ASME PTC 4.4 2008 R2013

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ASME PTC 4.4 Gas Turbine Heat Recovery Steam Generators – Reaffirmed: 2013

Published By	Publication Date	Number of Pages
ASME	2008	156

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Category: ASME

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Description

The object of this Code is to establish procedures for conducting performance tests of Heat Recovery Steam Generators (HRSGs) used to recover gas turbine exhaust energy. The steam generator may include supplemental firing. This Code provides standard test procedures yielding the highest level of accuracy consistent with current engineering knowledge and practice. (a) The purpose of this Code is to determine the following: (1) capacity of the unit at specified conditions. (2) energy input from gas turbine exhaust and supplementary firing. (3) gas side pressure drop. (4) steam/water side pressure drop(s). (b) This Code provides methods for converting the performance at test conditions to specified operating conditions. A determination of any or all of the performance items listed above may be used for the following purposes: (1) checking the actual performance against guarantee. (2) comparing these items at reference conditions. (3) comparing different conditions or methods of operation. (4) determining the specific performance of individual parts or sections of the HRSG unit. (5) comparing the performance when firing different fuels. (6) determining the effects of changes to equipment. Also, this Code addresses steam generators whose primary function is to recover heat from gas turbine exhaust. Methods noted in this Code may also be used for testing other heat recovery units which may include the following: (1) Units heating water only. (2) Units using working fluids other than water. (3) Units obtaining hot gas heat input from sources other than gas turbines. (4) HRSGs with fresh air firing capability. This Code does not cover the following testing: (1) fired steam generators which primary function does not include the recovery of heat from gas turbine exhaust. These are addressed in PTC 4 and PTC 34. (2) auxiliary equipment such as pumps and fans that are addressed in PTC 8.2 and PTC 11, respectively. (3) deaerator performance that is addressed in PTC 12.3. (4) equipment noise emissions that are addressed in PTC 36. (5) gaseous emissions to atmosphere. (6) steam purity.

PDF Catalog

PDF Pages	PDF Title
5	CONTENTS
6	Figures Tables
7	NOTICE
8	FOREWORD
9	COMMITTEE ROSTER
11	CORRESPONDENCE WITH THE PTC COMMITTEE
13	Section 1 Object and Scope 1- 1 OBJECT 1- 2 SCOPE
14	1- 3 TEST UNCERTAINTY
15	Section 2 Definitions of Terms, Symbols, and Conversion Factors 2- 1 DEFINITIONS OF TERMS
18	2- 2 SYMBOLS
22	2- 3 CONVERSION FACTORS
24	2- 4 DESCRIPTIVE FIGURES
26	2- 4- 1 Typical Gas Turbine Heat Recovery Steam Generator Diagram
27	2- 4- 2 Typical Three Pressure Level HRSG With Supplementary Firing
28	2- 4- 3 Typical Two Pressure Level HRSG With Feedwater Heater and Supplementary Firing
29	2- 4- 4 Typical Single Pressure Level HRSG With Feedwater Heater and Supplementary Firing
30	Section 3 Guiding Principles 3- 1 INTRODUCTION 3- 2 PLANNING FOR THE TEST 3- 2.1 Test Procedure 3- 1- 1 Typical Range of Uncertainties
31	3- 2.2 Responsibilities of Parties 3- 2.3 Test Boundary 3- 2.4 Required Measurements 3- 2.4.1 Gas Turbine Exhaust. 3- 2.4.2 Ambient Conditions. 3- 2.4.3 Water and Steam Streams. 3- 2.4.4 Auxiliary Firing Input. 3- 2.4.5 Auxiliary Systems. 3- 2.4.6 Gas Side Pressure Drop. 3- 2.4.7 Steam and Water Pressure Drop.
32	3- 2.5 Design, Construction, and Startup Considerations 3- 3 PRIOR AGREEMENTS
33	3- 4 TEST PREPARATIONS 3- 4.1 Schedule of Test Activities 3- 4.2 Test Apparatus
34	3- 4.3 Test Personnel 3- 4.4 Equipment Inspection 3- 4.5 Preliminary Run 3- 4.6 Documentation of Correction Methodology 3- 5 CONDUCTING THE TEST 3- 5.1 Starting and Stopping Tests and Test Runs
35	3- 5.1.1 Starting Criteria. 3- 5.1.2 Stopping Criteria. 3- 5.2 Methods of Operation Prior to and During Tests 3- 5.2.1 Equipment Operation. 3- 5.2.2 Proximity to Design Conditions. 3- 5.2.3 Blowdown. 3- 5.3 Adjustments Prior to and During the Test
36	3- 5.4 Application of Corrections 3- 5.5 Duration of Runs 3- 5.6 Number of Test Runs 3- 5.3- 1 Suggested Maximum Permissible Variations in Test Conditions
37	3- 5.7 Number of Readings 3- 6 CALCULATION, ANALYSIS, AND REPORTING OF RESULTS 3- 6.1 Causes for Rejection of Readings 3- 6.2 Repeatability of Test Runs
38	3- 6.3 Comparison of Capacity From GT and HRSG Heat Balances 3- 6.4 Test Uncertainty 3- 6.2- 1 Repeatability of Runs
39	3- 6.4.1 Pretest and Post- Test Uncertainty Analyses. 3- 6.5 Test Report
40	Section 4 Instruments and Methods of Measurement 4- 1 INTRODUCTION 4- 2 GENERAL 4- 2.1 Supplements 4- 2.2 Location and Identification of Instruments 4- 2.3 Sources of Error 4- 2.4 Instrument Calibration 4- 2.4.1 Definition of Calibration.
41	4- 2.4.2 Reference Standards. 4- 2.4.3 Ambient Conditions. 4- 2.4.4 Instrument Ranges and Calibration Points. 4- 2.4.5 Timing of Calibration. 4- 2.4.6 Calibration Drift.
42	4- 2.4.7 Loop Checks. 4- 2.4.8 Quality Assurance Program. 4- 2.5 Plant Instrumentation 4- 2.6 Redundant Instrumentation
43	4- 3 TEMPERATURE MEASUREMENT 4- 3.1 General 4- 3.2 Measurement Systematic Uncertainty for Temperature
44	4- 3.3 Typical Applications 4- 3.3.1 Temperature Measurement of Fluid in a Pipe or Vessel. 4- 3.2- 1 List of Potential Sources and Typical Ranges of Uncertainties
45	4- 3.3.2 Temperature Measurement of Products of Combustion in a Duct.
46	4- 3.3.3 Inlet Air Temperature.
47	4- 3.3.4 Inlet Air Moisture Content.
48	4- 4 PRESSURE MEASUREMENT 4- 4.1 General 4- 4.2 Measurement Systematic Uncertainty for Pressure 4- 4.3 Air and Gas— Static and Differential Pressure 4- 4.3.1 Method of Measurement.
49	4- 4.4 Steam and Water— Static and Differential Pressure 4- 4.4.1 Method of Measurement. 4- 4.4.2 Installation. 4- 4.2- 1 Potential Pressure Systematic Uncertainty Limits
50	4- 4.5 Barometric Pressure 4- 4.5.1 Method of Measurement. 4- 5 FLOW MEASUREMENT 4- 5.1 General 4- 5.2 Flowmeters 4- 5.2.1 Compliance With Code Requirements. 4- 5.2- 1 Maximum Allowable Flow Measurement Uncertainty
51	4- 5.2.2 Plant Design Considerations. 4- 5.2.4 Calculation of Flow. 4- 5.2.5 Accuracy and Other Characteristics of Flowmeters. 4- 5.2.6 Selection of Flowmeters. 4- 5.2.7 Energy and Mass Balance Calculation. 4-5.3 Air and Exhaust Gas 4- 5.4 Liquid Fuel
52	4- 5.4.1 Method of Measurement. 4- 5.5 Gaseous Fuel 4- 5.5.1 Method of Measurement. 4-6 LIQUID AND GASEOUS FUEL SAMPLING 4- 6.1 General 4- 6.2 Measurement Systematic Uncertainty for Sampling 4- 6.3 Methods of Liquid or Gas Sampling
53	4- 6.4 Fuel Analysis 4- 6.5 Methods of Fuel Analysis 4- 7 POWER MEASUREMENT 4- 8 DATA COLLECTION AND HANDLING 4- 8.1 Data Collection and Calculation Systems 4-8.1 Data Collection and Calculation Systems 4- 8.1.2 Data Calculations. 4- 8.2 Data Management 4- 8.2.1 Storage of Data. 4- 8.2.2 Manually Collected Data. 4- 8.2.3 Distribution of Data.
54	4- 8.3 Construction of Data Collection Systems 4-8.3.1 Design of Data Collection System Hardware. 4- 8.3.2 Calibration of Data Collection Systems. 4- 8.3.3 Use of Existing Plant Measurement and Control System.
55	Section 5 Calculations 5- 1 INTRODUCTION 5- 1.1 General Discussion 5- 1.2 Data Reduction 5- 2 INTERMEDIATE CALCULATIONS 5- 2.1 Air Composition Calculations 5- 2.1.1 General.
56	5- 2.1.2 Data Required 5- 2.1.3 Calculations
58	5- 2.2 Molar Flow Change Due to Fuel Gas Combustion 5- 2.2.1 General. 5- 2.2.2 Data Required 5- 2.2.3 Table of Combustion Ratios. Table 5- 2.2.3- 1 Combustion Ratios
59	5- 2.2.4 Calculations 5- 2.3 Molar Flow Change Due to Fuel Oil Combustion 5- 2.3.1 General. 5- 2.3.2 Data Required
60	5- 2.3.3 Calculations 5- 2.4 Fuel Gas Heating Value 5- 2.4.1 General. 5- 2.4.2 Data Required 5- 2.4.3 Fuel Compound Heating Value Table. 5- 2.4.4 Calculations
61	Table 5- 2.4.3- 1 Fuel Compound Heating Values 5- 2.5 Fuel Oil Heating Value 5- 2.5.1 General. 5- 2.5.2 Data Required 5-2.4.3-1 Fuel Compound Heating Values
62	5- 2.5.3 Calculations 5- 2.6 Gas Enthalpy 5- 2.6.1 General. 5- 2.6.2 Data Required 5- 2.6.3 Enthalpy Equation Constants. Table 5- 2.6.3- 1 Constituent Enthalpy Equation Constants 5-2.6.3-1 Constituent Enthalpy Equation Constants
63	5- 2.6.4 Calculations 5- 2.7 Gas Turbine Gas Composition 5- 2.7.1 General. 5- 2.7.2 Data Required 5- 2.7.3 Calculations 5- 2.8 Desuperheater Spray Water Flow by Heat Balance 5- 2.8.1 General.
64	5- 2.8.2 Data Required 5- 2.8.3 Calculations 5- 2.9 Extraction Flow by Heat Balance 5- 2.9.1 General. 5- 2.9.2 Data Required 5- 2.9.3 Calculations 5- 3 GAS FLOW BY HRSG ENERGY BALANCE 5- 3.1 HRSG Gas Flow Calculations 5- 3.1.1 General.
65	5- 3.1.2 Data Required 5- 3.1.3 Calculations.
67	5- 3.2 Duct Burner Gas Composition 5- 3.2.1 General. 5- 3.2.2 Data Required 5- 3.2.3 Calculations
68	5- 3.3 HRSG Heat Loss 5- 4 GAS FLOW BY GAS TURBINE ENERGY BALANCE 5- 4.1 Gas Turbine Gas Flow Calculations 5- 4.1.1 General.
69	5- 5 WEIGHTED CAPACITY 5- 5.1 General 5- 5.2 Data Required 5- 5.3 Calculations
70	5- 6 CORRECTION OF TEST CONDITIONS TO GUARANTEE 5- 6.1 Correction of Steam Flow for Superheat 5- 6.2 Capacity 5- 6.3 Duct Burner Fuel Flow
71	5- 6.4 Gas Side Pressure Drop 5- 6.4.1 General. 5- 6.4.2 Data Required. 5- 6.4.3 Calculations.
72	5- 6.5 Steam Side Pressure Drop 5- 6.5.1 General. 5- 6.5.2 Data Required. 5- 6.5.3 Calculations
73	Section 6 Report of Results 6- 1 GENERAL 6- 2 SECTION 1: EXECUTIVE SUMMARY 6- 3 SECTION 2: INTRODUCTION 6- 4 SECTION 3: TEST DATA 6- 5 SECTION 4: DATA REDUCTION, CORRECTIONS, AND RESULTS
74	6- 6 SECTION 5: APPENDICES
75	Section 7 Uncertainty Analysis 7- 1 INTRODUCTION 7- 1.1 Pretest Uncertainty Analysis and Test Planning 7- 2 UNCERTAINTY CALCULATION 7- 2.1 Pretest and Post- Test Uncertainty 7- 2.2 Uncertainty Calculation Procedure
78	7- 3 GUIDANCE FOR DETERMINING SYSTEMATIC ERRORS
79	7- 3.1 General Rules 7- 3.2 Systematic Error in Measured Parameters From Instrumentation 7- 3.3 Systematic Error in Gas Turbine HRSG Exhaust Temperature and Stack Temperature
81	MANDATORY APPENDIX I EXHAUST FLOW BY GAS TURBINE ENERGY BALANCE I- 1 INTRODUCTION I- 2 GENERAL Fig. I- 2- 1 Exhaust Flow
82	I- 3 DATA REQUIRED I- 4 CALCULATIONS
83	I- 5 GAS TURBINE MISCELLANEOUS HEAT LOSS
84	NONMANDATORY APPENDICES A SAMPLE HRSG HEAT BALANCE CALCULATIONS
95	B SAMPLE GAS TURBINE HEAT BALANCE CALCULATIONS
105	C UNCERTAINTY SAMPLE CALCULATION
121	D FUEL SENSIBLE HEAT D- 1 INTRODUCTION D- 2 FUEL OIL D- 3 FUEL GAS
122	Table D- 3- 1 Specific Heat at 124 F 14.7 psia 100 psia 300 psia Table D- 3- 2 Specific Heat at 100 psia D- 4 REFERENCES
123	E GAS ENTHALPY EQUATION DERIVATION
126	F HRSG HEAT LOSS F- 1 HRSG HEAT LOSS F- 1.1 Insulated Casing Design Criteria
129	G BYPASS DAMPER LEAKAGE
130	H UNCERTAINTY WORKSHEET FORM