ASME PTC 4 锅炉性能试验规程实际应用

2019 Babcock Power Inc. All Rights Reserved 1 Riley Power Babcock Power Environmental Babcock Power Services Boiler Tube Company of America Vogt Power Thermal Engineering International (USA) Inc. TEiC Construction Services TEiC Heat Exchanger Services Struthers Wells ASME PTC 4 Boiler Efficiency 锅炉性能试验规程锅炉性能试验规程 Practical Application Brian Vitalis Senior Technical Advisor PTC 4 Launch Event in Xian China 4-6 June 2019 2019 Babcock Power Inc. All Rights Reserved 2 Utility Boiler Image Fuel sampling at feeders Flue gas and air duct measurement grids 2019 Babcock Power Inc. All Rights Reserved 3 Scope of Presentation Practical Use / Application of Code 1.Code Structure and Practical Application 2.Section 1: Objectives, Scope, System Boundary 3.Section 3: Guiding Principles a)Diagram of losses and credits b)Agreements prior to test, test planning 4.Section 4: Measurements a)Output steam-side measurements b)Fuel QrF QrL 100QpL QrBQrL-QrFQrO - 100 输入热量 输出热量 100）（）燃料效率（ (%) 外来热量损失输入能量输出能量 能量平衡： , = = 100% - Losses + Credits 2019 Babcock Power Inc. All Rights Reserved 12 Fig. 3-1.1-1 Efficiency Losses and Credits Subtitle guiding principles Credits Input Output energy added to steam or working fluid Losses , = = 100% - Losses + Credits 2019 Babcock Power Inc. All Rights Reserved 13 Fig. 3-1.1-1 Efficiency Losses and Credits Primary / typical credits to calculate guiding principles Primary Credits 2019 Babcock Power Inc. All Rights Reserved 14 Fig. 3-1.1-1 Efficiency Losses and Credits Primary / typical losses to calculate guiding principles Primary Losses estimated or calculated 2019 Babcock Power Inc. All Rights Reserved 15 Section 3: Guiding Principles Prior Agreements include in Test Procedure guiding principles For boiler acceptance, testing (and test procedure) typically by Independent Party. Otherwise, by Supplier. Test Procedure outlines objectives, test matrix, plans, etc. Good practice is to include the Prior Agreements refer to 3-2.3. In addition to the usual test planning details, examples include: interpretation of any relevant contract requirements; target test uncertainties; unit cleanliness and any sootblowing to be conducted during test; parameters to be estimated rather than measured; fuel to be fired, sampling methods, laboratory to be used, etc.; method for determining data outliers; corrections to be used for comparison to contract conditions, including any correction curves; 3-4: Test Uncertainty to be used only for evaluating the quality of the test. (not to imply a tolerance or margin on the result) 2019 Babcock Power Inc. All Rights Reserved 16 Section 4: Instruments and Methods of Measurement highlights instruments and measurement methods Reference info for methods and instrumentation. Fuel sampling guidance. Flue gas duct test grid requirements. Lists example instrument accuracy / Systematic Uncertainty. Plan / design the test to suit the particular needs and objectives of all Parties. 2019 Babcock Power Inc. All Rights Reserved 17 Section 4: Instruments and Methods of Measurement Output: Water / steam side measurements instruments and measurement methods from Fig. 3-1.1-1 Permanent plant instrumentation is normally provided at all terminal points. This data should be collected. For routine tests, this data may be relied on. Confirm recent calibration records. For acceptance tests, install temporary test instruments at provided taps 2019 Babcock Power Inc. All Rights Reserved 18 Section 4: Instruments and Methods of Measurement Fuel / Air / Flue Gas Measurements instruments and measurement methods Plant weather station / cooling tower data. Track variation during test duration. Ash: Typically estimate / agree on flow distribution. (assign uncertainty) Presume temperature = flue gas at location, except bottom ash see 5-14.5. Samples are collected, sent to lab for unburned carbon analysis. Flue gas: Typically multi- point measurement grid in ducts. Depending on need, air ducts may also have multi-point grids. Fuel: Extent of sampling depends on test objective. Sample from all feeders. Seal to prevent moisture loss. Laboratory analysis of HHV and ultimate analysis. (Calculate LHV if desired.) 2019 Babcock Power Inc. All Rights Reserved 19 Section 4: Instruments and Methods of Measurement Fuel / Air / Flue Gas Measurements instruments and measurement methods Flue gas duct test grids Air duct test grids Fuel samples at feeders Air Heater 2019 Babcock Power Inc. All Rights Reserved 20 Section 4: Instruments and Methods of Measurement Flue gas duct grids: Temperature, Oxygen (sometimes flow, emissions, CO2) typically 1m2 each Flue gas duct cross-section AH inlet test ports AH outlet test ports Air Heater flue gas flow multi-probe test ports 2019 Babcock Power Inc. All Rights Reserved 21 Grid data chart examples Flue gas grid data chart examples Oxygen AH inlet Oxygen AH outlet 2019 Babcock Power Inc. All Rights Reserved 22 Section 4: Instruments and Methods of Measurement raw data - DCS instruments and measurement methods 2019 Babcock Power Inc. All Rights Reserved 23 Section 5: Computation of Results highlights calculations Data reduction. Basic calculations of fuel, air, flue gas. Calculation of efficiency losses, credits, efficiency. Corrections to standard or design conditions. Section 5-19 specifies enthalpy of air, flue gas, and other substances. Some of the pre-calculations required include: 1.AH leakage and undiluted flue gas outlet temperature. 2.Spraywater flow rates by heat balance. 3.FWH heat balance and RH steam flow. 4.Tempering air (bypass) flow from mill air mixing heat Example in Appx B. Spray attemperation and feedwater heater / reheat steam flow calculations are described, but calculations are on the Output form only. excerpt from Fig. 3-1.1-1 2019 Babcock Power Inc. All Rights Reserved 26 Section 5: Computation of Results 5-4: Output Calculation examples are in Appendix B 2019 Babcock Power Inc. All Rights Reserved 27 Section 5: Computation of Results 5-11, 5-12: Combustion Calculations (air, flue gas) calculations Calculations are extensive, but straight-forward. Forms CMBSTNa,b,c. Blank in Appx A; Example in Appx B. Forms also cover air heater leakage, undiluted flue gas temperature, sorbent reactions, and sulfur capture. 2019 Babcock Power Inc. All Rights Reserved 28 Section 5: Computation of Results Efficiency losses and credits are described in the order presented in Fig 3-1.1-1 calculations Primary Losses excerpt from Fig. 3-1.1-1 5-14: Losses 5-15: Credits Calc Forms EFFa,b,c and RES 2019 Babcock Power Inc. All Rights Reserved 29 Section 5: Computation of Results 5-18: Corrections to Standard or Design Conditions calculations Test fuel and inlet conditions (temperatures) typically differ from design conditions. Most corrections involve substitution of the design condition for the test condition, and repeating the affected calculations. Some adjustment calculations are prescribed. (e.g. AH exit gas temperature as affected by a difference in inlet air temperature.) Note that while the test condition value has uncertainty, the design condition does not. Notably, this includes the entire fuel analysis and heating value. Therefore, uncertainty of corrected results is less than that of the test result. (5-18.14) In response to prior meeting in China (2016), a correction for off-design feedwater temperature is being developed. In addition to efficiency corrections, corrections are provided for: 5-18.11 Air and gas resistance 5-18.12 Steam or water pressure loss 5-18.13 Steam temperature and desuperheating spray 2019 Babcock Power Inc. All Rights Reserved 30 Section 5: Computation of Results 5-18: Corrections to Standard or Design Conditions calculations Ability to m