressure to LP
Turbine


Crossover temperature to LP
Turbine


3.1.2. Other Information Required for Turbine Efficiency Calculation
In addition to the information previously defined, this function block requires the following design data:

Information Notes Available
Expected Turbine
efficiency curves
Design values (from manufacturer).
Typically quoted as a function of generator load.

3.2. ASME Standard: Steam Turbines PTC 6 1996
This standard is used by Exaquantum/PPC for evaluating the performance of steam turbines operating
either with a significant amount of superheat in the initial steam (typically fossil fuelled units) or
predominantly within the moisture region (typically nuclear fuelled units).

For turbines operating in a regenerative or reheating cycle, PTC-6 states that steam turbine performance
shall be expressed as Heat Rate, thus:

Output
cycle the to heat Net
Rate Heat =

Where Net heat to the cycle represents the boiler heat input to the turbine cycle.

Heat rate is the heat consumption per hour per unit output, with units of kJ/kWh.
This takes into account the useful energy from the steam vs. the electricity generated.


Figure 3-2Heat Balance around Turbine Cycle


TN GMSCD0903-01E Exaquantum/PPC Instrumentation Requirements: Technical Note
16

Net heat to cycle = Heat added to Main Steam Steam Losses - Heat returned from Turbine
or
= Heat flow entering turbine Heat flow leaving turbine

Where:
Heat added to Main Steam =
(Heat in Main Steam Heat in Feedwater Heat in Superheat Spray Heat in Reheat Spray)
Heat flow entering turbine = HP turbine inlet heat flow + IP turbine inlet heat flow
+ LP turbine inlet heat flow
Heat flow leaving turbine = HP turbine outletheat flow + Feedwater to steam generator heat flow

Where:
(Heat flow = Enthalpy Flow rate)

3.2.1. Instrumentation Required for Turbine Efficiency Calculation
In addition to the instruments previously defined, this function block requires the following measurements:

Measurement Notes
Available
in your
plant
Gross power from generator

HP turbine inlet flow rate See Section 3.1.1 for temperature and pressure.

HP turbine exhaust flow rate See Section 3.1.1 for temperature and pressure.

IP turbine inlet flow rate See Section 3.1.1 for temperature and pressure.

LP turbine inlet flow rate See Section 3.1.1 for temperature and pressure.

Feedwater temperature

Feedwater pressure

Feedwater flow rate


3.2.2. Other Information Required for Turbine Efficiency Calculation
In addition to the information previously defined, this function block requires the following design data:

Information Notes Available
Max rating of
generator.
Constant




TN GMSCD0903-01E Exaquantum/PPC Instrumentation Requirements: Technical Note
17

4. GAS TURBINE PERFORMANCE CALCULATIONS
Exaquantum/PPC will allow energy efficiency improvements to be made by tracking Gas Turbine
operating variation from design values.
4.1. ASME Standard: Gas Turbines PTC 22 1997
This standard is used by Exaquantum/PPC for evaluating the performance of gas turbines operating on a
gas fuel.


Figure 4-1Gas Turbine efficiency calculations

(1) Gas turbine thermal efficiency
Thermal efficiency is calculated from the heat input and power measurements as follows:

100
(kJ/h) input Heat
(kW) output Power
(%) efficiency Thermal =

Heat rate (HR) is basically a reciprocal of thermal efficiency. It can be calculated from the heat input
divided by the power output or thermal efficiency.

(kW) output Power
(kJ/h) input Heat
(kJ/kWh) rate Heat =

(2) Determination of power output
Gas turbine power output shall be measured by determination of the electric generator output. Net
electrical power output of a gas turbine with a generator is equal to the electrical output at the
generator terminals minus the electrical power separately supplied for generator excitation and other
specified plant auxiliaries.

(3) Determination of heat input on gas fuels
To determine the heat input while operating on a gas fuel, the following parameters shall be
determined:
(a) Density at operating conditions
(b) Volume flow
(c) Gas composition, including moisture content (gas constant from chromatograph analysis)
(d) Heat value

TN GMSCD0903-01E Exaquantum/PPC Instrumentation Requirements: Technical Note
18

The fuel gas heat input is calculated from the following equation:

(kJ/h) heat Sensible
(kJ/kg) value heat Low (kg/m3) Density (m3/h) flow Volume (kJ/h) input Heat
+
=


4.1.1. Instrumentation Required for Gas Turbine Efficiency Calculation
In addition to the instruments previously defined, this function block requires the following measurements:

Measurement Notes
Available
in your
plant
Fuel gas temperature Operating temperature at the flow meter

Fuel gas pressure Operating pressure at the flow meter

Fuel gas dew point temperature For calculation of mole fraction of water in the fuel

Volumetric fuel flow
If a turbine meter is used, this is calculated from the
frequency and calibration factor K.

Turbine meter frequency
If a turbine meter is used, provide calibration factor K for
calculating the flow rate from the frequency.

Power output Net power output

4.1.2. Other Information Required for Gas Turbine Efficiency Calculation
In addition to the information previously defined, this function block requires the following design data:

Information Notes Available
Calibration factor K
If turbine meter is used, the volumetric fuel flow is calculated from
the meter frequency and calibration factor K.

Methane Mole fraction of dry gas fuel composition (from chromatograph)

Ethane Mole fraction of dry gas fuel composition (from chromatograph)

Propane Mole fraction of dry gas fuel composition (from chromatograph)

Iso-Butane Mole fraction of dry gas fuel composition (from chromatograph)

N-Butane Mole fraction of dry gas fuel composition (from chromatograph)

Iso-Pentane Mole fraction of dry gas fuel composition (from chromatograph)

N-Pentane Mole fraction of dry gas fuel composition (from chromatograph)

N-Hexane Mole fraction of dry gas fuel composition (from chromatograph)

Carbon dioxide Mole fraction of dry gas fuel composition (from chromatograph)

Nitrogen Mole fraction of dry gas fuel composition (from chromatograph)


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5. UNIT HEAT RATE PERFORMANCE CALCULATIONS
Heat rate is the heat consumption per hour per unit output, with units of kJ/kWh.
This takes into account the useful energy from the fuelvs. the electricity generated and is an indication of
overall plant performance.
5.1. ASME Standard: Overall Plant Performance PTC 46 1996
Employing thisstandard allows Exaquantum/PPC to determine the performance of the entire heat cycle of
an integrated system which can be used for either comparison to a design number, or to trend
performance changes over time of the overall plant.


Figure 5-1Plant Performance

5.1.1. Instrumentation Required for Plant Performance Calculation
In addition to the instruments previously defined, this function block requires the following measurements:

Measurement Notes
Available
in your
plant
Steam Coil steam flow

Generator VAR

Auxiliary Power


5.1.2. Other Information Required for Plant Performance Calculation
In addition to the information previously defined, this function block requires the following design data:

Information Notes Available
Gross Turbine-
Generator Heat Rate
curve
Design values (from manufacturer).
Typically quoted as a function of Gross Generation.

Condenser Back-
Pressure deviation
effect curve
The effect that a change in condenser back-pressure will have on
the unit heat rate.
Quoted as a function of Main Steam flow.

TN GMSCD0903-01E Exaquantum/PPC Instrumentation Requirements: Technical Note
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Information Notes Available
Superheat Steam
temperature deviation
effect curve
The effect that a change in Superheat Steam temperature will have
on the unit heat rate.
Quoted as a function of Throttle Steam temperature.

Reheat Steam
temperature deviation
effect curve
The effect that a change in Reheat Steam temperature will have on
the unit heat rate.
Quoted as a function of Reheat Steam temperature.

Superheat Steam
pressure deviation
effect curve
The effect that a change in Superheat Steam pressure will have on
the unit heat rate.
Quoted as a function of Throttle Steam pressure.

Reheat Steam
pressure deviation
effect curve
The effect that a change in Reheat Steam pressure will have on the
unit heat rate.
Quoted as a function of Reheat Steam pressure drop (between
Cold Reheat Steam pressure and Hot Reheat Steam pressure.

Auxiliary Power
standard curve
The expected loss to Auxiliary power.
Typically quoted as a function of gross power from generator.

Steam Leakage
Other losses of steam specific to the plant.
Typically quoted as a function of Main Steam flow.

Max rating of
generator.
Constant.



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6. UNIT DEVIATION COST CALCULATIONS
Each deviation of an equipment item from its optimum design setting will result in a performance cost.
These performance costs can be calculated as a monetary cost by taking into account the cost of fuel.


Figure 6-1 Unit Deviation Costs
6.1.1. Other Information Required for Unit Deviation Cost Calculation
In addition to the information previously defined, this function block requires the following design data:

Information Notes Available
Cost of fuel



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7. CONDENSER PERFORMANCE CALCULATIONS
The expected (optimum) value of the condenser pressure is calculated as a function of the saturated
steam temperature in the condenser, and as a function of the Limiting Terminal Temperature Difference.


Figure 7-1CondenserFlow Diagram

7.1. ASME Standard: Steam Surface Condensers PTC 12.2 1998
Employing this standard allows Exaquantum/PPC to determine the following performance indexes:

o Difference in steam pressure between the calculated value and design value.
o Difference in tube-side pressure drop between the measured value and design value.

Above indexesare calculated by the following parameters.
- Heat load
- Heat transfer coefficient
- Log mean temperature difference (LMTD)
- Tube-wall resistance
- Fouling resistance
- Shell-side resistance
- Tube-side resistance

7.1.1. Instrumentation Required for Condenser Efficiency Calculation
In addition to the instruments previously defined, this function block requires the following measurements:

Measurement Notes
Available
in your
plant
Condenser back pressure

Cooling water inlet temperature
For calculations of specific heat, thermal conductivity,
viscosity, density, heat load, LMTD and fouling resistance

TN GMSCD0903-01E Exaquantum/PPC Instrumentation Requirements: Technical Note
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Cooling water outlet
temperature
For calculations of specific heat, thermal conductivity,
viscosity, density, heat load and LMTD

Cooling water flow rate For calculation of heat load

LP turbine exhaust steam
pressure
For calculation of saturated temperature

LP Turbine exhaust steam
temperature
For calculation of saturated temperature

Condensing steam/water flow For calculation of shell-side resistance

Tube-side pressure drop For calculation of pressure drop deviation


7.1.2. Other Information Required for Condenser Efficiency Calculation
In addition to the information previously defined, this function block requires the following design data:

Information Notes Available
Limiting terminal temperature
difference
Constant, from manufacturers data

Condenser heat transfer
correction factor
Constant, from manufacturers datain case of no
calculation

Tube thermal conductivity Condenser design data

Tube outer diameter Condenser design data

Tube inner diameter Condenser design data

Outside tube surface area Condenser design data

Cooling water flow area Condenser design data

Cleanliness factor Condenser design data

Heat load Condenser design data

Cooling water flow-rate Condenser design data

Condensing flow-rate Condenser design data

Cooling water inlet temperature Condenser design data

Cooling water outlet
temperature
Condenser design data

Tube-side pressure drop Condenser design data

LP turbine exhaust steam
pressure
Condenser design data

LP turbine exhaust steam
saturated temp.
Condenser design data

Bulk average temperature Condenser design data

Specific heat capacity Condenser design data

Thermal conductivity Condenser design data

Viscosity Condenser design data

Density Condenser design data

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Number n tube-set outlet
temperature (fouling)
Condenser test data where n indicates the tube-set
number

Number n tube-set outlet
temperature (clean)
Condenser test data where n indicates the tube-set
number

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8. FEEDWATER HEATER PERFORMANCE CALCULATIONS
The expected (optimum) operating envelope of a feedwater heater can be characterized by the difference
between the drain inlet and drain outlet.



Figure 8-1Feedwater Heater Flow Diagram
8.1.1. Instrumentation Required for Feedwater HeaterPerformance Calculation
In addition to the instruments previously defined, this function block requires the following measurements:

Measurement Notes
Available
in your
plant
Feedwater inlet temperature
In a cascaded heater system, can be measured at the
output of the previous heater.

Feedwater outlet temperature
In a cascaded heater system, can be measured at the
input of the next heater.

Inlet steam temperature
In a cascaded heater system, can be measured at the
output of the previous heater.

Inlet steam pressure
In a cascaded heater system, can be measured at the
output of the previous heater.

Drain inlet temperature
In a cascaded heater system, can be measured at the
output of the previous heater.

Drain outlet temperature
In a cascaded heater system, can be measured at the
input of the next heater.


8.1.2. Other Information Required for Feedwater HeaterPerformance Calculation
In addition to the information previously defined, this function block requires the following design data:

Information Notes Available
Expected terminal
temperature difference
curve
The expected temperature drop between the inlet/outlet drain
temperatures.
Typically quoted as a function of generator load.

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9. AIR HEATER PERFORMANCE CALCULATIONS
The efficiency of an air heater can be characterized by the differential temperatures of the air/gas flows.



Figure 9-1 Air Heater Flow Diagram
9.1.1. Instrumentation Required for Air Heater Performance Calculation
In addition to the instruments previously defined, this function block requires the following measurements:

Measurement Notes
Available
in your
plant
Gas inlet temperature
In a cascaded heater system, can be measured at the
output of the previous heater.

Gas outlet temperature
In a cascaded heater system, can be measured at the
input of the next heater.

Air inlet temperature
In a cascaded heater system, can be measured at the
output of the previous heater.


9.1.2. Other Information Required for Air Heater Performance Calculation
In addition to the information previously defined, this function block requires the following design data:

Information Notes Available
Expected Air Heater
efficiency curve
Typically quoted as a function of Main Steam flow.

TN GMSCD0903-01E Exaquantum/PPC Instrumentation Requirements: Technical Note
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10. OTHER INFORMATION
Please indicate in the space below, any other information that might be relevant to your system, for
example:
- Manual feeding of fuel
- Variation in fuel grade
- Reliability of Instruments
- Accuracy of Instruments
- Age of plant etc.

Additional Information about your system















































TN GMSCD0903-01E Exaquantum/PPC Instrumentation Requirements: Technical Note
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