ecrreli Topics: EPRI CS-3800 Steam turbines Project 911-1 Boilers Final Report Plant cycling December 1984 Power plant dynamics Thermal modeling Cyclic-Duty Turbine and Boiler Operating Practice and Guidelines Prepared by Westinghouse Electric Corporation Orlando, FloridaEPRI CS-38008 SUBJECTS TOPICS AUDIENCE BACKGROUND OBJECTIVES ‘APPROACH RESULTS REPORT SUMMARY ‘Steam turbines and related auxiliaries / Plant systems and performance assessment / Bollers and related auxiliaries Steam turbines Power plant dynamics Boilers Thermal modeling Plant cycling Generation engineers and designers Cyclic-Duty Turbine and Boiler Operating Practice and Guidelines Utilities can greatly increase the effectiveness of coal units in cyclic operation by modifications suggested in these guide- lines. Commonwealth Edison Company, for example, projects annual savings of $217,000 from implementing cyclic-duty guide- lines devised for a 505-MW power station. Rising fuel costs and increasing nuclear generating capacity are two of many factors promoting a growing trend toward cycling fossil fuel units. Many such plants are now specified for cyclic operation from the start. Others are assigned to cyclic operation after years of baseload operation. + To provide field validation of present techniques for modeling fossil fuel power plants. + To develop general operating guidelines for using turbines and boilers in cyclic duty. eld tests at the Commonwealth Edison Company 505-MW Collins Unit 5 ‘monitored 249 boiler and turbine variables on a continuous basis for 4 months. During the project, analysts also developed an analytic boiler model with a limited capability for turbine thermal analysis, which they vali- dated against the field test data. In one series of eight cycling tests, boilers and turbines operated at three load levels in two-shift, load-following, startup, and other modes. The analysts used those data in the newly devel- ‘oped boiler model and a proprietary Westinghouse turbine model to est mate cyclic-life expenditures. From the estimates, they developed operating recommendations for Collins Unit 5, which they generalized for other power plants. + The field tests provided data for a complete evaluation of both turbine and boiler models. The boiler model developed in this project, modified ‘according to this evaluation, has been incorporated in the Modular Modeling ‘System (MMS) of computer codes described in EPRI report CS/NP-2988. + In the test unit i: proved difficult to control steam temperature during startup and initial loading—a problem throughout the industry. The test data‘suggested that automatic temperature control systems using digital or feed-forward analog techniques might offer a solution. + Hybrid-pressure operation—a combination of sliding-pressure and sequential-value operation—was recommended as the optimum control strategy for the test unit and for the industry in general. Hybrid operation also improved thermal efficiency with low loads. Single-value operation, however, was preferable for more rapid load following—particularly in two-shift operation. EPRI PERSPECTIVE The generic operating guidelines presented in this report will greatly help utility engineers evaluate the use of specific units for cyclic opera: tion. In addition, the boiler and turbine models are also available for detailed dynamic analyses of specific subsystem controls or compo- nents in the MMS computer codes. Related research is discussed in EPRI reports CS-2340, Cycling of High- Pressure Steam Power-Generating Units With Drum Boilers, and CS-3717, Assessment of Fossil Steam Bypass Systems. Those studies indicate that utilities can realize significant improvements in plant startup times and operating ccsts by coordinating boiler, turbine, and balance-of-plant operations. A typical 600-MW unit experiencing 200 hot starts annually, for example, can save $600,000-$900,000 in yearly fuel costs when ‘equipped with superheater or small-turbine bypass system. Applications of the MMS codes were explored in a workshop under EPRI Project RP1184, PROJECT RP914 EPRI Project Managers: John B, Parkes; Thomas McCloskey Coal Combustion Systems Division Contractor: Westinghouse Electric Corporation For further information on EPRI research programs, call EPRI Technical Irformation Specialists (415) 855-2411. ORDERING INFORMATION EPRI CS-3800, Final Report, December 1984, 482 pages. EPRI Members _ If this report is nct available from your company libraries or your Technical Information Coordinator, you can order it from Research Reports Center PO. Box 50490 Palo Alto, CA 94303 (415) 965-4081 For information adout the MMS computer codes, call the Electric Power Software Center (214) 655-8883, Nonmembers You can order this report in print or microfiche from Research Reports Center. Price: $35.50 _ Cverseas price: $71.00 (California residents add sales tax.) Payment must accompany order. For information about the MMS computer codes, call EPRI Technical In‘ormation Specialists (415) 855-2411Cyclic-Duty Turbine and Boiler Operating Practice and Guidelines Cs-3800 Research Project 911-1 Final Report, December 1984 Prepared by WESTINGHOUSE ELECTRIC CORPORATION Steam Turbine Generator Division University Boulevard and Alafaya Tail Orlando, Florida 32817 Principal Investigators HF. Martin JL. Barkan Project Manager H. F. Martin Prepared for Electric Power Research Institute 3412 Hillview Avenue Palo Alto, California $4304 EPRI Project Managers J.B. Parkes T.H. McCloskey Availability and Performance Program Coal Combustion Systems DivisionORDERING INFORMATION Requests for copies of this report should be directed to Research Reports Center (ARC), Box 50490, Palo Alto, CA 94303, (415) 965-4081. There is no charge for reports ‘requested by EPRI member utiities and affilates, U.S. utility associations, U.S. government agencies (federal, state, and local), media, and foreign organizations with which EPRI has an information exchange agreement. On request, RRC will send a catalog of EPAl reports, Feceach Categories: Steam turbines andreas auviars Plant ystems and perfomance assessment Bojer ana ested srianes Coyrght © 188 Electric Power Research neue Ie AL NOTICE ‘This report wa prepared by the ongarizatins) named blew as an account werk sponsored bythe Electr Power Research ints, nc. EPR, Nether EPRI, members HEPA the rgaiatots) named below Na ay Berson acting en bel of any of hem: (a) makes any waranty exes er ple, wh respect othe eof 37 Intomaton. soparats, metodo" access deloseg mh report or ha such oe may hot ings oaely ‘ned igh: oF) assumes an lables wih respect to neue oor fr damages retin am th use anyinirmaton, apearats, method or rocers closed » steno. Propareaty \esthahouse Elec Corporation (ftando, Flonds|ABSTRACT The object of this project was to improve the reliability and economy of cyclic operation of turbines and boilers. Continuous measurements of 249 variables were gathered for fifteen months forming the basis for validation of the turbine thermal and boiler models. A cyclic operation tes: program studied various modes of operation. The turbine and boiler cyclic life expectancies were estimated using calculated results or estimates made based upon measured temperature distributions. The operating reconmendations developed for the specific test plant and the experience gained during these tests were used as a basis for developing operating recommendations for the entire electric utility industry. The validation of the turbine thermal models was satisfactory; however, the boiler modeling approach requires some additional work.ACKNOWLEDGMENTS While the efforts of a considerable number of people and groups were required to complete this project, particular recognition should be given to the following: ‘© Commonwealth Edison Company ~ Engineering Department = Collins Station Personnel, in particular K. Wanninger © Babcock & Wilcox Company = 0. Durrant = R.A, Smoak © Westinghouse Electric Corporation = Power Generation Service Division T. Haug 6. Miller oN. Moll = Steam Turbine Generator Division D. Darkow V. Donato R. Lincoln L. B. Podolsky L. Gray S. Belfor G. Cowan P. ViscovichSection SUMMARY 10 2.0 3.0 4.0 CONTENTS INTRODUCTION Program Objectives DESCRIPTION OF PLANT ANALYTIC MODELS Boiler Model Spray Attemperator Connective Nodule Divider Module Drum Boiler Economizer Feedwater Heater High Pressure Turbine Intermediate and Low Pressure Turbine Steam Attemperator Superheaters and Reheaters Valve Turbine Model CYCLIC TEST PROGRAM Philosophy of Test Program Results and Discussion Test 8 Test Test Test Test Test Test Test vii Page sl Lt Ld 21 34 341 32 342 32 3:3 34 3-4 3-5 3-5 35 346 41 a1 4-2 4-2 45 4-13 4-18 421 4-23 4-25 4-28Section 5.0 6.0 CONTENTS (Continued) Thermal Stress Analysis Drum Headers Economizer Windbox. Turbine Stationary Parts Turbine Rotor Data Acquisition and Operating History Data Acquisition System Instrumentation Data Reduction MODEL VALIDATION Turbine Heat Transfer Analysis Philosophy of Test Program HP-IP Rotor Heat Transfer cylinder Heat Transfer Open Loop Tests Open Loop Simulation Startup Simulation OPERATING RECOMMENDATIONS Reconmendations for Collins Unit No. 5 Recommendations for the Electric Utility Industry Method of Operation Temperature Matching Boiler Feedpump Operation Saturated Steam Dump and Drain Flow Temperature Control vit Page 4-31 431 4-37 fata 445 447 gna? 4-48 4-51 4-55 4-56 5-1 Sel 5-2 5-17 5-27 5-29 5-43 6-1 6-1 6-11 en 6-13 6-15 6-18 6-18Secti CONTENTS (Continued) Prewarming Maintaining Vacuum Restart Times and Costs 7.0 CONCLUSTONS AND RECOMMENDATIONS References APPENDIX A APPENDIX B APPENDIX C. APPENDIX APPENDIX E INSTRUMENTATION Rotor Bore Thermocouple Telenetry System Design of Rotor Bore Thermocouple Assembly Induced Power and Antenna System Rotor Bore Telemetry System Instrumentation Rotating Test Calibration of Transmitters Field Experience Temperature and Pressure Instrunentation Selection of Data Points Diagram for Collins #5 Test 1/0 List for Collins #5 Test Cycle Steam Thermocouples Turbine Stationary Metal Thermocouptes Cylinder Modi fications Pressure Transducers Evaluation of Instruments and Operating Experience DATA ACQUISITION SYSTEM Software Programs General Arrangenent of Data Acquisition System Hardware Cabinet Design DATA REDUCTION PROGRAMS BOILER MODEL PROGRAM DAILY OPERATION SUMMARY Temperatures Before Rolling Maximum Rates of Change Breakdown of Hours at Load in Percent ix Page 6-19 6-20 6-20 71 Al Ad a3 AT Al A-13 Al A-18 A-18 An18 30 A-30 A3L Aad Aad B-1 B-1 B-2 Ba ca bl El £3 e148 E24CONTENTS (Continued) Section Page APPENDIX F BOILER MODEL Fal Model Scope Fel Macro Structure F.2 Steam Properties F-3 Spray Attemperator Fog Connective Module F-7 Divider Module F-8 Drum Boiler F-10 Economizer F-20 Feedwater Heater F.25 High Pressure Turbine F-33 Intermediate and Low Pressure Turbine F.37 Steam Attemperator F-38 Superheaters and Reheater F238 Valve F-42 References F-45Figure 21 3.1 32 3:3 34 35 346 37 4-1 4-2 4-3 4-5 4-6 47 48 4-9 4-10 cote 4-12 413 44 4-15 ILLUSTRATIONS Bypass System Diagram Steam Plant Kinetics Program Simplified Flow Chart Secondary Superheater Outlet Tenperature for Variable Pressure Operation Reheater Outlet Temperature for Variable Pressure Operat ion Secondary Superheater Outlet Tenperature for Constant Pressure Operation Reheater Outlet Temperature for Constant Pressure Operation Secondary Superheater Qutlet Tenperature for Qual Pressure Operation Reheater Qutlet Temperature for Dual Pressure Operation Turbine Operation Summary - Tes: 8 - 3/19 Boiler Operation Summary - Test 8 - 3/19 Turbine Operation Summary - Tes: 8 - 3/20 Boiler Operation Summary - Test 8 - 3/20 Turbine Operation Summary - Test 24 - 5/7 Boiler Operation Summary - Test 2A - 5/7 Turbine Operation Summary - Test 24 - 5/8 Boiler Operation Summary ~- Test 2A - 5/8 Turbine Operation Summary - Test 28 - 5/14 Boiler Operation Summary - Test 28 - 5/14 Turbine Operation Summary - Tes: 28 ~ 5/15 Boiler Operation Summary - Test 2B - 5/15 Fuel Flow - Test 2A - 5/8 Fuel Flow - Test 2B - 5/15 Stean Temperature Control Using Steam and Water Attemperation Steam Temperature Control Using Steam and Water Attemperat ion Ki Page 23 37 3-8 3-10 3-11 4-3 4-3 44 a4 4-6 4-6 47 47 48 4-8 4-9 49 4-10 anFigure 4-17 4-18 4-19 4-20 4-21 4-22 4-23 4-24 4-25 4-26 4-27 4-28 4-29 4-30 4-31 4-32 4-33 4-34 4-35 4-36 4-37 4-38 4-39 4-40 4-41 4-42 ILLUSTRATIONS (Continued) Turbine Operation Summary - Test 1 - 6/2 Boiler Operation Summary - Test 1 - 6/2 Fuel Flow - Test 1 - 6/3 Turbine Operation Summary - Test 1 - 6/3 Boiler Operation Summary -Test 1 - 6/3 Throttle Steam Temperature Control with Spray Water Attemperation ~ 6/3 Throttle Steam Temperature Control with Spray Water Attemperation ~ 6/3 Turbine Operation Summary - Test 3 - 6/4 Boiler Operation Summary - Test 3 - 6/4 Throttle Steam Temperature Control with Spray Water Attemperation - Test 3 - 6/4 Throttle Steam Temperature Control with Spray Water Attemperation - Test 3 - 6/4 Fuel Flow - Test 3 - 6/4 Turbine Operation Summary - Test 7 - 6/2 Boiler Operation Summary - Test 7 - 6/2 Fuel Flow Test 7 Turbine Operation Summary - Test 6 - 8/4 Fuel Flow - Test 6 - 8/4 Turbine Operation Summary - Test § - 6/11, 6/12 Boiler Operation Summary - Test 5 - 6/11, 6/12 Turbine Operation Summary - Test 5 - 6/12 Boiler Operation Summary - Test 5 - 6/12 Fuel Flow - Test 5 - 6/12 Turbine Operation Summary - Tes: 4 - 8/4 Turbine Operation Summary - Tes: 4 - 8/5 Fuel Flow ~ Test 4 - 8/5 Drun Metal Temperatures During Startup - Test 1 xii Page 4-14 4-14 4-15 4-16 4-16 4-17 4-19 4-19 4-20 4-20 4-21 4-22 4-22 4-23 4-24 4-24 4-26 4-26 4-27 4-27 4-29 4-29 4-30 4-30 4-33Figure 4-43 4-44 4-45, 4-46 4-47 4-48 4-49 4-50 4-51 4-52 4-53 4-54 4-55 4-56 4-57 4-58 4-59 4-60 4-61 4-62 4-63 4-64 ILLUSTRATIONS (Continued) Drum Metal Temperatures During Startup - Test 3 Feedwater Flow and Temperature During Startup - Test 1 Feedwater Flow and Temperature During Startup ~ Test 3 Drum Metal Temperatures During Startup - Test 7 Platen and Primary Superheater O.tlet Header Temperatures - Test 1 Platen and Primary Superheater Outlet Header Temperatures - Test 3 Reheat and Secondary Superheater Outlet Header Temperatures - Test 1 Reheat and Secondary Superheater Outlet Header Temperatures - Test 3 Reheat and Secondary Superheater Outlet Header Tenperatures - Test 7 Platen and Primary Superheater Outlet Header Temperatures - Test 7 Feedwater Flow and Temperature - Test 7 Windbox Temperatures - Test 1 Windbox Temperatures - Test 3 Windbox Temperatures - Test 7 Typical Boiler Drum Pressure Decay Temperature Difference Between Rotor and Cylinder at First Reaction Stage High Pressure Turbine Temperature Difference Between Rotor and Cylinder at Third Stage Intermediate Pressure Turbine Data Acquisition System Block Diagram Daily Sunmary Plot of Turbine Data Daily Summary Plot of Boiler Data Automatic Turbine Control Alarms Startup Summary and Load Distribution Page 4-34 4-35 4-36 4-37 4-38 4-39 4-40 4-41 4-42 4-43 4-44 4-46 4-46 4-50 4-50 4-52 4-52 4-53 4-57 4-58 4-58 4-59Figure 4-65 5-6 5-7 5-8 5-9 5-15 5-16 517 5-18 ILLUSTRATIONS (Continued) Page Typical Data Reduction - Program II Plot 4-60 HP Turbine Inlet Conditions for a Cold Start - 7/18 5-3 HP Turbine Steam Temperatures for a Cold Start - 7/18 5-4 HP Turbine Steam Pressures for @ Cold Start - 7/18 5-4 IP Turbine Steam Tenperatures for a Cold Start = 7/18 5-5 Comparison Between Calculated and Measured Rotor Bore Temperatures for a Cold Start - Generator End Gland Region - 7/8 5-5 Comparison Between Calculated and Measured Rotor Bore Tenperatures for a Cold Start - HP Exhaust 5-6 Comparison Between Calculated and Measured Rotor Bore Temperatures for a Cold Start - First Reaction Stage-7/18 5-7 Comparison Between Calculated and Measured Rotor Bore Temperatures for a Cold Start - Contr) Stage - 7/18 5-7 Comparison Between Calculated and Measured Rotor Bore Temperatures for a Cold Start - IP Dummy - 7/18 5-8 Comparison Between Calculated and Measured Rotor Bore Temperatures for a Cold Start - IP Rotor Inlet = 7/18 5-8 Comparison Between Calculated and Measured Rotor Bore Temperatures During Cold Start - IP Third Stage - 7/18 5-9 Comparison Between Calculated and Measured Rotor Bore Temperatures During Cold Start ~ IP Fifth stage - 7/18 5-9 Comparison Between Calculated and Measured Rotor Bore Temperatures During Cold Start ~ IP Exhaust 5-1 Comparison Between Calculated and Measured Rotor Expansion During cold start 512 Rotor Temperature Distribution on Turning Gear 5-13 Rotor Tenperature Distribution During Speed Control = 2200 RPM 5-13 Rotor Tenperature Distribution After Synchronization 5-14. Comparison Between Calculated end Neasured Rotor Temperatures: Steady State-Full Power Bald HP-IP Inner Cylinder Temperature Comparison at Low Load (105 MW) 5-18 rivFigure 5-20 5-21 5-22 5.23 5-28 5-25 5-26 5-27 5-28 5-29 5-30 5-31 ILLUSTRATIONS (Continued) HP-IP Inner Cylinder Temperature Comparison at High Load (569 MN) Comparison Between Calculated and Measured HP Turbine Cylinder Temperatures During Cold Start = Impulse Zone, Governor End Comparison Between Calculated and Measured HP Turbine Cylinder Temperatures During Cold Start = Impulse Zone, Generator End Comparison Between Calculated and Measured IP Turbine Cylinder Temperatures During Cold Start ~ HP Exhaust, Comparison Between Calculated and Measured HP Turbine Cylinder Temperatures During Cold Start = IP Extraction Comparison Between Calculated and Measured Temperatures Low Pressure Turbine Blade Ring No. 1 - 105 MW Steady State Comparison Between Calculated and Measured Temperatures Low Pressure Turbine Blade Ring No. 1 - 465 Mil Steady State Comparison Between Calculated and Measured Temperatures - LP Turbine Inner Cylinder ~ 357 MW Steady State Comparison Between Calculated and Measured Temperatures - LP Turbine Inner Zylinder Near Vertical Centerline Base - 357 WW Steady State Comparison Between Calculated and Measured Temperatures - LP Turbine Inner cylinder Near Vertical Centerline Cover - 357 YW Steady State Comparison Between Calculated and Measured Throttle Pressure and Temperature and Reheat Temperature Response to a Step Decrease in Fuel Flow - 500 MW Comparison Between Calculated and Measured Feedwater Flow Response to a Step Decrease in Fuel Flow - 500 MW xv 5-20 5-20 5-21 5-21 5-22 5-23 5-24 5-25 5-25 5-31 5-31Figure 5-32 5-33 5-34 5-35 5-36 5-37 5-38 5-39 5-40 5-41 5-42 ILLUSTRATIONS (Cont fnued) Comparison Between Calculated end Measured Throttle Pressure and Temperature and Reheat Temperature Response to a Step Decrease in Superheater Spray Flow - 500 MM Comparison Between Calculated end Measured Spray and Feedwater Flow Resporse to a Step Change in Superheater Spray Flew - 500 MW Comparison Between Calculated end Measured Throttle Pressure and Temperature and Reheat Temperature Response to a Step Change in Fuel Flow - 250 MW Comparison Between Calculated and Measured Feedwater Flow Response to a Step Decrease in Fuel Flow - 250 MW Comparison Between Calculated and Measured Throttle Pressure and Temperature and Hot Reheat Temperature Response to a Step In- crease in Gas Recirculation - 250 MW Comparison Between Calculated and Measured Feedwater Flow Response to a Step Increase In Gas Recirculation - 250 MW Comparison Between Calculated and Measured Throttle Pressure and Temperature and Reheat Temperature Response to a Step Decrease in Superheater Spray Flow - 250 Mi Comparison Between Calculated and Measured Spray and Feedwater Flow Response to a Step Change in Spray Flow - 250 MW Comparison Between Calculated and Measured Throttle Pressure and Temperature and Reheat Temperature Response to Opening the 501 Valve = 250 MW Comparison Between Calculated and Measured Feedwater Flow Response to Opening the 501 Valve - 250 MW Comparison Between Calculated and Measured Throttle Pressure and Temperature and Reheat Temperature Response to a Step Decrease in Fuel Flow - 125 MW ai 5-34 5-35 5-35 5-35 5-36 5.37 5-37 5-37 5-38 5-38 5-39Figure 5-43 5-44 5-45 5-46 5-47 5-48 5-49 6-1 6-2 6-3 6-4 6-5 6-6 6-7 6-9 6-10 6-11 6-12 ILLUSTRATIONS (Continued) Comparison Between Calculated and Measured Feedwater Flow Response to a Step Decrease in Fuel Flow - 125 Mit Comparison Between Calculated and Measured Throttle Pressure and Temperature and Reheat Temperature Response to a Step Lecrease in Superheater Spray Flow - 125 MW Comparison Between Calculated and Measured Spray and Feedwater Flow Response to a Step Decrease in Superheater Spray Flow - 125 Mil Comparison Between Calculated and Measured Throttle Pressure and Tenperature and Reheat Temperature Response to Opening the 518 Valve = 125 Mi Comparison Between Calculated and Measured Feedwater Flow Response to Opening the 518 Valve - 125 Mi Throttle Pressure and Load for Startup Simulation Superheater Outlet Temperature for Startup Simulation Turbine Operation Summary - 10/14, 10/15 Boiler Operation Summary - 10/14, 10/15 Turbine Operation Sunmary - 10/15, 10/16 Boiler Operation Summary - 10/16 Fuel Flow ~ 10/15 Drum and Throttle Pressure and Saturated Steam Dump Valve Position for Hot Start - 10/15, 10/16 Turbine Operation Summary - 9/29, 9/30 Boiler Operation Summary - 9/29, 9/30 Main Steam Temperature Control Using Steam Attemperator ~ 9/29 Reheat Steam Temperature Control Using Steam Attemperator - 9/29 Fuel Flows - 9/29 Turbine Sunmary Plot of Load Following Combined with Two Shift Operation ~ 2/18, 2/19 xvi Page 5-39 5-40 5-40 5-a1 5-1 5-44 5-44 6-3 6-3 6-4 6-5 6-5 6-6 6-7 6-8 6-9 6-10 6-106-16 6-17 Ael a2 a3 a4 A-6 AAT AB Ad A-10 Ae12 A13 Aad AAAS AA16 A-W7 ILLUSTRATIONS (Continued) Superheater Outlet and Throttle Steam Temperature During Loading - Tests 2A and 23 Superheater Outlet Temperature Response Prior to Rolling Turbine Boiler Feedpump Turbine Speed Control With and With 501 Valve Rotor End Cooling with and without Vacuum Turbine Cylinder Cooling with and without Vacuum Rotor Bore Thermocouple and Support System (Spider) Prior to Installation in Rotor Detail of Spring Loaded Thermocouple Support View of Thermocouple Support Showing Thermocouple Attachment Stationary Telemetry Antenna Rotating Telemetry Antenna Telemetry Transmitter and Antenna Assenbly Rotor Bore Telementry Block Diagram Telemetry Antenna and Associated Electronic Equipment r Bore Telemetry Test Telemetry Antenna Mounted to Rotor in Heater Box Test Facility Comparison Between Measured Temperatures from Heater Box Test and Calculations During Shutdown Telemetry Transmitter Calibration Test Block Diagram Typical Speed Sensitivity of Faulty Rotor Bore Temperature Measurement. Instrumentation Interconnection Diagram Longitudinal Section of Turbine with Thermocouple Locations Multiple Sensing Head Thermocouple Assembly Thermocouple Installation for Single High Pressure Turbine Thermocouple Heater Box Test Facility for R aii 6-17 6-21 6-21 a2 Ad Aq12 Ald A-16 AA19 4-32 A-33 38Figure A-18 19 20 Ae21 AA22 A-23 Ae24 B-l oa 0-3 0-4 0-5 0-6 0-7 Fel F3 Fa F5 F-6 ILLUSTRATIONS (Continued) Thermocouple Installation and Wire Routing at the Horizontal Joint of the High-Intermediate Pressure Turbine Thermocouple Wire Routing on the High-Intermediate Pressure Turbine Inner Cylinder Detail of Thermocouple Wire Routing Transition fron Inner to Quter Cylinder of High-Intermediate Pressure Turbine Installation of High-Intermediate Pressure Turbine Outer Cylinder Thermocouple Prior to Adding of Insulation Typical Thermocouple Installation and Wire Routing in the Low Pressure Turbine Typical Thermocouple Installation and Wire Routing in the Extraction Regions of the Low Pressure Turbine ‘View Showing Thermocouple Wire Transition from Inner to Outer Cylinder in the Low Pressure Turbine Data Acquisition System Block Diagram TURBLP - Macro Structure First Blade Group Extraction Point Blade Group 8GR2 Blade Group BGREAC Plant Model Schematic Plant Model Schematic Spray Attemperator Model Connective Flow Model Flow Divider Model Drum Boiler Model Economizer Model Feedwater Heater Model Feedwater Heater Model xix Page A235 A-36 4-37 4-38 39 AAO coy 83 0-26 0-27 p-27 0-28 0-28 0-37 0-38 FT Fo Fell F-21 F-26 F-26Figure F-8 F.9 F-10 Fell Fez ILLUSTRATIONS (Continued) Feedwater Heater Model Feedwater Heater Model High Pressure Turbine Model Sequential Valve Model Superheater Model xTable, 1 at a2 43 4 54 6-1 Al hee Fa TABLES Test Program Cyclic Operation Tests Summary of Two-Shift Operation Tests Summary of Operating Hours Number of Starts at Various Values of Temperature Comparison Between Plant and Model Initial Conditions Fuel Flows During Start-Up Telemetry System Status (July, 1979) Instrumentation List Boiler Model Input Parameters Ratio of Two-Phase to Single-Phase Frictional Pressure Loss xxi Page 1-3 4-61 4-62 4-63 4-64 5-45 6-22 Als A-20 o-2 F-15NOMENCLATURE specific heat meval specific heat water diameter hydraulic diameter heat transfer coefficient, enthalpy seal height equation constar Tength moisture fraction mass speed, rpm pressure Prandtl Number heat flow radiative heat flow thermal conductivity convective heat flow heat flow at wall Reynolds Number radius time temperature internal energy effective heat transfer coefficient volume, velocity specific volume mass flow steam quality valve position constant xxGREEK SYMBOLS seal clearance dynamic viscosity kinematic viscosity density angular velocity avfe ge gl se sl wl ww susscziPTs air deun fluid, fuel furnace exit gas entering gas leaving heater inner liquid metal outer riser saturated steam steam entering steam leaving water entering water leaving water walls and enclosure xviiSUMMARY This program has as its overall objective the improvement in the economy and reliability of cyclic operation of turbines and boilers. Toward this objective, ‘this study has produced the following infornation based on data collected from the Conmonwealth Edison Company's Collins Station Unit 5, © Continuous data collection for a period of 15 months in a cyclic duty plant. © Validation of turbine component temerature distribution modeling techniques. © Validation of major elements of the boiler model. © Cyclic operating recommendations for the Collins Station Unit No. 5. © Cyclic operating reconmendations for the Electric Utility industry. An unattended Data Acquisition System continuously monitored 249 variables and stored the data on magnetic tapes, changed on a weekly basis. A series of data reduction programs converted data to engineering units and provided summaries of the operation on daily and total project bases. The analysis techniques used to predict turbine component temperature distributions were validated using measurements of both tionary component and rotor metal ‘temperatures. The rotor bore measurements were obtained using radio telemetry. This is the first time that this has been successfully performed on an operating steam turbine. These temperature distributions are the bas’s for thermal stress analysis of cyclic operation. The data was analyzed using various computerized heat conduction pro- grams. The heat transfer coefficient corre’ations used produced good agreement with measured data.In addition, a boiler model was developed for studying transients in cyclic oper- ation. The model was extensively detailed for the boiler components but simplified for the turbine and feedwater system, A series of open loop tests, conducted to validate this model, consisted of small perturbations of one variable at a time with as many of the controls manually controlled as possible. These perturbations con- sisted of changes in spray flow, turbine throttle steam flow, air flow, fuel flow, and division valve position, These changes were approximately one to five percent. Test results and calculations were in general agreement. In areas where modeling improvement are required, the necessary modifications are identified. Successful modeling of loading ramps was not possible because of problems identified by the open loop test analysis. This modeling and validation data collection effort represents a significant step towards successful transient modeling of cyclic duty boilers. A series of eight cyclic operation tests was conducted to test various cyclic operation strategies. The cyclic life expenditure of the turbine and boiler was estimated for these transients from either a direct temperature measurement or by calculations. The fuel flows were also compared to identify major variations during the startup and loading phases of these tests. Based on analysis of these transients, and a combination of economic, cyclic life expenditure, and plant operating preference considerations, a recommended operating procedure for the Collins unit was developed. These recommendations are directed towards maximizing advantages of the station equipment. Based on the experience gained from analysis of the cyclic operation tests and additional calculations, a series of operating recommendations was developed for the electric utility industry. These reconmendations are broad in scope and attempt to define factors that should be considered when designing a cyclic duty plant, or converting an existing plant to cyclic duty, The validation of the temperature distribution analysis technique, the boiler modeling effort, and the cyclic operation test experience provide an excellent basis for analyzing cyclic operation at any plant. CONCLUSIONS The objective of providing information to improve the reliability and economy of cyclic operation in turbines and boilers was achieved.Heat transfer coefficient correlations for rotors and stationary parts were validated for use in predicting turbine temerature distributions. The correlation in many instances reproduced measured temperature within + 10°F. Temperature distribution calculations are important because they are the first step in predicting thermal stresses and cyclic life in turbines and boilers. A particular modeling technique was developad and applied to the Collins Station Unit 5. The modeling technique was evaluated using the results of open loop tests at three load levels, The tests indicated the following areas need improvement: © Convection heat transfer formulation. © The pressure response of the model was much faster than the plant. @ Numerical calculation errors associated with the word size of computer used. These changes should be implemented in some future effort and the boiler model updated. This would then allow the use of this boiler modeling technique for predicting the pressure and temperature reszonse of cyclic plants. This information could then be used for cyclic life evaluation of turbine and boiler components. Reconmendations for Collins Station operating procedures are based on these tests, and input from the plant operating personnel and the boiler and turbine manufacturer's, These procedures will allow loading at 2 per minute and a light off to 95% load time of two and one-quarter hours. In addition, the reconmended procedures minimize fuel flow both during Tow Toad operation of the unit and during starting. The experience and information gained during testing and analysis has been extended to operating considerations for other cycliz duty plants. The following kinds of information will be useful for plant design, conversion of existing plants and identifying duty cycle: © Percent time at load. @ Daily maximum loading and unloading rates. © Daily maximum rates of steam temperature change. @ Daily initial values of turbine rotor and cylinder temperatures. $-3Steam temperature control during loading was a major problem in this test program. Indications are that this problem exists in other plants, The data obtained on the response characteristics of superheaters and reheaters is useful input for the development of better automatic control systems. These systems should be digital to facilitate field tuning. The data acquisition system operated successfully in the unattended mode, The experience gained is documented for future Field test programs, On-line plotting of the shutdown and startup permitted quick analysis of the transient. Since cyclic duty plants shutdown and restart at hours when the plant technical staff is generally not available, plots of key variables provide an excellent record and analysis tool. The rotor bore telemetry system operated quite well considering that it was a prototype design. This design could be further developed and applied to turbines on @ routine basis, S-4Section 1 INTRODUCTION PROGRAM OBJECTIVES The desire to operate large fossil steam generating plants in a cycling mode is becoming more prevalent as nuclear generating capacity and fuel costs increase. New fossil units in the 500 MW class are being specified for cyclic duty. In addition, older units are being assigned to cyclic duty after years of base load operation. Cyclic operation can be broken into two general classes: two-shift and load following. In two-shift operation, the unit is tripped off line, generally in the evening, and restarted the next day. The unit is generally out of service 6 to & hours, In load-following operation, the unit is not tripped, but the load is varied to meet system requirements. In practice, combinations of these two modes of operation occur. Cyclic operation in any form requires more extensive engineering analysis than does base load operation because plant behavior must be predicted and the corresponding component low cycle fatigue analyzed. The major components that require study are the boiler and turbine, The plant behavior can be predicted using computer models which predict the response and the interaction of the various components in a power plant during transients. The specific transients in question are the unloading and restarting transients as opposed to the more rapid response transients such as unit trips and overspeeds. Once the plant behavior is defined in terms of flows, pressures and temperatures, component thermal stresses can be analyzed using analytical or computerized solutions depending on the complexity of the model, and the transient. The thermal analysis of turbine parts requires the ability to predict surface heat transfer coefficients. This thermal analysis is the first step in calculating stresses for cyclic life prediction. LlSince fuel costs are high and are expected to continue rising, the operating philosophy must not overlook the plant performance in the interest of being too Conservative in minimizing thermal stresses. The thermodynamic effects of part load operation for the various modes of operation commonly used in cyclic operation is discussed in Reference 1, Differences in heat rate of 200 Btu/kW-hr are possible. The data collected during this project denonstrates that part load performance is a significant factor in cyclic operation. To provide the electric utility industry with tools for studying various models of operation, this project, "Metal Temperature and Thermal Stress in Cyclic Turbines and Boilers," was initiated, This project had the following objectives: @ Validate plant modeling techniques. @ Validate turbine heat transfer coefficients. @ Develop operating recommendation for cyclic duty. © Develop a history of cyclic duty operating data to be used as a resource by the utility industry. The data for study and validation of models was gathered on a continuous basis for a period of 15 months at Commonwealth Edison Company's Collins Station Unit No. 5. The cyclic operation tests and the boiler model validation tests are listed in Table 1-1, 1-2Table 1-1 TEST PROGRAM cyclic Testing Hybrid Operation, Hybrid Operation Using Division Valves. Single Valve Operation Using Division Valves. Constant Pressure Operation. Constant Pressure Operation Using Bypass System, Start After Weekend Outage, Start After Weekend Outage Using Bypass System. Hybrid Operation With Modified Throttle Pressure - Load Ramp. Model Validation Tests 500 MW © Firing Rate Reduction. © Air Flow Increase. @ Gas Recirculation Flow Increase, © Main Steam Attemperating Spray Flow Decrease. © Reheat Steam Attemperating Spray Flow Decrease, @ Turbine Control Valve Position Increase. 250 MW © Firing Rate Reduction, © Air Flow Increase, © Gas Recirculating Flow Increase, © Main Steam Attemperating Flow Decrease. Reheat Steam Attemperating Spray Flow Increase. © Division Valve Position Increase, 125 Mi Firing Rate Reduction. © Main Steam Attemperating Steam Flow Increase. © Reheat Steam Attemperating Steam Flow Increase. © Main Steam Attemperating Spray Flow Decrease. @ Division Valve Position Increase, 13Section 2 DESCRIPTION OF PLANT The Collins Unit No. 5 is a 505 MW unit, The turbine was manufactured by Westinghouse Electric Corporation and the boiler by the Babcock and Wilcox Company. The boiler is oil fired but is convertible to coal. The unit has three one-half capacity boiler feedpump turbines. Two feedpumps are turbine driven and one is motor driven, The steam for the steam driven pumps is taken from the main steam line, The gland steam system is supplied from main steam of one of the five boilers in the plant, Vacuum is generally maintained when the unit is off-line, The boiler is isolated by a series of valves after a unit trip. The turbine systen consists of a combined high pressure (HP) and intermediate pressure (IP) turbine. There are two double flow low pressure (LP) turbines. Seven stages of feedwater heating are supplied fron turbine extractions, The turbine is controlled using a Digital Electro-Hydraulic (EH) control system. This system provides a governor valve management feature for bumpless transfer between single and sequential valve operation at any time during operation, The DEH control system is capable of automatic speed and load control with rates of change based on a continuous calculation of existing and anticipated rotor stress in the HP and IP turbines. The boiler is a natural circulation type unit with 28 dual register burners on the front and rear walls. The unit uses air diversion ports and gas recirculation to the windbox for NO, control. The maximum continuous capacity is 4,000,000 Ib/hr (500 Kg/Sec) main steam flow at 2400 psig (16,548 kPa) and 1005°F (541°C), The boiler can supply dry auxiliary steam from either the drum or superheated steam fron the main steam line for off-line gland seals ‘and other uses. The boiler is designed for cyclic duty with capability for constant or variable pressure operation. 21The unit is equipped with a bypass system (Figure 2-1). This system is capable of various modes of operation designed to control drum and throttle Pressure and steam temperatures. This system permits the following operations: © Separate control of throttle and drum pressure by use of the 500 and 501 valves, © Higher steam temperatures at low flows (pre-loading) by using the combination of firing to maintain gas temperature and the 502 valve to control pressure. © Improved steam-turbine metal temperature matching for lower turbine temperatures during cold and warm starts by using the 518 valve at Tow flows. ¢ Improved control of reheat temperature by using the 519 valve. The unit is equipped with an analog control system for integrated boiler turbine control. This system is capable of converting load dispatcher signals into parallel demands to the turbine and boiler, The turbine control subsystem is capable of interfacing with the turbine DEH control system, for separate control of drum and control valves and the 501 valve (refere Subsystem controls fuel flow prior to synchronization to give a desired furnance gas exit temperature. After synchronization, fuel flow is based primarily on the load index, with correction from throttle or drum pressure, depending on the mode of operation. Boiler-follow, turbine-follow or integrated system mode may be selected after synchronization. rottle pressure, by using the turbine Figure 2-1). The firing demand The reheat temperature control operates gas recirculation dampers and reheat: spray valves. At low flows, the 519 valve can be used to control reheat outlet ‘temperatures. The superheat temperature control regulates a variety of startup and on-line conditions. The system can use the 518 valve at low steam flows. Water attemperation is the general method of controlling steam temperature. The set point for main steam and reheat steam temperature is the same. However, a bias can be introduced into the reheat temperature control.HP TURBINE Pale CONDENSER DRUM Figure 2-1, Bypass System DiagramSection 3 ANALYTIC MODELS Two analytical modeling schemes were used in this program, The first is the Boiler Model. This model was developed as part of this program and is described in detail, The second is referred to as the Turbine Model is an existing proprietary computer code. This model was used to simulate the turbine response only using boiler characteristics supplied by the boiler manufacturer, The Boiler Model included a simplified turbine model to provide sufficient flow and temperature input to the Boiler Model, BOILER MODEL The Boiler Model as developed except for minor modifications, uses the B & W Modular Modeling system. The model was used to simulate the open loop tests and modifications for the startup and shutdown are described in Section 5, The model is written in ASCL, a similation language. The components modeled in detail are as follows: © High Pressure Feedwater Heater. © Drum and Furnace. © Primary Superheater. © Platen Superheater, © Secondary Superheater. © Reheat Superheater, © High Pressure Turbine, © Intermediate Pressure Turbine. © First and Second Stage Kater-Spray Attemperators with Valves. © Saturated Steam Attemperators with Valves,© Division Valve (501 Valve). © Saturated Steam Dump Valve (502 Valve). The boiler feedpump, deaerator and the remaining feedwater heaters are modeled with much less detail. ‘Steam properties are generated by curve fits. Some are single function, and some are over regions matched at the boundaries. When using an implicit, variable step integration algorithm, smoothness is very important. Any discontinuities, Particularly in pressure, will result in drastic increases in computational cost. The following paragraphs discuss the major assumptions of the model. The detailed equations and logic are developed extensively in Appendix F. Spray Attemperator The attenperator sprays water into the steam path to reduce temperature. The calculation includes pressure loss through the steam path and pressure loss through the spray control valves and spray nozzles. The equations make the following assumption: © Water and steam flows are turbulent. © Flows do not reverse. Connective Module The connective module is not a physical model. It performs the strictly mathe. matical function of allowing other modules to be interconnected, Some modules require upstream and downstream pressures in order to calculate a flow rate. The connective module provides for the interconnection of these modules and ensures a Properly defined pressure so that the flow rates through the two modules will be equal. Divider Modute The divider module permits the use of branches with as many as nine separate flow paths. This module has no flow resistance and cannot store mass or energy.Drum Boiler This module models the steam generation po-tion of a natural circulation drum-type boiler. The model is applicable to all tyzes of boiler fuels. The model does not calculate flue gas flow dynamics. The water side is a single downcomer-riser loop. The model assumes perfect steam separation. User supplied data will show the effects of steam/feedwater mismatches, and shrink and swell. This module has three general interconnections: air side modules (such as air preheaters and fans), water and steam side components (economizer and superheater) and fuel handling equipment. The following assumptions are built into this module: © Feedwater does not mix or exchange eneray with resident water inside steam drum prior to being drawn down the downconer. @ Homogeneous two-phase flow is assumed. © The entire tube side portion of saturation temperature. e riser is assumed to be at the © The rate of change of internal energy and enthalpy are assumed to be equal in the riser, © The drum has perfect separation. © The flue gas is an ideal gas. Time constants associated with changes in flue gas mass storage are negligible. © Thermal radiation is the dominate furnace heat transfer mechanism. © Flows do not reverse, Economizer The heat transfer to the flue gas side of the economizer is by radiation and convection. Tube side is by convection only. This module calculates pressure drop fon the feedwater side for an established flow. The assumptions used in developing the economizer model are as follow: © Flue gas mass storage is negligible. © Connecting piping and headers follow the water temperature.@ ALT Flows are turbulent. © There is negligible difference between specific internal energy and enthalpy. © — Subcooled water properties are identical to saturated properties at the saturated fluid enthalpy equal to the subcooled fluid enthalpy. Feedwater Heater This module simlates a shell and tube feedwater heater with distinct regions for drain cooling, condensation and desuperheating, The module computes the flow rate through the tubes but requires entering and leaving drain flows, and heating steam flows as inputs. The shell side of the heater is a mass storage device with no pressure loss. The drain valve and level control must be provided externally to the module. The following assumptions were used in developing the model. © to reverse flows. © Wh drain Flashing. © Liquid-vapor equilibrium, # The tube side flow rate fs unifom through the tube, Horizontal heater. © All flows are turbulent. High Pressure Turbine The high pressure turbine model developed for use with the boiler model is greatly simplified, However, the formulation is assumed adequate for the purpose intended. The model consists of a governing valve, an impulse control stage and a variable number of reaction blade groups. Extraction points may be placed between the blade groups. The model does not include a turb‘ne control system. The model of the governing valves and control stage does permit sequential valve Operation with partial arc. The tested unit is capable of either single or sequential valve operation.The modeling permits the calculation of flow rates and efficeincy for off design conditions. This is accomplished without the use of proprietary information from available heat balance information. Intermediate and Low Pressure Turbine This model represents a series of reaction blade groups in the same manner as the reaction blade portion of the HP turbine. The interceptor valve is not modeled. Steam Attenperator This module mixes steam from two sources, The application is the low load steam ‘temperature control of main and reheat stean temperatures by mixing with saturated steam from the drum of the boiler. The enthalpy leaving the module is calculated from conservation of energy, Superheaters and Reheaters A single module is developed for use with any gas to steam heat exchanger. These components all assume cross-flow type heat exchangers, transferring heat between gas and a compressible single phase fluid on tha tube side, In modeling of boilers it may be desirable to divide the primary superheater into two or three modules for greater resolution. This module permits this division, The solution uses the following assumption: © Flue gas mass storage is negligible. @ Connecting piping and headers fol’ow the steam temperature. © The steam flow may be assumed to be incompressible. @ ALI flows are fully developed turbulent. Radiation and convective heat transfer is used, A single node metal mass model is used for heat transfer and metal mass storage. Valve This module represents a valve with steam flowing with sufficient pressure drop that compressibility is considered. The module can be a model of any type of valve.The following assumptions are included: © Fully turbulent flow. © Flows do not reverse, © Steam is treated as an ideal gas for flow rate calculation. @ The flow is adiabatic, # Mass storage is negligible, TURBINE MODEL The turbine and feedwater system was modeled using the Westinghouse Dynamic Steam Plant Kinetics computer code (SPK). SPK is also a Modular Modelling Program that includes components of the required types. The exact formation of this program is not presented in this report. This model provides more detailed information in the turbine than does the model used in the boiler model. Figure 3-1 is a simplified flow chart of SPK. The SPK model includes models of feedwater heaters, valves, condensers, pumps, mass storage devices, turbine and turbine control systems. Considerable effort is built into the exact modeling of the control system including the feedback loops. In addition, proprietary information on blading performance is included to more accurately characterize off design performance. In addition to components that describe the fluid behavior, SPK includes a heat conduction model for the turbine temperature distribution calculation. The heat transfer correlations, validated in this model, are built into the SPK program. The boiler model in SPK was not used in tris study. Boiler parameters were supplied by BaW for use in conjunction with SPK, These parameters consisted of main steam and reheat temperature - flow curves with parameters of gas recirculation. These curves are shown in Figures 3-2 through 3-7. Before cyclic testing at Collins, SPK was exercised using the input boiler parameters to study transient behavior. This approach was used for various modes of operation to determine the following items:Allowable loading and unloading rates. Overnight cooling, Locations of maximum stress, T INTIAUIZATION -——+cureur [perTuRsarion| STEAM HEAT vatves | | trans fl suneine | |eclteATo en 8 isren || Pipes | ___+f oureur No. i ‘srmeots: =TME be) Tu = TIME Liner . No'= NUMBER OF STATION: ror INTHE CYCLE. Figure 3- . Steam Plant Kinetics Program Simplified Flow Chart 347The heat transfer validation work discussed in Section 5 was done using one of the two dimensional and axisymmetric heat conduction programs available. This type of Program is better suited to this type of analysis than the program built into SPK. However, the modeling in SPK has sufficient accuracy for studying, on a parametric basis, the cyclic life expenditure for various operating procedures. 10004 a 900-4 a MINIMUM TEMPERATURE s BASED ON MINIMUM 2 soo GAS RECIRCULATION z / 2 / é 700+ / ivimum TempenaTuRE wiTH / STEAM ATTEMPERATION. 6004S 20 6 ~~ «80~—=—«100 PERCENT OF MAIN STEAM FLOW (100% = 4x 108 LB/HR) Figure 3-2, Secondary Superheater Qutlet Temperature for Variable Pressure Operation 381000-4 900-4 E $ ‘MINIMUM TEMPERATURE ol BASED ON MINIMUM = GAS RECIRCULATION z 7004 F t / MINIMUM TEMPERATURE WITH 600] STEAM ATTEMPERATION : — 80 100 PERCENT OF MAIN STEAM FLOW (100% = 4x 108 LB/HR) Reheater Outlet Temperature for Variable Pressure Operation 10004 ® MINIMUM TEMPERATURE i BASED ON MINIMUM & GAS RECIRCULATION 2 6004 l E o / 5 / = 700 r / MINIMUM TEMPERATURE WITH / STEAM ATTEMPERATION 600+ PERCENT OF MAIN STEAM FLOW (100% = 4x 108 LB/HR) 00 oe SCSSCSSCO Figure 3-4, Secondary Superheater (utlet Temperature for Constant Pressure Operation 39‘MINIMUM TEMPERATURE BASED ON MINIMUM GAS RECIRCULATION / 7 MINIMUM TEMPERATURE WITH ‘STEAM ATTEMPERATION —/ 9$8.004¢@ 3 1000-4 00-4 a z 2 8004 = o = 2 r004 600 Figure 3-5 Operation 10004 900-4 e = 2 800+ 5 a 2 = £700. 600. 500 ° Figure 3-6, 20 6 160) PERCENT OF MAIN STEAM FLOW (100% = 4x 108 LB/HR) Reheater Outlet Temperature for Constant Pressure MINIMUM TEMPERATURE BASED ON MINIMUM GAS RECIRCULATION / MINIMUM TEMPERATURE WITH _j STEAM ATTEMPERATION PERCENT OF MAIN STEAM FLOW (100% = 4x 10° LB/HR) pe 20 rr) Secondary Superhes r Outlet Temperature for Dual Pressure Operation1000-| p00 wh : INIMUM TEMPERATURE E8004 BASED ON é MINIMUM GAS RECIRCULATION : E1004 7 /winimum TEMPERATURE WITH coo] _/ STEAMATTEMPERATION / —) soo} wa 7 PERCENT OF MAIN STEAM FLOW (100% = 4x 108 LB/HR) Figure 3-7. Reheat Outlet Temperature for Dual Pressure OperationSection 4 CYCLIC TEST PROGRAM PHILOSOPHY OF TEST PROGRAM A series of tests were planned to evaluate the cyclic life expenditure, overall fuel costs and operational difficulties associated with various methods of cyclic operation, These tests included two shift operation and weekend starting. The tests are tabulated in Table 4-1. The tests were planned jointly between the host utility and the contractors. The test program attempted to maximize the use of the special design features of the plant, as well as to provide data for units which lacked these particular features. However, all tests were conducted within the following host utility guidelines, © 10,000 cycle life ¢ Maximum Toading and unloading rate of 2 percent per minute. © Maximum load for tripping unit of 50 MM. Because of the demands of the system and occurrence of problems, not all tests were conducted exactly as planned, This led to the repeat of one test and the identification of problems that were either corrected or factored into future tests. Tests 1 and 2 were hybrid operation tests that essentially studied the advantages of using division valves to control throttle pressure independently of drum pressure. The use of division valves also permits the steam attemperating of main steam and reheat steam with flow from the boiler drum, Test 2 was repeated because of ‘temperature control problems caused by feeding forward too large a spray flow. Test 3 was a test of sliding pressure single valve operation, The throttle pressure control below 1800 psi (12,411 KPa) was obtained using the 501 valve.Tests 4 and 5 studied the use of constant pressure for cycling units. These tests were for application to boilers that cannot operate using sliding pressure in the strict sense of the word because of design constraints. Test 5 took advantage of ‘the steam dump from the boiler drum to the condenser that is provided with the 502 valve of this boiler system, The reason for this test was to study the benefits of this retrofittable system, Tests 6 and 7 studied the problems of starting after a weekend outage. In test 7, the full advantages of the 502 valve and the steam attenperating system for throttle and reheat steam (518 and 519 valves)were used. Test 6 represents the situation that exists in many plants that have no special design provisions for sliding pressure operation, Test 8 is the method that Commonwealth Edison operating personnel had selected prior to the test program. The throttle pressure ramp is the same ranp that would be used for single valve operation. The control valves, however, are in the sequential mode. RESULTS AND DISCUSSION A chronological discussion of the test data grouped according to type of operation is most appropriate. This approach reflects the insight gained as the test program progressed. Test 8 was conducted first since this was the normal method of operating, and no new problems would be ercountered. Test 8 Figures 4-1 and 4-2 show the operation for the day of the shutdown (3/19/81). The ‘maximum unloading rate for test 8 was 0.9 Mi/min and the shutdown was uneventful. The 501 valves were used to produce a minimum throttle pressure of approximately 1050 psi (7240 KPa) while maintaining a minimum drum pressure of approximately 1500 psi (10,340 KPa). During this test it was discovered that no measurement of fuel flow was obtained by the data system during startup because of the insensitivity of this measurement to small fuel flows. In addition, the control room totalizers were inoperative. All sutsequent fuel flow measurements during startup were obtained by recording fuel nezzle pressure and the number of burners in service, a procedure which is accurate within + 20 percent. This is because the flow coefficients used were extrapolated into these low flow regions. During Test 8, the minimum admission valve point was three of the eight turbine valves. This was changed to four valves for all subsequent valve tests. 4-2‘TIME IN HOURS, Turbine Operation Summary - Test 8 - 3/19 TIME IN HOURS, 100) 200) 400) 600, oe $ € fee 8 22 @ § @ § g g 8 8 mn avor Oo 5 cot) Suwa -ma-19 uve #2 fe ff # ee cg gos ¢ 8 8 8 iow Rau -osa4¢_v ‘visa aungsaud nav g@ ¢ € # @ & 8 a 4 g 2 8 8 @ & & GObx) WiSd -3UNSS3Yd FTILLOBHL + AN3OYRd = NOLLISOd ATA LOS + £ me 2 @ Fow® foaa-Swarnvar’ nw X 8 Fou soad-an$iistino vso38 x ‘4930 - dal IW3H3Y LOH 3 JDIG-dWSLIFTLNOHY 4930 “N31 30V18 18813 14 72 Boiler Operation Summary - Test 8 - 3/19 Figure 4-2. 43FIRST STAGE TeMP- DEGE = DEGE utter Teme SH OUTLET Tet 3 8 + 501 VLV POSITION- PERCENT 8 5} s270| 00], 0 i se aes 4 i0|sm0| 0 to i 220} a) | he N \ ™ sof feo| ao] an Pp In. i in | 44 lal nol a To I\\ tg 7 | | 80 150}200) 200. | \ | | ol ok a \ Ti HY Ee Bbal =f 17 wold 20 | 90% 120|Srs0 pay \ | + la" fo | | iil TIME IN Hous \ o 2 4 6 8 0 1 14 1 1 20 2 0 Figure 4-3, Turbine Operation Summary - Test 8 - 3/20 3 100) 200) 400 8 20] 2701 260 Koy 8 g 20 70] 2101 290 MP" DEGF [x10 8 PSTA AR 60 « 180} 5240. 3 8 ‘© _WAIN O1 FLOW a 8 & ‘B OAUM PRESSURE RH SEC 8 8 8 8 Figure 4-4. Boiler Operaticn Summary - Test 8 - 3/20 44The unit was restarted on 3/20 with a high aressure (HP) first stage rotor temper- ature of 796°F (424°C), The data for the day of restart can be seen in Figures 4-3 and 4-4, The throttle steam temperature had decayed continuously overnight; however, the secondary superheater outlet temperature dropped significantly because the operation of the boiler feedpump turbines. This will be discussed in detail. The turbine first stage temperature decreased to 693°F (367°C) before synchronization. This produced a mismatch stress during rolling equal to shutdown stresses for the HP rotor, The temperature control of main steam during starting was difficult and the throttle temperature reached a value of 1018°F (548°C) which produced the maximum HP thermal stress. The unit was loaded at an average loading rate of 1.2%/min and a maximum rate of 2%/min. The temperature control problem limited this loading rate, The turbine was synchronized in single valve mode of operation. However, transfer was made to sequential valve operation at approximately 0652 hours to limit thermal stress during the main steam temperature excursion. The maximum rates of change of throttle and first stage steam temperature were 427 and 455°F/h (237 and 253°C/h), respectively. These rates are excessive. The rate of throttle pressure change for this transient, as a function of Toad, was the same as would be used for single valve operation. This opens the governor valves too quickly and has two un- desirable effects; poorer heat rate at low loads and a rapid rise in first stage temperature during loading. Test 2 Tests 2A and 28 were performed to study hybrid operation using division valves (501) to control throttle pressure with drum pressure dependent on firing rate and with operation of the saturated steam dump (502 valve). Figures 4-5 through 4-12 present the summary information for tests 2A and 2&, The time scale for summary plots and all other plots using the data system for cays 5/7 and 5/8 are off by one hour because the data system clock had not been corrected for daylight saving time. During test 2A, the large attemperating spray flow, as feed forward, kept the 518 valve (steam attemperating valve) from opening, The subsequent overspraying produced the erratic main steam, hot reheat and first stage temperature history during loading that is illustrated in Figure 4-7, This temperature characteristic produced high rotor stresses in the high pressure rotor during loading at 442 MW. The test was rerun as test 28, The calculated fuel flows are illustrated in Figure 4-13,2 14 18 18 2 Turbine Operation Summary - Test 2A - 5/7 10 100) 300) 400) 600 gI° i] 2 | o | $8 § e € gees 2 ¢ © 8 € ¢ ge pees inn avoto g wots) Sud -ndra udu aoe 8 f gf @ @ es f F F ge sg g # FF OLX) Wdd -033dS_V 04x) WiSd -3HNSS3Hd WHO 8 ¢ § € 8 8 &@ € @ ¢ 8 8 @ 2 8 gs ¢ s € 8 8 OLX) _WISd -3UNSS3d TOU + ANSOWAd - NOILISOd ATA 109+ & 2 ° 8 3 2 ° Fom® B2q-Snaifwaid uve x ® F Fioudsoa§-an$i isfno soak x ® 2Bo- anatase SSO TSHIRTS X 3030 - dal 3OVIS 18813 Dax 2 2 14 «16 18 10 Boiler Operation Summary - Test 2A - 5/7 Figure 4-6. 4-622 3 2 18 \ 2 Turbine Operation Summary - Test 2A - 5/8 3 g g $$ 8 $ @ 8 g 8 fs 8 ° » § @ 8 F eg s ese s mw=avor O. 5 ors)“ unseit- mdr 116 nivei_O g @o£ e@ ¢ @ 8 #¢ © G g 22 8 @ & & & Wd -33dS_V WiSd -3YNSS3Yd WNYD T g 2 2 8 8 &@ &@ & © @ € © @ 8€ @ @ &@ a 2 visi -sunssadasuiow + a ANZO'ad “NOULISOd AIA 108+ 8 2.8 8 8 ge se & ¢ 4 28,8 & 430 -anai Was NVA X 4930 -an3l lwaHau lon 3930 -aN3L avis 1Sul4_X 3 2 B 8 ‘wordtsoad-anS. isting Wisose x Gososuaaicainons 12 ia “i618 20 22 10 Boiler Operation Sunmary - Test 2A - 5/8 Figure 4-8. 4718 16 14 2 Turbine Operation Summary - Test 28 - 5/14 : 3 z |? z 3 3 $$ ¢ § $ 8 g gs a 8 e @ € 8 @ ¢ € @ g a 4 mn“avor © g cor wud - mots vONv_O. 8 Bf eff,% * ° £2 € € € 2 ¢ ¢ & # a 8 aw -a3ad5_v wor) “visa aungsausninsa_v 2 2 8 @ 8 & 8 & © g 8 @ &@ 8 3 ¢ 8 8 & vis -auhssag suiows + a 1N35u34 "NOUIGOd MA Os + 8 Baq-Swarhvakuvil x ® * e $B ratino e* 3930-31 IvSHaN LOH 3930 -dWal3ovisisuls X Fon soa6 -awSi iztinowsoas x S080 ana EAinone 22 2 1 16 ta 70 Boiler Operation Summary - Test 28 - 5/14 Figure 4-10. 4-8I< SEGr0|La0 888 |b dd.gs0}51e0 355° gz" EE S85 [4 le £25 jy DibbaeolE 2016 gee oe nz fe oz |e |e EPS IF ool’ wxx [+ ]a 20 0] 2 alo. 100) 100 Seo Gz "5 as [a = Beo| ge) 2 zu |2 |e Piso] 5 so ne13°R Ge je fe Br | Salk 5540} 340 ra iz go |2 Bo! 8 ao 5 xx |+ fo 20] 20. 10] 10 oo Ao. 480. 220} «20 220] 260 200} 200 = e 100 | 200 5 g is 120{ 80 lo to} 120 «| ol 6 Figure 200, «00 sco au. } 2 E = 150| S200. 12015160 iz 0 |= 120 lo oo} a. 2» ° Figure 4-12. Boiler Operation Summary - Test 28 - 5/15 49 10 70 TIME IN HouRs 2 2 14 4 16 18 18 18 20 Turbine Operation Summary - Test 28 ~ 5/15 hy ot ‘TIME IN HOURS. 20 2 0The turbine was unloaded on 5/14/80, using the 501 valve to maintain a minimum drum pressure of 1800 psi (12,411 kPa) and while sliding the throttle pressure to a minimum pressure of 1000 psi (6895 KPa). Both main steam and reheat steam temperatures were well maintained. The load swing at 2000 hours on 5/14, was caused by an increased system denand resulting fron the loss of another unit. This delayed the shutdown approximately 1-1/2 hours. 2s 20. ‘oTAL FUEL 1 FLOW -KLB 30 é 70 “TIME OF DAY 5/08/80 Figure 4-13. Fuel Flow ~ Test 2A - 5/8 During the restart the turbine eccentricity was high because the unit came off turning gear sometime during the night. This introduced a long delay in rolling the turbine to synchronization speed. The fuel flow for this time period is shown on Figure 4-14, Before firing the boiler, greater than normal problems were encountered with fan starting and lighting of burners. While lighting the burners during this period, the 502 valve was opened manually, then placed on automatic control to control drum 4-10pressure. The 501 valves were used to control throttle pressure. ‘TOTALFUEL FLOW-RLB «0 30 eo 79 ‘TIME OF oaY 5/15/80, Figure 4-14. Fuel Flow - Test 28 - 5/15 After the eccentricity problem had been eliminated, the speed of the turbine was increased with a minimum of cooling thermal stresses. This mismatch stress was minimized because of the peculiar operation caused by the eccentricity problem. After synchronization, the main steam temperature set point was 915°F (491°C) and the main steam attemperating valve (518 valve) set to control main steam temperature. The first stage water sprays were brought in manually at 0730 hours (90 MW) and the 518 valve started opening at the same time. Second stage sprays were manually brought in at 28,000 Ib/h. Figures 4-15 and 4-16 show the inter- relationship of the spray flow, temperature, temperature set point, 518 valve, and load for the north and south sides of the boiler. The temperature control was substantially better. However, tube metal alarms occurred during use of the 518 valve. Two tubes were 55°F (31°C) over the alarm temperature and all others were 10 to 20°F (6 to 12°C). All alarms c’eared by 0750 hours. The applicability of these alarms for short periods of time and at reduced pressures is questionable. 4-11S40. 100) 200 90] 180, 20] 160; 70 |p 1404 60) 120120 50} 1004 100 4} 80} 80 x |+ Ja 20} 60) 60 20} 0} 4. 10} 20] 20. of oo. Figure 4-15. 100) 200) 200. 90} 180} 180 90} 160) 160) 70},-140 140 ie |e 60] 120* 120. 50} 100) 100 le je ie 4} 20] 0 kt | 30] 60} 60 20} 40} 4 10} 20] 20. ol oo. Egg] C81 - LOAD INMEGAWATTS } {~~ Fa. FIRST STAGE SPRAY WATER- [ d \ NORTH \ J {800} FS - SECOND STAGE SPRAY WATER- J iB NORTH P go] F2 ~ STM-ATTEMPERATOR vLV y 760 Posmion j (O | tswas- suPentesrer ourter jf | i TEMP" sso sco. sole TIME IN HOURS | sy 5/15 5/18 ‘Steam Temperature Control Using Steam and Water Attemperation 10507 1000 os. 200|— 81 - LOADIN MEGAWATTS sso] F9- STM ATTEMPERATOR VLV, POSITION. so0] FS ~ SECOND STAGE SPRAY WATER evo FLow SOUTH 6 | F4 — - FIRST STAGE SPRAY WATER |/ P FLOW SOUTH lo] Tsw23- SUPERHEATER OUTLET | ‘TEMPERATURE, °F 0 pe Figure 4-16. Steam Temperature Contrcl Using Steam and Water Attenperation 4-12Shortly after synchronization, the unit was held due to drum evel control and a falling drum pressure, both related to burrer operation problens. The drum pressure fell 480 psi (3310 KPa). However, 501 valve action limited the throttle pressure swing to 195 psi (1345 KPa). The drum tengerature rate of change limit was slightly exceeded at this tine. The throttle pressure ramp was set to have four valves fully open and full throttle pressure at 65% load. The unit was rolled, synchronized and loaded to 133 MW in Single valve mode, At this point, transfer to sequential valve was made to minimize HP rotor stresses. At 0820 the loading rate was reduced to 5 Mi/min and the load target increased to 500 MW. The ramp rate was reduced because of the operators concern about fan Power. A post-test analysis indicated that this fear was unjustified and probably due to the operator's inexperience with rapid loading. The average loading rate during the test was 6.3 MN/min or 1.3%/min with a maximum loading rate of 2t/min, Test 1 On 6/2/1980, the unit was unloaded without using the 501 valve. The sunmary plots for this shutdown are shown as Figures 4-17 and 4-18, At 20% load, the fires in the boiler went out and the unit immediately tripped, Before the unit tripped, the temperature control of main and hot reheat steam was quite erratic. The boiler was lighted with no problems and the calculated fuel flow plotted on Figure 4-19. The boiler pressure ramp for loading was such that full drun and throttle pressure were reached at 312 Mi. Additional loading was obtained by opening the governor valves. This turbine loading concept is the sane as in tests 2A and 28 except the 501 valve was not used to control throttle pressure. Firing rate was used to control both dru and throttle pressure. 4-133 2 Turbine Operation Summary - Test 1 - 6/2 $8 3 8 @ 8 £ 8 a 8 2 8 8 8 @ 8 8 2 ¢ 8 ¢ * mwavot_O 5 wor) “und -mdrg WO NIWA_O. $8 8 8 § 8 8 8 8 * 2 8 & § 8 € $ 8 # fe © iow tie ~“G334S_V word) “visa sungsaud wag _7 ge € € 8 @ & 8 8 & @ @ @ @ 8g ¢ ss 8 8 ¢ fiom)” visa - suesais ulouL + 4NBOWRd “NOMLISOd ATA 108+ S Biy® Baad z s = 8 2 Siisfrodsost x® © F Fow® a0 Smaak ut x = oixt 930 - dni tatinow'soas’ x 3030" GNaL IWGHaUIOH 3930-dNalISUnOWe 3930 -aW31 39v18 1S8l4 Boiler Operation Summary - Test 1 - 6/2 Figure 4-18, 44FUEL FLOW KuB/H FUEL FLOW ‘TOTAL FUEL FLOW-KLB «30 30 oho “WME OF DAY 6/03/80 Figure 4-19, Fuel Flow - Test 1 - 6/3 Figures 4-20 and 4-21 show the summary plots for test 1 startup. The turbine valves were in single valve mode until approximately 120 Mi, and were then transferred to sequential valve. Figures 4-22 and 4-23 show the relationships between spray flow, desired inlet temperature ramp and throttle steam temperature. The first stage water flow measurements were not functioning properly at this time. The temperature control becane erratic at approximately 240 MW. ‘This temperature control limited the loading rate. However, the cyclic life for the entire operation was still above 10,000 cycles. The maximum HP heating stress was at 0701 hours during the rapid recovery of the throttle steam temperature, Steam attemperation was not used because the 501 valve was not in service. In addition, steam attemperation cannot be used above 25 percent load. Boiler feedpump turbine control was improved during this test because a relatively low head ex’sted since the S01 valves were not used during rolling. The loading rate at 0651 hours was reduced to 8 MW/min because of ‘the operators’ concern for fan loading. The average loading rate was 1.6t/min with ‘a maximum loading rate of 2.5%/min. No superheater metal alarms were encountered.18 16 100) 300) 400) 6007 eleme 3 zing? 2 mos i SS} | te $2 8 8 8 § 8 fs fo we g &@ € 8 ¢ gs 8 ¢@ uwavot 5 w/e - mots 5 nivel_O $a ees etre g ges ee 8 4 8 town! Raw-Gaa8_v isd aungsausnnua_o &@¢ ¢ @ 8 8 &@ @ € ¢ 3 2 8 ¢ ¢ 8s 8 8 6 Tono™ vis -auhssadaswiow + ANSDuRE "NOUISOd ATA 108 + 3 26 3 2 2 6 Fou® £30 Snaifavar’ ww? x * 8 Fooufsoab-anfh wfhrorfsoaé x ® $339 SHELVSNGN & Gosdransenineys % (4930 -dW3130V1S 1suls X 2 14 16 18 Boiler Operation Summary - Test 1 - 6/3 10 Figure 4-21. 4-16200) 200) 100) 1050) 600, 180] 180] 901 1000} sao. See ATURE Pont — 160] 160] 80} 950} 480 f+ 140} 140] 70} 900} 420 NN gs ]g'%] 6} 880) a0 = 100f* 100] 50423800] 200} St - LOAD, MW eee 18W23 - THROTTLE > aol® ao reo. TEMPERATURE, °F * sol ao 40° 750/240) Fg - STM. ATTEMPERATOR + [a jo VLV. POSITION 3. - FIRST STAGE WATER, 0] 60) 90) 700) 180 ‘SPRAY, NORTH \ F5 _ - SECOND STAGE 40} 40] 20) 650) 120 WATER SPRAY, \ NORTH 4 ~~ TIME IN HOURS ol 0! ol sso. 5 6 7 8 9 Figure 4-22. Throttle Steam Temperature Control with Spray Water Attemperation - 6/3 200) 200) 100) 1050) 600 wo] so| | om] aso] temenarune fe Point | j 160} 160] 80] 950} aso. Vv ES 3” is) oo} 880 sO & s00|® 100. 504<) 800} 300. | © sol aol® aol2reolZoun| St. - LOAD. MW | B07 80) 40" 750)°240) TSw23- THROTTLE + |s 0 TEMPERATURE, °F Fo -swarrenpenator | ee | ie ce VLV. POSITION Fa - FIRST STAGE WATER ©] | 2} 60] 120 Spray, sourH Fe - SECOND STAGE Waren sem, | 2} =| 10} oo] oo Sourn | ~ f, Time mw Hours of of of 550! o. 4 3 6 7 3 8 Figure 4-23. Throttle Steam Temperature Control with Spray Water Attemperation - 6/3Test 3 The unit was shut down using sliding pressure single valve control on 6/3/1980. The shutdown is depicted on Figures 4-20 and 4-21. The drum pressure was limited to a ‘minimum of 1500 psi (10,340 KPa) while sliding the throttle pressure to approxi- mately 1050 psi (7240 kPa) using the 501 valve, The start-up summary plots are shown on Figures 4-24 and 4-25. The unit was rolled with 1050 psi (7240 KPa) throttle pressure and 1500 psi (10,340 KPa) drum pressure. The entire speed control and load control was done with single valve operation, Since in single valve operation the rotor is hotter than in hybrid mode, restarting requires a higher throttle temperature for matching, In this instance, the unit was rolled within the acceptable limits of throttle steam temperature. However, the mismatch stresses at synchronization (cooling HP rotor) exceeded the shutdown stress of the preceding day. The temperature control was again difficult. The maximum stress during loading occurred at approximately 0643 hours during loading at 268 MW, when the main steam ‘temperature had just reached 1000°F (538°C), The variation of main steam tem- perature with Iu.d and spray flow, is illustrated in Figures 4-26 and 4-27. The calculated fuel flow prior to loading is illustrated in Figure 4-28, During loading, the unit was tripped out of integrated control on several occasions. The problem developed when the turbine valves did not open fast enough and the air flow control went out of range, When this happened, the turbine control system was used to control load. The problem was observed in other tests, but not to the same degree. The reason valves did not respond is there is no pressure correction in the demands of integrated control system. Since the throttle pressure varies more slowly with load in this type of operation, the problem of remaining in integrated contro] was most severe during this test. The cyclic life of the unit for this test was greater than the 10,000 cycle life limit. The overall loading rate was 1.6% per minute with a maximum loading rate of 2.4% min, Startup after weekend outages tests were performed in Tests 6 and 7. Test 6 did not use the $02 valve or the steam attemperator valves. Test 7 was the more normal startup procedure used at this plant. 4-188 4 16 2 3 3 0 1 Turbine Operation Sunmary - Test 3 - 6/4 TIME IN HOURS 3930 - dWaL aDvi8 1981 = Oe ° So 7 a _ i g $ @ ¢ @ 8 @ * » § € § € ¢ g Bg ee mnavor 5 (corn) Sunid-mora 10 Nivri_O 3 #2 ¢@ 22 @ es ec ge gg ge gs 8 8 au -o3308_¥ wort) Swsssaungsaudnnwa_v 8 2 2 8 8 #8 8 & © g$ 8 &@ & 8 83 ¢ 8 & & wish -sunssae swlowna + angouae "Nolllboa mA 108 + g Bao Snardwas nw’ x ® F * 8 Bio Fsos8-awhistino sess x * * B35 HEE GEN Gosdsataienthons a g 1% 16 (18 Boiler Operation Sunmary - Test 3 - 6/4 2 10 25. Figure 4: 4-198 8 Broo lS, roof 1007 $0)2,900) 2001 os: — LOAD, mw e Is |p ‘TSW23- THROTTLE B sof s0f® a0 {750{0 200. TEMPERATURE, °F ro stm. fof Pp ATTEMPERATOR: 60] 60) 20{ 700) 10 VL. POSITION \ Fo - FinsTstace \ wo] 4} 201 650) 120 WATER SPARY, ¥ \ FS - SECOND sTAGe 20] 2 10] 00} 60 WATER SPRAY. 4 3 6 7 Figure 4-26. Throttle Steam Temperature Control with Spray Water Attemperation — Test 3 - 6/4 200) 200) 100) 1050) 600 120] 120] 20] 1000] seo he-— sis © Toe yr 100) 50800) 800) cst - LOAD, MW | 7 5 |g | tsw2a- Home sim 2 wolf col sol ro Bea, TEMPERATURE: °F x Fo STM ATTEMPERATOR ia VLV. POSITION 0} 60} 20} 00] 180] Fa FinsT STAGE WATER SPRAY, SOUTH Fé - SECOND STAGE =] 0] 9] S50) 120 WATER SPRAY. a nN soure w 3 6 7 a 9 Figure 4-27. Throttle Steam Temperature Centro! with Spray Water Attemperation — Test 3 - 6/4FUEL FLOW KLB/HR 25: 20: FUEL FLOW 10. TOTAL FUEL FLOW-KLB. 4:30 5530 830 ‘TIME OF DAY 6/04/80 Figure 4-28. Fuel Flow - Test 3 - 6/4 Test 7 The summary plots for test 7 are shown on Figures 4-29 and 4-30. The fuel flow, as a function of time, is shown in Figure 4-31, The boiler was fired late on the previous night. The rotor temperature in the area of the first stage was 502°F (261°C). The unit could have been rolled as early as 0200 hours, but since power was not required until 0430 hours, the unit was not rolled. Therefore, as can be seen in the fuel flow, two burners were renoved from service until prior to rolling. There is a significant difference between the superheater exit temperature and the throttle steam temperature prior to rolling because the only steam flow is to drain, The drain lines are 1-1/2 in, (38 mm) lines which should pass approximately 1.0% of full flow at 1000 psi (6895 KPa) throttle pressure. Prior to rolling, this difference has been reduced to 44°F (24°C).2 14 16 18 TIME IN HOURS Turbine Operation Summary - Test 7 - 6/2 10 r (a o 2 4 6 8 S288 8 8. 8 Tom" faq -awai Was Nv x 4930-dW3l vaHawON 3930 -dWalS0visisuld X 10. ° 100) 300) 400) 600 1-29, Figure 4, TIME IN HOURS, 100) 200) 400 109, 8 8 § 8 8 € (or) “wne't- mors 10 Nivd_O g¢ ¢ 8 @ 8 8 Ba 8 z 8 & S ox) “viss“aungsaudwnya_v IN3OUSE “NOULISOS ATA 108 + 2 s & F028 -an$i zo ifs 03 SosdPansr eathon & x* * 10. 10 2 4 te 18 Boiler Operation Summary - Test 7 - 6/2 10 Figure 4-30. 4-22TorALFuEL Flow: KL, ‘TIME OF DAY 6/01 6/02 FUEL FLOW KL /HR cn a ce: a FUEL FLOW Figure 4-31. Fuel Flow Test 7 The turbine was rolled and accelerated. A steam chest differential temperature limit caused a slight hold at approximately 3100 rpm, The mismatching stresses were acceptable with rotor being slightly cooled. The unit was synchronized and loaded to approximately 190 Mi and held due to system demand. The main steam temperature rose faster than required, causing a high rotor stress. The 518 valve had been automated prior to synchronization; however, it didn't control properly with the spray flow used. The reheater temperature control of the 519 valve was set to control at 10°F (6°C) less than main steam. At approximately 0525 hours, the 518 valve closed automatically. The first stage spray was on automatic control. At 0643 hours, the load was increased with acceptable control at a rate of 7.3 MW/min with a maximum rate of 9.6 MW/min, No superheater tube metal alarms were observed during this start. Test 6 The data for the weekend startup without use of the 602, 518 and 519 valves (Test 6) was inadvertently erased by station personnel. Therefore, only manually obtained data, and the data obtained by the on-line plotting of the data system is available. Figure 4-32 shows the startup data obtained fron these various sources. The fuel flow was determined in its normal fashion and is illustrated as Figure 4-33,FUEL FLOW 8 Figure 4-32, Turbine Operation Summary - Test 6 - 8/4 10 TOTAL FUEL FLOW -KLB FOELFLOW KLBHR a a a a ) ‘TIME OF DAY 8/04/80 Figure 4-33, Fuel Flow - Test 6 - 8/4Observations at startup indicate the turbine was slightly hotter for test 6 than for test 7. On the basis that the same rotor temperature existed as for test 7, the unit could have been rolled at approximately 0358 hours for test 6 and 0154 hours for test 7, Referring to the appropriate fuel flow curves, a fuel flow of 25,009 1b is obtained for test 7, and 21,000 1b for test 6, The results indicate little or no benefit to using the 502 valve to control throttle pressure for a weekend startup when approximately a 700°F (371°C) throttle temperature is sufficient. However, operation is less difficult using the $02 valve to limit drum pressure as compared to varying firing rate. During rolling, prior to transfer to governor valve control, a hold was necessary to warm the steam chest to above the saturation temperature. This hold was necessary because of the higher throttle pressure resulting from a firing for temperature while not using the $02 valve. This hold lasted approximately 31 minutes. The pressure was 1963 psig (13,535 KPa) at roll, and then dropped to 1438 psig (9915, kPa) at synchronization. Considerable difficulty was experienced in getting burners into service. Loading holds at 110 and 340 MH were due to this problem. In addition, considerable difficulty in controlling main steam temperature was experienced. This difficulty appears to be partially attributable to ovespraying, as well as burner problems. AS a result rotor stress limits were reached at 76, 109, 232 and 462 MW. The average loading rate was 3.2 MW/min, The maximum loading rate attained was 5.7 Mi/min. Constant pressure tests were conducted for obtaining information on cycling units that do not have variable pressure capabilizy. This was accomplished by maintaining full throttle pressure until some low load and then ramping the pressure quickly down to the minimum pressure. Test 4 was conducted without using the 502 valve during startup and test 5 used the 502 valve during restarting. Test 5 Figures 4-34 and 4-35 show the summary plots for the shutdown of test 5. The pressure was kept constant until 138 MW and then ramped to 1155 psi (7964 KPa) at 48 MW. This ramp is too steep since it resulted in a large change in fuel flow. The main steam and reheat temperatures dropped sharply to 890°F and 836°F (477°C and 447°C), respectively. With the feed pump capacity of this plant, this ramp could be 4-25RH OUTLET TEMP- DEFG x x 8 3 8 g 8 i G 3 a g F_THROTILE PRESSURE PSIAKIOT a 8 @ 8 2 3 3 8 PEED RPM 8 & g if 0) 0) ohn manna, o 2 4 6 Figure 4-34. Turbine Operation Summary - Test 5 - 6/11, 6/12 s0} 270} s60 | ff a re Brel 20) woo Ege cole s00 5 240; z F | 3 Bapee= © so s20 100! so 1208 00 BE Pp 3 201% 9045 120 + 8 a 8 o 8 « 8 02 4 6 TIME IN HOURS, 10 10 2 2 4 é TIME IN HOURS ol of oo. ee ene 14 16 16 120 Figure 4-35. Boiler Operation Summary - Test 5 - 6/11, 6/12 4-26Turbine Operation Surmary - Test 5 - 6/12 TIME IN HOURS 100) 300) 400) 00 3 § 3 3 & 3 o 3 g 3 g 3 SFE EE dato ® g FF B® Hevhovbonino’ * eet tot) * FF tee ee ee FF obo au “0335 v jorx _visa-auinsssua wnua v @¢2 28 « 8 &€ 8 g 8 8 @ 8 2 ¢ 3 @ ¢ woivyigi -3unssaus siouNL IN3OUSd -NOWLISOM ATA 108+ @ ¢ 8 $8 @ ¢ a 2 @ 8 $a 2@ 8 & & + 2 Wolx) 4930 -dwal vais Nivm Xx 3030 SWAIN GuION 3930 -dW31 3¥IS 1SuI Worx) 4530 -dwat Ls11nd Hs 53s x 4930 “dW3LISUNO HY Boiler Operation Summary - Test 5 - 6/12 -37. Figure 4, 427Slowed considerably. The first stage temperature dropped to 707°F (375°C), with a stress evel well within limits. However, the unit was ramped from only 60% Power. The first stage and IP rotor temperatures cooled to 678°F and 737°F (369°C and 392°C), respectively. Figures 4-36 ard 4-37 illustrate the restart. Fuel flow for this start-up is illustrated in Figure 4-38, Prior to turbine rolling, the boiler was tripped because of a high drum water level. This level problem was caused by the failure of the blowdown valves to function. Additional problens were encountered due to not receiving proper indication that burners were lit. The turbine was rolled at 0636 hours. Since the power was not required, the turbine was reduced in speed to delay the synchronization. The turbine was reaccelerated at 0654 hours and synchronized at 0707 hours without problens. As can be seen from Figure 4-36, the temperature control was not good. The turbine valves were transferred to sequential valve at 0725 hours (72 MM) to arrest the sharp rise in first stage temperature. However, overspraying caused a subsequent drop in main steam temperature. This was corrected by transferring back to single valve. At 0750 hours (283 WN), the valves were once again transferred to sequential valve. The valve manipulation managed to limit rotor stress to acceptable levels. The average loading rate was 6.6 MW/min over the transient. The maximum loading rate was 10 MN/min when the temperature ranp was under control. Test 4 Test 4 data was lost along with data from test 6 as previously mentioned. However, data system on-line plotting and recorded observation are available. Figure 4-39 illustrated the summary information for the shutdown using constant pressure. A Slower pressure ramp was employed. However, since the unit was tripped from such a Tow Toad (36 MH), the main steam and reheat steam temperatures still fell off sharply to 890°F and 864°F (477°C and 462°C) respectively. The accompanying first. stage temperature dropped off to 749°F (398°C). Rotor stress in this case was still well below limits. The first and second stage sprays could have been reduced more. At the trip point the first and seccnd stage spray flows were still 20,000 and 30,000 1bm/h. 4-28* THROTTLE TEMP. FIRST STAGE TEMPE 25: 20. 15. FUEL FLOW 10 Par Figure 4-39. Figure 4-38, 20001 FUEL FLOW KLB/HR TOTAL FUEL FLOW-KLB. 6330 TIME OF DAY 6/12/80 7:30 Fuel Flow - Test 5 - 6/12 fees SN ~ 2218 2230 Turbine Operation Summary - Test 4 - 8/4Peco sol Baal Pf 3 alet hoe 2 E Elster lal El send Hele! oa era eae Te Figure 4-40. Turbine Operation Summary - Test 4 - none Figure 4-41. Fuel Flow - Test 4 - 8/5 4-30 8/5Figure 4-40 illustrates the restart transient, The turbine was rolled with a throttle pressure and temperature of 1887 psig and 808°F (13,011 KPa and 431°C). This matching is at the lower end of acceptability. Figure 4-41 illustrates the calculated fuel flow for this event, The ‘uel flow to roll was 15,300 1b. The total fuel flow to roll for test 5 was 14,500 Ib. However, significant differences exist between the two tests. For test 4 the initial throttle temperature prior to firing was 70°F (371°C) while for test 5 this same value was 808°F (431°C). A more appropriate analysis would be that the rise in pressure caused approximately a 50°F (28°C) rise in matching temperature. Because the rotor was matched low, higher stresses were obtained after synchronizing and during loading for test 4 than for test 5. The unit was loaded at an average loading rate of 8.6 MN/min. This was acconplished by transferring back and forth between sequential and single valve. Table 4-2 summarizes the results of the cyclic operation tests after overnight and weekend outages, THERMAL STRESS ANALYSIS The temperature distributions of the boiler, as measured, were used as the basis for analyzing the acceptability of the stresses developed for various modes of oper ation, Selected tests were chosen for detailed study. In the turbine, stress analysis of certain segments of the turbine cylinders and rotors was performed. In other areas, measured temperature differentials were used a8 a basis for comparing operating transients with stress analysis results that were Previously obtained, The basis of the stress analysis varied depending on the structure fron analytical methods to finite element computer analysis. Drum The drum of a utility boiler is the thickest pressure part. For this project, thermocouples were installed on the outside circumference of the drum, and within one-quarter inch of the inside of the drum, at the boiler centerline, These are thermocouples BMT-1 through BMT-10 (see Appendix A). The purpose of these ‘thermcouples was to observe top to bottom differentials and rate of change of drum netal temperatures. 4-31Thermocouples BHT-1 through BMT-5 are located near the drum inside surface. They were installed by drilling a quarter inch hole from the outside of the drum to within one quarter inch of the inside surface and installing a sheath thermocouple so the end rested on the bottom of the hole. Thermocouples BMT-6 through BMT-10 are located on the outside surface of the drun near a corresponding inside surface measurement. To reduce the effect of the penthouse air temperature affecting the reading, the thermocouples were covered with insulation. Figures 4-42 and 4-43 are data plots for two different overnight startups. On June 3 the 501 valve was not used (100% open) and June 4 the 501 valve was used to control throttle pressure. The data shown is the drum top and bottom thermocouples and a riser tube temperature. The riser tube contains saturated water and is the connection between the furnace tubes and ie drum, The riser tube measurement follows the saturation pressure change and is the most representative temperature measurement of saturation conditions of the fluid. Thermocouple BMT-1 measures the inside surface temperature at the top of the drum which is in contact with saturated steam. Thermocouple MT-6 measures the outside surface temperature of the drum at the sane location as BMT-1. Thermocouple BMT-5 measures the inside surface temperature at the bottom of the drum which is in contact with subcooled water. ‘The riser tube tenperature which follows fluid temperature, is observed to decrease first. This occurred when the 501 valve vas opened, before firing was initiated, thus allowing drum pressure to decrease. As the unit is fired, drum pressure increases as shown by the riser tube temperature. For both startups, synchronization was shortly after 0600 hours. After synchronization, the riser temperature is seen to increase as pressure is increased. It is seen that the ‘inside surface temperature at the top of the drum does not follow the fluid temperature change until after synchronization. This is because there is little steam flow from the drum until after synchronization. The change in the inside Surface temperature at the bottom of the drum is associated with feedwater flow. Feedwater for these two days is illustrated on Figures 4-44 and 4-45, respectively. When feedwater is added to the drum, it subcools the water entering from the risers. As the unit is fired, the bottom inside drum temperature increases. After synchronization, depending on unit load, the degree of subcooling varies. These are the temperature effects that cause thermal streses in the drum. 4-32The top to bottom temperature gradient, which causes drum bending has an effect on flexibility of riser, supply, and other tubes or pipes attached to the drum; and stresses in the drum due to the non-linear temperature gradient combined with the effects of other loading, The top to bottom temperature differential limit is 25°F (125°C) at 500 psi (3448 KPa) and 120°F (49°C) at maximum load operating pressure, The limit is a straight line function between these two points. The riser tube temperature change is typical of daily operation at the Collins Station which does not approach the limit. ! | INDICATION OF RATE (OF CHANGE LIMIT. 65 ' LIGHT-OFF 4:48 ‘TURBINE ROLL 5:42 SYNCHRONIZATION 6:02 fl | | ! ! 1 jl I ‘TEMPERATURE -F DAUM INSIDE TOP. — DRUM INSIDE BOTTOM Y —— - — baum oursipe tor Bs ‘TIME - HOURS 6/03/80 Figure 4-42, Drum Metal Temperature During Startup - Test 1 4-33,—prum oursipe Tor DRUM INSIDE TOP. — = rum Inside BoTrom —— ——niser 1 1 1 1 1 ' INDICATION OF RATE [OF CHANGE LimT TEMPERATURE -F LIGHT-OFF 4:33, TURBINE ROLL 5:42 SYNCHRONIZATION 6:01 ‘TIME - HOURS 6/04/80 Figure 4-43. Drum Metal Temperature During Startup - Test 3 The limit for rate of heating temperature change is 375°F/h (208°C/h) and for cooling 450°F/h (250°C/h), again, these ar2 not exceeded. From the monthly data summary it was found that when the maximum rate of temperature exceeded the limit, the calculated rate was from a time when a fictious jump in the data value occurred as seen on Figure 4-45 for saturation temperature. 4-34FEEDWATER FLOW-KLB/HR. sood- owTorr 44s Onaiwe nous 42 SYNCHRONIZATION 692 200d 1000 d y $ : s ‘ie - HOURS e/os/a0 1 — - -- —reeowsrenro economizer SurrLr eae a eitonateo conn tune -—- —— ~~ — — — — FURNACE WALL TUBE ~— ‘600}- ' soo, é G : B00} 300} i TIME - HOURS 6/03/80 Figure 4-44. Feedwater Flow and Temperature During Startup - Test 1 4-35© UGHT-oFF 429, = TURBINE ROLL saz a SYNCHRONIZATION 6:01 z Z E 3 e # $ 8 + i TiME-Houns | i roy 7007 i hon 1 40 | 1 00} sod i — ~ =~ —reeowaren 0 economzen : ———rrtvruae B sco = = sitonateo conn, Tuse = Furnace wall TUBE TIME -HOURS Figure 4-45. Feedwater Flow and Temperature During Startup - Test 3 4-36Figure 4-45 illustrates the drum behavior for the start after a weekend outage. This startup used the 501 valve. oso INDICATION oF RATE | OF CHANGE LIMIT LIGHT-OFF 23:25 (6/01/80) / TURBINE ROLL 4:08 S SYNCHRONIZATION 424 sso} ‘TEMPERATURE -F DRUM OUTSIDE TOP )RUM INSIDE TOP )RUM INSIDE BOTTOM ‘TIME - HOURS 6/02/80, Figure 4-46, Drum Metal Temperature During Startup - Test 7 The operation of the unit at Collins with the 501 valve is such that cyclic ‘temperature changes on the drum are below the calculated limits for an unlimited number of cycles, Operation without the 501 valve provides acceptable cyclic life. Headers Thermocouples BNT-13 through BMT-28 were placed on the outlet headers of each component to observe top to bottom temperatures, and rates of temperature change of these headers. Computer analysis has shown that the secondary outlet has the lowest rate of temperature change. For an unlimited number of cycles, the secondary outlet can accept temperature changes of 375°F/h (208°C/h) at design pressures. Headers with thinner walls can accept higher rates of temperature change. Since actual operating pressures are lower than the design pressure, the actual limit rate is higher than the 375°F/h (208°C/h) under operating conditions. 437Figures 4-47, 4-48, 4-49 and 4-50 show the temperature curves for the various Component outlet headers. The limits for any of the headers are not approached. The reheater at low pressure realizes its maximum rate of temperature change shortly after synchronization at 0600 hours when steam is admitted through the reheater and IP turbine. From all the curves, it is seen that the bottom of the header warms faster than the top. This results because the tubes are attached to the lower part of the headers, producing a faster warming rate. 2001 LIGHT-OFF 4:48 PLATEN OUTLET HEADER TURBINE ROLL 5:42 SYNCHRONIZATION 6:02 ‘TEMPERATURE -F TIME - HOURS 6/03/80 — ~~ - —Tor, Bolten CENTERLINE 00° —————20TTOM, BLA. CENTERLINE PRIMARY OUTLET HEADER, —— - Tor, Near SIGEWALL —— — oor TUBE. NEAR SW TEMPERATURE -F 8 s 3 5 T ‘5 ‘TIME -HOURS 6/03/80, Figure 4-47, Platen and Primary Superheater Outlet Header Temperatures - Test 1 4-38PLATEN OUTLET HEADER LIGHT-OFF 4:33 TURBINE ROLL 5:42 ‘SYNCHRONIZATION 6:01 700, TEMPERATURE -F ‘TIME -HOURS 6/04/80 PRIMARY OUTLET HEADER see —--- —ror.o1en cenrenuine Borrow eth CENTERLINE Tor neansioewau T= = nese uae nean sw sod Bro}. : : e soo, sed TIME - HOURS 6/04/80, Figure 4-48, Platen and Primary Superheater Qutlet Header Temperatures - Test 3 4-39Figure 4-49. REHEAT OUTLET HEADER 3 LIGHT-OFF 4:48 TURBINE ROLL 5:42 SYNCHRONIZATION 6:02 ‘TEMPERATURE -F 00 45 $ 35 € ee 7 75 % as TIME - HOURS 6/02/80, 1 _/INDICATION OF RATE SECONDARY OUTLETHEADER —,/ OF CHANGE LIMIT g z . 7 _ ——— BOTTOM, BLR. CENTERLINE el —— _~ — TOP, NEAR SIDEWALL = sorrom.nean sw 109 as TIME - HOURS 6/03/80 Reheat and Secondary Superheater Outlet Header Temperatures - Test 1 440Figure 4-50. 1009; REHEAT OUTLET HEADER LIGHT-OFF 4:33 00 TURBINE ROLL 5-42 = SYNCHRONIZATION €01 & g = sco # 00) * $ $ + TIME HOURS 6/04/80 == = 10F,soten centenune BOTTOM, BLA. CENTERLINE = Tor neae sibewaLe == = sorrow, wean sibewaLe 1000, / SECONDARY OUTLET HEADER f . / a INDICATION OF RATE/ § (OF CHANGE LIMIT / é 3 ‘TIME - HOURS 6/04/60 Reheat and Secondary Superheater Outlet Header Temperatures - Test 3Figures 4-47 and 4-48 show comparisons of superheater temperature change to enclosure (roof tube). In the design of the unit, this temperature differential affects the length of the superheater tube legs between where they pass through the roof and attach to the header. The length must be long enough to permit the deflection of the tubes resulting from the different rates of temperature change of the header and roof. As can be seen, the difference between the header and roof ‘temperature increases gradually as the unit warms up resulting in no limitation to cycling for this unit, Header to roof tenperature differential values used in the design of this unit were 250°F (139°C) for primary and platen outlet headers, and 300°F (167°C) for the secondary outlet and reheat outlet headers. Figures 4-1 and 4-52 illustrate the same data for starting after a weekend outage. 1000 REHEAT OUTLET HEADER, 4 UGHT.OFF 23:25 6/01/80) a a TURBINE ROLL 408 i 3 soc SyNCHRONZATION 424 fo 2 (a aa é fff g a = coo # TIME -HOURS 6/02/80 SECONDARY OUTLET HEADER 1000, INDICATION OF RATE OF CHANGE LIMIT 200) 2 = — — —- —TOP, BOILER CENTERLINE soo, BOTTOM, BLN. CENTERLINE 5 = tor Nese sIDEWALL # — sorrow, nean sw ‘TIME - HOURS 6/02/80, Figure 4-51, Reheat and Secondary Superheater Outlet Header Temperatures - Test 7 4-42750) 650 & TEMPERATURE -F g PLATEN OUTLET HEADER, ped LIGHT-OFF 23:25 (6/01/80) TURBINE ROLL 4:04 SYNCHRONIZATION 4:24 t z + 4 $ $ + $ "TIME -HOURS 6/02/80, PRIMARY OUTLET HEADER, cs = : E oa Sohion ata cemren ne ‘dl es See 4 eco aes Figure 4-52. Platen and Prinary Supecheater Outlet Header Tenperatures = Test 7 4-43,Economizer Thermocouples BMT-29, 30, and 31 were installed in economizer stringers as chordal thermocouples. These were to monitor the surface temperature of the stringer tube on the side facing the gas stream. Located in the gas stream, they were not expected to last for the complete test. The thermocouple sheath was run through the convection pass roof into the penthouse ard then to the same junction box as the other metal thermocouples. During checkout of the project thermocouples, these were found to be cut inside the penthouse, Although repaired during an outage, they failed because of the heat in the penthouse enclosure when the unit was restarted. As a result, no data was collected from tiese thermocouples. 5 £ IGHT- OFF 23:25 z Tinaiwe mots coe 4 TYMCHMOMEATION 424 z 2 & z E a pI Epp} ‘ime nouns 0/270 109 tod & sod : FEEDWATER TO ECONOMIZER i gurrci Tose — = — saturated conn. Tusk = FURNACE WALL TUBE 3 = ‘TIME - HOURS 6/02/80, Figure 4-53, Feedwater Flow and Temperature - Test 7 4-44When the instrumentation was selected for this project, cyclic stress on the economizer inlet header was not recognized as an area to investigate. Figures 4-44, 4-45 and 4-53 are plots of feedwater flow, and temperature to the economizer. The temperature was measured by a thermowell located in the feed line to the economizer. What has been observed on several other units is that with initial feedwater flow prior to rolling the turbine, there is a sudden flow of cold water to the unit that results in a rapid decrease in economizer inlet header temperature, The header inlet temperature then returns to its previous value. Measuring this effect would require installing thermocouples on the economizer inlet header in the gas stream. Because the temperature transient can be rapid, the frequency of recording data should be less than one minute between data points. The temperature excursion has not been observed on all cycling boilers and there is no indication that it occurs on this unit, Therefore, it was decided not to monitor the economizer inlet header for this project. Windbox Figures 4-54 and 4-55 illustrate the windbox temperatures for the overnight operation tests with and without the use of the 501 valve. Figure 4-86 illustrates the same data for startup after a weekend outage. Thermocouples 8MT-33 through BMT-38 were installed to observe pressure part to non-pressure part temperature variations. BMT-33 is located on a furnace wall tube in the windbox. BNT-34 is located on the truss close to BMT-33, 8NT-35 is located on the truss away from the furnace wall. All show no unexpected temperature changes. As expected, the operation of the boiler was not limited by any cyclic stress limitation but from the ability to control steam temperature and its relation to overfiring and underfiring of the boiler during pressure ramps. 4-05TEMPERATURE -F = - - ~~ == suppuy use —— = — Furnace waut type 00+ —— —— —— TRUSS NEAR FURNACE WALL — ~ — - = TSS NEAR OUTSIDE CASING SAT. CONNECTING TUBE LIGHT. OFF 4 TURBINE ROLL 5:42 ‘SYNCHRONIZATION 6:02 45 5 35 ¢ 65 7 75 8 3s ‘TIME - HOURS 6/02/80 Figure 4-54, Windbox Temperatures - Test 1 800 = = = ~~ == surpuy use —— = — Fonnace war tupe — — — TAUSS NEAR FURNACE WALL — = = - = thus near ouTsIDE casiNG SAT, CONNECTING TUBE TEMPERATURE -F LiGHT OFF 4:33 TURBINE ROLL 5:42. ‘SYNCHRONIZATION 6:01 4 3 $ 7 TIME -HOURS 6/03/60 Figure 4-55, Windbox Temperatures - Test 3 4-46Turbine Stationary Parts Stress analysis of the HP-IP inner cylinder was performed using a finite difference shell analysis. This analysis includes the effects of both thermal and pressure stresses. The analysis identified @ section of the inner cylinder in the impulse zone as the limiting area for cyclic operation, However, comparison with the rotor for the same transients demonstrated that in all cases the rotor is limiting for cyclic operation. Finite element analysis had been previously carried out for the inner cylinder of the low pressure turbine. The limiting stresses are proportional to the appropriate temperature differences. These temperature differences were obtained directly from Field data. Comparison still indicated that the HP-IP rotor is limiting in cyclic operation. Turbine Rotor Since all studies indicate that the rotor is the limiting item during cyclic operation, considerable more work was done on rotor analysis, Using the SPK model, the most critical segments of the rotor for various modes of operation were identified, These studies indicated that the first reaction stage of HP turbine and the third stage of the IP turbine were the locations limiting cyclic operation. The stress analysis work assumed that the surface tangential and axial thermal stresses are proportional to the difference between the surface temperature and the volume average temperature. Previous finite element analysis indicated that this assumption is valid for the axial gradients present in these rotors. Temperature time histories for the shutdown and startup transients of tests 1 and 3 were calculated. These calculations were mde using measured steam conditions and the heat transfer coefficient correlations that were validated as part of this study (see Section 5), 4-47These calculations therefore consider the axial effects on temperature gradient. However, the axial gradient effect on stress is ignored. The calculated cyclic life for these two transients were also estimated ignoring axial gradients. This type of calculation was the basis for the estimates that are tabulated in Table 4-2, The comparison between the various calculations are tabulated below: cyclic Life One Dimensional Two Dimensional Temperature Test Temperature Analysis Analysis 1 14,000 33,000 3 8,200 11,700 In both cases the limiting stress occurred at the first reaction stage of the HP turbine. The one dimensional (radial) mocel produces a higher cyclic life than is actually occurring. For these extreme cases, the error in the calculated stress used to predict cyclic life varies from 9 to 18 percent. The greater the stress level, the smaller the error in ignoring exial heat flow. DATA ACQUISITION AND OPERATING HISTORY Data was gathered on a continous basis from July 13, 1979 to October 24, 1980. This data is summarized on a daily basis in Appendix £. Not all data is available for the entire time period due to data acquisition, and instrumentation problems discussed in later sections. However, sufficient data was collected to provide an operational history of this plant during this time period. Typically the unit is unloaded in steps. Sometimes the load is held at what is considered minimum stable boiler load, approximately 120 Mil. When the unit is released, it is unloaded further to approximately 5 percent or less before tripping. This low load is chosen to prevent potential problems in the deaerating heater due to flashing. However, when the unit tripped from higher loads, no Problems developed. Unloading in this manner makes it difficult to maintain high main steam and reheat steam temperatures. However, on this particular boiler, the drop in main steam and reheat steam with load was not generally a problem. In general, the turbine was not excessively stressed during unloading transients due to forced cooling. 4-48Hybrid operation is typically used over the entire load range. However, the throttle pressure ramp normally employed is the same pressure load ramp that would be used for single valve operation. This produces essentially single valve performance over much of the load range. The typical loading and unloading rates are 4 MM/min. This rate is quite slow compared to the capabilities of the boiler and turbine. However, it is acceptable to this system, Overnight the boiler is "bottled up" using an isolation valve and the 500 and 501 valves of the BAW system. A typical drum pressure decay is shown in Figure 4-57. The 500 and 501 valves are ogened prior to firing the boiler in order to supply steam to the steam driven boiler feedpump turbine. The superheater outlet header is cooled significantly during this process. This situation is discussed in Section 6, During firing the boiler before restarting, burner ignition can be a problem and can cause delays in starting. The problem can be either failure to light or failure of the light-off indication in the control room. Vacuum is maintained during most shutdowns using steam fron the auxiliary header which is supplied by one of the five main toilers at the plant. This can be done with the subject units boiler operating as an auxiliary boiler for the station, or from one of the other boilers. Temperature control was usually a problem and during loading, higher than desired rates of change on main steam and reheat steam were seen periodically (Appendix £). Normally, the short periods of time involved did not cause severe stress problens for the boiler or the turbine. As previously noted, the steam temperatures were quite erratic. Once the unit is on-line, any load following occurs at rates of 3 to 4 MN/min. Generally, this does not produce additional significant stress cycles superimposed fon the two shift operating stresses. 4-49LIGHT - OFF 23:25, TURBINE ROLL 4: sor SYNCHRONIZATION 4:24 550 : 5 aso =~ — ~~ surety use & —— - — Furnace watt tuse g — — _— TRUSS NEAR FURNACE WALL 2 — = = ~ = Truss Near oursive casing ge ‘SAT. CONNECTING TUBE. 0 t % + 4 3 € T 3 ‘TIME - HOURS 6/02/80 Figure 4-56, Windbox Temperatures - Test 7 \y pia -onumpncssunc.rsi | \ 81 - LOAD, MW | so 0 \ | x] oo time om Hours 50 os oa os Figure 4-57. Typical Boiler Drum Pressure Decay 4-50‘The unit is not operated every day. In fact, the unit was off-line 58% of the time, A tabulation of the percent of total time and operating time at various load levels is tabulated in Table 4-3. The fact that approximately 50% of the operating time is spent at loads less than 60% indicete that efficency considerations are important. These facts were considered when the hybrid mode, as defined by test 1, was recommended for operating the plant. The normal startup occurred after overnight outage. However, a considerable nunber of starts were accomplished with conditions that were consistent with conditions that exist after weekend outages or longer. The startup data, based on measured temperatures, is defined in Table 4-4, This tabulation indicates the potential error in using cylinder temperature to indicate rotor temperature. Figures 4-58 end 4-59 illustrate the measured temperature differences between rotor and cylinder for high pressure and intermediate pressure turbines as a function of time from trip. The variation of this data with and without vacuum being maintained through the entire shutdown is, illustrated. However, important variables, such as; unloading rate, change in first stage and reheat temperature, gland steam, and time that vacuum was broken, are not included, These items contribute to the scatter in the data, However, the data can be used to demonstrate the potential errors in matching rotor temperature that can exist if cylinder temperatures are used for rotor temperatures. DATA ACQUISITION SYSTEM A Computerized Data Acquisition System, DAS, was installed for this test that can accurately 1og 280 data points and store them on a digital magnetic tape. The system used was a Hewlett Packard System 1000 Model 21 with an IEEE 488 standard 488 bus. The data logged are millivolt signals from pressure and temperature transducers. One hundred of the 280 points of data were remotely scanned 250 ft from the main DAS systen. This system operated in an industrial environment (power plant) and ran unattended except to replace tapes weekly. 451TEMPERATURE DIFFERENCE (ROTOR - CYLINDER) Figure 4, g Reaction ‘TEMPERATURE DIFFERENCE (ROTOR -CYLINDER) 3 L + DIFFERENCE WHILE MAINTAINING VACUUM + DIFFERENCE WHEN NOT MAINTAINING VACUUM r TIME FROM TRIP IN HOURS. a © 10 20 30 40 50 60 70 80 90 100110 120 130140 -58. Temperature Difference Between Rotor And Cylinder At First Stage High Pressure Turbine +__ DIFFERENCE WHILE MAINTAINING VACUUM + DIFFERENCE WHEN NOT MAINTAINING VACUUM + ‘TIME FROM TRIP IN HOURS: be, © 10 20 30 40 50 60 70 80 90 100110 120 130 140 Figure 4-59, Temperature Difference Between Rotor And Cylinder At Third Stage Intermediate Pressure Turbine 4-82The computer software includes a compiler hat allows for program development and modifications, The computer operating syszem includes all software drivers and hardware interfaces necessary to allow for Fortran callable read/write statements to the peripherals included with the system. The data system computer operating system is an RTE (real time executive) operating system, This system allows several prograns to occupy the computer memory at the same time, Depending upon each programs priority and input output demands, the prograns will run independently and at the same time, The DAS system Block Diagram is illustrated in Figure 4-60. DISPLAYCONSOLE | COMPUTER KEYBOARD DATA INTERFACE BUS 1 DATA JRECORDER wana I T INTERFACE MON CARRIER VOLT METER, PRINTER eecer INTERFAC DEDICATED REMOTE LINE APPROX. 300 Fr. h MOT CARRIER INTERFA ‘SCANNERS TINPUTS “| ocaL2 REMOTE omparnrors Eas Fy TOFAST scan | t \ SCANNER REMOTE CRPaPINPOTSH] Sanne 2 =! READY TO FAST SCAN Figure 4-60, Data Acquisition System Block Diagram 4-53To avoid the accumulation of an excessive amount of data, @ reading rate controller is included in the system, In the original proposal of the data system, this was to be an analog type controller. However, the multi-program feature of the data system lends itself readily to a digital approach. The controller sanples up to 12 key variables and compares each to two limits, A rate is chosen for sampling the entire data array based on which limits the variables are within. Both the limits for each variable and the time between scan are inputs and can be changed easily from the system console, The time between scans has been chosen as 20, 10, and 5 data sets per hour. There are six computer programs for this project included in the computerized data system used at Collins. Listings for three of the programs are in Appendix B. The data acquisition system operated in tie Philadelphia Electric Companys Eddystone Plant from July to October, 1978. This was done to facilitate debugging of the system, Data was gathered on turbine metal temperatures, steam plant conditions, speed and load, for Unit #4. After installation the, data system ran unattended except for weekly tape changing. The major difficulty encountered at Collins Station was the result of power failures and/or electrical testing. The system was connected to the essential service bus and not the uninterruptable power supply. This was done since original estimates of Power consumption exceeded the available capacity on the uninterruptable system. After a power failure the tension in the arms of the tape recorder drive was lost. and this required tape changing. An annunciator light in the control room indicated that this problem had occurred, The original power estimates obtained from the Suplier were too high, and apparently based on many systems operating simultaneously. A more realistic requirenent would have been one-fifth of the original estimate and would have allowed wiring to the uninterruptable power supply. The only repair required by the DAS during 18 months of operation was replacement of @ scanner card. Frequent operation of the printer dried out the ribbon considerably, resulting in a more frequent ribbon replacement than had been anticipated. 4-54The data system operated quite successfully. The system was used as a backup to the BAW fast scan system during open-loop test?ng. During this time data was gathered twice a minute, This back up practice prevented rerunning of one of the open Toop tests. During cyclic duty operation tests, the plotting capability provided quick insight into the causes of the behavior witnessed during that test. This permitted discus- sions of the test inmediately after each test and facilitated the planning of future tests. INSTRUMENTATION The instrumentation for this project was extensive and is discussed in detail in Appendix A. A total of 249 variables were measured on a continuous basis for 15, months. The specific area of instrumentation are as follows: 100 turbine metal temperatures © 39 boiler metal temperatures © 35 steam and feedwater temperatures ¢ 10 control signals © 12 gas or air temperatures © 17 pressures ¢ 18 flow measurements © 21 miscellaneous signals The turbine thermocouples were distributed as follows: 42 stationary part temper- atures in the HP-IP turbine, 18 HP-IP rotor bore temperatures, 2 steam chest and 38 stationary part temperatures in the LP turbine, The 18 rotor bore temperatures measurements are unique to this test program since this was the first time that high, and intermediate pressure rotor bore temperatures were measured on an operating steam turbine. Inductive power was used to allow continuous operation of the telemetry system. The boiler metal thermocouples are distributed in the following manner: 10 in the drum, 3 in the primary outlet header, 2 in the roof tubes near the side walls, 3 in the platen outlet header, 4 in the secondary cutlet header, 4 in the reheater outlet header, 3 in the economizer stringers and 10 at other miscellaneous locations. 4-55A substantial amount of instrumentation was used for boiler model validation. These points are identified in Appendix A. DATA REDUCTION Data tapes were changed approximately on a weekly basis and sent to the Westinghouse Computer Center in Monroeville, Pennsylvania. Various schemes were tried for transmitting this data to Babcock and Wilcox Company (B&W). The final scheme consisted of recording a tape of reduced data in engineering units and forwarding this tape to B&W. The weekly tape changing concept expedited the reduction of data and also prevented accumulating Targe amounts of faulty data due to some malfunction in either the instrumentation or the data systen. Essentially three data reduction and manigulating computer programs were developed. The listing of these programs are in Appendix C. These programs consisted of the following: I, Data Reduction - This program converts analog data to engineering units. II. Data Plotting - This program calculates certain variables and allows for plotting of any five data pcints on the same graph for one or two days. IIL, Data Summary - This program produces an summary of the data. The Data Reduction Program I converted the raw data (voltages) to engineering units. In so doing, it applied the appropriate calibrations. The standard "E" type thermocouple conversions were applied to all boiler thermocouple data. The stationary turbine metal thermocouples used specific calibration information for each reading, This was done since these thermocouples were to be used for validating heat transfer models. The telenetry system calibrations were applied to all rotor thermocouples without any specific thermocouple calibration included. Specific thermocouple calibration was not warranted in this case after comparing the effect of applying specific wire thermocouple calibrations on the overall error potential, In instances where plant sensors were used, the calibration information provided by Baily Meter, or Sargent and Lundy Engineers, were used without correction. However, eleven pressure transducers were installed specifically for this test. Calibration information specific to each transducer was applied in this instance. These calibrations included the effects of water legs where necessary. 4-56Program I produced a tape of data converted to engineering units for further analysis. In addition, daily summary plots and calculations for each day were also developed as shown in Figure 4-61 through 4-64, These daily summaries allowed a quick overview of that particular day's operation. They highlighted any potential sensor malfunction. In addition, they illustrated any plant malfunction such as water induction. Program I, in addition to producing a enginzering unit data tape and daily summary, provided input to the summary program (Program III). The results of this summary are discussed in Section 4, 100) 300) 400) 600. 8 270] 260] s40 8 g THROTTLE PRESSURE PSA ION 8 8 s g 360. MEM. DEGF (X100) 3 & 8 8 8 B_ SPEED RPM 8 FIRST STAGE TEMP - DEGE HO? RENEAT TEMP. BEGE g 8 © LOAD- MW ® X Main’ steal eng TIME IN HOURS, o 2 4 6 8 10 14 1 18 2 2 0 wer 728 Figure 4-61. Daily Sunmary Plot of Turbine DataEo] 0,820: g lz 80] § 0} 20) fo 6 E ae (8 SB eos eof nol #2 oo] sol sold a 8 bE ES o|S elt 30/3 °em me |z PB 25 »|8 05 sold aX [+ | lO 0} 20) oo to} 10] 30 TIME IN HOURS \ ol ol o 4 16 18 a 0 iar 1128 Figure 4-62. Daily Sumary Plot of Boiler Data DATA COLLECTION FOR 7/27/1979, BEGINNING ATO:6 ME. TIME. ATC ALARMS FIRST VALUE —LAST_-—-VALUE NO. P GLAND (STM-MTL TEMP DIFF GT 200 - GEN END 0. 2.45955E+02 2205 -2148sse+02 125 P GLAND (STM-MTL) TEMP DIFF GT 200- GOV END 278 201715E+02 2333 -200900E+02 60 Figure 4-63. Automatic Turbine Control AlarmsDATA COLLECTION FOR 7/27/1979, BEGINNING AT 0:6 START UP CONDITIONS. FIRST STAGE METAL TEMP (DEEP) = 553.5 FIRST STAGE METAL TEMP (MID-POINT) = 570.5 IP BLADE RING TEMP = 581.4 MIN IP ROTOR BORE TEMP = 501.0 IP BORE TEMP AT STAGE 3 = 604.2 MIN HP ROTOR BORE TEMP = 547.1 HP BORE TEMP AT FIRST STAGE = 559.6 GLAND STEAM TEMP AT ROLL = 595.8 TURBINE IN SINGLE VALVE MODE AT SYNCHRONIZATION THROTTLE SUPERHEAT = 113.3 ‘THROTTLE TEMP AT ROLL = 665.5 DRUM PRESSURE = 1389.7 ‘THROTTLE PRESSURE = 1063.8 LP CYLINDER AXIAL TEMP DIFFERENTIAL = 1415 INTEGRATED LOAD = 5591.3 MW- HOURS —_357.8 AVERAGE MW AT LOAD INTEGRATED FUEL FLOW = 2860625.6 LBS INTEGRATED EFFICIENCY = 34.87 PERCENT REMOTE CONTROL SELECTED = 13.69 HOURS. SINGLE VALVE MODE = 6.80 HOURS MAX Max PARAMETER UNITS RATEUP TIME RATEDOWN- TIME Loap PCT/MIN 9 10.06 12 2293 MAIN STEAM TEMP DEGF/HR 3639 22.63 3108 22.03 FIRST STAGE TEMP DEGF/HR 335.6 776 555.5 22.86 HUT REHEAT TEMP DEGF/HR 367.7 116 248.6 21.63 SPEED RPM/MIN 85.0 6.86 DRUM SAT TEMP. DEGF/HR 140.8 6.21 -202.1 776 BREAKDOWN OF HOURS AT LOAD IN PERCENT ZERO 0-10 10-20 20-30 30-40 40-50 50-60 60-70 70-80 80-90 90-100 OVER 100 TOTAL 825 41 70 45 65 87 4335245 6.32 «2.99 0.00 23.85, Figure 4-64. Startup Sunmary and Load Distribution 4-59The major problems encountered during the data reduction phase of this project were as follows: © Correcting for calibration drift of some pressure transmitters. © Obtaining all input information from tapes that did not have an end of tape record. This was caused by loss of power or the data tape not being changed as frequently as desired. @ The time lapses between data gathering and reduction due to mail delays. One data tape was erased on site by mistake, No data was lost due to loss of tapes or inability to read the data from the tape. The results of the data plotting program (Program III) capabilities are demonstrated in Figure 4-65. This figure shows the comparison of the superheater outlet tempera- ture and throttle steam temperature for two different days superimposed on the same plot. sn Ss kr ix cSt - LOAD, MW vo] a] co) RETR Sem ane 960] 950) 4801 | 600} 600] 60 J / {tem nouns — 50! sso] q+ aa 4 5 6 7 8 6/3 6/3 Figure 4-65. Typical Data Reduction - Program IT PlotTable 4-1 CYCLIC OPERATION TESTS (Description of Tests) Test_No. Dates of Tests 1 Shutdown and restart after overnight using hybrid 6/2-3 operation sliding drum pressure. 2a Same as Test No. 1 except 501 valve used to 5/7-8 control throttle pressure, 2B Repeat of Test 2a. 5/14-5/15 3 Shutdown and restart after overnight using single 6/3-4 valve sliding pressure using 501 valve. 4 Shutdown, using constant throttle pressure to 36% 8/4-5 power, and restarting with same pressure ramp after overnight outage. Boiler fired without using 502 valve. 5 Same as test 4 except constant pressure maintained 6/1l-12 to 25% power and boiler fired with 502 valve. 6 Startup after weekend outage without use of 502, ays 518, and 519 valves. 7 Same as Test 6 except 502, 518 and 519 valves used. 6/2 8 Shutdown and restart using hybrid valve mode except 3/19-20, same pressure ramp used as single valve operation. 4-61Table 4-2 ‘SUNMARY OF THO-SHIFT OPERATION TESTS cyclic Fuel Flow Time to Time to Test No. Test Type Life Cycles to Load (1b) —Synchronize(h) Load(h)** 1 Hybrid 33,000 156,000* 1,25 0,99 2A Hybrid 4,300 151,000* 7 1.09 28 Hybrid 38,600 159,000*, *** 2.35 1.22 3 Single Valve 11,700 159,000* 1.40 0.99 4 Const. P. = = 1.50 0.93 5 Const. P. 15,400 165,200 1.45 1,21 ‘SUNMARY OF STARTS AFTER WEEKEND OUTAGE 6 Hybrid ~- - 4.0 2.70 7 Hybrid 6,000 318,133 4.9 3.05 * Estimated to be on conmon loading schedule to 95% power ** Estimated from average loading rate to 95% power *** Corrected for hold due to eccentricity 4-62Table 4-3 SUMMARY OF OPERATING HOURS Percent Time Load Range of Percent of (in percent) Total Time On-line Time 0 58.4 0.0 0-20 19 4.6 20-40 12.0 28.8 40-60 7 Wt 60-80 7.3 17.5 80-100 10.1 24.3 over 100 3.2 nT 4-63Tabie 4-4 NUMBER OF STARTS AT VARIOUS VALUES OF TEMPERATURE HP. First HP, First Temperature Range Stage Rotor Stage Cyl. IP Rotor IP Blade Ring Below 250 1 2 1 2 250-350 1 1 1 1 350-450 a 13 6 6 450-550, 18 19 12 a 550-650 23 20 a 16 650-750 22 a7 18 25 750-850 29 1 4 32 Above 850 1 0 10 0 4-64Section 5 MODEL VALIDATION TURBINE HEAT TRANSFER ANALYSIS Philosophy of Test Program A total of 100 turbine metal temperature measurements were included in this test program. These 100 measurements were allocated as follows: © 18 H-1P rotor bore © 42 HP-IP stationary parts © 38 LP stationary parts © 2 steam chest These thermocouples were installed primarily for heat transfer coefficient eval- uation. However, some thermcouples were installed to provide insight into turbine operation from direct measurement. To determine heat transfer coefficients, the steam conditions, speed and load are needed. Certain conditions were determined directly from measurement. However, to Supplement these measurements, calculations were made to identify variables such as turbine flow, stage by stage pressures and temperatures, seal leakage flows, and extraction flows. The calculation techniques used to develop this information are not discussed in this report since they are generally available. The heat transfer coefficients correlations validated by this program can be broadly applied to tur- bines of different construction and blade path design philosophies. The heat transfer coefficient correlations were validated using the inverse ap- proach. Simply stated, this involves varying boundary conditions in a heat conduc- tion model until satisfactory agreement is obtained between test and calculated values. The heat conduction models were detailed finite difference models of the high, and intermediate pressure turbines rotor and cylinders, and the low pressure turbine cylinder and blade rings, The heat conduction program used to calculate the temperature distributions in these various models has the following capabilities: Sel© Metal properties variable with temperature @ Transient or steady state solution capability * Boundary conditions (temperature and heat transfer coefficient) that can be varied with tine © Surface to surface radiation To evaluate the heat transfer coefficients from test data, a combination of steady-state and transient heat transfer analysis was required. In locations where at steady-state heat conduction controls the temperature distribution, transient analysis was required, In other locations steady-state heat transfer was deemed adequate to evaluate heat transfer coefficients. He-IP Rotor Heat Transfer The rotor heat transfer coefficients in the high and intermediate pressure turbines are quite high at load. Therefore, it is quite difficult to validate heat transfer coefficient correlations using either steady state or transient data at load. This is true since with high surface heat transfer coefficients heat conduction will dominate. For this reason the rotor heat trasnfer coefficients were validated using transient data on speed control. This was accomplished using cold start data from the July 18th, 1979 startup. Prior to the July 18th startup, the turbine had been shut down for strainer removal and other miscellaneous maintenance items, During this outage, an extensive check- out of the rotor telemetry system was made (Appendix A). The telemetry was func- tioning properly after this outage and data was obtained from 11 of eighteen thermocouples. The rotor segment modeled for analysis was the region between the centerlines of the umber one and two bearings. The bore of the rotor is assumed to be an adiabatic surface, The rotor was modeled in the blade path to allow one temperature and one heat transfer coefficient for the entire stage. This type of boundary condition definition was deemed satisfactory considering the fact that rotor bore temperature Measurements are the measured quantity. In certain regions of the rotor, 5-2projections from the main rotor body were eliminated and replaced with the conduction equivalent, The heat capacity of these regions was not included. This introduces only a slight error with the rates of temperature change considered. Figures 5-1, and 5-2 illustrate the steam conditions used to calculate the high pressure rotor temperature distribution, Figure 5-3 shows the measured pressures across the high pressure turbine which were used to calculate flow through the reaction blades of the high pressure turbine. Figure 5-4 illustrates the temperatures used to calculate the temperature distribution in the intermediate pressure section of the rotor. 200) 100) 400) 200. P1__ - THROTTLE PRESSURE, PSIA 90} 90} 360) 0. ‘TSW1 - THROTTLE TEMPERATURE, °F S10 - SPEED APM cSt - LOAD, MW 140] 70} 200) 140 a | = 120}. 60}-240} 120 pe | sn so Samo ‘ —— Esa l® sol e0|® 8 8 3 8 Soy ey aoa TIME IN HOURS me Figure 5-1, High Pressure Turbine Inlet Conditions for a Cold Start ~ 7/18100) 100) 400) 200. Tsw2 - FIRST STAGE STEAM TEMPERATURE, °F a two] TSW3”COLDRENEAT STEAMTEMPERATURE."F =. | =) esto - SPeeD. RPM i est”: toap, aw | * TSW3 (K10») 838 8 % 8 8 & 8 a 8 ‘TIME IN HOURS ee Figure 5-2, High Pressure Turbine Steam Tenperatures for a Cold Start - 7/18 100) 200) 200) 500) 400. 90} 180} 190} 450 aso. FIRST STAGE PRESSURE (HIGH RANGE), PSIA FIRST STAGE PRESSURE (LOW RANGE), PSIA COLD REHEAT PRESSURE (HGIH RANGE), PSIA COLD REHEAT PRESSURE (LOW RANGE}, PSIA. | SPEED, RPM | 80) 160} 160} 400] 220. 70} 140} 140] aso. 60} 120) 120} 300} 240. 50) 100} 100} 250} 200. TIME IN HOURS ee wR Ba Figure 5-3. High Pressure Turbine Steam Pressures for a Cold Start - 7/18 5-4100) 100 8 Tsw6 (x10, 8 Tew4(xi0") 8 x + 8 8 8 8 8 8 ro} 10) Figure 5-4, 100) Figure 5-5, 400) CSi0,10y % 3 8 Intermed 200) T5W4 - IP INLET TEMPERATURE, °F ‘TSW6 - IP EXIT TEMPERATURE, °F ro S10 - SPEED, RPM 681 - LOAD, MW —< fT 9 0 1 2 8 4 6% 6 4 Hiate Pressure Turbine Steam Temperatures for a Cold Start - 7/18 TR2_- ROTOR BORE TEMPERATURE, °F S10 - SPEED, RPM cSt - LOAD, MW Ty = CALCULATED ROTOR TEMPERATURE o | aaa 7 Comparison Between Calculated and Measured Rotor Bore Temperatures for a Cold Start - Generator End Gland Region - 7/8 5-5Figure 5-5 through 5-13 show the comparisons between calculated and measured temperatures for each of the nine axial locations in the turbine bore. These thermocouple locations are illustrated in Appendix A. Prior to the start, the rotor was on turning gear with gland steam for almost 55 hours. This fact required an analysis to initialize the rotor's axial temperature distribution. Inputs to this analysis were the measured cylinder temperatures and gland steam temperature. With the exception of the measured rotor temperature TRIO, which is located in the IP dunny area, the initial agreement was quite good. 100) 100) 400 90) 90) 380, ‘TR3 - ROTOR BORE TEMPERATURE, °F TRA” ROTOR BORE TEMPERATURE, °F S10 - SPEED, RPM m0) 80) 320, CS1_ - LOAD, MW Gl = CALCULATED ROTOR TEMPERATURE 70] 70| 200 = | 200} -20) = |3 |e ® 501 ™ sol 200 z |2 j2 | aol ao] 160)? % 0 + 0 42010 z0| 20] 0. ro] 10] 4 TIME IN HOURS o! of o. ————— 9 wo 6) 6 Bt ma m8 Figure 5-6. Comparison Between Calculated and Measured Rotor Bore Temperatures for a Cold Start ~ High Pressure Exhaust 5-6100) 100) 400) 200: 1) - CALCULATED ROTOR TEMPERATURE 0] 901 360] 10] TRS - ROTOR BORE TEMPERATURE, °F TRE - ROTOR BORE TEMPERATURE, °F S10 - SPEED, RPM 0] 80) 920) 160) OST - LOAD, MW 7 io ole 40. Bseo. Xo * 30 20. TIME IN HOURS o) ol ol okt 9 10 17 Figure 5-7. Comparison Between Calculated and Measured Rotor Bore Temperatures for a Cold Start - First Reaction Stage - 7/18 4100) 400 200 Tilo : ROTOR Bone TEMPERATURE, °F 10 " 681) - Loap MW. a = CALCULATED ROTOR TEMPERATURE ? 1 apne ne as ea ol ol okt 9 0a 2 13 Figure 5-8. Comparison Between Calculated and Measured Rotor Bore Temperatures for a Cold Start - Control Stage - 7/18100) 400 90] 260) 80} 320, oo? ao. + |, 30. 10. °. Figure 5-9, a Cold Star 100 90} 360. 80] 320. 70} 280. + 04 “120. 20} @. 10] 40 Figure 5-10, =. Comparison Between Calculated and Measured Rotor Bore Temperatu ‘t= IP Dummy = 7/18 200 140] o- TRIO - ROTOR BORE TEMPERATURE. S10 - SPEED, RPM f——| 81 = LOAD, MW TIME IN HOURS i, a 2 “to wee TRI1 - ROTOR BORE TEMPERATURE, °F S10 - SPEED, RPM S1_ = LOAD, MW. J © CALCULATED ROTOR TEMPERATURE rd TIME IN HOURS 9 2 1s Wa 18 10 16 1 CALCULATED ROTOR TEMPERATURE | 7 res for 7 Comparison Between Calculated and Measured Rotor Bore Temperatures for a Cold Start - IP Rotor Inlet - 7/18 5-8100) 400 90} 360) 90/320) 70} 280] | oo Figure 5-11. During Cold oo les mle a Eleese or E wlBrold + le bo Plies ais oo ee Figure 5-12. TRIS - ROTOR BORE TEMPERATURE, °F S10 - SPEED, RPM cst - LOAD, Mw | - CALCULATED ROTOR, TEMPERATURE i TIME IN HOURS be 9 wo ae ag ta a c 7 ‘omparison Between Calculated and Measured Rotor Bore Temperatures Start - IP Turbine Third Stage - 7/18 200) Ma TRIS - ROTOR BORE i TEMPERATURE, °F 160. S10 - SPEED, RPM | csi - Loo, Mw 7 1 GatciuateD ROTOR | SEMPERATURE 120 100 "| | «| eo Pho TIME IN HOURS 9 to aes ea Comparison Between Calculated and Measured Rotor Bore Temperatures During Cold Start - IP Turbine Fifth Stage - 7/18 5-4The value of TR2 is in general predicted high because the gland steam temperature measurement is made in the supply pipe and not at the gland itself. The other end of the turbine TR17 (reference Figure 5-13) is also predicted high. The maximum deviation fs approximately 20°F (11°C). The measured rotor temperatures at the exit of the high pressure turbine, TR3 and TR4, are illustrated in Figure 5-6. At this location two thermocouples were active and agreement with each is considered excellent. Data and calculation for the first Stage region of the high pressure rotor are shown in Figure 5-7. Throughout the speed control range, there is excellent ayreement between these two measurements. However, as discussed in Appendix A, TR6 Is in error as the speed is increased from 2100 to 3600 rpm. The agreement between calculated and measured values is good with a maximun deviation of 11°F (6°C). Figure 5-8 shows the measured temperature distribution under the control stage (TR7), This area should be analyzed using a three dimensional model due to the holes for cooling flow under the control stage. This effort was outside the scope of this project. However, to model the complete rotor, the boundary conditions in the area were modified to account for this complex geometry. As shown, @ maximum error of 34°F (19°C) was obtained. It was confirmed that this error had a negligible effect on the remainder of the high pressure rotor calculated temperatures. In the area of the IP dummy (TR10), the agreement between measured and calculated results were the poorest. The initial calculated temperatures were off by 22°F (12°C) while the maximum deviation during the heating transient was 21°F (12°C). After increasing speed, the signal of this thermocouple became quite erratic as dis- cussed in Appendix A. The flow in this area is a mixture of steam from the HP exhaust and exhaust of the control stage, Therefore, a source of error in this area is the steam temperature, However, the temperatures in the area of the first stage IP turbine (TR11), and the stationary flow guide temperature THP12 are also affected by the mixed cooling flow temperature. Figure 5-10 shows the comparison between calculated and measured temperatures for the location of TR11. The agreement between test and calculation is quite good through the speed and load range. Analysis of THP12 data, a stationary part temperature, also confirmed the flow and mixing assumption that agrees with calculation of TRL.The data at the third stage of the IP inlet turbine (TR13) shows excellent agreement up to the increase in speed. This comparison is plotted as Figure 5-11. The maximun deviation is approximately 10°F (6°C). The IP thermocouple in the region of the fifth stage showed excellent agreement through the speed range. This comparison is illustrated in Figure 5-12. However an error of 22°F (12°C) is observed during the loading. The exhaust end of the IP rotor thermocouple TRI? agrees well with data through the speeed and load range, This comparison is illustrated in Figure 5-13. 100) 400 90] 260. TRI7 - ROTOR BORE ‘TEMPERATURE 80) x20. S10 - SPEED, RPM est - LOAD, Mw = CALCULATED ROTOR, 70) 290 ‘TEMPERATURE Seg 5s 50} 200) E 40{8360 + |a 20} 120 20} 80. 10] 40. ol o. m8 m8 Figure 5-13. Comparison Between Calculated and Measured Rotor Bore Temperatures During Cold Start - IP Turbine Exhaust The comparison between measured and calculated rotor expansion can be used as check of the measurements of temperature and therefore the calculations of temperature distribution, This is a gross check due to the potential errors introduced in the manipulation of the measurements of rotor d'fferential expansion, cylinder expansionand thrust bearing housing movement to obtain an absolute rotor growth. These values must be combined with rotor shrinkage due to centrifugal stress. The Comparison between this “psuedo" measured and calculated value of growth is illustrated in Figure 5-14. This agreement is satisfactory. os: © carcuaten oe A MEASURED 0.3: 02 EXPANSION IN INCHES ot, 4 . 6 7. 3. TIME IN HOURS Figure 5-14. Comparison Between Calculated and Measured Rotor Expansion During Cold Start Isotherm plots for the entire rotor are most instructional for viewing the types of radial and axial gradients produced during transients. Figure 5-15 shows the almost purely axial gradient developed during turning gear operation with gland steam, The time of this figure is shortly after rolling. Figure 5-16 shows these isotherms after rolling the turbine with steam for 3 hours and 45 minutes. The high pressure rotor has an almost entirely axial gradiext while the IP turbine stil] has a pronounced radial and axial gradient, This is due to the smaller rotor diameters and the higher heat transfer coefficients in the HP turbine. Figure 5-17 shows the isotherm distribution approximately one hour after loading. 5-12RADIUS - INCHES. RADIUS - INCHES TEMPERATURES CURVE VALUE pone’ 250 a ane @ os ie asa 224 ie 2608 2 be 2 bre 23 06s 180] ae alr 4 3 aro #3823 a 140) 7 4 4| 100 lo} 6.00} | 200 7 7 —— 000 #09 400 600-800 100. 120.440.160.180. 200200, LENGTH - INCHES Figure 5-15, Rotor Tenperature Distribution on Turning Gear TEMPERATURES CURVE VALLE yee eo? 260). a dea 8 ober 12 2ass ens 220, 3 be se boars aos weol. 36 aaa trae 140}. wo 4g 6.0 200 r 1 600 800 700.420, 740, LENGTH - INCHES. Figure 5-16. 5-13 760: 780. Rotor Temperature Distribution During Speed Control - 2200 RPMTEMPERATURES CURVE VALJE 1 1663 260) 4 206.4 a 2593 333 16 3663 2 © 4202 2604737 2% 827 325805 366340 100 6875 Ih a fa 5 0 sok [4 | a : Ll 2.00! 7 7 Ooo 200 a0 saa B90 00 40.4018. 80.280 88 LENGTH- INCHES Figure 5-17, Rotor Tenperature Distribution After Synchronfzat ion M 854M 709M 867m 8s M50 770 ot Csr Ons Cos cas Coe fo Moe 260] 220 fal 3 iso 5 | $40} | 3 | g = , se ooo PN 70 55 \ fay 0] 71 76 ey 2.001 53 Sco 288 aed S00 wd Yoo. 80 adhd Sg = Measured Temperature Isotherns: 80 = 885.1; 1 = 160.5 LENGTH - INCHES C = Celeulated Temperature Figure 5-18. Comparison Between Calculati State - Full Power ed and Measured Rotor Temperatures: 5-14 SteadyThe comparison of measured and calculated temperature at high power is less revealing for two reasons as stated previously. These are due to heat transfer coefficients are quite high and that the telemetry signals were erratic. However, a comparison is illustrated in Figure 5-18 of the calculated isotherms, and measured to calculated temperatures. A discussion of the heat transfer correlations must include the logic behind applying these values and the limits of their applicability. This discussion is in the following paragraphs. The high pressure turbine blade path was calculated using flat plate heat transfer in the blade path and straight seals on the rotor body between rotating rows. The straight seal correlation is obtained from 2eference 2. When the Reynolds number, based on twice the clearance, is below 8700, equation (5-1) is used. However, when the Reynolds number is above 8700 equation, (5-2) is used: 0.6 -04085 4) 0-.075 T= o.22re (3) (a) (5-1) 0.8 TBs ogre (9) (5-2) The flat plate correlation recommended is equation 5-3. The Reynolds number in this equation has a characteristic dimension of length. AL = 0.0096 ne? pret (5-3) In the blade path of the IP turbine, the sizuation is somewhat more complicated because of the use of side entry, as opposed to, “tee” root blades. In the seal area, stepped seals are used and the correlation for stepped seals are shown as equations (5-4) and (5-5). Equation (5-4) applies to Reynolds numbers based on twice the clearance of less than 6000 and equation 5-5 is applicable to Reynolds nunber of greater than 6000. 0.6 My) -0.56 hes = 0.98 Re (Ly (5-4) 0.7 Hy -0.56 0.410 Re (Lh (5-5)The heat transfer to the steeple of a side entry blade is more complicated. In normal practice, one would assume no floy through the small clearances of the blade root (due to clogging by deposits). Wher this is true, the heat transfer into the rotor body is dominated by the face heating on the inlet and exit sides of the root. The first stage of the IP rotor has cooling flow and this fact is always ‘included in the analysis. The face heating is determined using rotating disc heat transfer. The correlation based on radius is shown as equation (5-6). This equation is developed in Reference 3. 2 We ory Ca) 08 ps8 (5-6) When the disc does not start from zero radius, approximately a 30% higher coefficient is applied for the geometries in use. If the Reynolds nunber is quite low, the laminar correlation should be applied below Reynolds numbers of 180,000. This correlation is based on References 4 and 5 and is shown as equation 5-7, (5-7) However, the unit was only in service 3 months when the cold start of July 18, 1979 was run, Therefore, it is possible that the side entry serrations were not clogged. This effect was estimated to increase the surface heat transfer in the regions of the steeple by 30%. This correction was necessary to obtain the calculated tenperatures presented in Figures 5-11, 5-12 and 5-13. In regions of the rotor where the axial velocity effects are small relative to the rotational effects, rotating cylinder type heat transfer is assumed. The correlation used is developed in Reference 6 and shown as equation (5-8). AR = 0,043 (CRY) 9-7 pr 0-36 (5-8) In areas where axial flow passes through a passage formed of a rotating surface and a stationary surface, the flow becomes complex. When axial flow is relatively low, vortices called Taylor vortices develop and they dominate the heat transfer. As the axial velocity increases the effect of Taylor vortices diminishes. The correlation, shown as equation 6.9, was developed in Reference 7. BE = (A, + Ay) Re?-8 prl/3 (5-9) 5-16wheres rp = outer radius ry = inner radius b= rary Rye ML w2b/ v Ry = V 2b) v a 2 o.ozo/}i + a 0.0218 Stepped Seal Correlations (equations 5-4 and 5-5) were used in the gland and dummy seals. The rotor ends were calculated using the disc heat transfer equations 5-6 and 5-7, Cylinder Heat Transfer The location of the HP-IP cylinder temperature measurements are shown in Appendix A. The analysis concentrated on the inner cylinder of HP-IP turbine, All HP-IP blade ring thermocouples were apparently destroyed during turbine erection. However, the total heat transfer coefficient correlation “package” will allow determination of these values, The analysis of the HP-IP turbine required steady state and transient analysis to establish the levels of heat transfer coefficients that are valid over the entire operating range. Two steady state calculations were performed at 105 and 569 MW.The transient analysis used was the same cold start transient used to validate the rotor heat transfer. Figures 5-19 and 5-20 show the isotherm distributions and the comparisons between measured and calculated temperatures for 105 and 569 MW, respectively. The maximum deviation from calculated to measured values of calculated temperature is 37°F (21°C) and this is in an area of steep axial and radial gradients. Transient calculations were made using the same heat transfer correlations that satisfied the steady state analysis. CALCULATED TEMPERATURE DISTRIBUTION ALCULATED TEMPERATURES MEASURED M MEASURED VS. CALC! ee “ ener 682 679 629 585, VERTICAL & os LOCATION LS 588 Mw «€ B79 -C on es2 661 ea7 sot 548653 VERTICAL LOCATION Figure 5-19, HP-IP Inner Cylinder Temperature Comparison at Low Load (105 NW) 5-18CALCULATED TEMPERATURE DISTRIBUTION MEASURED VS. CALCULATED TEMPERATURES, MEASURED =_M CALCULATED =~ \ ore 828 19M = - VERTICAL «= @ LOCATION CI 735 € BASE on VERTICAL LOCATION Figure 5-20, HP-IP Inner Cylinder Temperature Comparison at High Load (569 MW) 6700673781 793 834 Figures 5-21 and 5-22 show the comparison between calculated and measured temperatures in the first stage zone of the HP-IP turbine during a cold start. In all cases the calculated response is somewhat lower than measured values. However, measured data is matched as steady state is reached. Figure 5-23 shows the transient response of the temperatures in the high pressure exhaust zone. The transient agreement is not as good as steady state. However, again the steady state agreement is good. Figure 5-24 illustrates the comparison between calculated and measured values in the IP cylinder in the extraction zone. This data again illustrates the same behavior showing that the calculated temperatures in general respond slower than measured data. The delayed response is not explainable at this time, This increase was not included in the correlation. 5-19MeasuneD ~ CALCULATED 7 3 aaa Figure $-21. Comparison Between Calculated and Measured HP Turbine Cylinder Temperatures During Cold Start-Inpulse Zone, Governor End. 8 P22 THEA (X108) Aw s 8 °° MeasuneD caLCULATED 8 101 a 7 Te Te Figure §-22. Comparison Between Calculated and Measured HP Turbine Cylinder Temperatures During Cold Start-Impulse Zone, Generator End———— wensuneo - <= = == catcuaTeD wo} = @ = wo E sod ° ea Figure 5-23. Comparison Between Calculated and Measured HP Turbine Cylinder Temperatures Ouring Cold Start - HP Exhaust measured = CALCULATED arena 401 005 aaa We em Figure 5-24. Comparison Between Calculated and Measured IP Turbine Cylinder Temperatures During Cold Start - IP Extraction 5-21To analyze the low pressure turbine heat transfer, only steady state calculations were used. Additional blade path calculations were required to define intermediate pressures, temperatures and seal leakage flows. Essentially, four independent heat conduction models were used to correlate low pressure turbine temperature measurements with calculations, These models were as follows: The number one blade ring. © The inner cylinder at 3 ci-cumferential locations which included a high concentration of thermocouples. Since bosses for thermocouples were needed in certain areas to minimize the cylinder stress, an analysis of the effect of these bosses was developed. The comparison between calculated and measured blade ring temperatures are shown in Figures 5-25 and 5-26 for 105 MW and 465 MW load conditions. The agreement of both measurements at the two load conditions is excellent. M MEASURED ¢ CALCULATED 500 514 M FIRST EXTRACTION oi 510 ZONE PRESSURE = 23.5 PSIA TEMPERATURE 405°F INLET ZONE 500 PRESSURE = 44.4 PSIA TEMPERATURE = s3s°r { 520 ‘490 508 M 508 Figure 5-25. Comparison Between Calculated and Measured Temperatures Low Pressure Turbine Blade Ring No, 1 - 105 MW Steady State 5-22M MEASURED © CALCULATED inst EXTRACTION Zone 620m 560\ | pnessune = 60 PsiA moo TEMPERATURE = 490° eo evo seo seo rm 7 ZONE PRESSURE = 155.5 PSIA 630 ZL TEMPERATURE © 842" ‘r0 e20 L | ats wee Figure 5-26. Comparison Between Calculated and Measured Temperatures Low Pressure Turbine Blade Ring No, 1 ~ 465 MW Steady State Figure 5-27 illustrates the calculated temperature distribution at 357 MW at a Tocation 10 degrees below the horizontal joint. This section includes measurements on the extraction walls and the inlet stationary ring. The comparison between calculated and measured values is acceptable. Of particular interest is the comparison between measured and calculated values in the wall between extractions 2 and 3 of this cylinder. Extraction 3, at this load and inlet condition, is approximately 1.8% wet. The calculation assumed single phase type heat transfer on this wall, The data supports this assumption: if the single phase heat transfer were augmented substantially by moisture, the measured value of temperature would have been approximately 70°F (39°C) Tower. 5-23-RESSURE, PSIA -MPERATURE,"F THERMAL SHIELD Ec 500 300 260 ra Heso 23M zac a0 EXTRA Pras TE tascsan 2ND ExT Prise T= a0 180 210 160 M- MEASURED (C= CALCULATED Figure 5-27. Comparison Between Calculated and Measured Temperatures - LP Turbine Inner Cylinder - 357 MW Steady State Figures 5-28 and 5-29 illustrate the comparison between calculated and measured temperatures in the wrappers of the base and cover near the vertical centerline. The thermocouples, installed in the wrapper, used bosses which extended through the thermal shield. In the base, there is reasonably good agreement between the measured and calculated results. In the cover, the agreement between calculated and measured values are not as good. This is due to the fact that the bosses are exposed to high velocity wet steam. This aroduces errors which were calculated to vary from 190°F (106°C) to 4°F (2°C), depending on the temperature level. This effect is not seen in the base due to the low velocity that exists in this area. 5-2430M Mm eC arc THERMAL SHIELD mer © 2NDEXTR Poise Te 20 M- MEASURED (C- CALCULATED, Figure 6-28. Comparison Between Calculated and Measured Temperatures - LP Turbine Inner Cylinder Near Vertical Centerline Base - 357 MW Steady State s21M_ 357 M_ 308M 201M somata UF mesans rama, P= PRESSURE, PSIA ‘T= TEMPERATURE, >F Figure 5-29, Comparison Between Calculated and Measured Temperatures - LP Turbine Inner Cylinder Near Vertical Centerline Cover - 357 MW Steady State 5-25The HP-IP and LP cylinder temperature distributions were calculated using the heat transfer coefficient correlation discussec in the following paragraphs. Locations where the flow was separated anc did not fi11 the entire flow area, flat plate heat transfer correlations were usec as depicted in equation 5-10, This correlation is valid for Reynolds numbers (Re,), based on length, greater than 500,000. The calculated values of heat transfer coefficients are strongly dependent on the assumptions made and the specific geometry in question. This requires some familiarity with the specific component. Most specific situations permit "bracketing" the potential situations reasonably well for thermal analysis of the structure. Heat transfer in inlet and extraction manifolds is strongly dependent on the circumferential flow distribution in that equipment. The extraction manifolds always have the take-off pipes to the heater in the base. Therefore, the flow distribution has an orientation that produces higher heat transfer coefficients in the base. These manifold calculations were made using equation 5-11. 023 ao prof (5-11) This relationship is used when the steam is superheated or the moisture content negligible, However, when moisture becomes important, the correlation developed in Reference 8 is used and described in equation 5-12. x | Io 10.28 6x j0.87 Gry ot (5-12) The region between the shrouds of the rotating blades and the blade rings contain seals to limit leakage. If the seal extended over a large segnent of the shroud, some reduced value of equations 5-1, 5-2, 5-3 or 5-4 would be used. This reduction is usually $08. However, in the geometry studied the seals occupied only a small portion of the shroud, and the heat transfer is represented more exactly by the work of Reference 9, This correlation is depicted as equation 5-13. 5-262 0.846 h re \?» qe ( an) (5-13) 2 ue 2, mm 2m)? + EH) wheres Re Vy = axial velocity The minimum Reynolds number is 10,000. For heat transfer between the cylinder and a thermal shield, radiation and free convection would dominate. The spacings are such that the non-transparent radiation aspects of the steam are negligible. OPEN LOOP TESTS Open loop tests were performed at approximately 500, 250, 125 MW using manual control. °All the protection control features were active while holding most control variables fixed. The only controls which vere on automatic were furnace draft and feedwater. For each test, a single input quantity was changed, held to near steady state, and returned to the original value, 500 MM - Basic Input Quantities and Procedures Firing rate 243,400 1b/h Air flow 4,320,000 1b/h Air temperature 526°F (274°C) Gas recirculation flow 370,000 1b/h First stage spray 228,600 1b/h Second stage spray 41,870 Tb/h Reheat spray 0 500 and 50] valves Open Power 500 YW Test 1, Firing rate was reduced quickly to 233,450 1b/h. 2. Air flow was increased to 4,615,000 1b/h 3, Gas recirculation flow was increased to 500,000 Ib/h 5-274. The $56 valve position was decrzased to bring second stage spray to 14,226 1b/h. Ten minutes later, the 556 valves were closed to bring first. stage spray down to 204,000 1b/a. 5. The 558 valve was opened to allow 24,900 1b/h reheat spray flow. 6, The turbine valve was opened producing an immediate drop in throttle Pressure from 2200 psi (15,169 kPa) to 2180 psi (15,031 kPa) and an increase in first stage pressure from 1554 psi to 1587 psi, Turbine additive valve position signal ‘ailed to record. 250 MW - Basic Input Quantities and Procedures Firing rate 122,000 1b/h Air flow 2,510,700 1b/h Air temperature 479°F (248°C) Gas recirculation flow 479,000 Ib/h First stage spray 116,332 1b/h Second stage spray 36,535 1b/h Reheat spray 9,373 Ib/h 501 valves 89.9%, 64.1% 500 valve Closed Power 24a mi Test 1, Firing rate reduced to 113,000 1b/h 2. Increase air flow to 3,033,000 1b/h 3, Increase gas recirculation to 570,800 1b/h 4. Close 558 valve to decrease first stage spray to 71,000 Ib/h 5. Open 558 valve - increase reheat spray to 15,000 1b/h 6. Open 501 valve to 98.5%, 70.88 5-28125 MW ~ Basic Input Quantities and Procedures Firing rate 69,800 Ib/h Air flow 1,727,000 1b/h Air temperature 458°F (237°C) Gas recirculation flow 865,222 Ib/h First stage spray 100,660 16/h Second stage spray 38,790 Ib/h 501 valves 80%, 80% 500 valves Closed Power 124 MW Test 1, Decrease firing rate to 60,130 Ib/h 2, Open 518 valve to 29.5% Open 519 valve to 32.88 4, Decrease first stage spray to 50,600 1b/h Note: Only one ‘spray transmitter was working during this series of tests. 5. Open 501 valve to 87.8%, 91.9% The tests at 500 and 250 megawatts were recorded on both Kestinghouse and B&W recording systems. The Westinghouse systen recorded all variables every 30 seconds. The BAW system recorded 30 variables at two samples per second. A faulty tape caused the loss of most data on the B&W recorder at 125 MW. OPEN LOOP SIMULATION Open loop tests were simulated for the runs at 500, 250 and 125 MW. At 500 MH, the model states were set to the measured states, and measured boundary conditions were applied. The boiler heat transfer parameters were modified to make this a steady state condition, The turbine parameters were not changed fron those calculated from the heat balance. The turbine valve was then set to yield the measured throttlePressure. The model was then allowed to come to a steady state which was different because of the turbine model parameters. Table 5-1 presents measured and model values for the three loads. Examining the data for 500 Mi, the feedwater temperature error is attributable to the error in reheat pressure, The noticeable errors are a reheat pressure which is too high and reheat absorption which is low. The steady states at 250 and 125 MW were generated by applying the measured boundary conditions and then adjusting the 501 valve and turbine valve to get a reasonable match on pressures. The turbine valve position measurement was not found to be reliable. At both of the Tower loads, reheat pressure continues to be high and reheat absorption low. As load is decreased, model boiler efficiency is Tow as shown by the errors in economizer outlet gas temperature (TGEC). These errors are attributed to the heat transfer formulation used in the convection pass components. The heat transfer from flue gas to metal was calculated as proportional to the difference of leaving gas temperature and metal temperature. The original formulation used average gas temperature to metal temperature. It was removed because although more accurate under ordinary conditions, it can lead to a violation of the second law of thermodynamics. At this point, it has been shown that a log mean temperature difference formulation is compatible with the rest of the model and is the most accurate one. The formulation used in the simulation runs is not sufficiently accurate across the load range. Figures 5-30 through 5-47 show certain model responses compared with the plant responses for nine selected transients. It seems reasonable to use pressure and temperature as general categories and further differentiate between the dynamic response and the steady state change. Using this approach, the model and plant steady state responses are compared numerizally and the dynamic responses are compared quantitatively. Fuel Flow 500 Mw Model Plant Throttle pressure 100 psi(590 kPa) 106 psi (731 KPa) Superheat temperature 38°F (21,1°C) 24.5°F (13.6°C) Reheat temperature 40°F (22.2°C) 29°F (16.1°C) 5-30Model reponses have less damping than plant and are too fast as shown in Figures 5-30 and 5-31. THROTTLE STEAM on TEMPERATURE-F 08 ‘TIME-SECONDS MeAsuRED caccutaTeD ‘THROTTLE PREBSURE- S10 08 TIME- SECONDS Figure 5-30, Comparison Between Calculated and Measured Throttle Pressure and Temperature and Reheat Temperature Response to a Step Decrease in Fuel Flow - 500 MW Measuneo ooo0 5 GALCULATED FEEDWATER FLOW- KLB/HR ° “0 ‘30 3855 ‘TIME- SECONDS Figure 5-31. Comparison Between Calculated and Measured Feedwater Flow Response to a Step Decrease in Fuel Flow - 500 MWDecrease S.H. Spray Flow 500 Mi Model Plant. Throttle pressure +7 psi {48.2 KPa) 2 psi (13.8 kPa) Superheat temperature 22°F (12,2°C) 28°F (15.6°C) Reheat temperature 18°F (10°C) 30°F (16.7°C) Model response is too fast as shown in Figures 5-32 and 5-33. Decrease Fuel Flow 250 MW Model Plant Throttle pressure 90 psi (621 KPa) 88 psi (621 kPa) Superheat temperature 40°F (22.2°C) 22°F (12,2°C) Reheat temperature 35°F (19.4°C) 18°F (10°C) Pressure overshoot is not as severe as 500 Mi. All responses are still too fast. These responses are shown in Figures 5-34 and 5-35. Increase Gas Recirculation 250 MW Model Plant Throttle pressure 4 psi (27,6kPa) 8 psi (55.2 KPa) Superheat temperature 19°F (10.6°C) 19°F (10.6°C) Reheat temperature 17°F (9,4°C) 17°F (94°C) The agreement is excellent. However the response is still too fast and has insufficient damping of pressure response, See Figures 5-36 and 5-37. Decrease S.H. Spray 250 MW Model Plant Throttle pressure 48 psi (55.2 KPa) -9 psi (62.1 KPa) Superheat temperature 43°F (23,9°C) 41°F (22,8°C) Reheat temperature 35°F (19.4°C) 28°F (15.6°C) Pressure response is much too fast as can be seen in Figure 5-38. The spray flow and feedwater flow is depicted in Figure 5-39. Qpen 501 Valve 250 Md Model Plant Throttle pressure 4.5 psi (31 KPa) 6 psi (41.4 kPa) Superheat temperature 28°F (15,6°C) 17°F (9.4°C) Reheat temperature 24°F (13.3°C) 32°F (17.8°C) 5-32Pressure dynamic response is much better than for fuel upsets. Temperature response is still too fast. See Figures 5-40 and 5-41, Decrease Fuel Flow 125 Mi Mode] Plant Throttle pressure 180 psi (1241 KPa) 140 psi (965 KPa) Superheat temperature +IL°F (6,1°C) ~24°F (-13.3°C) Reheat temperature 421°F (11,7°C) -20°F (-11.1°C) Plant responses are critically damped and the model is underdamped as shown in Figures 5-42 and 5-43. Decrease S.H. Spray 125 MW Mode Plant. Throttle Pressure 14 psi (95.5 KPa) 0 psi Superheat temperature 82°F (45.6°C) 55°F (30.6°C) Reheat temperature 60°F (33.3°C) 31°F (17.2°C) See Figures 5-44 and 5-45, During this test, only one spray flow transmitter was working so the response amplitude should not be compared too critically. Pressure dynamic response is good. Open 518 Valve 125 MW Model Plant Throttle pressure 9 psi (62.1 KPa) 3 psi (20.7 kPa) Superheat temperature 4°F (2.2°C) 12°F (67°C) Reheat temperature 41°F (06°C) ~6°F (~3.3°C) Dynamic agreement is good except that the beginning of the temperature response is much too fast. See Figures 5-46 and 5-47. 5-33to20p THROTTLE ‘TEMPERATURE-F ‘TIME- SECONDS 58 8 8 “000 *s000 "00 gy ‘THROTTLE PRESSURE- PSIG ‘TIME. SECONDS ° "To" ‘200 "00 Figure 5-32, Comparison Between Calculated and Measured Throttle Pressure and Temperature and Reheat Temperature Response to a Step Decrease in Superheater Spray Flow - 500 MW = E 5 FIRST STAGE £ MEASURED 5 ~MGALCULATED é SECOND STAGE ‘TIME. SECONDS ‘TIME: SECONDS FEEDWATER FLOW- KLA/HA 7005" "000 "S00 Figure 5-33, Comparison Between Calculated and Measured Spray and Feedwater Flow Response to’a Step Change in Superheater Spray Flow - 500 MW 5-34‘TEMPERATURE-F 0 "oat 200 ‘300 ‘TIME. SECONDS carcutaTeD MEASURED ‘THROTTLE PRESSURE ‘TIME. SECONDS Figure 5-34. Comparison Between Calculated and Measured Throttle Pressure and Temperature and Reheat Temperature Response to a Step Change in Fuel Flow - 250 MW x ———— weasuneo coer sees GALGULATED FEEDWATER FLOW- KLB/HA 200 7 "oo ‘80 "3000 ‘TIME-SECONDS Figure 5-35. Comparison Between Calculated and Measured Feedwater Flow Response to a Step Decrease in Fuel Flow - 250 MW 5-36no + oa i- ws I wc a ee ee ae pe 3 eet ua Es E 1080! "00 ‘seo ‘TIME. SECONDS Figure 5-36. Comparison Between Calculated and Measured Throttle Pressure and Temperature and Hot Reheat Temperature Response to a Step Increase in Gas Recirculation ~ 250 MW t000¢ MeAsuaeD ~ CALCULATED FEEDWATER FLOW- KLB/HR 3 ‘TIME- SECONDS Figure 5-37. Comparison Between Calculated and Measured Feedwater Flow Response to Step Increase in Gas Recirculation - 250 NW 5-36‘TEMPERATURE-F ‘THROTTLE PRESSURE. PSIG Figure 5-38, Ci Temperature and g i 5 5 1 En E so4aky ‘TIME- SECONDS MeasuneD ‘CALCULATED 100 "300 ‘TIME. SECONDS comparison Between Calculated and Measured Throttle Pressure and Reheat Temperature Response to a Step Decrease in Superheater Spray 2004 MEASURED ~ CALCULATED ‘SECOND 00 RST STAGE erat ‘TIME. SECONDS Aca "60 "3800 ‘TIME SECONDS Comparison Between Calculated and Neasured Spray and Feedwater Flow Response to a Step Change in Spray Flow - 250 MW 5-37220) TEMPERATURE-F o “Toe ‘0 ‘000 ‘TIME SECONDS ———— neasuneo aed * vee es GALCULATED ‘THROTTLE PRESSURE 0 co ‘3500 "3000 ‘TIME. SECONDS Figure 5-40. Comparison Between Calculated and Measured Throttle Pressure and Temperature and Reheat Temperature Response to Opening the 501 Valve ~ 250 MW MeasuneD ~ CALCULATED FEEDWATER FLOW- KLB/HA “pe efurene Figure $41. Comparison Between Calculated and Measured Feedwater Flow Response to Opening the 501 Valve - 250 MW‘TEMPERATURE-F ‘TIME- SECONDS A MEASURED 2 + CALCULATED Fg pf ‘TIME- SECONDS Figure 5-42, Comparison Between Calculated and Measured Throttle Pressure and Temperature and Reheat Temperature Response to a Step Decrease in Fuel Flow - 125 MW 1000, MEASURED, <7 + CALCULATED FEEDWATER FLOW- KLO/HR ‘6 ‘20 ee ‘aio0 ‘TIME-SECONDS Figure 5-43. Comparison Between Calculated and Measured Feedwater Flow Response to a Step Decrease in Fuel Flow - 125 MW 5-39‘Troms ‘TEMPERATURE-F 45 ——--_-_——z, ‘TIME: SECONDS 1140 MEASURED M Sos CALCULATED ‘THROTTLE PRESSURE. PSIG 10405 ‘000 ‘io ‘08 ‘00 ‘TIME- SECONDS Figure 5-44, Comparison Between Calculated and Measured Throttle Pressure and Temperature and Reheat Temperature Response to a Step Decease in Superheater Spray Flow ~ 125 MW 150 MEASURED, caLCULATED. FIRST STAGE SECOND STAGE >RAY WATER FLOW- KLB/HR, TNE SECONDS FEEDWATER FLOW- KLE/HR o To00" 2000" ‘TIME. SECONDS Figure 5-45. Comparison Between Calculated and Measured Spray and Feedwater Flow Response toa Step Decrease in Superheater Spray Flow - 125 NW ‘300 5-40TEMPERATURE-F TIME- SECONDS MEASURED 129, caLcuLaTe 100%} j ‘0 ‘w00 “SECONDS: 1 Figure 5-46, Comparison Between Calculated and Measured Throttle Pressure and Temperature and Reheat Temperature Response to Opening the 518 Valve - 125 MW E so; MEASURED. i — wae, i ply i e oe ‘od ‘6 ‘TIME- SECONDS Figure 5-47. Comparison Between Calculated and Measured Feedwater Flow Response to Opening the 518 Valve - 125 MWThere are two additional observations when comparing the model and plant. The first is that the spray valve model flows agree excellently with measured flows so they should not be considered as a source of error. The second is that the model feedwater controller was unstable when the plant gains were used. It was necessary to reduce the drum level feedback. In the compared responses, overall feedwater flow is similar, but the detailed structure of the reponses is different. Considering the differences discussed above, it appears that the model should be examined in the following areas: © Convection pass heat transfer formulation. @ Any storage terms which would a*fect the speed of response. ¢ The ratio of superheat to saturated absorption. © The pressure flow characteristics of the turbine, Examination of the model shows an obvious improvement can be made by using a log mean temperature difference formulation. The new furnace module added a separate metal temperature equation which represents a significant storage term but it dropped the downcomer energy balance equation. Restoring the downcomer equation should help the pressure dynamics and will affect the control of drum level, It is not clear whether this change will allow the use of actual plant gains in the model. A specific model of the roof and convection pass enclosure may help. Analysis of individual components over the load range is inconclusive for Collins 5. It would appear that it should be included as a matter of principle since there are units for which it is necessary. It will be necessary to make the change in a full model and to evaluate the results to determine its impact on the Collins simulation, The pressure flow characteristics of the turbine strongly affect the shape of the pressure response. Experiments on another drum boiler mode! indicated that seemingly insignificant changes in turbine flow modeling would change the damping of the pressure response to changes in turbine valve position or firing rate. The first three modifications should be evaluated before approaching the turbine modeling as source of error, 5-82,STARTUP. SIMULATION The model was modified to allow variable speed on the turbine and a proportional plus integral controller was installed to control throttle pressure by manipulating either the turbine or 501 valve as appropr‘ate, Function generators were installed s0 that the recorded time variable boundary conditions could be read into the model. When running the model, it was discovered that it would not run below 5% steam flow. The reason for this is that the pressures leaving the various superheaters are states, At 100% load, the pressure drops through the superheaters and attemperators range from 15 psi (103 KPa) to 50 psi (345 KPa). These pressure drops scale as the square of flow. At SE flow, the smaller drops are 0.1 psi or less. Since the pressure is about 1000 psi (6895 KPa), it means that the integration errors per step must be less than 10° to prevent reverse flows. The model does not allow flow reversals, This integration error tolerance would not ordinarily be @ problem, but we are using the GEAR integration algorithm which is built into ACSL. GEAR is an implicit integration algorithm which requies 2 mode] Jacobian which is calculated by numerical differentiation. The ACSL implenentation uses the integration error tolerance as the perturbation size to calculate the Jacobian, To get down to 1% steam flow, which would allow rolling the turbine, would require an error tolerance ‘of 10°, On an 18M computer with a 32 byte word, a perturbation of 1 part in 108 produces a Jacobian that is meaningless, If ACSL had been run on a CDC computer, this problem would not have arisen. The problem was discussed with the authors of ACSL and they have confirmed that the IBM version will be modified to permit independent control of Jacobian perturbation and integration error tolerance. After identifying this problem, three attenpts were made to match a startup at about 20 Mi and follow it up, The results were neaningless because there was no way to generate an appropriate set of initial conditions for the model when the boiler is already moving at 20 MW. Figures 5-48 and 5-49 show throttle pressure, megawatts, and throttle temperature for the best of the three attempts. The startup would have appeared more successful if the model had a control system, The control system was left out of the study to reduce costs, 5-43If the model dynamics matched the plant, and an appropriate set of initial conditions could be generated, the startups should have worked. Since neither of these conditions was met, it is not surprising that the attempt to model the startup was a failure, It would be worthwhile to try again to simulate the startups after the ACSL integrator has been modified and the model changes have been implemented. With Varge discrepancies in model dynamic behavior, open loop startups as attenpted here are not likely to succeed. 26°) norm PRESSURE SETPOINT ‘mors rnesgune . ae meAsuneo E 2 oo e fF E E i 4 : te E 3 A 5 5 z ‘ 3 1500} = «0! E Em vel > rue. minures TMe-nuTES Figure 5-48. Throttle Pressure and Figure 5-49, Superheater Outlet Load For Startup Simulation Temperature for Startup Simulation 5-44Table 5-1 COMPARISON BETWEEN PLANT AND MODEL INITIAL CONDITIONS 500 tw 250. M4 125 ti PLANT ~~ MODEL PLANT MODEL PLANT MODEL 187A 473 485 416 429 365 381 °F TSEC 536 541 505 516 503 543 oF Teec G6 664 sre 616 S41 638 °F WFW 3.3066 3.386 1.5066 1.55E6 8.0265. 7.6765 Vb/hr TSB0 970 960 958 922 930 914 oF TSRHO 958 933 953 890 aie 862 oF TSHP 626 634 636 602 549 537 oF psc 2210S 2285=SstTl~S=Ssi1086=St092S 08k pst PSDF 2400 2426 1873 1879 1428 1419 psia Psp 534 587 260 279 143 11 psta PoP «15691588 760 770 408 403 psia were: TSS7A. - temperature water leaving high pressure heater TSEC = temperature water Teaving economizer TGEC - temperature gas leaving economizer WK = feedwater flow 1380 = temperature of steam leaving secondary superheater TSRHO - temperature of steam leaving reheater TSHP - temperature of steam leaving HP turbine P80 - secondary superheater outlet pressure PSOF = drum pressure PSRHO - reheater outlet pressure POH —- first stage pressure of HP turbine 5-45Section 6 OPERATING RECOMMENDATIONS RECOMMENDATIONS FOR COLLINS UNIT NO. 5 The operating recommendations for Collins are based on the equipment that is presently in the plant. Therefore, only sliding pressure operation was consider~ ed, The operating recommendations are also based on the present temperature control system with the units being ofl fired. The operation of this particular plant does not require rapid load following capability. The unit is normally operated with load changing rates of 4 MM/min. Therefore, as can be seen from the test results summary, hybrid operation is the most desirable method of operating this unit, This conclusion was reached inde pendently by Collins technical staff personnel before testing. From a performance standpoint, the use of the division valves (501 valve) to maintain a higher drum pressure than throttle pressure is undesirable. This is due to the added feed pump power, and the throttling loss across the 501 valve. Therefore, the decision was made that the unit should be shut down by using constant pressure and sequential valve operation until the control valves are at the 50% admission point. The drum pressure and throttle pressure are reduced from that point to control load. The 501 valve fs kept open. This procedure does not maintain a high drum pressure but does allow a greater change in turbine steam temperatures. However, the decision whether or not to use the 501 valve during startup is more involved. With the pressure ranp being employed (consistent with hybrid mode operation with 60% minimum admission), the 501 valve would be open at 190 HW or 230 MM depending on whether a 1500 psi (10,343 KPa) or 1800 psi (12,411 KPa) minimum rum pressure is used, Therefore, the steady state thermodynamic benefit is not significant during starting, In the event that a hold is established below 38% load, which isn't normally the case, the 501 valve could be opened to improve efficiency, With these considerations in mnd, it was decided to use the 501 valve based on transient starting considerations only. 6-1Table 6-1 shows a comparison of fuel flows for tests 1, 28, 28, and 3 during various phases of the startup. The loading fuel flows are adjusted to be on the same basis, adjusting the integrated fuel flow and load for each test, to the same loading basis. This approach points out that usirg the 501 valve, to maintain a difference in drum and throttle pressure, allows the drum pressure to rise somewhat independently of the throttle pressure. greater boiler feed pump flow is required due to the increased head, Table 6-1 indicates that prior to loading, there is only @ slight difference in fuel flow (3,700 It). During loading, however, the energy necessary to increase drum pressure up to 1500 psi (10,343 kPa) is not required. This was estimated to be 8000 Ib fuel. The difference may be outside the range of measurement accuracy when comparing test data. A larger effect on fuel consumption during startup results from delays due to unforseen equipment problems. The potential fuel savings, combined with the use of the 501 valve on weekend or cold starts to permit steam attemperation is desirable, weighed in favor of using the 501 valve for daily hot starting, This consideration is primarily directed to operational simplicity. The use of the 502 valve keeps the drum and throttle pressure lower during firing for temperature. Since on most hot starts, cooling occurs in the first stage region of the turbine, the use of the 502 valve appears beneficial after overnight outages. Without any turbine matching considerations, the superheater bypass (502), main steam attemperator (518) and reheat steam attemperator (519) valves would not be used at all. For loading, the unit throttle and reheat temperature ramps of 200°F/h (111°C/h) are acceptable. However, controlling these ramps was quite difficult for the Collins Unit No. 5, To provide better temperature control, the first stage spray flow was manually operated at approximately 75 MM. The spray flow was 100,000 1b/h. The recommended loading rate was 10 MW per minute. The minimum drum pressure was initially recommended to be 1800 psi (12,411 KPa), However, due to boiler feed pump considerations this limit was reduced to 1500 psi (10,343 KPa). The use of the motor driven pump would have eliminated this constraint. The minimum throttle pressure was set to 1000 psig (6895 KPa). At approximately 100 MW, the second stage spray flow was automated to control to the temperature ramp. At 200 MW, both stages of spray flow were automated. 6222 2 1 1% 18 10 Turbine Operation Sunmary - 10/14, 10/15 1 20 22 16 Boiler Operation Summary - 10/14, 10/15 100) 300) 400) 600, oo) - e fe fe es fof § °° 5 8 8 8 8 8 ge 2 ae © MIN aVOT_O. 5 (01x) YH/GT- MOIS TONIVN _O. e222 @ 8 # @ es F Fe es see ee Fs who tau -uae v iSuo *isdeautosauy nso 2 £ g 2 z g g B 8 8 8 3 e 3 8 g 8 g 2 . fe 2 i 3 3 g obuvicd -aunssalea oun + wnoesd-NOUSOUAALGE Gan eee g Oe 2 8 8 3 e 3 3g g 3 & 2 ° ut = dW31 WWa1S NIV " Gorx) 4930-dW3L131LNOHSO3S Xx sag gar Topi Ba Sua F o30-anaL SunOHs Figure 6-2. 6-3A startup to test all of the above recommendations was attempted. Figures 6-1 ‘and 6-2 show the shutdown prior to starting on the following day. During overnight cooling the first stage rotor had cooled to 717°F (381°C). This extra cooling was Produced by a lower than normal gland steam supply temperature, This facilitiates matching but will potentially produce higher loading stresses. Figures 6-3 and 6-4 show the summary plots for the startup. A slight delay in startup was caused due to difficulty in opening the interceptor valves. During the shutdown period, the $01 valve was not closed since in the normal mode of shutting down at this plant, the 501 valves would have been controlling during shutdown. The boiler isolation valve was closed. However, unusually large drops in superheater outlet and throttle steam temperature were encountered during rolling of the feed Pumps prior to boiler firing. The fuel flows are plotted as Figure 6-5. To keep the drum pressure under control, the 502 valve was operated manually. A plot of 502 valve position, drum, and throttle pressure are shown as Figure 6-6. This action produced a substantial amount of flow to be dumped to the condenser, This flow was integrated to be 270,000 1b as compared to 125,000 and 133,000 1b for test 1 and test 2A respectively. These factors tend to negate the significance of the before loading fuel flows. 4 16 18 Turbine Operation Summary - 10/15, 10/16 6-4RH OUTLET TeMP- DEGF * x (x10 ‘SECS H OUTLET TEMP- DEGF 100. 10 501 VLV POSITION - PERCENT 8 8 8 2 8 Sy HOT & ‘ORUM PRESSURE- PSIA + 8 a 8 oO 8 Fi FUEL FLOW KLB/HR OR KLB o 2 4 6 8 0 2 1 16 18 20 22 0 ‘igure 6-4. Boiler Operation Summary ~ 10/15 25 201 15] FUEL FLOW 10 FUEL CONSUMED 5:0 60 70 TIME OF DAY 10/15/80 Figure 6-5. Fuel Flow - 10/15 65100) 200) 200 P14 - DRUM PRESSURE, PSI 90} 270} 270] P1_- THROTTLE PRESSURE, PSI M12 - 502 VALVE POSITION 70} 210} aro. Figure 6-6. Drum and Throttle Pressure and Saturated Steam Dunp Valve Position for Hot Start - 10/15 After synchronization, the input temperature ramps for control purposes were 200°F/h (111°C/h), At 65 Mil, the first stage sprays were initialized at approximately 70,000 1b/h. When the second stage sprays were automated, a problem developed due to transmitter problems. Manual operation was required initially until the auto-balance feature of the control system negated the transmitter failure. The cycling of second stage spray caused a substantial departure from the desired temperature ramp and caused the main steam temperature to rise sharply to 1023°F (551°C), The transfer to sequential valve was made at this time (220 MW) to prevent high rotor stresses. The throttle pressure ramp was somewhat less than desired. This caused difficulty staying in integrated mode. Even with the difficulties encountered the average loading rate was 9.3 Mi/min. with @ maximum rate of 12.6 Mi/min. 6-6For startup after a weekend outage, the reconmended procedure was specified to be similar to the start after overnight outage with the following exceptions. Transfer to sequential valve at 5k load. Loading rates of § MW/min. to 325 MW with a 20 minute hold at 125 May Loading rate from 325 ¥W to full load equal to 3 NW/min. Main steam temperature ramp at 100°F/h (55.6°C/h). Reheat temperature ramp is the sane as main steam (requirement of control system) except off set by 100°F (37.8°C). A test was conducted to verify this procedure. Figures 6-7 and 6-8 are the summary plots for this test, The rotor temperature in the region of the first stage had cooled to 543°F (283.9°C). This was somewhat hotter than previous weekend starts. 14 16 18 20 Turbine Operation Summary - 9/29, 9/30 675 20| 00} 270} 60 = ig 10| 80/5240 |Saz0) Sle vol . 5 10/8 10} 210) 200 gee ele SS ole ool sno: © Boo] col seofdiauo #5 (6 & & © 2 s015 so|zts0|Gaw uo |b kg 5 = {> 401% 1205160: 3e 3" le |z zg |z PoE © B 3018 3015 90{2120 * X 20) + 2049 60/0 80 8 8 of of of o- ee o 2 6 8 10 i i 1 is 2 2 0o Figure 6-8. Boiler Operation Summary - 9/29, 9/30 Number two fuel of] was needed to warm the boiler, This is not usually needed after @ weekend outage but the boiler was cooler than usual. The drum pressure was 130 psi (896 KPa) as compared with 240 psi (1655 kPa) on test 7. The unit was rolled with a lower than ideal throttle condition. However, it was still within allowable limits. Ouring rolling, a turbine control system problem developed that required use of manual control, A 35 min. hold was required to warm ‘the steam chest prior to transferring to governor valve control. The control problem prevented conducting the startup as planned for the following reasons: © The transfer to sequential valve was not possible. © Integrated control was not possible. © The main steam temperature contrcl using the 518 valve was done manually to decrease rotor stress 6-8Figure 6-9 illustrates the main steam temperature control using the 518 valve (steam attemperator). The reheat steam attemperator was controlled on automatic. Figure 6-10 shows the variation of reheat temperature and 519 valve position during loading. Except for some overshoot after synchronization, the reheat temperature control was good. The use of the reheat steam attemperator is to minimize IP rotor stress. The fuel flow is plotted as Figure 6-11. The fuel to roll the turbine was 27,500 Ib as compared to a previous flow using the 532 valve of 36,500 Ib. The fuel flow during the previous startup without using the $02 valve was 22,000 Ib. Since the throttle pressure would drop off during rolling, and after synchronization, the ideal throttle temperature would only increase by 55°F (30.6°C) without using a 502 valve or the 501 valve to limit throttle pressure. The temperature levels required for a weekend startup are far enough from gas temperature (79%) to be attainable. However, if the turbine is hotter, the main steam temperature required at higher pressure is too close to the non-rolling gas temperature limits of 1000°F (537.8°C). 100) 200) 200) 550) 600 90} 190 180} 500} sao. 80) 160) 160) 450) 480) CS1 -LOAD, MW 3W23-SUPERHEATER e ourter Tem & Fa FIRST STAGE xo. SPRAY FLOM, NomTH FS -SECONDSTAGE e800], 20 SPRAY FLOM, s sour Fo -siavaLve Position o of of 0. Figure 6-9. Main Steam Temperature Control Using Steam Attenperator - 9/29 6990} 180. 20} 160. mln cSt -LOAD, MW ‘TSW25 - REHEATER OUTLET TEMP..°F FT -RLH. SPRAY FLOW Fi0 “519 VALVE POSITION Figure 6-10, Reheat Steam Temperature Control Using Steam Attemperator - 9/29 8 T FUEL CONSUMED FUEL FLOW KLB/HR OR KL. 8 +0 20 30 40 TIME OF DAY 9/29/80, Figure 6-11, Fuel Flows - 9/29 6-10RECOMMENDATIONS FOR THE ELECTRIC UTILITY INDUSTRY The stress analysis efforts defined in Section 4 demonstrate that for the loading rates tested, either hybrid operation or single valve sliding pressure operation is acceptable for the Collins Unit No. 5. This experience cannot be directly extended to the industry due to differences in plants and control systems, as well as, design differences that exist in various suppliers’ boilers and turbines. However, the validated turbine heat transfer calculation techniques combined with the observa~ tions and insight developed as part of this program can be combined to produce useful input to cyclic operation at any plait. The following discussion outlines considerations in developing an operating recommendation that can be made specific to a particular plant. The items included in this discussion are: © Method of Operation (hybrid, single valve, etc.). © Temperature matching. © Boiler Feedpump Turbine Operation, © Temperature Control Ouring Loading Including Steam Attemperation. © Use of Division Valves. © Pre-Warming. © Maintaining vacuum, Method of Operation Hybrid operation minimizes heat rate when operating under partial load. For the Collins unit, the minimum governor valve admission point to begin sliding pressure is optimized at 50%, When considerable time is spent at partial load, the difference in performance between single valve sliding pressure and hybrid operation can be substantial. For example, heat rate differences at 50% power could be as large as 200 Btu/kW-hr, Therefore, fron a pure efficiency standpoint, hybrid mode of operation is ideal, However, if the uni: requires load following at rapid rates, Single valve operation may be necessary, pavticularly if load following during daily operation is to be combined with two shift operation, Figures 6-12 illustrate this type of operation, However, the load changing rates and corresponding temperature changes are slow enough to allow this type of operation to be superimposed on two shift operation for the unit tested. The capability to transfer from single to Sequential valve anytime during loading allows flexibility in choosing an operating strategy that permits load following during the day, as well as, high efficiency capability when long periods of low load operation are required.3 8 ogo 8 s. 3 MAIN STEAM TEM- DEGF g's FIRST STAGE TEMP- DEGE FOr REHEAT TEMP. DEGE 8 z x 8 Figure 6-12. Turbine Sunmary Plot of Load Following Combined With Two Shift. Operation - 2/18, 2/19 The shutdown of a unit during single valve sliding pressure will yield lower stresses during shutdown. However, as was shown in Section 4, the rotor will be hotter after an overnight outage, This has the advantage that a smaller change in metal temperature is required to return the turbine to full or partial power. This advantage is offset by the disadvantage of requiring a higher steam temperature to match rotor temperatures during rolling, and early loading of the unit. The tests conducted during this program showed that tensile stresses due to mismatching more than offset the gains made in keeping the tensile stresses low during shutdown. In addition, during loading with single valve operation the first stage temperature will quickly becone independent of Toad and only a function of throttle steam temperature. This means that reducing loading rate will only have an indirect effect of controlling thermal stress since the change in steam flow and firing rate affect the throttle temperature, A unit which is shutdown using sequential valve operation will be cooler. Matching the rotor temperature will be considerably easier and require less time and fuel flow. However, if daily loading of the unit is done with sequential valve operation, a considerable problem could develop in matching the rotor temperature during the early loading phases of the transient. If 6-12mismatch is necessary, it is better to have hotter steam then cooler since this will not, when combined with the heating transient produced during loading, increase the stress range of the transient. However, producing cooler than desired steam temperatures is more the normal situation in the overnight operation of steam plants. In this mode of operation a control system which allows transfer from one valve mode to another, as demonstrated in te hybrid valve startups of Section 4, Provides the ideal situation. Since many plants do not have this capability, a study of the operation characteristics of tre boiler, combined with thermal analysis of the rotor, could be undertaken using the heat transfer analysis techniques discussed in Section 5 of this report. The logical course of action to be taken is as follows: © Shutdown the unit using sequential valve hybrid mode, with restart using single valve operation. If main steam temperature is dif- ficult to control during early loading the throttle pressure ramp could be modified. The ramp should be increased if temperature rises rapidly, © Shutdown the unit using sequential valve hybrid mode. With restart using sequential valve, the turbine should be rolled and loaded with as low a throttle pressure as pernissible. The rate of throttle pressure change or the loading rate will ow provide some control on the rise in first stage temperature. © For units that are capable of only single valve operation some forced cooling could be introduced by increasing the minimum throttle pressure during shutdown, This should only be done if matching is difficult during restarting. Temperature Matching The economy of precise matching was investigated for the Collins unit. The most useful data is obtained from test 2A when the gas temperature was high, This test Showed that at turbine roll the rate of change of superheater outlet and throttle stean temperature was 2.97 and 0.70°F/min, (1.65 and 0.39°C/min.) at a fuel flow of 13,500 Ibm/h. Therefore, increasing superheater outlet and throttle steam temperature prior to rolling is an extremely expensive and difficult venture. For example, to increase throttle stean 50°F (27.8°C) would use up approximately 3800 pounds of fuel and take approximately 17 minutes. With the two 1.5 inch (38.1 mm) diameter drain lines in the main steam piping, the ability to raise the throttle steam temperature is exceedingly more difficult. Figure 6-13 shows the variation in throttle steam and superheater outlet steam temperature for tests 24 and 28 during rolling and early loading. Note that at synchronization, the throttle steam temperature increased approximately 50°F (27.8°C) while the superheater outlet temperature increased 78°F (43.3°C). The differential temperature at synchroni- 6-13zation is 68°F (37.8°C) with the superheater exit temperature higher. This increase in throttle steam temperature prior to synchronization can be factored into temperature matching considerations. This is true since the heat transfer coefficients to the rotor are low at low speeds, and therefore the highest mismatch stress will occur after synchronization. Once the characteristics of the particular boiler system are known, studies can be made to evaluate the degree of mismatch that can be tolerated at roll, and its effect on reducing turbine rotor temperatures during rolling and early loading, s/s 1050) 1050) 600 she fx 1000} 1000} so cst - LOAD, Mw ‘TSW23 - SUPERHEATER, ‘OUTLET TEMP. °F ‘TSW1 - THROTTLE STEAM 950) 980) 480 Figure 6-13. Superheater Qutlet and Throttle Steam Temperature Quring Loading Tests 2A and 28If rotor stresses during shutdown (cooling) are minimized, the acceptable mismatch (steam cooler than rotor) can be increased with little or no change in cyclic life. This is true since another tension cycle would be introduced without a corresponding compression cycle (rotor heating). Since this amounts to a cycle with a strain range of approximately one-half the tension strain calculated, it will have, in general, a negligible effect on cyclic life. A good strategy therefore would be to do some cooling of rotor during shutdown, but to do it in such a fashion (unloading rate control and temperature control) as to minimize tensile stresses. This would allow a greater margin of tensile stress for mismatching prior to loading the unit. Calculations were made to study the effect of a poorer temperature match for test 3 of this program. The temperature was assuned to be 50°F (27.8°C) lower at turbine roll and synchronization, During loading the temperature was assumed for calcula- tion purposes to rise quickly to the same value as that of test 3. The two cases were considered to have equal temperature at 26 percent load. The combined effect of higher tensile stresses during cooling and resultant higher compressive thermal stress during loading reduced the cyclic life expectancy from 11,700 cycles of test 3 to 8,000 cycles. This is a 42°F (23.3°C) poorer mismatch than the value recommended by the operating instructions for this unit. Boiler Feedpump Operation The boiler feedpump system at the Collins plant consists of two turbine driven and one motor driven feedpunp. These are sized for 50% of maximum feedwater flow. The steam driven pumps are supplied from the main steam line, or from extraction steam. The plants operating staff desired not to use the motor driven punp at any time. This placed two restrictions on the startup procedure: one, that flow from the main steam line was required early; and, two, that the drum-to-throttle pressure was limited, as mentioned earlier. To provide steam to the turbine driven feedpumps, the 501 valve was opened near lightoff, prior to when gas temperature equaled, or was greater than the main steam line temperature. As a result, a decrease in superheater outlet and throttle temperature occurs, Figure 6-14 illustrates this effect for two different days. On 10/15/80, the 501 valve was open 80 minutes prior to the gas temperature reaching the secondary outlet temperature, and a ccoling of 210°F (116,7°C) was observed, 6-15It is believed cooled overnigi that this resulted from steam from the superheated tubes, which ht, cooling the steam lines, On 6/4/80, the 501 valves were opened 40 minutes prior to the gas temperature being greater than the secondary outlet temperature, a occurred. ‘900F —4 ‘s00F — Toor —| 600F — Toor — 150°F (83,3°C) decrease in the superheater outlet temperature DATA’ 801 VALVE . ‘SEC. OUTLET THROTTLE ROLL SYNC. 10/18/80 FEGT SEC OUT. THROTTLE SYNC. 501 VALVE ‘OPENED, ‘DATA DATA — — — EXPECTED WITH 501 V. 6/04/80 CLOSED UNTIL FURNACE EXIT GAS ‘TEMPERATURE IS GREATER THAN, ‘THE SECONDARY OUTLET TEMP. Figure 6-14. Superheater Outlet Temperature Response Prior to Rolling Turbine 6-16This same temperature decrease is seen on units with or without a 501 valve. The 501 valve allows flow to the main steam line to be prevented until gas temperature reaches or exceeds main steam line temperature. This procedure, plus rapidly increasing gas temperature, results in a substantial reduction in pre-rolling fuel flow. The second restriction limited the drum to throttle pressure differential to 500 psi (3448 KPa). The drum and throttle pressures for rolling were 1500 psi (10,343 KPa) and 1000 psi (6895 KPa), respectively. The higher the differential, the more difficult feedwater control was with the turbine driven feedpumps. Figure 6-15 iMustrates operation with and without the 501 valve. For Collins, the restriction was not considered acute enough to revise the operating procedure other than to limit the differential to 500 psi (3448 kPa) instead of 800 psi (5516 KPa) at the start of the test progran. oa oa $00) 4007 «ie S10 - TURBINE SPEED, RPM 90) 360) MSA - BOILER FPT SPEED, RPM fo} 220 6/3 - 501 VALVE OPEN 6/4 = 501 VALVE 10}, 280 SONTROLLING 00} 20 mel & sol zoo 0) 100 s |e = 301° 120. a jo 20) wo wo} ol oo 6/3 Figure 6-15. Boiler Feedpump Turbine Speed Control With and Without 501 ValveSaturated Steam Dump and Drain Flow The use of the 502 valve to keep drum and/or throttle pressure low while firing to obtain 1000°F (537.8°C) furnace exit gas temperature was studied. The conclusion reached is that during @ warm (weekend outage) or cold start, the increase in fuel flow is not justified. However, when the turbine is hotter and the desired steam temperature increases to be a higher percentage of furnace exit gas temperature, increasing the throttle pressure will have a detrimental effect on turbine matching. Therefore, a 502 type valve will probably be effective for hot starts, but not warm or cold starts. Using the §01 valve without the 502 valve would increase the feed pump head for @ turbine driven pump an unacceptable amount for this plants operations procedure. In adcition, some turbines do not use pilot valves to control speed. This may make raising the throttle pressure an unattrac- tive solution for turbine speed control considerations. The data gathered for tests without using @ 502 valve can be extended to estimate the effect of increasing drain sizes to provide better throttle steam temperature response. This is true since the throttle pressure increased to 1900 psi (13,101 KPa) as compared to around 1000 psi (6895 kPa) for all other tests. This would amount to a 90% increase in drain flow. The results indicate only 2 14% improvement in the rate of change of throttle steam temperature. The effect on secondary superheater outlet to throttle steam differential changed somewhat, but not appreciably. This temperature differential is affected markedly by rolling to synchronous speed. This flow would be of the order of 2& of design throttle flow, The conclusion can be drawn that the drain lines are not really properly sized or located to affect throttle steam. The differential in main steam to throttle tenperature could be reduced to 50°F (28°C) or less by designing drain systems to obtain approximately 2% of full load flow at the start up pressures. The boiler manufacturer recommends a drain system sized for 4% flow at 1000 psi (6895 KPa), An oversized drain valve could be an independently controlled system from the conventional drain system. Therefore, it could be used to increase main steam pipe flow during or before turbine roll after the gas temperature has been increased to its desired value. Temperature Control Temperature control during early loading was difficult on most tests. The response of the boiler tube metal appears to be the problem at low steam flow. Recognizing this fact, a control system which can factor a variable time constant into the system could be developed. In order to accomodate field experience a digital control system should be employed. The mdeling procedures developed and tested in this project should be a first step in developing a control system design. If the 6-18in-place control system is not digital, the course of action to obtain better control would be to empirically develop a manual control feed forward approach during the early stages of the loading. This procedure worked reasonably well on the unit tested, The use of steam attemperation during starting could be extremely useful, due to the ease of controlling temperature with this system, since it would have a smaller time constant for producing a change in superheater outlet temperature. Some difficulty was experienced with tube metal alarms during operation of the steam attenperating system, These alarms were affected by maldistribution of burners in service, The validity of these alarms for short term transient behavior could be reviewed. In addition, a control system design which uses steam attemperation with high gains up to some limit and uses spray flow with a lower gain could be developed. The use of the division valves (501 valve) has been discussed in previous sections. There appears to be little justification for using these valves when unloading the unit. There can be a considerable penalty in performance in using this valve at low load. However, during startup, the ability to develop a drum pressure higher than throttle pressure during hot starts appears to reduce the overall loading fuel flow. This is due to not dumping the heat that will increase drum storage energy to condenser during preroll firing of the boiler. This drum storage energy would need to be added later in the transient to increase drum pressure. Using the operating Procedures and system load demands at the test plant, the unit would not normally be operated at loads where the 501 valve would be throttling. This is due somewhat to the steeper throttle pressure-load ramp required for hybrid operation. If operation does not require immediate loading to a higher unit load, the 501 valve could be opened and the boiler operated at full variable pressure. Prewarming During startup after weekend outages, holds were required to increase the steam temperature above the saturation temperature before transferring valve mode, or to control the allowable thermal stresses across the steam chest. The startup at normal throttle pressure required a 5 minute hold to control thermal stress. The startup, where throttle pressure was allowed to rise, required a 20 minute hold to heat the steam chest prior to transfer to governor valve control. As stated in Section 4, this is due primarily to the higher saturation temperature at the higher throttle pressure, It would appear that these types of holds would not warrant a steam chest pre-warming scheme.Maintaining Vacuum The philosphy at this station was to maintain vacuum unless the unit was shutdown for repairs or long outages. The advantages of this procedure are reduced starting time, slower rotor and cylinder cooling rates, and minimizing leakage of impurities into the system, Figures 6-16 show the comparison between rotor end cooling with and without vacuum, Figures 6-17 show the comparison between outer cylinder cooling with and without vacuum. Note that cylinder cover to base temperature differentials ‘increase markedly when vacuum is broken. These differentials could cause signifi- cant distortions which may lead to seal rubs depending on the cylinder support system of the particular unit. These advantages must be weighed against the auxiliary steam demands to maintain vacuum, and the time required for restarting. An operating philosophy should consider these trade-offs and establish an appropriate course of action depending on the estimated length of outage. Restart Times and Costs The surmary of two shift operation tests shown in Table 4-2 demonstrate that an ofl fired unit can achieve @ restart time of 2 to 2.5 hours. This is Tess than the average times presented in (10). A restart time (boiler Tight off to full load) of 2 hours is an obtainable target. The tno most significant items in reducing costs during restarting are keeping the boiler and piping hot overnight and during early firing, and reducing the necessity for high throttle steam temperatures for matching purposes. The data from Table 6-1 iMustrates that savings of 10,000 pounds of fuel of1 are readily attainable, Even greater savings can be achieved for a sy fn the preceding paragraphs. m that factors in the concepts outlined Significant savings can also be obtained during steady state operation by selecting the most efficient off-design operating mde. The hybrid mode of operation is reconmended, This issue is discussed in detail in Reference 1. 6-20Figure 6-17. ports — a he” sora iss fas | 200} 8mf i Want wo] 70 We aaGT so] 0 wo] so | Epp a _fh E solo 30 oo ic a - BEVERATOR ew sco] 10 earentie eareatone ee Peanentanee ns a “a YEU * as fa = pct 2 ache a Figure 6-16. Rotor End Cooling With and Kithout Vacuum eons _ _ ae pk 10/23 10/24 10/24 10 ee Te OT aoe —— | wo ol ‘i eo 850) | F sn wo , seovmne 0) 80) THP 25- HP OUTER CYL wrouener so] 0» iewun saeenn es sl 0 « a sa ol sol. a “| Turbine Cylinder Cooling With and Without Vacuum 6-21Table 6-1 FUEL FLOWS DURING START-UP (Pounds ?er Hour) Test Test Test Test Item 1 2A 2B 3 Fuel Flow to Roll 11,000 14,000 22,000 18,800 Fuel Flow During Rolling 5,300 8,000 12,500 3,900 Fuel Flow to Load 139,000 129,000 131,000 136,000, 6-22Section 7 CONCLUSIONS AND RECOMMENDATIONS The objective of providing information to improve the reliability and econony of cyclic operation was achieved. A considerable effort was put forth to achieve this objective. The following paragraphs define in detail the relationship that the individual tasks have towards these ends and the degree of success on achieving the initial objective. Heat transfer coefficient correlations for use in predicting turbine temperature distributions were validated, These correlations apply to rotors and stationary parts. The correlation in many instances reproduce measured temperature within 10°F (+ 6°C), Temperature distribution calculations are the first step in predicting thermal stress and cyclic life. A particular modeling technique was developed and applied to the tested plant. The modeling technique was evaluated using the results of “open loop" test at three load levels. The tests indicated problems in the modeling on certain specific areas. These areas are as follows: © Convection heat transfer formulation. © The pressure response of model was much faster than the plant. © Numerical calculation errors associated with the word size of computer used. The areas to be investigated and methods to resolve these problems are identified for future development. In some future effort these changes should be implemented and the boiler model validated. This would then allow the use of this boiler modeling technique for predicting the pressure and. temperature response of cyclic duty plants. This information could then be used for cyclic life evaluation of turbine and boiler components. Operating recommendations that are based on the analysis of tests are developed for the Collins Station. These reconmendations reflect the input of the plant operating personnel, and the boiler and turbine manufacturers. These procedures will allow 7-1loading at two percent per minute and a light off to 95% load time of 2.25 hours. In addition, the reconmended procedures minimize fuel flow both during the low load operation of the unit and during starting. The experience gained during testing and analysis is extended to develop operation and design considerations for cyclic duty plants. This discussion is broad in scope and addresses considerations for plant design and operation of existing plants. In addition, the considerable information accumulated is extremely useful in identi- fying duty cycle, The following items are identified: © Percent time at load. © Daily maximum loading and unloading rates. © Daily maximum rates of steam tenperature change. © Daily initial values of turbine rotor and cylinder temperature. ‘Steam temperature control during loading was a major problem in this test program. Indications are that this problem does exist in other plants. The data obtained on the response characteristics of superheaters and reheaters is useful input for the development of better automatic control systems. These systems should be digital to facilitate field tuning. The data acquisition system operated successfully in the unattended mode. The experience gained is documented for future field test programs. On-line plotting of the shutdown and startup permitted quick analysis of the transient. Since cyclic duty plants shutdown and restart at hours when the plant technical staff is generally not available, plots of key variables could provide an excellent record and analysis tool. The rotor bore telemetry system operated quite well considering that it was @ prototype design. Ths design could be furzher developed and applied to turbines on a routine basis. The test program and subsequent reviews have helped identify some specific programs for future work. These reconmendations are tabulated as follows; * The modeling concept developed as part of this program should be modified as outlined and validated. ¢ A program to develop better automatic temperature control strate- gies should be initiated, 7-2© The results of this program should be used to validate the results of the various on line rotor stress controllers or rotor life monitors. © The program did not study turbine cooling off-line, The data included in this report should be applied to developing a useful turbine cooldown analysis. REFERENCES 1 3. 4 G. J. Silvestri, 0. J. Aanstad, and J. T, Ballantyne. A Review of Sliding Throttle Pressure for Fossil Fueled Steam Turbine Generators. Proceedings, American Power Conference, 1972, Chicago. VM. Kapinos, and L. A. Gura. Investigation of Heat Transfer in Labyrinth Glands on Static Models. Thermal Engineering, Vol. 17, No. 11, 1970. E. C. Cobb, and 0, A, Saunders. Heat Transfer from a Rotating Disc. Proceedings of the Royal Society, Series A, Vol. 236, 1956. S. Ostrach, and P. R. Thornton. Compressible Laminar Flow and Heat Transfer about 2 Rotating Isothermal Disc. NACA Technical Note 4320, August 1958, S. L. Sou, Laminar Flow Over an Enclosed Rotating Disk. Transactions of American Society of Mechanical Engineers, Vol. 80, 1953. D. Dropkin, and A, Carmi, Natural Convection Heat Transfer fron a Horizontal Cylinder Rotating in Air. Transactions of the Anerican Society of Mechanical Engineers, Vol. 79, 1957. L. M. Zysinamolozhen, and M. P. Polyak. Heat Transfer in an Annulus between Stationary and Rotating Coaxial Cylinders, Thermal Engineering, Vol. 17, No. 6, June 1970, E. J. Davis, and M, M, David, I & EC Fundamentals, Vol. 3, No. 2, May 1961. C. Gazley, Jr, Heat Transfer Characteristics of the Rotational and Axial Flow between Rotating Concentric Cylinders. Transactions of the Anerican Society of Mechanical Engineers, Vol. 80, 1950. 7-310. Survey of Cyclic Load Capabilities of Fossil-Stean Generation Units. Electric Power Research Institute Report £1-975, February 1979.Appendix A INSTRUMENTATION ROTOR BORE THERMOCOUPLE TELEMETRY SYSTEM Design of Rotor Bore Thermocouple Assembly The design of the rotor bore thermocouple assembly is based on several requirements: The thermocouples must be accurately positioned along the axis of the rotor bore, The thermocouple junction must be held in firm contact with the rotor bore surface, @ Differential thermal expansion in both the axial and radial directions between the thermocouple assembly and the rotor must be considered along with centrifugal force to preclude fatigue failure of the pipe. © Materials were selected to minimize galling of the rotor bore and to provide adequate strength levels at elevated temperature. ¢ Thermocouple wires must be prevented from breaking, The bore thermocouple assembly consists of a pipe with x shaped spider members welded at intervals along the pipe. Glass insulated thermocouple wires are routed through the pipe to the ends of the spiders, two to each location. The thermocouple Junctions are spot welded in grooves in soft metal buttons at the tip end of the spider arms. A flange is welded to one end of the pipe to support the pipe at the end of the rotor bore, Three groups of six thermocouple pairs pass out through three holes in the rotor end plug, by way of three grooves in the coupling face, to the three transmitters located in coupling 20lt holes. See Figure A-1 for bore thermocouple assembly in position to be inserted into rotor bore. The thermocouples were accurately positioned by fastening all spiders to a pipe of sufficient length to reach from the rotor coupling to the most distant point at which temperatures were measured, a distance of 20 feet, To hold this 20-ft long Pipe perfectly straight would be difficult, If the pipe did not have sufficient flexibility the force required to push it in a straight rotor bore would be excessive. On the other hand the pipe must be strong enough to carry alternatingaxial tensile and compressive loads caused by centrifugal force and friction during thermal changes. In addition the stress levels in the pipe must be low enough to preclude fatigue failure. Figure A-1. Rotor Bore Thermocouple and Support Systen (Spider) Prior to Installation in Rotor AeThe spider was made in halves with the thermocouple junction spot welded in a groove fon the surface of @ plug at the ends of the x shaped spider members. Each x member was made in halves to allow centrifugal force to move the halves outward until the ‘thermocouples contacted the bore surface, One half of each x member was welded to the pipe on alternate sides. Coil springs force the free half of each x member to contact the rotor bore at zero, or low speed, see Figure A-2, At high rotor speeds centrifugal force holds the x members against the bore thus ensuring firm thermocouple contact. The combination of springs and centrifugal force also ensured that there would be no change of rotor balance caused by the assembly changing its center of rotation, The thermocouples were spot welded to the x menber half that was welded to the pipe, see Figure A-3. Experience has shown that a bundle of wires, in this case thermocouple leads, in a relatively large bore of a rotor cycled in speed, will eventually become tangled and result in wire failure. Ay confining the wire bundle in a relatively small bore, wire breakage is prevented. Therefore, the wires were installed in the pipe carrying the x members and is another reason for using pipe instead of a solid bar. The tips of the free half of the x member carries the centrifugal force of half an x. The welded half of the x carries the centrifugal force of half an x plus the pipe if its center is not coincident with the axis of rotor rotation, This tip load plus slight axial movement due to differential thermal expansion could wear, scratch, fret, or gall the rotor bore surface. Nodular iron plugs were finally selected as the wearing surface material since it contains graphite which makes it self lubricating. Noduar iron is also strong enough at temperature to withstand the centrifugal force, It was desirable to limit the centrifugal force of each half x so the sum of the axial friction force of all x's remained low enough for the selection of a reasonable pipe area, for the reason previously explained. To meet this requirement an x shaped member was selected instead of a circular menber which would have a higher centrifugal force. Induced Power_and Antenna System To provide continuous data collection capability, an induced power system was used as opposed to a battery powered telemetry system. The induced power system supplied power to four Acurex Model 2180 six-channel thermocouple transmitters. In this application only three transmitters were used, The primary, stationary, coil consisted of four turns of 20 gage, Teflon insulated wire wound on a Micarta ring,Figure A-2. Detail of Spring Loaded Thermocouple Support Figure A-3, View of Thermocouple Support Showing Thermocouple Attachment Adsee Figure A-d. The Micarta ring was mounted on a steel ring supported on the bearing housing to locate it at approximately 3/8 inch from the rotating Micarta ring. Excitation was supplied by 2 160 KHz oscillator connected to the series tuned primary. Two turns of 20 gage Teflon insulated wire made up the secondary, rotating, coil. This coil was also wound cn a Micarta ring. The rotating Micarta ring was mounted on a spcial HP-IP coupling spacer which supported it above the surface of the coupling, see Figure A-5. Lead wires from the transmitters, located in the coupling bolt holes, were connected to one turn of the secondary coil, The primary and secondary coils were separated by about 3/8 of an inch. Each transmitter had its own antenna made from shielding braid that was pressed flat and cemented in a groove in the rotating Micarta ring. The length of the antenna was less than 1/4 wave length of the carrier signals, The transmitting antennae were kept short to avoid standing waves and subsequent large variations in field strength that cannot be compensated for at the receiver. This arrangement avoids the loss of signal. Figure A-#. Stationary Telenentry Antenna AASFigure A-5. Rotating Telemetry Antenna The receiving antenna was made up of four quadrants. Flat braided shielding was cemented in the stationary Micarta ring and terminated through a 75-ohm resistor in series with 33 PF capacitor. The other ends were connected to a four way power conbiner and the output was connected to the receiver. The stationary steel ring that support the Micarta presents a uniform ground plane to the antenna, thus eliminating one cause of standing waves. A 75 ohm resistor matched the impedance of the antenna to the receiver to eliminate another cause of standing waves. The 33 PF capacitor presents a high impedance to any stray 160 KHz signals from the induced power system, which eliminates noise from this source, In addition the receiving antenna was split into four sections, each of which is less than half the wave length of the carrier to prevent cancellation of the carrier signal. If this arrangement were not made, the rotational traveling wave would be cancelled by the counter rotational traveling wave. These cancellations of carrier signal are more severe than those caused by standing waves. The transmitters for this telemetry system were installed in Micarta capsules that were mounted in the coupling bolt holes of the HP-IP turbine, The assembly is shown in Figure A-6, AsROTATING: STATIONARY ANTENNA RING. ‘TRANSMITTER, TRANSMITTER, CAPSULE HP: TURBINE ROTOR THERMOCOUPLE wines ™ BORE SPIDER ASSY. Figure A-6, Telemetry Transmitter and Antenna Assembly Rotor Bore Telemetry System Instrumentation The telemetry transmitter is designed to measure the temperature of 6 Chromel Alumel, Type K, thermocouples and transmit these temperatures from the rotating turbine to a stationary receiver. The telemetry system instrumentation consists of the following components. Transmitter (6 channel) Receiver 3. Demultiplexer Inductive power supply oscillator DC power supply for oscillator Micarta capsules for adapting the transmitters to the turbine rotor coupling bolt holes.A block diagram of the rotor bore telemetry instrumentation is shown in Figure A-7. The system operates in the following manner. The de power supply provides a nominal 20 volts dc to the 16C kHz power oscillator. The oscillator puts out a 160 kHz sine wave to the stationary inductive power antenna coil, the coil is actually the inductance in the oscillator resonance circuit. The 160 kHz signal is inductively coupled to the rotating cofl which picks up the 160 kHz signal and feeds it to a rectifier circuit in the transmitter. The induced power provides the transmitter with its required power. Thermocouple signals are input to the transmitter which contains an analog scanner. The output of the scanner is clocked by the 160 kHz induced power signal to a radio frequency (RF) voltage control oscillator. The analog scanner in the transmitter sequentially presents the outputs of each of the six thermocouples, plus the module temperature and calibration voltage, to the voltage control oscillator at a 5 kHz rate. The RF signal from the voltage control oscillator is amplified and fed to the rotating RF antenna. FM DISCRIMINATOR OUTPUT | L__starionany [—=cALiBraTion ‘COMPONENTS: [ZERO CHANNEL, “ROTATING COMPONENTS™|_L ain GAP monare) TEMPERATURE ‘SIMULTANEOUS, OUTPUT OF 6 DATA CHANNELS PER TRANSMITTER 6 SENSORS cLock our RECTIFIER AND| I REGULATOR 160 Kz ocr stoyz20 vac BUILT INTO rowen se rowen |_10/220 TRANSMITTER [1E__] osctttaron tone || \Linpuenve powen con POWER || IN Figure A-7. Rotor Bore Telemetry Block Diagram AeThe signal from the RF rotating signal is picked up by the stationary antenna and detected by the FM rec frequency within a range of 88 to 108 MHz. The FM receiver unit has five er. Each transmitter can be set to a different RF independently tuneable receivers so that each receiver can select a different transmitter. The detected and demodulated output of each receiver is routed to a demultiplexer which also has a clocking signal from the 160 kHz oscillator. The demultiplexer sorts out each of the six thermocouples, the calibration, and the zero signals obtained from the output of the receiver and distributes them to eight analog sample and hold amplifiers. The output from the analog sample and hold amplifiers is updated every two milliseconds and routed to the data acquisition system, The antennae and electronic equipment are shown in Figure A-8, Rotating Test Rotating tests of all high pressure rotors are conducted for each unit to ensure stability at operating temperatures, These tests are conducted in a heater box which has no stationary blades. The box is divided into four temperature zones as shown in Figure A-9. Heat is supplied with electrical heaters. Figure A-8. Telemetry Antenna and Associated Electronic Equipment AoLP. ROTOR, H.P. ROTOR & ana - += - ‘ TEST TEST TEST Test TEST TCS TC-4 TC-3 To2 TH -LOCATION OF TEST THERMOCOUPLES. Figure A-9, Heater Box Test Facility for Rotor Bore Telemetry Test The decision was made to run the telemetry system in the heater box to validate the design and mounting of the bore thermocouple measuring system and the telemetry system, This test would represent field operating conditions. Figure A-10 shows the stationary and rotating antenna mounted for the heater box test. Before running the rotating test in the heater box, an evaluation of the telemetry system was made to determine two characteristics of the transmitter: The first was the output of the transmitter as a function of the thermocouple junction temperature; and second was the shifts in the transmitter output as a function of the changes in the temperature of the transmitter in the coupling bolt hole. These ‘are the main causes of inaccuracies in the measurement of the bore temperature due to instrumentation; the error can be as mich as 35° at 1000°F. This test showed that the linearity and drift are repeatable and the transmitter can be calibrated to correct for this condition. The nonrepeatable readings can therefore be reduced to about 5°F which is well within the manufacturer's specification of 0.5% of readings. Because the transmitter being used for this test was not the one actually being used on the field test and because the calibration is a costly and time consuming task, the results of these tests were used to indicate only that such calibration should be performed on the actual transmitters prior to their installation at the Collins plant. Calibration data was not prepared for the heater box test. During the heater box test an Acurex 2189 transmitter was mounted in the rotor coupling bolt hole and six of the thermocouples from the bore system were connected to it. Because of @ supplier delivery problem, a transmitter calibrated for a 2000°F range instead of ‘the 1000°F that was ordered for this program, was used in the heater box text, TheFigure A-10. Telemetry Antenna Mounted to Rotor in Heater Box Test Facility output from the telemetry systems demultiplexer was fed to a volt meter and scanner system that in turn outputs the data to a teleprinter, The printed record consisted of six thermocouple readings, the capsule temperature, the two capsule calibration voltages, and the time when the data was sampled. To determine that the telemetry system output was reasonable, an analysis of the heater box data was performed for a shutdown transient for balancing after 26-1/2 hours of operation, This time period included a 20% overspeed test and 14 hours at 3600 rpm with design temperature. The comparison between measured and calculated results are illustrated in Figure A-I1. The location of the thermocouples measured during the heater box test is shown in Figure A-9. Only data for five of the six channels of the transmitter was available because of a connection failure. The heater box data was analyzed using the same800 700 600 —— — CALCULATION OF T/C 1 “Pp x == == CALCULATION oF C2 ™™ CALCULATION OF T/C 3 oN = catcutation oF ve : 500] —--—GALULATION OF 15 © DATATICN batarce & patarics 400 X DATATIC : DATATICS ° 7 2 3 4 ‘TEMPERATURE °F TIME IN HOURS Figure A-11. Comparison Between Measured Temperatures from Heater Box Test and Calculations During Shutdown axisymmetric heat conduction computer programs that were used to analyze the field test results. The comparison of the calcu’ated and measured temperature for the steady state analysis are tabulated below: Thermocouple No. Calculated Measured (Reference Figure A-9) Temperature °F Temperature °F 1 842 839 2 51 857 3 861 61 4 09 801 5 756 760 The telemetry system monitored the heater tox test continuously for 32 hours. The system operated successfully and the only failure was a thermocouple connection.Calibration of Transmitters The three telemetry transmitters for measuring the rotor bore temperatures were received from Acurex Corporation after approximately 12 months delay because of a redesign problem the manufacturer encountered. The calibration technique used for a single transmitter for the heater box test is illustrated in Figure A-12. The three transmitters were set up in much the same fashion; the one difference was that an oi! and a salt bath were used instead of the electric furnace thermocouple cali- bration unit because the maximum temperature of electric furnace goes to only about 700°F and the salt bath can be taken to 1000°F. The calibration was proceeding satisfactorily when several inputs of the telemetry capsule multiplexer failed. The capsules were returned to the supplier for examination and repair which took approximately a month. When the capsules were returned a factory representative examined the test set up to see if he could determine the cause of the failures. His examination revealed a rather complex failure mode and he concluded that there was a rather high common mode voltage existing between our salt bath and the secondary coil of the inductive power supply. Also, the way the thermocouples were being soldered to the transmitters allowed a conducting salt path from the acid flux to form to the transmitters case. This, along with a high resistance at the soldered joint due to a leaching of the gold plating from the capsule input terminals, allowed the high common mode voltage to be present between one input of the transmitter and its case which caused the failure of the input MOS/FETS. ‘The solution to these problems was to provide a better ground to the salt bath and pre-tin the thermocouple leads with the acid solder and then use a high temperature eutectic solder to connect the thermocouple wires to the capsule. The thermocouple wires were thoroughly cleaned before solde~ing and the eutectic solder did not Teach the gold from the transmitter pins. After this repair, calibrations were run on the transmitters. Field Experience ‘The capsules were then installed at Collins in the HP-IP rotor coupling bolt holes and the stationary antenna was put in place, When the transmitters were checked two bore thermocouples were open: TR 1 and TR 9 which are both connected to the same transmitter,‘THERMOMETER, ICE BATH ree ‘COUPLES REF To TRANSMITTER VOLTMETER Te CALIBRATOR DATA LOGGER THERMOCOUPLE ‘& TRANS. TEMP. Figure A-12. Telemetry Transmitter Calibration Test Block Diagram These two positions were shorted at the capsule with thermocouple wires to avoid any additional problems. Since there are two thermocouples at each bore location, we were still able to obtain data from these locations. The rotor bore temperature telemetry systen initially gave reasonable data on all of the active channels but as the test progressed over the first few months it had two problems: The first was that the signals were responding to exciter voltages and appeared to be a function of turbine speed, The other was the demodulating card in the telemetry receiver for one of the transmitters required a field repair by the ge problem. When the unit was shut down for strainer removal, frayed wires in the transmitters and associated wiring were supplier to correct a high calibration vol: repaired where possible, but since the wire paths into the rotor bore down the coupling face were not accessible, repair and inspection was limited, Table A-l lists the status of the telemetry systen after the July inspection and repair.Thermocouple Now n 12 1B u 15 16 uv 18 Transmitter No. Table A-1 TELEMETRY SYSTEM STATUS (uly, 1979) Location = Dumny = Dury 8th Reaction Stage 8th Reaction Stage First Reaction Stage First Reaction Stage Control Stage Control Stage 1.P, Dummy 1.P. Dummy Cooling Passage Cooling Passage Third Stage Third Stage Fifth Stage Fifth stage Exhaust Exhaust Status Bad Erratic Bad Good Good Speed Sensitive Good Speed Sensitive Bad Speed Sensitive Good Bad Speed Sensitive Good Good Erratic Erratic Speed Sensitive Figure A-13 shows the type of situation that has existed in the system. Thermocouple TR15 is functioning properly while TRI6 drops sharply with increasing speed, a condition probably due to centrifugal force causing frayed wires in the rotor bore to have another contact point.810 - TURBINE sreeD ‘TRIS - ROTOR BORE TEMPERATURE IPSTH STAGE ‘TRI6 - ROTOR BORE TEMPERATURE IP STH STAGE. -- 7 3 9 romenee) 213 ia as 778 m8 Figure A-13, Typical Speed Sensitivity of Faulty Rotor Bore Temperature Measurement After restarting the turbine, we found the calibration of the repaired transmitter still did not meet factory specifications, It gave consistently higher readings than the other two. The calibration constant of the transmitter (Number 3) was corrected based on the assumption that the faulty transmitter should read the average value of the other two transmitters. This transmitter is the one that had its demodulating card repaired in July of 1979, Even when data isn't available at load, the values of the majority of the remaining thermcouples cone into general agreement on turning gear. It is felt that sufficient data has been obtained for use in developing heat transfer coefficientcorrelations for the rotor. Therefore, rotor cool-down data is still available. In November of 1980 (the end of the project) turbine bearing Number 3 was opened to install lift pumps which exposed the turbire coupling that contained the telemetry transmitter. It was decided to check the calibrations of the three transmitters and hopefully resolve the discrepancies in the calibration, especially the one transmitter that had continuously given higher readings. The calibration check consisted of injecting a known millivolt signal into one or more input channels on each of two of the three transmitters. The input channels chosen were ones which were known to have shorted or open thermocouples. The analysis of the calibration test confirms that transmitter nunber 2 gave results that agree with the original calibration. Transmitter nunber 1, which could not be calibrated while we were at the site because work was being done on the turbine bearings, and the rotor could not be rotated, gives data that agrees with transmitter number 2, Because of this agreement we concluded that the original calibration for transmitter number 1 is still valid. Transmitter nunber 3, which is ‘the one which had its demodulating card repaired, gave a calibration curve that indicates the correction factor being applied for data from this transmitter is realistic. The test confirmed that transmitter 3 has a “zero shift" with transmitter temperature, and a slope (°F/MV) that is lower than the other two transmitters. Inspection of the thermocouple wire during the above calibration showed additional fraying of the insulation since the last inspection. Also, the transmitter and the Micarta sleeve did not slide in and out very easily in the bolt holes. This is probably due to sone deformation in the Micarta sleeve insulator. If this test is ever repeated additional design consideration should be given to removing the capsule with a jacking screw or puller assenbly. The cover plates over the trans- mitters successfully prevented any appreciasle amount of oi] from the bearing housing getting into the capsule area. The general conclusion that can be made about the temperature telemetry test is that even with the problem that occurred the trarsmitters were still all functioning after almost two years of operation. The data in general is repeatable over this time period and gives results which are accurate to approximately s10°F. It is highly recommended that if this test is repeated that a better thermocouple insulation material be used, A sheathed thermocouple should be used but this will require sone sort of transition to a flexible thermocouple extension wire before aeW?connection to the telenetry transmitter, The sheathed couple would provide the mechanical protection required at the high rotor temperatures. The extension wire would probably be used only at the coupling face and therefore would only have to withstand tenperatures of 200°F where a wire less prone to fraying could be used. TEMPERATURE AND PRESSURE INSTRUMENTATION Selection of Data Points The criteria for selecting of data points for the particular test program fall into three categories: 1. Turbine and cycle data used to estinate turbine stresses and obtain heat transfer correlations. 2. Boiler metal temperatures to estimate boiler stresses. 3. Cycle conditions and control parameters for model validation. Some data points serve more than one purpose. Compromises were made on the amount. of redundancy needed. For example, no redundancy exists for cycle steam conditions, since most of these sensors could be replaced. In addition, the power plant was designed with a limited number of sensor locations available. Diagram for Collins # Test A simplified block diagram, Figure A-14, of the instrumentation for the test at the Collins Plant shows the transducers and thermocouples added to the turbine and boiler and the interconnection for the data acquisition systen. The primary purpose of this diagram was to provide the interface information by which Sargent and Lundy prepared the cable routing drawings for the test. But it also provided useful in merging the Westinghouse and the Babcock & Wilcox instrumentation, and in keeping a general overview of the instrumentation, It was also useful during the installation and debugging phase of the test. 1/0 List for Collins #5 Test The Westinghouse reference number is a nonvarying number that was originally established for the instrumentation lists, This number was retained since certain material had already been purchased and tagged accordingly. Sargent & Lundy engineers assigned different tag numbers for in-plant identification,Boner) |souen| HP METAL] | TUBE HTR,| We Te TuRB | | TURB press. | [StM. 1/¢| TELEMETRY ANTENNA Misc. INOW. ROUTED My ve re HP iP we] ei REMOTE FAST SCAN REMOTE DATA ‘SCANNER CONTROL SYSTEM UNIT NO. 5 ELEC. EQUIP. RM. no — Ly FRaws] femcey) | Ts!) Lewa. conrr.| | Das Svs. TOFAST ©]! JANNUN, SCAN pen | INPUT pe SS! ES Figure A-l4, — Instrumentation Interconnection Diagram The instrumentation list is tabulated as Table A-2. This list groups data points according to the type of measurement. The list also identifies whether the signal was wired to allow Babcock and Wilcox (B&W) to measure it with their fast scan system, The fast scan system was used for specific open loop test made for boiler validation test. In addition, the tabulation indicates the origin of the signal. All signals were either existing signals or were installed by B&W or Westinghouse for this test.Table A-2 INSTRUMENTATION LIST Ref. Now Identification Fast Scan Installed 8) cs-1 Unit Megawatts Yes Exist. Sto. cs-2 Boiler Turbine Demand No Exist. Sig. cs-3 Unit Rate of Change No Exist. Sig. cs-4 Throttle Press. Error No Exist. Sig. cs-5 Steam Flow Error No Exist. Sig. 3-6 S.H. Temp, Error No Exist. Sig. cs-7 R.H. Temp. Error No Exist. Sig. (5-8 Firing Rate Demand ves Exist. Sig. 5-9 Air Flow Demand No Exist. Sig. cs-10 Turbine Speed Yes Exist. Sig. TGA-1 Gas Temp. Probe North Yes Exist. Sig. TGA-1a Gas Temp. Probe South Yes Exist. Sig. T6A-2 Air Entering 1 Air Htr. Yes Exist. Sig. TGA-3 Air Entering §2 Air tr. Yes Exist. Sig. TGA-4 Gas Leaving 51 Air Htrs Yes Exist. Sig. TGA-5 Gas Leaving 52 Air itr. Yes Exist. Sig. TGA-6 Sec. Air Temp. 51 Airfoil Yes Exist. Sig. TGA-7 Sec. Air Temp. 52 Airfoil ves Exist. Sig. TGA-8 Gas Leaving Economizer N. ves Exist. Sig. T6A-9 Gas Leaving Economizer S. Yes Exist. Sig. TGA-10 Gas Temp. in Recirc. Plenum N. Yes Exist. Sig. TGA-11 Gas Temp. in Recirc. Plenum S. Yes Exist. Sig. TSW-1 Turbine Throttle Steam Yes Ww Tsh-2 First Stage Steam Temp. Yes Exist. Sig. Tsh-3 Cold Reheat Steam Temp. Yes Ww TSW-4 Turb. H.R. Steam Temp. Yes 4 A-20Table A-2 (Continued) INSTRUMENTATION LIST Ref. No. Identification Fast Scan Installed By TSH-5 ——Turb, Extract. Stage 2 Temp. No u TSH-6 LP. Turb. Inlet Temp. Yes x Tse? Ext Stm, Temp, to 54 Her. No w TsW-8 Ext, Stm, Temp. to 53 Htr. No ¥ TSH-9 Ext. Stm. Temp. to 52 itr. No “ TSW-10 Feedwater Temp, from 57A Her. Yes u TSi-11 Economizer Outlet-North Yes Baw TsWe12 Economizer Out et-South Yes BW Tsl-13 Primary S.H. Outlet-North Yes Baw TsH-14 Primary S.H, Outlet~South Yes Baw Tshi-15 —S.H. Attemperator-North Yes Baw TSW-16 S.H, Attemperator-South Yes Baw TSH-17— Sec. S.H, Platen Inlet-North ves Bay TSW-18 Sec. S.H, Platen Inlet-South Yes Baw TSW-19 Sec. S.H, Platen Outlet-North Yes Baw Tsi-20 Sec. S.H, Platen OutTet-South Yes Baw Tsli-21_— Sec. S.H. Inlet-North Yes Baw TsW-22 Sec, S.H. Inlet-South Yes Baw TSH-23 Sec. S.H. Outlet ves Baw TSW-24 Cold Reheat Steam In Yes Ba TsW-25 Hot Reheat Steam Out ves Baw TSH-26 —Feedwater Fr. S6A HP Ht, Yes u TsW-27 STA HP Heater Drain Yes x TSW-28A 502 Viv. Bypass Steam Yes Baw TsW-288 518 Viv. Bypass Stean Yes Baw TsW-29 Sec. SH. Outlet Legs Yes Baw Tsi-30 RAH, Outlet Legs Yes Baw AaTable A-2 (Continued) INSTRUMENTATION LIST Ref Now Ident’ ficat ion Fast Scan Installed 6 Ts¥-31 Condensate Punp Suct fon Yes 4 Tsie32 54 LP Heater Osicharge ves W T5H-33 Gland Steam Seat HR No ¥ TsW-34 No, 2 Turb. Brg. rain 0 “ Fel Feedvater to Econ. Inlet Hér. Yes Exist, Sig. F3 S.H. Wer. Spray Attenp. 1st Sta. Ne Yes Exist. Sig. Pot S.H. Wer, Spray Attemp. 1st stg. S. ves Exist. Sig. Fs S.H. Wer, Spray Attenp. 2nd St9. N. Yes Exist. Sig, F6 S.H. Wer, Spray Attemp. 2nd Sta. S. ves Exist, Sig. Fer Rul Water Spray Attenp. Yes Exist. Sig. Fe S.H. Bypass tm, Flow Yes Exist. Sig. F9 Ss. Sat. Stm, Attenp. 518 Viv. Pos. Yes Exist, Sig. Fo10 RAH, Sat. Stm, Attenp. 519 Viv. Pos. Yes Exist. Sia, Fal Total Air Flow Yes exist. Sig. F-16 51 GR Fan Mtr. Anps Yes Exist. Si. P1752 GR Fan Her, Amps Yes bxist. Sig. F518 Main O11 Flow to Exist. Sig. F-19—_DistilTate O11 Flow to Exist. Sig. F-28 Cond. Flow to Deaerator Wo Exist. Sig. Poa Turbine Throttle Press, ves Exist. Sig. Poe Turbine First Stg P Hi-Range Yes au Po3 Turb, Cold RH. P Hi-Range Yes u Pa Extraction Stm, to 57A Htr. Yes a Pos Turb, Hot Re Inlet Hr. ves # Po6 Extr. Steam to S6A Her, Yes Exist, Sig. par Turbine Crossover Yes 4 PB Extr, to 54 LP itr. No u A228Table A-2 (Continued) INSTRUMENTATION LIST Ref. Now Identification Fast_Scan Installed By pag Extr. to 53 LP Htr. No Ww P-10 Extr. to 52 LP Htr. No w Pol Extr, to SIA LP Htr. No w Paz Cond. Press. Narrow Range Yes Exist. Sig. P-13 Sec, S.H, Outlet Yes Exist. Sig. pole Boiler Drum Yes Exist. Sig. P-l7 Furnace Press. No Exist. Sig. P18 Turb, First Stg. P Lo-Range Yes aw P-19 Turb. Cold Ru, P Lo-Range Yes w Mel Boiler Drum Level Yes Exist. Sig. M2 Flue Gast Duct 02 No Exist. Sig. Med Additive Viv. Position Yes Exist. Sig. M58 51 BFP Turbine Speed Yes Exist. Sig. M58 52 BFP Turbine Speed Yes Exist. Sig. Me6A SSH Bypass 501-1 Cont. Viv. Pos. Yes Exist. Sig. 68 SSH Bypass 501-2 Cont. Viv. Pos. Yes Exist. Sig. MT Ist Stg. Attemp. Vv. 555.1 Pos. Yes Exist. Sig. M8 Ist Stg. Attemp. Viv. 555.2 Pos. Yes Exist. Sig. Meg 2nd Stg. Attemp. Viv, 556.1 Pos. Yes Exist. Sig. M10 and Stg. Attemp, Viv. 556.2 Pos. Yes Exist. Sig. Nel Rell. Spray Viv. 558 Pos. Yes Exist. Sig. Mel2 PSH Bypass Viv. 502 Pos. Yes Exist. Sig. Me13 Turb, Diff. Exp. Pickup 2A No Exist. Sig. No14 Tur. Casing Expansion No Exist. Sig. Nels: Brg. No. 2 Housing Motion No W N16 57A HP Hitr. Dr. Viv. Pos. Yes Ww Nel7 57A HP itr. Wer, Level Yes x Aa23Table A-2 (Continued) INSTRUMENTATION LIST Ref. Now Identification Fast Scan Installed 8; M-19 Automatic Turbine Control Alarms No u M-20 Control Valve Mode No W M21 Status of Integrated Control No uw BHT-1 Drum Top Outside No Baw BuT-2 Drum 45° Outside No Baw BHT-3 Drum 90° Outside No BaW BHT-4 Drum 135° Outside No Baw BuT-5 Drum Bottom Outside No Baw BNT-6 Drum Top Inside No Baw BnT-7 Drum 45° Inside No Baw BuT-8 Drum 90° Inside No Baw BMT-9 Drum 135° Inside No BaW BNT-10 Drum Bottom Inside No Baw BMT-11 Riser No aH BMT-12 Saturated Conn, Tube No Baw BHT-13 Primary Out. Hér, Top BIr. Ctr. No Ban BMT-14 Primary Out. Hdr, Btm. Bir. Ctr. No Baw BHT-15 Primary Out. Har. Bottom Bir. SH No Baw BHT-16 Roof Tube Near Bir. Sidewall No Baw BMT-17 Platen Outlet Hdr. Top Bir. ctr. No Baw BMT-18 —Platen Outlet Hdr. Bottom Bir. Ctr. No BaW BMT-19 —Platen Outlet Hdr. Bottom Bir. SH No Baw BMT-20 Roof Tube NR BIr, Sidewall No Baw BMT-21 Sec. Outlet Hdr. Top Bir. ctr. No Baw BMT-22 Sec. Outlet Hdr. Bottom Bir. ctr. No Baw BMT-23 Sec. Outlet Hdr. Nr. Sidewal] No Baw AzaTable A-2 (continued) INSTRUMENTATION LIST Ref. No. Identification Fast Scan Installed 8) BMT-24 Sec, Outlet Hdr. Nr. S.We No Baw BHT-25 RAH, Outlet Hdr. Top Bir. Ctr. No aH BMT-26 RH, Outlet Hdr, Bottom Bir. Ctr. No Baw BNT-27 RAH, Outlet Hdr. Top Near S.W. No Baw BHT-28 RH, Outlet Hide, Bottom Near SW No Baw BuT-29 Economizer Stringer Bir. Ctr. No Ba BHT-30 Economizer Stringer Bir. Qtr. Pt. No BaW BHT-31 Economizer Stringer Bir, SW No Baw BHT-32 Supply Tube No Baw BNT-33 Sidewall Tube in Gr. Hopper No Baw BHT-34 Front Wall Tube in Gr. Hopper No Ba 8NT-35 GR Hopper Casing No Baw BHT-36 Frontwall Tube Furn, Side No Ba BNT-37Frontwall Tube WB Side No Baw BHT-38 —Windbox Casing No Baw 8NT-39 Penthouse Casing No Baw THP-1 HP Exh, Inner Cyl. Base No W THP-2 «HP Exh, Inner Cyl. Base No W THP-3 HP Exh. Inner Cyl. Base No W THP-4 HP Exh, Stm, io aw THP-5 HP Blade Ring seal 6th Sto. No H THP-6 HP Blade Ring No W THP-7 HP Exh Inner Cyl, Base No W THP-8A HP. Impulse Zone Base No w THP-88 HP. Impulse Zone Base No w THP-8C HP Impulse Zone Base No W THP-9 HP Inner Cyl. Bolt No H AA25Table A-2 (Continued) INSTRUMENTATION LIST Ref. Now Identification Fast_Scan Installed 8) THP-10A IP Inlet Inner Cyl. Base No W THP-108 IP Inlet Inner Cyl. Base No Ww THP-10C IP Inlet Inner Cyl. Base No Ww THP-11 IP Inner Cyl. Bolt No Ww THP-12 IP Dummy Ring Base No Ww THP-13 IP Blade Ring 3rd Stg. No W THP-14 IP Extraction Inner Cyl. Base No W THP-15 IP Inlet Inner Cyl. Base No W THP-16 IP Inlet Inner Cyl. Base No w THP-17 IP Inlet Inner Cyl, Base No w THP-18 HP Outer Cyl. Mid-Span Base No w THP-19 HP Inner Cyl. Impulse Zone Base No W THP-20 HP Outer Cyl. Bolt No W THP-21 HP Outer Cyl. Flange No 7 THP-22 HP Inner Cyl. Base Impulse Zon2 No w THP-23 HP Inner Cyl. Exh. Base No 4 THe-25 HP Outer Cyl. Cover Mid-Span No u THP-26 HP Outer Cyl. Cover (Gen, End) No x THP-27 HP Outer Cyl. Base (Gen. End) No H THP-28 HP Quter Cyl. Base No 4 THP-29 HP Outer Cyl. Base No W THP-30 HP Outer Cyl. Base No ¥ THP-31 HP Outer Cyl. Base No W THP-32 HP Outer Cyl. Cover (Gov. End) No H THP-33 HP Outer Cyl. Cover (Gov. End) No 4 THP-34 HP Outer Cyl. Cover (Gov. End) No W THP-35 IP Extraction Inner Cyl. Cover No 4 AA26Table A-2 (Continued) INSTRUMENTATION LIST Ref. Now Identification Fast_Scan Installed 6, THP-36 IP Inlet Inner Cyl. Cover No W THP-37 HP Inner Cyl. Cover Impulse Zone No H THP-38 HP Inner Cyl. Cover Impulse Zone No u THP-39 HP Inner Cyl. Cover Exhaust No u Tst-4 Left Hand Steam Chest Deep No H Tsc-5 Left Hand Steam Chest Shallow No W TLP-1 LP cyl. Inlet Cover No W TLP-2 LP Cyl. Inlet Cover No aw TuP-3 LP Cyl. Inlet Cover No W TLP-4 LP Cyl. Extr. Cover No w TLe-5 LP Cyl. Extr, Cover No Ww TLP-6 LP Cyl. Extr. Cover No w TLP-7 LP Cyl. Exhaust Cover No Ww TLP-8 LP Cyl. Exhaust Cover No wu TLP-9 LP Blade Ring Cover No w TLP-10 LP Cyl. Inlet Cover No w TLP-11 LP Inner Cyl. Extr. Base No uw TLP-12 LP Inner Cyl. Extr. Base No wu TLP-13 LP Inner Cyl. Extr. Base No w TLP-16 LP Blade Ring Base No w TLP-17 LP Blade Ring Base No W TLP-20 LP Blade Ring Base No W TLP-21 LP Inner Cyl. Base Inlet Zone No W TLP-22 LP Inner Cyl. Base Extr. Zone No W TLP-23 LP Inner Cyl. Base Extr, Zone No W TLP-24 LP Inner Cyl. Base Extr. Zone No W A-27Table A-2 (Continued) INSTRUMENTATION LIST Ref. No. Identification Fast Scan Installed 8) TLP+25 LP Inner Cyl, Base Extr. Zone No Ww TLP-26 LP Inner Cyl. Base Bir. Ring Sipport No Ww TLP-27 LP Blade Ring Base No W TLP-29 LP Inlet Flow Guide Base No w TLP-30 LP Exhaust Flow Guide Cover No W TLP-31 LP Inner Cyl. Inlet Zone Flange No Ww TLP+32_ LP Inner Cyl, Inlet Zone Flange No aw TLP-33 LP Inner Cyl. Inlet Zone Flange No uw TLP-34 LP INner Cyl. Inlet Zone Flange No W TLp-35 LP Inner Cyl. Inlet Zone Flange No Ww TLP-36 LP Inner Cyl. Inlet Zone Flange No w TLP-37 LP Inner Cyl. Extr. Zone Flange No Ww TLP-40 LP Inner Cyl. Extr. Zone Flange No W TLP-41 LP Inner Cyl. Extr. Zone Flange No Ww TLP-42 LP Inner Cyl. Extr. Zone Flange No w TLP-43 LP Inner Cyl. Extr. Zone Flange No Ww TuP-44 LP Inner Cyl. Extr. Zone Flange No Ww TLP-45 LP Inner Cyl. Bolt No wu TR-1 HP-IP Rotor HP Dummy No W TR2 HP-IP Rotor HP Dummy No uw TR-3 HP-IP Rotor HP Exhaust No aw TR HP-IP Rotor HP Exhaust No W TRS HP-IP Rotor First Reac. Stg. No W TR-6 HP-IP Rotor First Reac. Stg. No W TR-7 HP-IP Rotor Control Stage No Ww TRB HP-IP Rotor Control Stage No uw TR-9 HP-IP Rotor IP Dummy No w AA28Table A-2 (Continued) INSTRUMENTATION LIST Ref. No. Ident ification Fast Scan Installed 8) TR-10 PIP Rotor IP Dunmy No u TR-1l_—HP-IP Rotor IP Inlet No “ TR-12—HP-IP Rotor IP Inlet No u TR-13—HP-IP Rotor IP 3rd Stage No 4 TR-14 HP-IP Rotor IP 3rd Stage No ¥ TR-15 —-HP-IP Rotor IP Sth Stage No w TR-16 _HP-IP Rotor IP Sth Stage No u TR-17——HP=IP Rotor IP Exh. No ¥ TR-18—HP-IP Rotor IP Exh. No " LEGEND cs Control Signal ToR Temperature Gas & Air TSW Temperature Steam & Water F Flow P Pressure " Wiscellaneous BMT Boiler Metal Temperature THe Turbine Stationary Metal Temperatures HP-IP TP Turbine Stationary Metal Temperatures HP-LP Ts¢ Steam Chest Metal Tenperature mR HP-IP Rotor Metal Temperatures A-29Cycle Steam Thermocouples The added thermocouples were ordered fron CGS Thermodynamics to the sane specifications used for the turbine stationary metal thermocouples but without brazed-on bullet heads. Continuous sheath thermocouples are being used for the low pressure extractions since the piping and thermal wells for these therno- couples are in the neck of the condenser, Therefore, sheath thermocouples provide protection against damage by high velocity wet steam. The low pressure inlet thermocouple was included in the group since it could provide a backup during installation and could be installed at a later date if needed. These thermocouples were ordered in advance of the other cycle steam thermocouples to ensure that they would be available before work in the condenser was finished. The thermocouples are Chromel-Alumel for the same reasons that the stationary metal thermocouples are this type. The remaining thermocouples are the sheathed type made from Chrome] Constantan (type £) with standard connectors to extension wire which facilitated cable routing for long distances. Most of the thermocouples were calibrated by themselves without extension wires, except the throttle, hot reheat, and cold reheat thermocouples which were calibrated with their respective connection wires to maximize the accuracy of these readings. Turbine Stationary Metal Thermocouples Thermocouples were purchased from CGS Thermodynamics. For the most part the thermocouples are sheath thermocouples with a bullet head brazed to the tip. The type braze is determined by the temperature of the environment, Handy and Harmon permabraze 130 is applied to locations where the temperatures could be above 750°F while the Handy and Harmon braze 541 is aoplied below 750°F. The turbine metal thermocouples are all chromel-alumel, type K. This choice was made for two reasons, For the quantity ordered, the material was more readily available than the type E thermocouples, and for installation reasons. Since the sheath were routed through the turbine after installing the junction, the sheath cannot be cut to the proper length and transitions made to standard wire until the routing is complete. Since alumel is slightly magnetic the use of the K thermocouple allows for simple identification of the wires after cutting the sheath to its proper length. A-30The bullet heads and spacers of the thermocouples are made of the sane material as the turbine cylinders. The specific nunber identifying the thermocouple and its Tocation in the turbine is stenciled on the thermocouples bullet head and on the sheath at the cold junction to aid in identification during assenbly. The thermocouples were checked with x-ray and electrically at 500 volts to ensure that the junctions were ungrounded. The thermocouples were also cycled thermally to check integrity. Premium grade wire was chosen and the thernocouples were calibrated at seven temperatures above the ice point, These calibrations were used in the Westinghouse data reduction program. Cylinder Modi fications The high pressure-intermediate pressure and low pressure turbine thermocouple Vocations are illustrated on a longitudina’ section Figure A-15. New thermocouple locations were added to provide information that was being obtained from standard turbine metal thermocouples at Eddystone. This was required since all the spare Junctions supplied were being used at Collins Unit #5. In addition, the wire size that would result in replacing the standard thermocouples with the one containing another element was unacceptable to Sargent & Lundy, Architect Engineer for the Collins Station. The thermocouple installation techniques were previously used on another unit. This particular design is patented by Westinghouse and is iMustrated on Figures A-16 and A-17. The low pressure turbine installation was completely new since this particular Tow pressure turbine is a different design than the one that was previously instrumented. Before making the modificat‘on drawings of the unit, a study was made to ensure that the internal locations chosen for the metal thermocouples were accessible in the field. The same fastening techniques as used prev‘ously were used at Collins. The major difference is that bosses were added to the outer wrapper and walls at the desired ‘thermocouple locations due to the structural considerations. The steam chest was modified to allow the “nstallation of shallow and deep thermocouples. This was necessary because the standard thermocouples’ spare Junctions were not available. AS31u013e907 @[dnosowuay, Yai aUiqun] Jo uOLz9—5 Leutpn316u07 sgt-w eunbiy AA32SECT “xx” Figure A-16, Multiple Sensing Head Thermocouple Assembly The turbines stationary metal thermocouples were installed with no significant problems. The installation was simplified by the development of special tooling and prior experience, The low pressure turbine was a more difficult installation because of the deep cavities in the extraction zone and because all of the inside thermocouples are made to exit from the inter cylinder in the area of the lowest pressure extraction, This is done to minimize stress in the wrappers, Figure A- 18 shows @ view along the horizontal joint of the HP/IP turbine looking from the generator end toward the governor end. The view shows thermocouple HP-13 leaving the inner cylinder through a fitting and joining another group of thermocouples crossing over to the outer cylinder and suoported along the entire length. Figure A-19 shows a closer view of this grouping and the supporting of the thermo- couples. Note the triple thermocuople (HP-10) at the centerline of the IP inlet A-33CAVITY FOR T/C ASSY. 1.843 DIA» ‘T/C ASSY. FOR STREAM MEASUREMENT 125} ‘SPACER 'SWAGE TO RETAIN T/C ASSY. 2655 SPHERICAL RAD. Figure A-17, Thermocouple Installation for Single High Pressure Turbine Thermocouple 4-34a4 Figure A-18, Thermocouple Installaticn and Wire Routing at the Horizontal Joint of the High-Intermediate Pressure Turbine A-36Figure A-19, Thermocouple Wire Routing on the High-Intermediate Pressure Turbine Inner Cylinderexiting the inner cylinder at the extreme left hand of the picture, Figure A-20 shows the view looking down at the horizor 1 joint in the same area as Figure A 19. Note how the wires are supported along the support lug of the inner cylinder onto the outer cylinder, The wires are then fed into the holes in the outer cylinders to exit the turbine. Figure A-20, Detail of Thermocouple Wire Routing Transition from Inner to Outer Cylinder of High-Intermediate Pressure Turbine Figure A-21 shows the view of the generator end of the HP/IP cover. This picture shows the routing of a surface temperature thermocouples along the outer cylinder of the HP/IP cylinder, AA37Figure A-21, Installation of High-Intermediate Pressure Turbine Outer Cylinder Thermocouple Prior to Adding of Insulation Figures A-21 and A-22 show the thermocouple routing techniques used in the low pressure turbine. Figure A~22 shows the fittings bringing low pressure thermo- couples 11, 16, 17, 26, 27 and 29 through the extraction wall. Thermocouples are not routed straight across to the next wall but are supported with clips around the inside fo the flange. The boss for thermocouple LP=10 is also shown. Figure A-23 shows the same area fron anotter angle. The previously mentioned ‘thermocouples are joined by thermocouple LP-40 and supported on route to the next Fitting location. The supporting of thermocouples is important in the extraction zones to ensure thermocouple reliability. Figure A-24 shows the region where the low pressure thermocouples cross over from the inner cylinder to the outer cylinder before exiting from the turbine. Note ‘that even though this is a low velocity region, thermocouples are rigidly sup- ported to ensure reliability. A328Figure A-22. Typical Thermocouple Installation and Wire Routing in the Low Pressure TurbineFigure A-23 Typical Thermocouple Installation and Wire Routing in the Extraction Regions of the Low Pressure TurbineFigure A-24. View Showing Thermocouple Wire Transition from Inner to Outer Cylinder in’the Low Pressure Turbine PRESSURE TRANSDUCERS Of the suppliers of pressure transmitters who submitted quotes, Westinghouse had Therefore, these transmitters were favorable experience with only one of thet selected for the pressure measurements usec to establish cycle flows. A second supplier's transmitters were chosen for the remaining locations where Westinghouse installed transmitters for the program. Tris selection was made to reduce cost. The transmitters pressure ranges were selected to cover the range of operation expected during testing. Special consideration was given to the first stage and cold reheat pressure transmitters. A high and low pressure range transmitter were installed for each of these measurements, Qual transmitters were used since these pressures were used to establish high pressure turbine flow and one trans~ mitter would not have given enough resolution and accuracy at its lower range of measurements, Reheat flow was obtained by subtracting the extraction flow and Aaadding the attemperator flow. The extraction flow was established using a differential pressure transmitter and cold reheat pressure transmitter. The differential pressure transmitters reading, however, could not be correlated with flow satisfactorily. Therefore, IP flows were obtained by alternate methods. hen the 13 pressure transducers were received from the suppliers, a five point calibration was run on each transducer by increasing the pressure in steps from 0 to full scale and then repeating the points on decreasing pressure steps back to 0. The transducers are all 4 to 20 ma output type transducers and each was calibrated with the series resistance across which the data system measured voltage in the installation at Collins, 11 transducers calibrated well within the plus or minus .25% of full scale limit for linearity and hysteresis specified by the manufacturers. The transducers were calibrated against the Westinghouse Steam Turbine Division Gilmore pressure calibration standard. The pressure transducers were then shipped to Collins for installation. EVALUATION OF INSTRUMENTS AND OPERATING EXPERIENCE The instrumentation was complete by May of 1979 but not all readings could be checked out under operating conditions until September. The delay was caused by the fact that the string of high pressure feedwater heaters and the gas recircu- lation fans were not brought into service until August. The station then started conducting heat rate tests. The boiler steam path thermocouple measurenents were delayed because the thermocouples for this project were mistakenly installed for the routine plant service thermocouples. Once this error was uncovered by Babcock and Wilcox, some delay was incurred before replacement thermocouples could be obtained. The plant heat rate tests started in August. Because the cold reference junction wasn't functioning properly, Conmonwealth Edison personnel disconnected the thermocouples needed to conduct their tests and inserted their own thermo- couples. A special wiring connection schene had been developed by Westinghouse to prevent this problem but the plan was cefeated by the reference junction failure, The heat rates tests were not concluded until January of 1980, Because of this, nine thermocouples were disconnected for a period of 4-1/2 months. The most important of these thermocouples were main steam and hot reheat steam. AA?The first stage pressure transmitter failed in December, and was replaced with a transmitter borrowed from Westinghouse in January, 1980. The failed transmitter was repaired and recalibrated. Rather than replace the repaired transmitter a swap was made with Westinghosue for the installed transmitter. Considerable calibration changes were required for the LP pressure transmitters because of zero drift and slope changes. These transmitters were supplied as a cost saving item for the low pressure turbine. Other calibration changes were required since a few of the Bailey Meter transmitters had different calibrations than were was specified for the job. The following is a summary of instrument malfunctions: Control Signals DATE © No failures. Gas and Air Temperatures © Gas temperature probe north. Installation Steam and Water Temperatures © Turbine second stage extraction. 12/79 © S.H. attemperator north. 1/80 © Secondary S.H. platen inlet south. 8/79 © Nunber 2 bearing drain temperature. Installation © IP inlet steam, 12/79 © Feedwater fron 568 heater 12/79 © 57A heater drain 12/79 © 54 LP heater discharge 9/79 Flows © One spray flow. 9/80 Pressure © First step pressure. Failed 12/79 - Repaired 2/80 © Extraction to 54 LP heater 6/80 © Extraction to SIA heater ay79 R83Miscellaneous Signals # Bearing housing movement. 9/79 @ Flue gas duct oxygen Installation Boiler Metal Tenperatures © BMT 29 economizer stringer. 7/73 © BMT 30 economizer stringer. 179 © BHT 31 economizer stringer, 7/73 Turbine Metal Tenperatures THE 4 HP exhaust steam, Installation © THP 5 HP blade ring seal. Installation ©THE 6 HP blade ring. Installation © TH 8 HP impulse zone. Installation THE 9-H inner cylinder bolt. Installation © TH 36 IP inlet innder cylinder tolt. 2/80 @ TLP7 LP cylinder exhaust cover. Installation © TLP 21 LP inner cylinder inlet base, 12/79 © TLP 40 LP inner cylinder extraction, Installation © TH 35 IP extraction cover 5/80 Rotor Bore Tenperature © Discussed previously The primary objectives of this test program were still attainable since adequate data had been obtained on the more critical sensors before their failure. The main problem encountered with the tengerature instrumentation was with the thermocouple reference junction. However, when it was operating correctly, it gave excellent results and it was convenient te connect and use. The two failures with reference junction were a power supply failure and the inability to hold the “ice point" when the anbient temperature got above 90°F. The Power supply failure was an inconvenience but repairable. The second failure is a serious design deficiency, even though the manufacturer's specification states the equipment will work to 105°F. To determine when the reference junction was not performing, an electronic reference function was added to one thermocouple that was reading the internal anbient Aadtemperature in the reference unit. Therefore, even if the reference junction failed again the internal temperature of the reference would be known and the proper temperature compensation could be made, This action was taken during the time it ‘took to replace the reference unit's power supply. After the units were replaced, the operation was satisfactory even though the refrigeration cycle time was excessive.Appendix 8 DATA ACQUISITION SYSTEM SOFTWARE PROGRAMS There were six computer programs written for this project included in the computer- ized data system. In addition to the operating software supplied by Hewlett Packard, a relay driver was also incorporated into the system to interface with the relay interrupt circuit from the generator breaker contacts. A general description of each of the six programs will follow. The initialization program, INALE, read in all the variables that were required by the other programs for the operation at initial startup of the Data Acquisition System (DAS). This program also indirectly scheduled the logging program through the use of a program called DAYFL. The program OAYFL, was scheduled to run at initialization and at 3:00 am every day. DAYFL did two things: first it put an end of file mark on the digital tape for each days data and, second, it scheduled the logging program in its “transducer checking" mode, When this was accomplished the program suspended itself to run again the next day at 3:00 am. DAYFL determined that all equipment was on and functioning before it scheduled the logging program. Failure of any DAS equipment to operate stopped the operation of the program and caused error messages to be written on the computer display console. The program INALE then rewound the tape and put the tape recorder in the on-line mode. The data logging program was called LOGDT. Each time this program was scheduled it took one sample of every point of data and recorded the raw data on the magnetic tape. This program was the means to detect the state of the display switches on the computer and run various options of this program depending upon the state of the switches. Some of these options were: © Print raw data on either the display console, the printer, or both. © Print data in engineering units on the display console, printer, or both. © Check if transducers were open. @ Print the time of day that the log of data is taken,The second program that scheduled the logeing program to run was called INTRP. INTRP was scheduled to operate each time the computer sensed that the generator circuit breaker relay had changed state, which occurs when the generator was synchronized or tripped off line. This program scheduled the logging program to operate continuously as long as INTRP was scheduled. INTRP remained scheduled for 2 to 5 minutes depending upon a time variable which was input by the program INALE. The reading rate controller program was called RRCTR. This program ran continuously once it was turned on, Its function was to sample selected variables and determine if they have varied by a predetermined ancunt. This program examined the variation of the variables and selected a time interval, which it then used to schedule the logging program. The selected time intervals were 3, 6 or 12 minutes. The time intervals and variation limits could be changed from the console. The program MONTR scaned and displayed up to 10 variables. This program also had the option of selecting various modes of operation depending upon which display switches on the computer were selected. Data could be outputted as raw data or, in engineering units, on either the display console or the printer. This program provided for on-line plotting of the 10 variables in engineering units on the printer, The plotting mode automatically disabled the printer from printing data. The display unit could still output data in this mode of operation. GENERAL ARRANGEMENT OF DATA ACQUISITION SYSTEM HARDWARE The data acquisition system consisted of two parts, a local data system and a remote data system, The local data system was in the electrical equipment room and the remote data system was located on the turbine floor next to the first low pressure turbine. ‘The remote and the local data systems were interconnected by a set of electronic instruments called common carrier interfaces; one was located in the remote system and the other in the local system, These two devices caused the input/output devices connected to the renote unit to operate as if they were connected to the local data system. This technique made it possible to use only two scanners and signal conditioners at the remote portion of the data system. This allowed the rest of the data system to operate in 82the electrical equipment room where the environmental conditions were controlled. The major components of the system located in the electrical equipment room were the computer, display console, tape recorder, digital voltmeter, printer, clock, and the other two scanners. The use of scanners at the remote location reduced the amount of cabling between the turbine and the electrical equipment room. A block diagram of the data acquisition system is shown in Figure B-1. The equipment was capable of continuously operating over a temperature range from 35°F (1.7°C) to 130°F (54.4°C). AI] equipment was mounted in standard 19 inch racks. The equipment racks supplied with the system had lockable doors, front and rear. DISPLAY CONSOLE | COMPUTER QO L_—_f yt [KEYBOARD RECORDER DATA INTERFACE BUS + Dara I I T— |inrenrace [common DisirAL CARRIER voit] [printer ||| [cock t _ SCANNERS para PATATINEUTS — LOcaL 1 SIGNAL TO FAST SCAN rot © SCANNERS i SRTATINEUE | | Sannten | | LLoear clusrémeace| | TOFAST SCAN | f REMOTE CABINET _| SarRUNFUTS—-| REMOTE | hs BIN ‘SRTATINEUTS “1 sCaNNER 1 | ' TOFASTSCAN | C \ ' ScaNNeR | Rewore |_| ' OEPATIMPUTE =| gegen 2 P=) READY | TO FAST SCAN Figure 8-1, Data Acquisition System Block Diagram B38CABINET DESTGN There were two cabinets in which the equipment was installed. The remote cabinet, located on the turbine floor, was the cabinet in which the data system was origi. nally received from the supplier. This cabinet was modified somewhat for the test. The modifications consisted of cutting an access hole in the base of the cabinet to route in the turbine metal thermocouples and moving the cooling fan and power access panel to the top rear of the rack fram the bottom rear, The rear door was also lowered 8 inches to accommodate the cooling fan. The local cabinet, in the electrical equipment room, was a double width unit with double doors front and rear. This cabinet was identical to the type of cabinet which Westinghouse uses for the Digital Electric Hydraulic Control System. The cable terminations for the digital systems used the Westinghouse “half-shell" termination strips which are the Same type as supplied with the DEH cabinet. The remote cabinet contained four half-shells and the local cabinet eight half-shells. These half-shells permitted the cable connections to be made to standard industrial type terminations instead of the electronic type termination that the data system used. The complete data system and cable termination half-shells were premounted in their racks to ensure that all pieces would fit properly with ample room for working. The data system was then removed and the cabinets shipped to the site. The listings of the programs used to control the data acquisition system are listed (on the following pages.Pace oot FTN BLT Progra DIMENS cannon cannon cannon cannon cannon cannon cannon cannon cannon cannon cannon cannon cannon reuse rower TRIP Log rcano nop cout uRITE® READE I b FoRMAT 2 Farmar READK t URITEC 9 Former ce TPAT, ren=18 Lutes READee, READ READCL, RERDCL, URITEC URITEC writes ti Farner scHeo TCHWD= CALL RESET v. CALL H cace w READ I HM INALE TOW [bAYF(3> LUCLK,LUCCL LUCeR. LuDSP, LUOPT.LUTR/LUYTH LudC8>, EPNTiCS). TPNT2¢8) MTHS. 1DAYS, THRE-MIMS,1SECS, ETEMECS> teu UTYPEC 12), 1DRRCC 12) recer TeoKD< 10> ACB 2>,BC2,23,002,29, D6 2,29, E622) pirsct2.2> AMVC 1969, BAVC 180), CM¥< 1089 Lesiec 108.2) connnc 109 TIME DEFAULT TIME =120 SEC ae-120 INS TEST -8 SCANNERS -CONS. sToREsi90 et + OLUINP CLK LU OF DATA CHPUT> 4.23 (L6H LU OF DATA ECHO) 2 LUEXO isd C*READ IN LUM VTM OPT CLE CCL COR TR OSP LUDCI.8)" 101.8) TPNT2¢L,89"> 8 8 UINP. © OLUVTH, LUOPT. LUCLK,LUCCL.LUCER-LUTR/CUDSP, TEN, LURE, LUINP. #)cLUDCLo,L=t.8> INP, @CEPHTLCLI.L=i,8) VINE, #>CEPNT2CL),L=t,8) LUEXO. 11 LUVTM,LUGPT LUCLK. LUCCL LUCCR, LUTR, LUDSP. ICM, LURL ECLUEMO 11 €LUOCL-Lat 83 LUEKO/ TiC EPNTECL/ Let 8) LUEKO,11>¢ EPHT2¢L9.L=1,8) Cacrsitms 3.039 STC.CF OW LURE 378+ 1 80R+L URL. ECCS, TCHND) OLTMETTER. LOCAL cet PrecLuce.. 6) preccuytn, x Te CONST, 85120 FORMATCACELS. 8.1, wetted, 20> 20 FORMAT(24H THERMOCOUPLE [MPUT DaTAs 18H UPPER RANGE FIRST) DO at L=t.2 bo 2 Jet.2 READCLULHEs # ACL iJ D-BCLed CCL IIDC LI SD, EC Led) 21 CONTINUE WRITECLUEKO,£203¢¢ ACLs 99+ BCLi I Dy CCLed Dy DCLad ECL DDD 1J=0,2),L81,2) e15.e) READ IN TORRC URITEC1. 30> 30. FORMATC4OH Ly LORRCCLD.ITYPECLI,DLTSCL. 13, OL TSC L299 boat g=tt2 36 READCLUIMP, ©)L/LID/LTYPE.DLTSL. DLTS2 LRCLI34, 31,33 33 1FCL-13934,36 34 1DRRECL=CLD. TTYPECLSLTYPE DLTScL.trevLTst DUTScL.2 =oLTS2 31 CONTINUE 32 URITECLUEKO,1329(CL, TORREC LD, TTYPECL. DLTSCL, 19, DLTSCL.299, thet,12) 132 FORMAT(2¢14, 1H, 9.116. 1H. FE 2,1. F622 READ IN WY DATA CONSTANTS URITECL. 40> 40 FORMATC44H READ IN MY CONSTANTS [D.A.8,C Carexecxeez>> ba at Jat, tcw URTTECLUEROs (ai CC Le AMVC LD VBHECLD CRUEL 2 .Let, LOND wRITEC1. 50) 50 FORMAT(GH MSKDP. 13H, IcoMD(3) IM SEC. > READCLUINP, # MSKDP.TCOMDCS > WRITECLUERO, Si OMSKDP, ICOMDC 3) 51 FORMATCIN®, iK6, 179 READ LasLe const. 161 FORMATC27H ENTER LABLES EXC GOL=PSTDD> Labi ssasose 60 READCLUINP, 61>, LABLI-LASL? 61 FORMATCT3, 1%, 2829 TCL 962.62. 63 63 TFCL-18) 64.65, 64 LABLECL. 1>2LRBLL CABLECL: 23=tRBL2 Ga To 60 ID OUT OF RANGE 86Pace 0803 6 vette tes. 69 FORMAT(I6H ID OUT OF RANGED co To 60 vRITect.6e> FORMAT(i4H END OF LABLES> READCLUINP. 67 LABLI,LABL2 67 FORMAT(2a2> Lyes=sasese LFCLABLI-TYES 360,66,68 66 CONTINUE WRITECLUEXO,619¢L. LABLECL, 19,LABLECL/ 29,4, Lo MRITECLUEKO.162>L. LiL 462 FORMATCT3,1N, 222/4HVES > ste vurw LISTEN CALL HPT ACLUYTH, 14) PUT CCL ON LINE IW HAND SHAKE nop Lace, cct ow LINE VRITECLUCeL, 1809 REMOTE CCI ON LINE URITECLUCCR, 1869 REMOTE CCI IM MANDSHAKE MODE 5 SEC TIME DELAYS cali EXECCI12.8,1,0, WRITECLUCER, (81> se> CALL EXECC12.0.1,0,~58> LOCAL CCE IM HANDSHAKE MODE WRITECLUCEL, 161) CALL EXECC12,0, 1,0, 100 FORWATCLHLD 101 FORMATCI HAD 180 IDAVFC29-545068, TDAYEC3>=460408 SCHEDULE DAYFL ONCE UITH WAIT CALL Enece 23, rOAYE > LocoT Has RUN ONCE REWIND TAPE TO BOT CALL EXECC3,4808+LUTR? SCHEDULE DAYFL STARTING AT 3am aN EVERY 24 HRS CALL EXECC 12. 10RYF.4. 24-3, 8,0,0) ENDpace FTH oer er PROGRAN DAYEL DIMENSION NaREC 3) ANEN=60G0T NaMEC 1 )=461178 WaNEC 202435048 NAME 3)=520¢08 SET SWITCH BIT ON cerTT 12> Tsuetssucts) ISU=10R¢ 15W, 100000) CALL rasRe1su) RUN LocoT REGSEXEC(24,NAMED END BBPace ogot TH Let PROGRAM LocDT CHANGES FOR STR TAPE LARGE DATA BLOCKS Mod COLLINS TEST ~- SCANNERS - CONS. STORAGE =180 CALL RMPARCIPRAM> ADDED DIMENSION IBUFCS6O>, Juec S207 DIMENSION [D5¢2759,¥5(275),LTIMEC 59. IPRANCS? DIMENSION CALCSCS>.LHCS>,LADLIGS> -LAGL EES) DIMENSION LacKac 10) Gonmon Lucte.tucce. COMMON LUDC E>, TPHTICg), FPHT2Ca) COMMON HUTHS. LOAYS. CHRS,MEMS.{SECS, ETEMECS> conMON teu COMMON IT¥PEC 12>, TORRE 12) Connon msKkoP common rect Common tonne 10> COMMON Az. 2>,862.29,602.2), 002,23, 602,2) COMMON DLTSCL2.2) COMMON anyc108>,Bnve L809. cHv<1e8> COnMON LaSLEC 100.2) ConMON ComND< 10) EQUIVALENCECLUTR »LOCEACL> EQUIVALENCE CIBUFC41>, JBUFC I> CALL RMPARC IPRAMD LOCK VOLTM, SCANNERS, +TAPE RECORDER TO THIS 7 eat Lure 1, Locra.to> REGHEXECCS, LUUTM+L6008> VRETECLUVTH. 104) 104 FORMATCLOHFIR2T2AOHOD TPNTS#1 TPNTS=8 LIEWo=-4 SCHED STC.CF OM LURL Luru=33 TCNWD=37B61e0B+LURL CALL EXECS, 1CKWDD rete BLcT +t CLEAR SCANERS Da 199 Tlu=t.g LUSCH=LUDC LUD URITECLUSCH,Le2> 199 READCLUVTH. 1o1>vOHY 8-9 UccR, LuDsP, LuoPT.LuTR.LuYTM PROGRAMeI ace 107 108 105 aoe READ CLOCKS ANO PUT OM TAPE HPIB CLOCK CONTINUE READS LUCLK, 10591STAT. IMNTH, TORY, THR) MEN, LSEC TEST ONLY WRITEC3, {105 .18TAT, IHNTH, TOMY. IMR, HIN-1SEC,ISTAT FaRmarcaz,512/2%.K6> IF CIsTaT-2e04082107, 108, 187 CONTINUE FaRwaTcaz. 512) COMP cLock CALL EwECC LL. UTI MED UMP 16297 IsTHe=298 TSTRP=296 WRITE CocoT ExEcruTe Time FoR TEST 96 Te rssuce 249,49 NATTECLUDSP.¢5>CLTIMECLED, Leet, 59 ForMar(* LOGOT ENECUTE TIME =*S13) LPs t39¥c 13947 46 URITECLUGET, 95 >¢LTIMECLLED, Let 8> CONTINUE Data Loccrnc CHECK BITT 12 FOR DAY FILE TFe185M0 129196,98 EMDFILE LOTR SET_ISTRP=-ISTRF TO INDICATE DAY FILE rTeND=1 SET FLAG TO DO TRANSDUCER OPEN CHECK AND THAT FOF WaS PUT ON TAPE CLEAR DISPLAY UNIT AND UPDATE HEADER AFTER FILE MARK Lock uNLOcK=EsccL>.cm) CSMALL> TUNLK= 155556 Locks19ss4e TOP OF PaGE=Fsc H (SMALL? tropc=i55s08 CLEAR DISPLav-Esc J TCLER=158028 WRITE ERODING AND TIME WRITECLUDSP, 902 >1UNLK,ITOPG.ICLER,TMNTH, [DAY, fCTORRCCL,L=t,10)Pace 8803 902 FORMATC3A2,13,2H 7,13 ,2K,9¢% 19, 3K 20K TS 2/2K-AWTIME, 12%. @MLOAD. 3X, C2HMATM THPULS. BTM STEAM, 3H, 2HEP, 5%, 2HLO,4X.7HHOT —— SHDRUAZ 30H 90 CONTINUE bo 999 tlust.g SET VIM RANGE =.1¥ =RLZTRVLT IRYLT=510618 Luscn=Lupe rLu> TRCLUSCH)999, 999,91 94 LPNTR=IPNTICTLUD TRC EPNTE 9999, 999,92 92 LPNTF=IPHT2CILU> LPC TPNTF 1999, 999.93 93 CONTINUE © "Fest vit RANGE stov. ty > Go TO (65,65,65 66,66, 65, 65,66). 1LU Preiimestisiere) S Celt ExECC2.LUVTM.IRVLT.L> 00 99 IPNT=EPNTB. PNT 6 € TEST [F _LTEND= 1 =DAYFIL & OPEN CHECK OF TRNSDUCERS % TC tre TTeMDIs3,93 © LUDCS! SREMOTE SCANNER IPHTOID 79 95 Lupp=Lupcs> © AUTO RANGE TRVLT=510678 CALL EXECC2,LUVTM, ERVLT 1 “ WRITECLUDD, Loa >TPNTO READ. LUYTH, LOL >VONY weITeC Lupo, 102) READS LUYTR, LOL YDAY 94 conTinus e TPNTS=IPHTS +t Cipuzeipnre i WRITEC LUSCH, 10 9LTPRT READS LUV TH, 101 9VSCIPNTS > TDSCLPHTS)=¢[LU~1)#L0g+ [PNT © 100 FoRMAT(T3> AOL FORMATCLEDS.6>pace 99 © ee 102 c 999 © c ez eo a1 € 6 106 © c © 1a08 c s08 © € © c re se 39 3? ose CONTINUE CLEAR SCANERS FORMAT CIHE> WRITECLUSEN, 1029 RERoc LUYTH, LOL >VORY CONTINUE TCOMDC 9 >= LPNTS WakE*senucT LPNTE=(LPNTS-(IPHTS/5 #5) EFC EPNTED31.61.02 [PNTN=IPNTS<¢S-TPNTED TPNTS=IPNTS#L Do 80 L=IPNTS.275 vsclowe.e TOS(L #999 TPNTS=IPHTH CONTINUE OTRACK TAPE RECOROER URITE CALL cone WPITEC IBUF, 1869 EMPIB, IMNTH, [DAY THR. MIN, [SEC LISTME LT IMECS),LTEMEC 4),CT IMEC). LTEMECZ>-ULTIMEC L> 2eISTRP,TPQAK! 55, IPRAMC I, TPRAMC I), TPRANC 2), LPRAMC {> 3. 1BLCT. 1comd< 169, 1 comD< 9> FORMATCTS, 1X, 512,2(2K, 15, 1%. 14,4123, 3189) caLt cove WRITEC JOUF, 8009¢ (TDSC IP >, VSC IPD), 1P=1,65) WRITE To TAPE GALL EXECC2.LUTR.TBUF.560> CL EXECS 3 GO6B+LUTRD do 1980 Le66.275, 70 ISTAREL TEINeL ees CALL CODE WRITECIBUF, B009¢(1DS¢ IP), VSC IF >), IP=ISTAR-TFIND CALL EXEC 2-LUTR,IBUF.560> CALL EXECC3,6900+LUTRD FORMATCSCIS.1%,F10 69) UMLOCK VOLTH, SCAHWERS, & TAPE RECORDER FROM THIS PROG CALL LuRac 1808008. LOcKR. 10) ST IF OUTPUT TO PRINTER IF So Lock IFC ISsuc59939,58 TRC 186uc 3989.57 CALL Lunas 1B,LUOPT.1) CONTINUEPace egos WRITE DATA ON DISPLAY OR PRINTER TSUT=ESSuC5) TFc IST 260, 61,64 6e Lupy=LuoPT these Go To 62 61 reutareeuea> IFC ISWT 63.64.64 63 Lupy=Luose rh 62 continue URITECLUDY, 163 >INPIB. IMNTH, LOAY, THR. MEM, ESEC) ALSTHE, LTIMECS >, LILMEC 4>,CTIMEC 39, LTIME (29 163 FORMATCIS. GM TEMESIX, 2036 1H.2¢ £2, 1H! 962, 7Xs TS 1% £4,312) WRITECLUDY, BOLIC CEDSCLI,¥SCL)9,L=L, LPRTS) got FORMATCSCIS.F IO. 69> Go TOC et. s4)TLL 64 CONTINUE c RESET BIT 1220 IF DAY FILE OM TAPE TRC LTEMD 367.68 [gu=TAND(ISW. 1677776) CALL USSR ESD 67 CONTINUE c TEST FOR ENGR. calc Ie fegwc 399178, 87 178 CONTINUE URITECLUOPT, 163 9IHPIB.IMNTH, IORY, IHR MIN, ISEC, EUSTHE. LTIMECS ), LTIMEC 49, CTIMEC 3), LTEMEC2> IFC ESSu (299270, 70 87 IFC Tssuc 23) 270,79 270 CONTINUE VRITECLUDSP, 163 )LHPIB.LMNTH, IDRY, IHR. MIN, TSEC, AESTHE, LTIMECS 3 LTIMEC @D,LTIMEC SD, LT EME CZ? 70 DO 78 Lh=t,IPNTS.5 FRAT =U TPNTESIPNTC+S Test DO_77 LI=LPHTC, LPNTE Letpserr> WTYPE=L/ toot LPNT=L-CHTYPE-E #100 c TYPE POINTER GO TO (271,71, 73,74. 275,273.72, 71). HTYPE MODIFY GO TO FOR COLLINS TEST FOR FLOW CAL 27t LEC IPNT~45 272.71 222 LFCOMV(IPNT)2274,71 274 CALCHANVC PHT #( (ONVC IPNT e¥SCLID410, 2/20. 204.5 co To 276Pace u 74 L ars za 276 e806 upc4) CONSTANTS TPNT=TPNT+8 Go To 7 uoc6) CONSTANTS TPNT=LPHT+ES PRESURE-SPEED-nEGW.-ETC CALCHANVC LPHT 1+ BNVC CPMT J4VSCLID#CHYC IPT 24¢ VSCLE #023 LABLLCT6)=LABLECIPNT. 1) LABL2C 16 =LABLEC IPT. 2> TEST IF TELEMETRY CALC tT 273 re ? 260 262 261 a ? 2 ar? 176 ars ara 78 TRCHTYPE-6 975,72 EST FOR K OR E TC ON LUDc6> LFCIPNTL CS -TPAT#E 1972, 73 TEMPERATURE TYPE K CONTINUE tcove=1 Go To 260 TEMPERATURE TYPE E CONTINUE reoe=2 CONTINUE cac=0.0 VONY=VEcLt>et1e00.0 Da 261 Li=t.2 TFC CALC-400 0262. 261 CALCHACICODE, LL I*BC TCODE, LL evDMY + LCCTCODE, LL d0c VOMYse2 40C TCODE LL ac VONYeHa De CONTINUE CaLc=CaLcet 432.0 LaBLI¢ 1692520408 LapLa¢ 16 2=280408 conTENUE canes¢ re Uxe re 2 16-641 CONTINUE LFC ISSWC 29976, 176 CONTINUE URITECLUDSP, £74 9¢CLXCLL-CALCSCLLI-LABLICLLI-LABL2CLL 9, LLL. 5) FORMATCSCI3,(X,F7. 11%. 2a2,449) LFCTSsuc 399175. 78 CONTINUE WRITECLUOPT.1779¢CLXCLL 9, CALCSC LUD /LABLICLL I, LABL2CLL >, LL=L 5 FORMAT(CACI3.1K.F?. 1+ 282,19, 13,1%,F? 1,282) CONTINUE ace79 CONTINUE UNLOCK PRINTER CALL LURG? 1 e808, LUOPT.1> TEST IF TRIP Icomncad = TRC ECOND(89)7.8 OR- TF INTRP= 8 CONTINUE po 9 Lists ENO.Pace rh © € ogo Bett PROGRAM INTRP DIMENSION IPRAM(S>.NAMEC 3) COMMON LUCLK.LUCCL LUCCR, LUDSE,LUGPT-LUTR.LUYTH GOMMON CUDC E>, TPHTiCe), LONT2¢8) COMMON ANTHS. 1ORYS. THRS AIMS, ISECS.ITIMECS> COMMON Tow COMMON ITYPEC 129, TDRRCC 12) COMMON MSKOP COMMON TBLCT COMMON TcONDC 109 COMMON ACZ, 29-062, 29,.062,2),D62-29,8¢2,2) COMMON DLTS(12,2) COMMON AMVC 108), BMV< L809, CHV 108) COMMON LABLEC 100,2) COMMON conno< 10> Ger TRIP TIME CALL EXECC IL. TPRAMD waMEsLocoT WaMEC 192461178 Manes 232435048 NanEC 3 2=920808 TPRAL=IPRANCL? TPRAZ=LPRAMC2) TPRA3=IPRAMC3) TPRAd™IPRAMC AD TPRAS=IPRAM(S) REGHEXECC 24, MANE, IPRA, TPRAZ, CPRAZ,IPRASTPRASD DELAY THIS PROGRAM IcomDcs SEC reomoc g>=-1conoc e> IpLY=rconpce> rreroLy3z.t 1 1oLy=-120 Teomoc a d=toLy 2 EFC IDLY#300013 3 CONTENUE COLL EXECC12,0,2,0,10L¥) OFF LogoT AFTER 2 MINS Econoce> B-16FIM BLT PROGRAM RRCTR HANGED FOR 9 TR TAPE LARGE DATA BLOCK WRITE MoD COLLINS TEST = SCRHNERS - CONST, STORE =108 DIMENSION TBUFCS6O). JBUFC 49>, KBUFC480>,LBUFC 48>,mBUF C408) DIMENSION MBUFC a00> DIMENS TON Lockacit> DIMENSION TCOMNC 80), COMONC 345> Dinenstom rrnsne3> DIMENSION [THECCS>,ITHELCS).VRRCS( 10), VRRCC LO), ryRRcec 10> DIMENSION Loot 3) DIMENS TOW VRRLSC 12> COMMON LUCLK, LUCCL CUCCR.LUDEP, LUOPT-LUTR-LUYTH CanMon LuDdCe>.TPNTiC 6D. FeNT2Ce> COMMON MNTHS. IOAYS, THRS/MLMS.TSECS, ITEMECS> Cannon tow COMMON ITYPEC 129, 1DRRCC 12> CanMon msKoP common rect Connon conve 10> COMMON ACZ,2>,8C 2.29.66 2,29, 002,29, E( 2,2) Connon DiTsci2.2) EanMON Any< 108). Bnve 1e0>,cHYC108> Common LaBLEC t60,2) CanHON Conn to> EQUIVALENCE CLUCLK.ICOMNCL >>, ACL. 1>,ComONe 1>> EQUIVALENCE CLUOPT, LOCKAC ED) EQUIVALENCE ¢IBUFC 41), 9BUFCL D>, CBUF COL), KBUFC 1). LCTBUFC 1213, LBUFC 19). TBUFC 161), MBUFC 129, ¢ TBUF( 161 WeuFC1>) Locorc 19461178 Lager a>=43s040 Lager 399526408 test pirsun7.s c TYPE TEST VaR LTE=s21038 TTeeS210 38 Inve4esz6s CALL EXECK 14, ETHSHDPace 802 © € bo 26 tate 26 CONTINUE TWALIZE RRC SET UP VOLT WETTER Call HPTECLUYTA, 14) URITECLUVTM. (04> 104 FORMAT(LONFIR2T2 ADO) THP TBs 297 IsTHE=299 TEND@te 896 CONTINUE wRITect.@> 8 FORMATCI2H RRC IMTATED? 31 CONTINUE TontT=0 80 30 Lat, TEND TFC TDRRC(L)=1 930,48 TONT=CCHT+E vRRccL>=0.0 vercseio=0.0 30 CONTINUE TEND=CCHT SAMPLE DATA FOR RRC bo 29 Do 25 Latte USE SUi5 TO TEST TAPE RECORDER FOR REUIND TFC ISU 015,898 Iswis OFF TEST tcu=0 898 CONTINUE TFC Tow e906. 895,094 895 CONTINUE Lock VOLTM, SCANNERS. TO THIS PROGRAM CALL Lunas 1B-LOCKA. 113 TEN DATA SAMPLES BEFOR DISPLAY ba 26 [=1,CEND Lac pata 27 TLUsTDRRCC £97190 TPNT=LOGID-1 TPHT=EDRRGC 1>-¢ TLUd#100 TLUstLued RaNGES.1¥ TRVLT=510618 GO TO (63,61, 61,63,63-61, 61.639, TLY RANGE=10VPAce og03 63 CRVLT=IRVET #2 61) CALL EXECC2.LUVTM, FRVLT. I> Lusen=tupe rLu> WRITEC LUSCH, 80) TPNT RERDS LUYTR, LOL )VTEMP tot FORMAT(LEL3.6) 100 FORMAT(T3> Look ANEAD TFC I-TEND 223, 22 23 Pieter TRC TLU-1-¢ 1DRRCC 1P13/106>922.20.22 22 CONTINUE uRtrectuscn,t03> 103 FORMAT (LHC) REDS LUYTH, LoL>vDMY 28 VRRCK TIEVRRCC T+ ¥TERP. PIS=PTS+1. 8 UNLOCK VOLTM, SCANNERS. FROM THIS PROGRAM CALL LURG 1800008, LoCKA. IL) CALL EXECC 12,6, 1-0,-28) 25 CONTINUE ce CALCULATE ENG. UNITS VRRC @ND STORE a 24 T=1, TER VEALC=VRRCCID/10.0 VRRCCr)=0.0 UFC ETYPECL 9-176 251,250,251 250 Lcove=2 Go To 260 251 CFC ITYPECL “17K 253.252.2853 252 cove co To 260 253 [CODE=IDRRCCT>-CTDRRECT/ 16094180 VRRCL( L)=ANVC ICODE HBMVCTCODE #VCALCS LCHYCTCODED#VCALCe¥CALC NON TEMP cate TEMP CALC 260 CONTINUE TENPC=8.0 VCALC=VCaLceteoa.o DO zer Lat. TFC TENPC-406. 9262, 261 262 TEMPC=AaC ICODE,L+B(TCODE, LoaveaLce ACC ICODE, L>eC¥CALCHez 4D(TCODE.L Jw (¥CALCH#IDe B19Pace god 264° CONTINUE VRRCLCTD*TEMPC#L 8432.0 © © 24 YRRCSC LDS¥RRCSC T+ VRRELCTD c . TEST IF WRITING TO DISPLAY IF So SKIP WRITE TFC TAND( ISU, MSKDP 929,224, .29 © peBuc 224 LFC Issue 14291224,29 1224 WRETECLUDSP, 124 9(VRRCLC I>, T=1, TEND 124 FORMAT(9X, 18F7. 1) 29 CONTINUE © CALCULATE READING RATE FOR LOGDT READ CURRENT COMPUTER TIME CALL EXECC 11, ITHECD CALCULATE TIME DIFERANCE DLT MAF LORTE CCC ITMECE 5 2-ITHELCS3 4244 LC TTHEGCS)~ ETHEL ( 439986046 LTHECC I) -TTHELC 39) 9968 2eCLTMECE 29-ITMEL(2)>>*FLOATC ITMECC1-ETRELC 129/180 8 UP ATE LAST TIME SAVED VALUE bo 130 tet.3 130 [TMELCL>=TTHECK £9 rRecu=4 bo 128 T=, 1ENo TEST + CALCULATE SLOPES FOR LOOT RATE VRRCS( L)=¥RRCSC I #10. 8/PTS SLOPE =(VRRCSC E>-VRRLS(L) #3600. O/DLTH VRRLSCT>=¥RRCSC ED TEST IF WW GT. 7.5 SPEED = = ww IF (172)354,355,354 385 CFCVRRCS(2)-DLTSWD354.356 356 [RRCU=4 354 CONTINUE Loc Re TEST Do 353 Jet. TFC ABS(SLOPED-DLTS(L, 999353,952 352 LFCIRRCU-J 953,351 351 TRRCU=d © DEBUG LF¢ S$WC 139)1353.383 1953 WRITECLUOPT, 1354 )IRRCM, 1,9 /SLOPE,DLTSC I. 9, DLTH 8-20Pi ace 353 12a 127 24 256 wor an ez ea 255 1258 FoRnAT¢3i4,3F10.2> CONTINUE CONTENUE TEST IF WRITING TO DISPLAY IF SO SKIP URITE LEC TANDC TSW, MSKDP) 627,129,127 VRETECLUDSP, 125 90L TH, CYRRESC ID, CONTINUE + EENDD CALC DELTA TEME STNCE LoGOT SCHEDULED CALL EXECC LL, ITMECD DLTW=FLOAT( (¢ CLTMEC( 5 )-ITMSH(5) #244 LCITMECC4 I~ ETRSHC 499946086 [TMECE 39-1THSHC 3) 9468 24 (LTRECE 23~ITMSHC299768.9 TFC TRRCU-LOGRRI294.256.255 CONTINUE FASTER RATE FOR LOGOT TEST IF HLocoT HAS RUN SINE LasT SCHED TFC DLTM+LODDL 291,03 LFCDLTM+FLOAT(LOGDL? 281.23 RUN IFCDLTMFFLORTCLOGDL+IRRCM 985, 82 LOGDL=LoGoL+IFINCOLTM? G0 TO 1255 CONTINUE CONTINUE TFCOLTM+LOGDL) 236.1255 TFCDLTM+FLORT(LOGDL>) 256, 1255 HAS RUN RESCHEDULE CONTINUE Loger=rercu SCHEDULE LocoT CALL EXECC12,LOGDT.3,LOGRR-LoGDL> SAVE LOGGING RATE Teonoc 109=LOGRR UP DATE SCHEDULE TINE CALL EXECC IL, ITMSHD B21PACE 0806 Lococ=-rrecw WRITE Loce Rate FOR Test OF RRCTR EFC TS5¥C0)999,98 99 WRITECLUDSP.95>LOGRR, (ITMSKC E>, 23 FORMATC*LOGGING RATES "ES: 4¥°T IME 98 CFC ISSWC 1))97,256 97 URETECLUOPT,95>L0GRR,.CITMSHC I>, 256 CONTINUE co To 3 PROGRAM REWIND SWL5 ON TEST IF IcW=t=HaS GOTTEN REWIND 15 [FC ICuI096.097, 1896 10U=0 SU=ON=REVIND TAPE, SET IC 897 CONTINUE tewet REUIND=PROGRAM RNTPE READ MPIB CLOCK AND COMPUTER CLOCK READCLUCLK, 105 >1STAT, MNTHE, LONYE, IHRE. MINE, ISECE CALL EXECC IL, TIMED UN LOCK SCANNERS AND VOLTHETTER CALL LuRaciaoeoes. LockA, 11) Lock TAPE RECORDER TO THIS PROGH Ipp=t WRITECLUTR, LL CALL CODE wRITEC teu, 119 11 FORMAT(30H END EPRI COLLINS NOS TAPE S8x> wriTe tines CALL CODE VRETECJBUF, 106) IMPIE.HNTHS. 1DAYS, [HRS. MINS, ISECS, BIMPIBSWNTHE TORYE, IHRE. MINE, ISECE, LESTME. ITIMECS 3. TTIMEC 4). 1T EMEC 3), ETEMEC2) 3, 1BLeT. teow 18), Tconde 9> 106 FORMAT(2CLS, 1%, 512), 15.1%, 14,312,318,8%) URETECKBUF, 700>¢ (1, COMME E)9,T=1, 60) WRITE To TAPE COLL EXECC2/LUTR.IBUF.5609 8.22Pace gor cali Exess. co00+LUTR? s caLt cove WRITECTBUF, 7809¢¢ I. LCOMNC I), 1261, 88> © 6 ORITECLUTR, 7OLI¢ CT, COMONCT 9, 1=1, 40> caLe cope URITECNBUF, 70L9¢¢T.COMONC TE), T=1, 58> © CuRITE To TAPE CALL EXECC2/LUTR,TBUF.560) CALL EXECS 3. 60004LUTRI 700 FORMAT(S(T5.1%, 16, 4X) Do 702 L251,330.70 vse LE=is+e9 CALL CODE © WRETEC TOUR, 70196 CL, COMON: 9 >-L=LS+LED © WRITE To TAPE CALL Exece2-LuTR.rBUF.seod 702 CALL ExECC 3/6800 sLUTR) CALL CODE SRITECIOUF. 701>C Cr+ COMOM. 199, 18931, 3899 cali cove WRITECLOUF, 701 9¢¢ 1, COMNDG E>) 13> WRITE LaBLES To TAPE WRETECMBUF. 2079¢(L.CLABLECL, E>, T21.2)>-L=1, 108) 707 FORMAT(I3, 1%. 2a2) c © write to tape CALL EXECC2,LUTR,IBUF.5609 CaLL EXECe3.ca004LUTRI c Go TOC 300, 3619. TPP 300 CONTINUE c 701 FORMAT(S(IS.E11.49> EMDFTLE LUTR EMDFILE LUTR € 1 sec veLay CALL EKEGC12.0.2.0,-1) e REVIND TAPE TO OFFLINEPace 189) 199: © © ras. 189 89) se a7 2 a0 aa 70 70 808 CALL EXECCS, S00R4LUTRI 6 CONTINUE TFC 1O-11 91655. 1094 S to=teet CALL EXEC 12,0.2,8,-1) 1 sec. DeLay co To 31 4 wrrTect. 19939 3 FORMAT(* TAPE IN REWIND MODE"? ta=1 co To 3 4 CONTINUE TEST LF TAPE AT BOT TEST IF TAPE aT BOT GET DrNantc status To TeaTS CALL EXEC 3,0600B+LUTR> cet status CALL EXECCL3. LOTR, EATS) Ustar=fAano¢1E0TS.3778) TavetaNbereaTs, 1400008 WRITE (1,ee9>tAV.tSTAT If statc 3 TURN SY 15 ON AcArM = co To 896 Tsustssucts> TFC Lay 81, 800,88 8 conTInuE IF CIAMD(TSTAT, 64 887,387,879 9 CONTINUE TRC TANDC [STAT. 7789881, 992.881 1 CONTINUE Tape fav Mots 0 URITEC1, 889) Ca¥. ISTAT 9 FORMAT(24H TAPE UNIT STATUS [aV=.K6. 4x. 6HISTAT so To 884 2 CONTINUE WRITECt. 704) 4 FORMAT(26H TAPE MOT AT START OF TAPED URC TANDC ISTAT, 19883, 894,083 3 CONTINUE wRITec 1,703) 2 FORMATC22H TAPE UNIT MOT OW LINED B-24Pace e809 LEC LANDC 16TAT 439005, 906, 085 5 VRITEC1,839) 888 FORMATCSON HO URITE ENABLE RING ON TAPE 33H TNSTALL RING AND RETRY SUITCH 15) Go ro 34 266 CONTINUE 884 CONTINUE 1SUs1ORC ISU. 1008089 CALL IssR¢ Tsu? WRITEC1, 705) 708 FORMATCZeH TAPE UNIT NOT READY’ 126H CHECK @ND RETRY SWITCH 15> co To 1096 962 conTINUE PROGRAM UTAPE WRITE BLANK RECORD READ HPTB Clock READC LUCLK, 105 DISTAT. MNTHS, [DAYS. HRS. MINS, [SECS 103 FORMATCAZ, 812) comp CLK READ CALL EXECC LL, ITIMED START FO TAFE TecctT=6 MNTHE®8 roavese THRE=0 Ineo Tsec caLL cope WRITEC IBUF, 12) 12 Formarcson EPRE COLLINS HO.9 TAPE 38x> CALL CODE WRITEC JOUF, 106 >{MPIO, MNTHS, TDAYS, HRS, MINS, ISECS, 2UMPIB, WNTHE, IDAYE. IHRE, NINE, ISECE. LESTME, ITIMECS >, LTEMEC 4), TT IMEC ED, ETEMEC2> 3, 1BLCT. conde 18>, TeomDe 9> WRITECLUTR, 700 9¢ CL, TCOMNC I 9, T=1, 652 tppe2 Go To 302 301 CONTINUE WRITE FILE GAP END FILE LUTR reuse 8-25PACE oee © © UNLOCK TAPE RECORDER CALL LURGC 1e08088, LUTR, 1> c wRITECt, 18929 1892 FORMAT(* TAPE RECORDER BACK ON LINE") Go To 896 ew B-26Pace sor FTM BLT PROGRAM MONTR MoD COLLINS TEST 8 SCANNERS CONT: DIMENSION [BUFRCS>,TxOLD¢ 18),1STHECS), LPTMECS) DIMENSION EMPCtOD. vnc 109 80 DIMENSION YHAXC LED. YHINC 103 DIMENSION LaBLIC 10>, LABL2¢ 19) DINENSTON LockAC 9) Connon COMMON LUCLK.LUCcL LUCCR.LUDSP.LUOPT.LUTR.LUYTH Common LudCe>. TPHTiCe), LPNT2Ce> COMMON MNTHS, DAYS. THRS.MINS,TSECS. LTIMECS) Connon tow COMMON ITYPEC 12), TDRROC 12) COMMON ASKDP Connon TBLCT COMMON TcoMD 109 COMMON C2, 29,862.29, 062/29, 062/29,E( 2-29 Connon oLTsct2.2) COMMON ANC 100), BMVc 180), cHYCtoa> COMMON LABLEC 100,2> EQUIVALENCE CLUYTH, LocKACE > FuncTrow THTPLOW)=¢N/643#256+TANDCN, 3778) ZERO FIELD 18 THPCLO=0 c L Tpeo © c © VOLT tisten © CALL HP IBC LUVTH. 14> REG=EXECC 3, LUVTM#I6008> e rPLoT=6 wRITECL, 105) 105 FORMAT(36H ENTER IDS OF POINTS TO BE MONITORED 139H SEPERATE BY COMMAS CUP TO Le POINTS)> READC 1 = EPC LD, EMPC 29, INPCS >. EMPC4 > EHEC 83, BMPS 65 ALNPC7 >, EMEC 89, TMPCO>, NPC 18D URITECL, 102)¢ IMPCL Is L2t, 10) 102 FORMAT iOr4) WRITECL, 106) 106 FORMAT(24H SECONDS BETWEEN Scans 29 READ( 1, # SECS B-27PRCE G02 nsecs=-nsecs c cmLL Lure 1B Locka, 99 ° 6 € TEST IF THIS IS @ PLOT REQUEST © wRITect. 108) 108 FORMATC™ PLOT REQUEST YES OR NOD READCL,109IPLOT, TPCT 109 FaRnat¢zaz) Tyesesas0se TFCIPLOT-IVES 118, tit, {10 © © pLaT Set uP ymax YHIN AND TIME 111 CONTINUE © Do 120-118 TRCIAPCLI-13120,119 119 CONTINUE WRITECL, 1129 EMP CLD. 112 FORMATCTENTER YHAX/YMIN FOR TD=". 14) RERDC 1 # YMAKCL I, YHINCLD c ¢ 128 CONTINUE c wrrreca.tts> 113 FORMATC* ENTER MAX TIME FOR PLOT (HRS) AND TIME PERINCH (MIM. 9") RERDC Lo # TIME, DLTME © Lock PRIMTER 6 CALL LuRAC 48, LuoPT.1> ¢ © END OF PLOT ENTRIES © © TURN ON S¥o € c Letssucts> LETORCL, 190889 sou: PLOT "SET UP" AND ANTS PLOT WRITE HEADER THITALE TIME CALL ExECC it, tsTMED © © TSLU=LUOPT+1008 UTEWL=IFIXCTINE* 60.496. /OLTHED+96 TFCITEML-2048 91083, 1082 teo2 rrexce2047 8-28Fi Ace 1603 Fe 1 a30 vr e a 9903 conTENUE ESET PLOTER THUFR(L #6981 IWUNB= 1 REG=EXEC(2, ISLU, IBUFR, INUMBD ORM LENGTH ¢=33°> TRUFRC1)=6982 TRUFRC2>=TNTPLE3168> tHuMe=2 REGHERECC2,ISLU, LBUFR-THUMED es TEXT LENGHT = ¢307 THUFRC1>=6988 TBUFR(23=INTPLEITEXLD REG=EXECC 2, 1SLU,1BUFR, INUKB) PLOT ORGIN — =TEXT CENGHT TRUFRC 13-6991 TBUFR(29=6 TBUFRC3>=INTPLE OD THuNB=3 REGHEXEC(2,ISLU. IBUFR. TNUMED iy? Peo Tem MOVE PLOT x=0, YeITEXL [BUFR( 1326977 LRUFRC3D=TNTPLE LIY3> REG=EXEC(2,ISLU, IBUFR. CMUNB ITE axts HARACTER FILL IBUFR(L)=464278256 IBUFRC 126958 TBUFRC2>=2566"126 TRUFR( 3 >=120256 REGHEXEC(2,ISLU, IBUFR, THUMB) LOT ¥ AXIS CEPRI PLOT ¥> [BUFR 1)=274256+97 [BUFRC1>=7989 TBUFR( 2 .=INTPLC 12069 TBUFR(39=INTPLCITP3) REGHEXECC2,ISLU, IBUFR- THUMB 8.29Pace ogo4 c Plot ¥ Tres “PLOT FILL TBUFRC 1986958 TBUFRC 292256095 TOUFR(3>=126256+10 REGHEXEC(2,ISLU, IBUFR»TMUMBD TBUFRC1>=7089 TRUFRC 29-0 IBUFR(3)=ENTPLCILY3) REG=EXEC(2,ISLU, IBUFR, THUMB? RESTORE ORGIMAL PLOT FILL = ~ TOUFRCL)=6958 TBUFRC 232460256 TBUFR( 323025645 REGSEKEC(2, ISLU, [BUFR, CNUNE> TEST IF END OF PLOT OR START 833 CONTINUE RESET PRINTER URITECLUOPT,8409¢6 NPCL. YHAXCL I. YAINCLI>-Let, 10> 846 FORMATC/S¢" ID YRAX YMIN "3,20 5¢T4,2¢1K/F 7.12999 URITECLUOPT. 841 ISTMECS), ISTHEC 4D, ISTHECS), ISTNEC 2), TIME, OLTHE Bet FORMATC* DAYE"LG" START TIME="3¢12*:*), It PLOT TINE =*F7.2°HRS AT “FE. 2°WINCINCHES™> DELAY FOR PREWT FINISH CALL EXECC12,0,2,0. 20> RESET PRINTER TBUFR( 1>=698L INURB=E REGHENECC 2, TSLU,TBUFR. INUNB) co To 300 831 CONTINUE TYOLO=INTPLCITEXL> NEXHT=ITEXL-96 NEXPC*ITEXL-16 8-30Pace 80s © c € © © c END OF PLOT SET UP WoT PLOT 11 CONTINUE CLEAR SCANNERS Do 20 tst.8 TFeLu(L 32 21 LuscN=LupcL> VRITEC LUSCH, 1039 READCLUYTM, 101 2¥HD. 20 CONTINUE 120.21 CALL LURG 1e08008, LocKA,9) Do MONITOR LOOP TEND=16 ee CONTINUE CURRENT TIME CALL EXECCAL,IPTHED CALL Lures 18, Locka.e> URITE AUTO RANGE wettectuytn,1e7> 107 FORMAT (2HR?> renT=t DO 998 Lat, TEND EMPL=EMPCLD ERC IMPL=13999,19 19 CONTINUE TLU=TMPL toe TEST IF VALID TLU AD POINT 1 TO 90 TFC 1LU 999.9 9 EFC ILU-@ 291,999 91 CPNT=CMPL-(ILU3 190-1 TRCIPNT-61933,999 92 [LU=tLuet Luse=LUde ELU> WRITECLUSCN, 1809 IPHT 100 FORMAT(T3> ENPCICHT = EMPCL> YMA LENT YM AKC LD YWTNC LONT>=YRINCL? TFC ICNT=~L 393.94 93 TMPCL =o23 cues 103 908 996 206 208 2o1 202 193 203 pe06 READCLUYTM, 101>¥HC ECNT> FORMAT(LEL3.6) LONT=ECNT#E Look ANEAD TEST TF Last TPCL=TEND 323, 22, moT Last TPiatet TFC teu CUMPCTPL 31063 922,28, 22 court nue AR SCANNER WRITECLUSCH, 103> FORMATCLHE > READS LUYTH, 101 2¥HD CONTINUE co To 998 CONTINUE EMPCL 20 CONTENUE END OF LooP URITECLUSEN, 1039 READC LUYTA, 101>90R TeND=tenT=t TFC IPLOT-1YES 9204, 201,204 CONT EHUE tee issue tt 90200, 201 WRITECLUOPT, £99 9¢¢ IMPCL, ¥HCLD DOL CONTINUE TEND LFc I8sW¢ 1099282, 203 WRITECLUDSP,1999¢C EMPCL 9, YHCL>>-L=t, TEND? FORWAT(S(I5.F10.6)) CONTINUE TEST FOR ENGR. CALC TFCISSWC 8370.87 B32Pace ogo? 87 IFC Issuc 9970.79 78 CONTINUE pore LerMecut TFCL977.277, 86 86 CONTINUE MTYPE=t/10041 LPNT=L-CHTYPE-1 #100 © TYPE POINTER © + TEND GO TO C27L + 71.73/74, 275.279.2726 71 ds MTYPE MODIFY Go TO FOR COLLINS TEST FOR FLOW caLC 271 CFC IPNT-469272-71 272 LFCOMYCIPNT 0274.74 274 CALCHANYCTPMT HC COMYC IPHT 4VMCLI D410. 9/20. 044.5 co To 276 Lupc4> constants 74 TPNT=IPNT#18 co To 71 wupcs> — conranrs 275 LPNT=TPHT+8S PRESURE-SPEED-nEGU.-ETC TL CALCHAMVCTPNT BMV CTPNT #VMC LI >FCMYCIPNT 200 VACLE #829 276 LABLICLT @LABLEC IPNT. 19 LABL2CLI WL ABLEC IPHT, 2> © TEST UF TELEMETRY CALC IF CMTYPE-6 975,72 © TEST FoR x OR © TC ON LuDc6> 273 LEC IPNTLCS-EPNT#L 1572, 73 TEMPERATURE TYPE K CONTINUE Tcove=1, co To 260 © TEMPERATURE TYPE E 23 CONTINUE tcove=2 260 CONTINUE caLc=0.6 VHC LTO =VKEL ED 1680 Do 261 Li=t.2 262 COLC=ACTCODE, LL I*B( 1CODE, LL De MCLI D+ 8-33PAGE ees LECLCODE LL DSC VCLI De42 2406 LEDDE LL I#C VMK LED OHS 34 DECLEODE, LE ec VAULT Drea) 261 CONTINUE Calerenbent e632.0 e LaBLICLT9=520408 Lapi2¢Liy=200408 75 CONTINUE YRC LTD =cALe 77 CONTINUE c LFC Issue 89976.176 76 CONTINUE URITECLUDSP, £74 9CC EMPCLLD, VMZLL D, LABLICLE 9, LABL2CLL DLL EL, TEND? 177 FORMAT CSCI3.1M/F 7.1, 1K, 2R2 AND c 176 TRE KPLOT-1YES 173,172,173 172 CONTINUE © PLOT ROUTINE c © Y=SECONDS FROM START OF PLOT © YaRLOATC (4 CIPTHECS Jn LSTHECS 04246 LCIPTRECA I~ ISTHEC 4) 9946046 IPTAEC3I-ISTREC T9206 2eCLPTMEG 23 ISTHECZ I> © Ye¥e96.0/¢68, 8HOLTMED LYS TE EXC YD LYSITERL-TY ce © TEST UF EXIT 6 LEC 1¥96 9808, 812 © 812 CONTINUE © © SAVE Last ry LIy3=1¥ © LRCNEXHT-LY 2@10,811 att CONTINUE © © CHANGE TO "+* CHAR FILL © IBUFR( 126958 TBUFR(2)=11869 TRUFRC 3814344 REGHEXEC(2, ISLU, IBUER, THUNB? © MOVE TO MEXKT leureci -6977 LBUFR( 220 TRUFRC 3 >=TNTPLENEXHT 8-34Pace sie 02 827 are e298 a2t anos REGHEXEC(2,ISLU, IBUFR, THUMB) PLoT +78 IBUFR(1 927809 TBUFRC 2 )=IKTPLC 1206 REGHEREC( 2, 15LU, 1BUFR.TNUMBD RESTORE ORIGINAL PLOT CHAR TRUFRC 1>=6958 IBUFRC2)=462255 TBUFRC 392342565 REGHERECE 2/1 SLU-TBUFR, INUNDD NEXHT=NEXHT-96 continue Le INTPLOLYD MULTI PLoT TEST ba got vat, TENO ae VAC I I=TMENGS) 981200, B/C YMRKE JD=THING IID TX= TF LEC XD LFCLI~29801,892 TBUFRE 1)=27 0256+65 [BUFFS 2 d IDH=TDS/toe [Tac 106-10He1 e710 [DURc 105-1 DT ef 0-1 He 1089 THUnES5Pace oate tec tow-t9923, e22 822 [BUFR 4)=264008+698+10H IBUFR(S )=( 10T+ 688 )e25e+1 DUC GOR co To 826 © 823 1ecIDT~19828,924 824 LBUFR( 4)=26 4008s 10T+698 IBUF RCS )=2 004084 10Ue25e+ 109008) co To are © 825 TBUFRC 4 >=26 4008+ 1DU+6eR c © 826 CONTINUE REGTENECC2.1SLU,TBUFR, INUMD? INURE =3 © DRAM Y AKIS € wor txoLocsoatm . TBUFRC 1926977 TBUFR(2 TBUFRC3>=1YoLD REG=EXEC(2,ISLU, BUFR. INUME? TRUFRC1>=7009 IBUFRC3D=1Y : free, tyoto=ry so To 299 c 880 CONTINUE ¢ © PLOT axes ar END © 1y3296 co ro 830 832 CONTINUE © © 173 CONTINUE Ire Lssuc 950178. 78 175 CONTINUE VRITECLUOPT LPP >CC TMPCLLD. VMCLLD/ LABLICLE >, LABL2CLLY9,LLat TEND? 174 FORWATCACTI,E?. £,1%, 202,149.13, FF. 0.1%, 2829 78 CONTINUE 79 CONTINUE © S © © UNLOCK LOLTH, SCANNERS, FROM THIS PROGRAM 299 CALL LURG te09608, LocKR.9) © ipet 8-36PAGE ert © DELAY SECONDS=NSECS. CALL EXECCI2,0.2,0,mSECS> TEST IF EXET Do set L=8,10 LEC TSSuCL) 368,301, 301 CONTINUE IF(IPLOT-IYES>380,838, 300 300 CONTINUE UNLOCK PRINTER CALL LuRes 1808008, LuOPT.1> ENOAppendix C DATA REDUCTION PROGRAMS Three data reduction programs were developed as part of this project. A brief description of the programs, the program I*stings and a dictionary of variables are included, The first data reduction program, COLL1, generated a tape of data in engineering units from a magnetic tape on which the Data Acquisition System stored the data as voltages. This program applied the appropriate sensor calibrations, A set of new variables calculated from input data was a'so calculated in COLLI. The new variables calculated are as follows: © HP turbine flow calculated from speed and pressures (HHP). © HP turbine flow scaled from first stage pressure (WHPS). © High pressure extraction steam flow calculated from pressure drop (W57). @ High pressure extraction heater drain flow calculated from pressure drop and valve position (Wi57D). The second data reduction program, COLL2, calculates additional variables from the data tapes generated by COLLI. In addition, the program provides for printing and plotting of the data for any group of variables over any desired period of time. Input to the program includes the required data tape generated by program COLL2 and a specification of the day, time and variables to be printed and/or plotted. The program COLL3 reads the summary information developed by COLI and provides a daily log of the operation and project sumary. CHortyerer 13309 rn u09 109 09 2 m9 m0) mw 09 m0) * 18/40/90 Laut Lin 29Nv WH /8S4NT ee (este vattasousny + (euse)antset (O90) 311469TH) Coane (7)aae7 ogee (Tog post +(09z)aTTa H1G)aMTL #(TOE)ONT na auress roster? yoayn +orezvIWAILT ss90+99TH60T 06/4907 6243 MAME! 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ASCL is a simulation language. Pages D-7 through 0-36 include the user input sheets for the various modules. The schematic of the plant model is shown as Figures 0-6 and D-7, These figures show the interconnection of the model and provide the "ID" for use with the module input sheets. The model parameters were calculated for 500 MW and are listed in table D-1. The first parameter KADOF is given as 28.2699871, This is the first input parameter for the drun boiler module DRUMNC. The KAD signifies that the number represents the cross sectional area of the steam drum in square feet. The DF is the module identifier in the boiler interconnection schematic. Pages D-39 through 0-57 contain the program listing, The use of this program requires a working knowledge of the ASCL simulation language. D-1Table D-1 BOILER MODEL INPUT PARAMETERS KADDF 28,2699871 KAES7A 11,9999980 KARDF 17, 9999923 KAWOF 12, 9999954 KBIHP 0,96599988 KBRLP 0,96599988 KCCSTA 2.55006-05 KCFEC 55899, 9919 KCFPL. 253015.899 KCFPS 176454.925 KCFRH 658399, 772 kcFss 231327.819 KCFS7A 0. KCPAL 17999, 9923 KCPAZ 20000.0000 KCPORV 1.0000€+06 KCPRA 200000.000 KCRDF 712500.000 KCSAL 418813.419 kesaz 478001.785 KCSRA 1,0371E+06 KCTS7A 0.00500000 KCVAL 2,00000000 Kcvaz 2,00000000 KcVDRV 5696.99859 KCVRA 200000000 kcvs01 512652.969 kevsoz 6859, 99870 kevsi8 6835.99853 kcvs19 13499,9942 KCWAL 8899.99961 0-2Table D-1 (Continued) KcwA2 10899.9919 KCHRA 134619903 KDFS7A o KoPH 200.000000 KOPLP 2000,00000 KDSS7A 1,4600E-04 KOTSIA 0.05599999 KEOHP 0,92449979 KELHP 0.96099987 KEILP 0.95019989 KeaLe 1,13939952 KESLP 0,94667987 KEALP 0,94949989 KESLP 090375995, KE6LP 0.73532991 KEW 1,00000000 KHODF 178,249740 KHE oO KIORY 500000000 KIE 100000000 KIFW 500000000 kIV 1,00000000 KLE o KLEVEL, 30000.0000 KMFOF 0,05999999 KWFEC 0.059999 KMFPL, 0.059999 MEPS 0.05999999 KMERH 0,05999999 KMFSS 0,05999999 KWMDF 2.5650E+06 KMMEC 708999.919 D-3KNOL Kn KMMRH Kneis KMMS7A KMPPL. KMPPS KMPRH kMpss KPORV KPFW KPV KSFS7A KDGOF KSSS7A KSTHP KSTSA KTVHP kucec kucPL Kuces KUCRH Kucss KUFOF KULOF KUREC KURPL, KuRPs: KURRH KuRSS kuSPL KUSPS Table D-1 (Continued) 0-4 166599,845 1,1000E+06 853999..900 439999..961 60000.0000 117999.935 107999, 992 103699.970 219999..980 ~0.49999980 2,9600E+06 000813000 0,04999998 0.029999 1,00000000 184.449863 oO. 2745,13530 152.299880 51.1615848 2. 2646E-05 21759,9868 3,5080E-05 7,.7335E-06 5.9970E-04 5.8478E-05 1,5872E-05 19,1399765 83,7299728Table D-1 (Continued) kusri 35,7299804 Kusss 39.6599864 kvADRY 2,00000000 KVASOL 100000000 kvaso 2,00000000 KVASIB 100000000 kvasi9 100000000 KVCS7A 60,0000000 KVODF 2250.00000 KVGOF 328337.860 KVGEC 29699.9931 KvGPL. 83750.0000 KvGPs 51999,9980 KVGRH 45499.9923 kvass 31599.9889 KVHS7A 300,000000 KVLS7A 20.0000000 KVNOF 1125.00000 KVPHP 0.374990 KVROF 321799755 KVSOF 5467,99755 KVSPL. 500,000000 KysPs 4660.99834 kvsRH 519.9980 kvsss 1399.99961 KVWOF 2629, 99820 KVWEC 3000,00000 KVWS7A 10.0000000 KVOHP 7.8720E-04 KVLHP 000209200 kviLp 000192356 KvalP 000145376 Kv3lP 000194300Table D-1 (Continued) KvaLP 000213800 KVSLP 0,00171779 KV6LP 000194257 KWIHP 53699.9511 KWVHP 235198.974 KWH 48499.9942 KWILP 145025.920 kwauP 281769.371 KW3LP 332827.281 KWaLP 667430.973 KWSLP 2,19376+06 KW6LP 5,1497E+06 KXT5O1 055000000 KxT502 0,57999992 KXTS18 0.600000 KXTS19 0,57999992 K20HP 2,27999973 D6USER WORKSHEET: ATTEMP you poset Lop, as che PosL Ho se | ATTEMP [> W> SL Rose jp _ fH st vow J wo we —? HOWE R > We —— MACRO Invocation: are (9 tt tt 1D SE We st NOTE! Actuator for spray valve must have same ‘10° CONSTANT PARAMETERS: (AI Parameters are Appended by 10) Flow Conductance, Steam [1bm/h/“(psi) (1bm/ft~)]: kes (1D) Flow Conductance, Spray Valve Full Open: Kev (1D) Valve Type: kya (10) 1. = Equal percentage 2 = Linear 3. = Quick open Fixed (Pipe) Flow Conductance in Water Line: Kee (10) = 7VARIABLES: HSE Host Hoo P > Se Pos Ro SE Wo SE wos Woo NE yo Enthalpy of Steam Entering Enthalpy of Steam Leaving Enthalpy of Water Entering Pressure of Steam Entering Pressure of Steam Leaving Density of Steam Entering Flowrate of Steam Entering Flowrate of Steam Leaving Flowrate of Kater Entering Spray Valve Position (Actuator must have same 1D) 08 (Btu/ Tom) (Btu/ 1m) (Btu/1b0) (psia) (psia) (1bm/Ft3) (1bm/h) (1ba/n) (1bm/h) (Fraction Full Open)USER WORKSHEET: CONC Pe ow powed FO Ao w= We ~| conne [5H we Howe | ba we wT owe MACRO Invocation: cONNC (*_—'y*§_t, wp i INITIAL CONDITIONS: Leaving Pressure (sia): (= VARIABLES: H+ WE ~ Enthalpy Entering H > WL ~ Enthalpy Leaving > WE ~ Pressure Entering > WL ~ Pressure Leaving > iL = Density Leaving WE - Flowrate Entering + WL ~ Flowrate Leaving + HL ~ Temperature Leaving D9 (Btu/Tbm) (Btu/1bm) (psia) (psta) (bmytt3) (bm/h) (ibevn) (°F)USER WORKSHEET: DIVIDE Pp >We Ww WE HWE ROWE T WE MACRO. Invocation: ov We VARIABLES: H > WE - Enthalpy Entering (Btu/Tbm) H > WL - Enthalpy Leaving (Btu/1bm) P + NE ~ Pressure Entering (psia) P+ WL ~ Pressure Leaving (psia) R+ WE ~ Density Entering (ibm #t3) R + WL ~ Density Leaving (Ibm/te3) W> WE ~ Flowrate Entering (bmn) W> WL ~ Flowrate Leaving (1bm/h) T + WE ~ Temperature Entering CF) T+ WL ~ Temperature Leaving CF)USER WORKSHEET: ORUNNC wore Hone WORE HORE a HOELE Wo Ele HOEle WoENE HO PHE p> p> we le w> W> We BES HO WE bas prune [>t kw Gas w--- Bas Bis Gwe SHS #3 MACRO Invocation: ORUMNC (* $y 1D We FLE FE FHE CONSTANT PARAMETERS: (AI] Parameters are Aspended by 1D) Cross Sectional Area of Steam Drum (ft2): Cross Sectional Area of Riser (ft2): Cross Sectional Area of Downcomer (ft2): Overall Height of Boiler (ft): Flow Conductance for Riser [1bm/h/“ psi) (iba Fe): Normal Water Level (NWL) in Steam Drum (in.): Moisture Fraction in Flue Gas: Mass of Metal in Furnace (Ibm): Heat Transfer Parameter for Furnace: Heat Loss Paraneter for Furnace: Volune of Downcomers (Ft3): dL ezzEEOOO 000 Kap (10) KAR (1D) KAW (ID) KH (19) KOR (10) KN (ap) kwe (ap) kam (10) KUF_ (10) ku (10) KW (19)USER WORKSHEET: DRUMNC (Continued) Volume of Water in Furnace Waterwalls and Enclosures (ft): Volume of Furnace (ft?) Volume of Saturated Region (ft? Volume of Steam Drum (ft3): Volume of Water Drum Inventory at NWL (Fe) INITIAL CONDITIONS: Enthalpy of Flue Gas Leaving (Btu/lbn): Enthalpy of Flue Gas Entering (Btu/lom): Density of Drum Fluid (Tom/ft3): Specific Internal Energy of Drum Fluid (Btu/Tbm): Recirculation Flow Rate (1bm/hr): VARIABLES: H > AE ~ Enthalpy of Air Entering Furnace H > FIE - Enthalpy of Fuel-Intermediate Level H > FHE ~ Enthalpy of Fuel-High Level HH > FLE - Enthalpy of Fuel-Low Level H > GL ~ Enthalpy of Flue Gas Leaving H > RE ~ Enthalpy of Recirculation Gas H» SL ~ Enthalpy of Steam Leaving H > WE ~ Enthalpy of Water Entering H+ WL - Enthalpy of Water Leaving L + ID - Drum Level P + SL ~ Pressure of Steam Leaving P > WE ~ Pressure of Water Entering P > WL ~ Pressure of Water Leaving ZRS + ID - Density of Saturation Region Fluid R > SL - Density of Steam Leaving R > WE ~ Density of Fluid Entering Drum R> WL ~ Density of Water Leaving D-12 KVR KVG kvs Kv KVN 1H ZK ZR zu __ ZIM (Btu/1bm) (Btu/Tom) (Btu/Tbm) (Btu/Tbm) (Btu/Tom) (Btu/1bm) (Btu/Tbm) (Btu/1om) (Btu/1bm) (in.) (psia) (psia) (psia) (ibm #e3) (ibm/#t3) (ibm/#e3) (ibm tt) —— (10) —— (10) (10) —— (10) —— (10) —_—— (6L) (10) nn) _—_ (10) (10)USER WORKSHEET: DRUMNC (Continued) GL - Temperature of Gas Leaving 1D = Temperature of Waterwall Metal SL - Temperature of Steam Leaving WL - Temperature of Water Leaving > ID ~ Internal Energy of Saturat‘on Fluid AE - Flowrate of Air Entering Furnace FIE - Flowrate of Fuel - Intermed’ate Level FHE - Flowrate of Fuel - High Level FLE - Flowrate of Fuel ~ Low Level GL - Flowrate of Gas Leaving RE - Flowrate of Recirculation Gas SL = Flowrate of Steam Leaving WE - Flowrate of Water Entering WL - Flowrate of Water Leaving (°F) (°F) (°F) (rr) (Btu/Tbm) (Ibm/h) (1bm/h) (1bm/h) (bm/h) (bm/h) (Ibm/h) (1bm/h) (1bm/h) (1bm/h)USER WORKSHEET: —ECONDP W>GE H OGE Ww WE - wo WL H > WE >] ECONDP [> H > WL ROWE) | W GL H OGL T GL DP ID MACRO Invocation: ECONOP ( CONSTANT PARAMETERS: (AI1 Parameters are Appended by 1D) Flow Conductance C1bm/h/Mpsi) (1bn/tt3)1: Ker (10) = Moisture Fraction of Flue Gas: kMF (10) Metal Mass, Heated (1bm): Km Metal Mass, Unheated (Ibm): kwp (10) = Gas/Metal Convective Heat Transfer Paraneter: kuc (1D) = Gas/Metal Radiant Heat Transfer Paraseter: eur (10) Volume of Flue Gas (ft3): KG (10) = Volume of Water (ft3): vw (10) = INITIAL CONDITIONS: Enthalpy of Flue Gas Leaving (Btu/1br): ee Enthalpy of Water Leaving (Btu/1bn): TH (wt) = p14VARIABLES: H> Ge He GL He WE - He WL oP + 1D > WE - 6 - +h +1D- + GE - *a- WE - + ML USER WORKSHEET: ECONDP (Continued) Enthalpy of Flue Gas Entering Enthalpy of Flue Gas Leaving Enthalpy of Water Entering Enthalay of Water Leaving = Pressure Drop through Water Side Density of Water Entering Temperature of Water Entering Temperature of Water Leaving Temperature of Heated Metal Flonrate of Gas Entering Flowrate of Gas Leaving Flonrate of Water Entering Flowrate of Water Leaving (Btu/Tbm) (Btu/tbm) (Btu/1bm) (Btu/1bm) (psia) (1bm/#t3) (Pr) (°F) (°F) (1bm/n) (abm/n) (om/n) (bm/n)USER WORKSHEET: FHHTR2 zevrsv dilll aano00 mmmmmm Bowe of mn es lke = WOME Slewarne) (GW WE Bo We SI PWS Me Powe SI vey Co, oe Ww BE HS BE wacR Ineocazion: FmTRe (tt 1D ‘DE ot CONFIG: drain cooler, drain cooler, CONSTANT PARAMETERS: (AI] Parameters —>-— WE condensing zone, desuperheat zone cendensing zone condensing zone, desuperheat zone cendensing zone are Appended by ID) PARAMETERS REQUIRED FOR ALL CONFIGURAT: Total shell side volume (ft): ONS Tube side volume in condensing region (ft): Axial cross sectional area (ft2): Condensing heat transfer parameter ‘in condensing zone: Fixed heat transfer parameter in condensing zone: Tube side heat transfer parameter condensing region: 0-16 KVE kee Ker KeT (10) kve KAE __ (10) _ (10) a (10) —— (10) —— (10)USER WORKSHEET: FWHTR2 (Continued) Fixed feedwater flow conductance: ker (10) = Mass of Metal (Ibm): KMM (1D) ADDITIONAL PARAMETERS FOR DRAIN COOLING REGION (CONFIG = 1 or 2) Fixed heat transfer parameter in drain cooling region: KOF_ (1b) = Shell side heat transfer parameter in drain cooling region: kos (10) = Tube side heat transfer parameter in drain cooling region: KoT__ (10) = Shel] side volume in drain cooler (ft): KVL (1D) = ADDITIONAL PARAMETERS FOR DESUPERHEAT REGION (CONFIG = 1 or 3) Fixed heat transfer parameter: KSF_ (10) = Shell side heat transfer parameter: Kss_ (10) Tube side heat transfer parameter: KsT____(10) = Tube side volume (ft3): KWW (1D) = INITIAL CONDITIONS: Enthalpy of Drain Flow Leaving (1,2) (Btu/Ibm): 1H (DL) = Enthalpy of Feedwater Leaving (1,2,3,4) (Btu/Ibm): 1H (WL) = Enthalpy of Feedwater Leaving Condensing Region (2,3) (Btu/1bm): 7H (1b) = Average Density of Shell-side (1,2,3,4) (Ibm/ft3): 9 ZIR_ (1D) = Average Specific Internal Energy of Stel1-Side (1,2,3,4) (Btu/Tbm) : zu (ab) = VARIABLES: H > DE - Enthalpy of Drain Entering (Btu/1bn) H > DL - Enthalpy of Drain Leaving (tu/1bn) H > SE - Enthalpy of Steam Entering (Btu/1bn) H > WE - Enthalpy of Feedwater Entering (Btu/tbn) HHL - Enthalpy of Feedwater Leaving (Btu/tbm) P + DE - Pressure of Drain Entering (psia) o-17mL SE WE We WE DE DL SE We USER WORKSHEET: (Continued) Pressure of Drain Leaving Pressure of Steam Entering Pressure of Feedwater Entering Density of Feedwater Entering Temperature of Feedwater Entering Flow Rate of Drain Entering Flow Rate of Drain Leaving Flow Rate of Steam Entering Flow Rate of Feedwater Entering Flow Rate of Feedwater Leav‘ng D-18 FWHTR2 (psia) (psia) (psia) (ibm/Ft3) (°F) (om/n) (on/n) (om/n) (Ibm/h) (bm/n)USER WORKSHEET: HPTVS essen lp se wo >see bow se Hosa) we ? Host bos oes oN Jo T T win 9 p_i_w Hoo R11 Tin MACRO Invocation: WPTVS (1, * tt 5 E x N= Number of Extractions Index Number for Extractions (1,2,..+s1,+++5N) CONSTANT PARAMETERS: (AI] Parameters are Appended by 1D) Stroke Velocity (fraction/sec) KsT__ (1D) = Small signal time constant for turbine valve: Kv (10) Fractional valve opening at first valve point (sec): KVP __ (ID) Flow coefficient for one control valve: KW (1D) = Time constant for pressure nodes (sec): kop (ID) = Flow coefficient for impulse stage: KWE (1D) = Velocity ratio coefficient for impulse stage: KvO_ (10) = Efficiency parameter for impulse stage: KEO_ (1D) = Cosine of turbine blade angle for impulse stage: KBI__—__(ID) = Cosine of turbine blade angle for reaction stages: KBR (10) = Flow coefficient for it? reaction stage: KWo (1D) = i Velocity ratio coefficient for it reaction stage: KV (ID) = Efficiency parameter for i*” reaction stage: KE (1D) = Efficiency parameter for low load operation: Keo (1D) = D-19USER WORKSHEET: INITIAL CONDITIONS: Initial Valve Position: Pressure Behind Governing Valve (psia): Extraction Pressure in it” stage (osia): First Stage Pressure (psia): VARIABLES: H » SE ~ Enthalpy of Steam Entering SL = Enthalpy of Steam Leaving i + ID - Enthalpy of Steam Entering Stage i i H 4 W W W ID - Power to Shaft Output (Continued) ID - Shaft Speed 1D - Impulse Chamber Pressure SE - Pressure of Steam Entering SL ~ Pressure of Steam Leaving HeTvs i + ID ~ Pressure of Steam Entering Stage i SE ~ Density of Steam Entering i + ID - Density of Steam Entering Stage i SE - Flow of Steam Entering SL - Flow of Steam Leaving i» ID - Flow of Steam Extracted after Stage i YA + ID = Turbine Valve Position YD + ID - Turbine Valve Position Demand UPSTREAM P + SE - Pressure of Steam Entering H > SE ~ Enthalpy of Steam Entering YD + ID - Turbine Valve Position Cemand W > SE - Flow of Steam Entering D-20 ran) Py (10) Pp (id) TPO (TD) (Btu/1bm) (Btu/1bm) (Btu/1bm) (Wegawatts) (ROM) (psia) (psia) (psia) (psia) (ibm/#t3) (ibm ft?) (bm/n) (Ibm/h) (1bm/h) (fraction) (fraction) (psia) (Btu/1bm) 0. to 1.0 (1bm/h)USER WORKSHEET: HPTVS (Continued) DOWNSTREAM P + SL ~ Pressure of Steam Leaving R > SL - Density of Steam Leaving W > SL ~ Flow of Steam Leaving H+ SL ~ Enthalpy of Steam Leaving T + SL - Temperature of Steam Leaving J+ ID ~ Shaft Power PO + ID RO + 1D 50 + ID 0+ 10 HO + 1D FIRST STAGE First Stage Pressure First Stage Density First Stage Entropy First Stage Temperature First Stage Enthalpy th EXTRACTION POINT P+ i» ID - Extraction Pressure R > i+ ID - Extraction Density S+i+.D Extraction Entropy T+ i> ID - Extraction Temperature Wei+D Hei+D zKV aw zP0 ZWy PTV pov IPv 1D 10 10 1D 1D 1D 10 Extraction Flow Extraction Enthalpy INTERNAL VARIABLES = Flow Multiplier = Valve Opening for Single valve = Governing Valve a P/P = Flow Through Single Valve = Impulse Nozzle Pressure = Derivative of Impulse Nozzle Inlet Pressure + Initial Impulse Nozzle Inlet Pressure p-21 (psia) (ibm/#t3) (1bm/h) (Btu/1bm) (°F) (Megawatts) (psia) (1bm/ Ft) (Btu/1bm) (°F) (Btu/1bm) 3 ) (psia) (bm te’ (Btu/Tbm) (°F) (ibm/h) (Btu/1bm) 3 ) (1bm/h) (psia) (psia/sec) (psia)(Continued) ZWI > ID - Impulse Stage Flow- Single Valve IRV > 1D ~ Impulse Nozzle Inlet Density ZSV > ID - Impulse Nozzle Entropy ZIV + ID Impulse Nozzle Temperature ZA +0» ID ~ Impulse Stage Pressure Ratio 2H + 0+ ID ~ Impulse Stage Isentropic Enthalpy ZV + 0+ ID ~ Impulse Stage Velocity Ratio ZEL + 0+ ID ~ Impulse Stage Ideal Efficiency ZEZ + 0+ ID ~ Impulse Stage Linear Approximation Efficiency ZEO + ID - Impulse Stage Efficiency 20 > 1D ~ Impulse Stage Power DPO + 1D = Impulse Stage Pressure Rate 1P0 > ID ~ Impulse Stage Initial Pressure ZA» i» ID ~ Reaction Group Pressure Ratio ZW > i + ID - Reaction Group Flow ZH + i+ ID ~ Reaction Group Isentrovic Enthal py ZV + i+ ID ~ Reaction Group Velocity Ratio ZE + i+ ID ~ Reaction Group Efficiercy 2) + i+ ID ~ Reaction Group Power IM + 1+ ID ~ Reaction Group Power Running Total PARAMETERS KVP + ID = Fractional Valve Opening at Final Admission KHV + 1D = Governing Valve Flow Coefficient KST + ID ~ Governing Valve Stroke Rate KTV > ID ~ Governing Valve Small Signal Time Constant KOP + ID - Connective Node Gain KWI + ID = Impulse Stage Flow Coefficient KVO + ID - Impulse Stage Velocity Ratio Coefficient N+ ID - Shaft Speed KEO + ID - Impulse Stage Efficiency Parameter KBI + ID ~ Cosine of Impulse Blade Angle USER WORKSHEET: HPTVS: D-22 (1om/n) (1bm/h) (ibm/#t3) (Btu/Tbm) (°F) (Btu/ibm) (MH) (psia/sec) (psia) (ibm/n) (Btu/1bm) (MW) (Mu) (1/sec) (sec) (RPM)USER WORKSHEET: HPTVS (Continued) K20 + ID - Linear Approximation Efficiency Parameter KW +4 > 1D - i* Reaction Group Flow Coefficient kv +4 +10 - i Reaction Group Velecity Coefficient ke >i +10 - ith Reaction Group Efficiency Coefficient KBR > ID - Reaction Group Blade Angle Cosine 0-23USER WORKSHEET: LPTVS Pp ose woseq ee H See} Lervs $ $ a >see P wl ns > 10 | N w>1 1D [woe oD w>3>107 PO1>ID P3251 P35 H>3131D HO2>—D H>3>D R>131D R>25— ROB T3150 T525D T3350 MACRO Invocation: LPTYS (‘oy *_ 10 SE CONSTANT PARAMETERS: (AI1 Parameters are Appended by ID) Cosine of Turbine Blade Angle for Reaction Stages: Time Constant for Pressure nodes (sec): Exhaust Annulus Area (ft): Flow Coefficient for it” stage: Velocity Ratio Coefficient for Nt” stage: Peak Efficiency in ith Stage: INITIAL CONDITIONS: Extraction pressure at it” stage (psia): VARIABLES: H + SE ~ Enthalpy of Steam Entering H+ SL ~ Enthalpy of Steam Leaving H+ i+ ID - Enthalpy of Steam Entering at i®” Extraction J > ID ~ Power to Shaft N > ID - Frequency of Shaft Revolution P + SE ~ Pressure of Steam Entering p24 Post Wwose HSL PONS ID HONSID RON SID TONS ID KBR KoP ___ 10) (10) = (10) = ¥ > (7D) = i+ (10) = i+ (10) KAA KW > ky KE> P+ i+ 1D (Btu/1bm) (Btu/Tbm) (stu/1bm) (Megawatts) (Rev/Min) (psia)USER WORKSHEET: LPTVS (Continued) P+ SL - Pressure of Steam Leaving P +4 > ID - Pressure of Steam Entering at ith extraction R > SE = Density of Steam Entering R +4 > ID ~ Density of Steam Entering at it Extraction W o> SE - Flow of Steam Entering W > SL - Flow of Steam Leaving W>4 > ID = Flow of Steam Extracted at ith point p-25 (psta) (psia) (ibm Ft3) (om #3) (ba/n) (ba/n) (on/n)USER WORKSHEET: LPTVS (Continued) Figure D-1 shows the structure of the model, The nunber of extraction points is specific by the user and macros are used zo build a model consisting of a first group followed by a variable number of ex:ractions and blade groups and last blade group. Figures 0-2 through 0-5 show the individual components used to assemble the model. BLADE GROUP -O> emer yep ed =83 | B82 Bee fecnel lecral-4 £O forced" 8 a syott SEO 3s = tw1 1D TW2 1D TW _N ID {P—1—1p jp 2 1 JP NID {H—1 =p [H—2 10 [HN 1D Figure D-1. TURBLP - Macro Structure 0-26USER WORKSHEET: LPTVS (Continued) oP 4 1ST BLADE — “croup [> -H _1_w >zw_1 ip >ZM_4 1D INTERNALVARIABLES RSE SSE TSE ZA_1_w ZH—1 PARAMETERS = KW__1 _1D Ke 1 1p Figure 0-2. First Blade Group Pli_pe >P_i_w ZW_i_p > zw_i_ ps Pips = Pitt Hi_Ds | oogne | LL ZW itt 1D Sh _i+1 1p ZWwitt pe Simiti ip INTERNAL VARIABLES Ri ID sii Tin za ZH Zs PARAMETERS KW KE Figure 0-4. Blade Group BGR2 zM_i_D, ZWwitt De INTERNAL VARIABLES PARAMETERS sw SH Js ao BGREAC

ID Figure 0-5. 3lade Group BGREAC 0-28USER WORKSHEET: LPTVS (Continued) AneuT H > SE - Enthalpy of Steam Entering (Btu/1on) N+ ID - Shaft Speed (Rem) P » SE - Pressure of Steam Entering (psia) P + SL ~ Pressure of Steam Leaving (psia) W +4 + ID - Extraction Flow at it" point (1bm/hy output H > SL = Enthalpy of Steam Leaving (Btu/tom) H 4 + ID - Enthalpy of stean at ith Extraction Point (Btu/1bm) J +10 - Shaft Power (ow) P +i +10 - Pressure at it” Extractior Point (psia) W > SE ~ Flow of Stean Entering (1bm/n) W > SL - Flow of Steam Leaving (1ba/n) INTERNAL VARIABLES R + SE - Density of Steam Entering (1pm #t3) S + SE ~ Entropy of Steam Entering (Btu/1bm) T + SE - Temperature of Steam Entering (°F) TA +1 + 1D - Pressure Ratio in it Group (Fraction) iH >i + ID ~ Isentropic Enthatpy in i” Group (Btu/1bm) ZW > 4 + 1D = Flow Through i*” Group (1bm/h) 1M +i > 1D = Power Senerated up to it” Group (om) DP > 4 > 1D - Rate of Change of Pressure at it Extraction (psi/sec) R +i +19 - Density at ith Extraction (Com #03) S +4 +10 - Entropy at ith Extraction (Btu/Tbm) T +i +1D - Temperature at ith Extraction °F) 2) +4 + 1D - Power Generated in it? Group (om) IV > N +10 ~ velocity Ratio in Nt” Group (Fraction) 0-29USER WORKSHEET: LPTVS (Continued) 2E + 10 - Efficiency of N*M Group (Fraction) H+ N+ ID ~ Enthalpy dut of N°” Group (Btu/Tbm) PARAMETERS KW + i > ID ~ Flow Coefficient KE + i» ID ~ Efficiency Parameter KDP + 1D - Connective Node Gain KV +N» ID ~ Velocity Ratio Coefficient KBR + ID ~ Blade Angle Cosine 0-30USER WORKSHEET: SATEMP ese posi) saTeme lowest wos LoHose H>s1>) wo ferose Jot su esa | wo sz H>s2 MACRO Invocation: SATEMP ("yt tt 10 3 38 a CONSTANT PARAMETERS: None INITIAL CONDITIONS: Leaving Enthal py (BTu/ib.): HSL) = VARIABLES: H+ S1 = Enthalpy Entering (Btu/1bm) H * S2 ~ Enthalpy Entering (8tu/Tbm) H+ SL ~ Enthalpy Leaving (Btu/tbn) P + Sl ~ Pressure Entering (sia) P + S2 - Pressure Entering (psia) P + SL - Pressure Leaving (psia) R* SL ~ Density Leaving (ibm ft3) W + SI ~ Flow Entering (bmn) W > S2 ~ Flow Entering (ibm/h) W > SL - Flow Leaving (bmn) T + SL - Temperature Leaving (CF) 0-31USER WORKSHEET: —SPRHTR Wose aaa posemoPacst W> SE | sparta fo > SL Hose | Rost ROSE > P Sgr Cowen Het —T GL HACRO Invocation: SPR ($s D te % TST TTT CONSTANT PARAMETERS: (ATI Parameters are Nppended by 1D) Flow Conductors 1ba/n/Apsi) (1bn/ft)]= Kern) = Moisture Fraction of Flue Gas: KM (10) = Mass of Heated Metal (1bm) Kw (19) Mass of Unheated Metal (1b): kup (10) Slagging Factor (Fractional Reduction in Transfer Effectiveness): Ksé_ (10) = Gas to Metal Convective Heat Transfer Parameter: KUC ___(I0) Gas to Metal Radiant Heat Transfer Parameter: Kur __ (19) Metal to Steam Heat Transfer Parameter: kus (10) = Volume of Gas (ft3): kve (10) Volume of Steam (ft3): KvS (ID) = INITIAL CONDITIONS: Enthalpy of Flue Gas Leaving (Btu/1bm): WoL) = Density of Steam Leaving (1bm/ft3): RSL) Temperature of Metal (°F): ut (9) Specific Internal Energy of Steam Leaving (Btu/Tbm): IU _____ (SL) = 0-32VARIABLES: H+ GE He GL H SE SL SE st SE au st GE aL SE sk Enthal py Enthal py Enthal py Enthal py Pressure Pressure of of of of of of USER WORKSHEET: SPRHTR (Continued) Flue Gas Entering Flue Gas Leaving Stean Entering Stean Leaving Stean Entering Stean Leaving Density of Steam Entering Temperature of Flue Gas Leaving Temperature of Steam Leaving Flow Rate of Flue Gas Entering Flow Rate of Flue Gas Leaving Flow Rate of Steam Entering Flow Rate of Steam Leaving 0-33 (Btu/Tbm) (Btu/1bm) (Btu/Tbm) (Btu/1bm) (psia) (psia) (ibm/re3) (°F) (°F) (1bm/h) (1bm/h) (1bm/h) (1bm/h)MACRO Invocation: VALVEC (*_____* NOTE! CONSTANT PARAMETERS: USER WORKSHEET: VALVE ree mo vaLvec mzr SE - Pressure Entering (psia) P * SL ~ Pressure Leaving (psia) R + SE - Density Entering (Ibn #03) W > SE - Flowrate Entering (Ibm/h) W + SL - Flowrate Leaving (Ibm/h) Y +10 = Valve Position (fraction) p-34USER WORKSHEET: VALVET el POWE faa oR WL w> We 4 be w> we Howe 9 VALVE! we RO We UID — —| MACRO Invocation: VALVEI ("____', * nt 1D Ve Ww CONSTANT PARAMETERS: (A11 Parameters are Appended by 1D) Associated Pipe Conductance: kop (10) Maximum Valve Conductance [1bn/h/Apsi) (1bn/ft9)]: KCY (1D) Valve Characteristic Constant: KvA_ (10) 1. = Equal percentage 2. = Linear 3. = Quick Open 4, = Square Root NOTE! Valve and Actuator must have sane 10, VARIABLES: H > WE = Enthalpy Entering (Btu/1bm) H + WL = Enthalpy Leaving (Btu/1bm) P + WE - Pressure Entering (psia) P + ~ Pressure Leaving (psia) R > WE - Density Entering (1om/ 3) W > WE - Flowrate Entering (Iban) W > WL = Flowrate Leaving (Iban) Y * 1D = Valve Position (Fraction) 0-36USER WORKSHEET: PI xy op by MACRO Invocation: Y = PI (YI, KP, KI, X, LL, HL, IC) NOTE: The arguments of this macrc are variable identifiers not module or stream identifiers. INITIAL CONDITION: Initial value of integral Ic = PARAMETERS: Proportional Gain KP = Integral gain (repeats/min) KI = Low Limit t= High Limit HL = VARIABLES: Y = Controller output Yi = Controller integral value X = Controller input 0-36> D> DD gem vay secfonuwnd_sor | ow [sot envralses arvewr|satlconne] ses | ot °F or Ps) ve ‘GoF u ‘ors Jso11/sor2|so13, B XS waves] rave] ALVE a8 ue ‘or t so ol cS wae asin deste oor | sc1L [rnuvecl #1, [cone $2 emura Sven *42[connel*o? t an cee ae “ Ton Shs 4 goa [Se ee % ” scafenntelssefsarewAS8 [ners SHAlcounc|eCd ow bodarreweseaconnckes 5 ae 4 be wep erp eref pe | Tow To #4 P gos fase sedspnen eee [smto| vrrvs [see $ i od Figure 0-6. Plant Model SchematicPSLP = 1.23 DAVO ors se sec [econor|_ss7a Fwarad we Fe | ps7a cee owo LP OM? ponvo = ee DRY Figure D-7, Plant Model Schematic 0-38stssseessMCVANCED CONTINUOUS SIMULATION LANGUAGE: + ACSL TRANSLATOR VERSION 4 LEVEL SE 81/042 10.39.00 PAGE PROGRAY COLLINS. oooocora crwarac ooccoaze 2zINIT INTEGER 22SEEO PROCEOURAL CONSTANT 2zscecs1121221112 eNO EQUIVALENCE (22T3CGyxICITG? GcTO 95953 SESSe00CALL ZENTLE 1F(221.£042)G0T0 99957 999986. CONTINUE MACROERC 220YKH CALL zznrTs 99957+eCALL ZZNITA 22ST=.FALSEs 55598,.CONTINUE, MACROEND MACROENO TERNT(T.GE.TSTOP) coovorse PROCECURAL (=7.CC«TSTCP) IFCT.GEsTSTCPIZZST=¢TRUCe END NACRCERD DERIVATIVE oocooess sococesa DRUMNCC HOF y#SECtyeAEtytRENG SOF YH *ULTy ocoooces TABLE ZOFDF42¢6412/140791000 95004410006 320605 Dl ne Seelee2seSsraseSpehpeTocOneSaden SeTs2e8edeT9yie4SylezBy lel Tle 08eler Ie sSoTehybet2y2eSgleTToledSeleQloley — 38e05150895013¢5e1092625 914720] oS5e]e bensy2ceSyer5¢he52¢3c18e2e2TolaToley | 10Ps432e5y12e1yh0h 99 092 0664169 SecEaloedyToTodeTaySelSe2e2elee 198 sy65ey 180.96 ySenySe55eZe4bel es 1b2by210241005950106305242062910y 293048 T4242442411 099649594056 4Z 0E2 SE7ty970y2Te3g1be2eTe62aGeTe2eSeoley ETT ap108 02542914 e909 eSBzel S0Bs9118s03ie 18 226930220107 2hROF-ZHFOF }/ C2HGOF ~2HFOFD ZOUDF=S6C0«+32+2s(KHODF*(ZRMOF-ZRROF)~144¢4(2UROF/KCROF) ABS (ZROF /KCRDF #2 TPRCE/2RFCFY/ —CKVROF/(KARUF #KAROF )#KVUDF / (KAWOF ¥X AWOF)) ZTPOF=ZDPOF (PSOF »2X¥0F ) CALL 22F2¢ 2099964209995 4209954=6 4125 Z0POF #PSOF 42KUOF MACROEAD. ZOUDF=(WSEC*HSEC-WSDF*HSOF=¥ML*HWL —-~2E00+4KVSOF*ZUSOF¥ZORDF+ZGFDFY = (360 0 +KVSDF *2RSOF) ZERDF= (USEC WSCF-WULD/ (36000 4KVSOF) ZHWOF=2HFOF-(WSEC/ 2HROFD#(ZHFOF=HSEC) ZCHOF=¢ZURDF*(ZEMDF=2HROFD*ZOFOF — ~3600 F ZRRDF=34/(14/2RFOF #(2XMOF/2099 (14 /2RGOF=16/ 2RFOFID ‘2RODF= (2RSOF *RVSOF ~ZRROF #KVROF) /KVDDF LEF=13.€2SGRT(KACOF )*2RDOF /2RFOF OWGOF=3. 6 -€> (WOOF + (2HADF-HGOF )~ZOGDF) * (“GD F446 04) /KVGOF HGOF=INTVC(OMCCF IHGOF) TDF=CCC3e7646-7-1¢T87IE-T#KMFOF) SHGDF*(=1 .0340E-S+ 1464343 =4#KMFLFD #HOOF KVROF #2HROF *20R0F 9/(3600¢#XVROF #2280 0-39steesADVANCEC CONTINUOUS SIMULATION LANGUAGES#aseenes ACSL TRANSLATOR VERSION 4 LEVEL SE 61/082 10439409 Pace $4 16-S.eK¥FOF DD HCCE HED. UGDF=VAESVRC“UFLESuFIESuPHE 2GGOF=KUFAF*2FEGF*CAESCAEET#TGOF + 435542TADF +460) #44-ABSCZTMOF #4506) 04) 2UFOFSUFLE*MFIE*uF HE 2PBDF=C6e8VFLESES+UFIEeGe*HFHED 1 ¢5¢420F FD WAE*KEEOVRE*HRESUFLE*HELESUFIESHEIE #UFHESHFHED /UGOs (Ss TE86E-7-16 7E71E-7 KF FOF )*2HOF + (-140588E-5¢ 1e64383E-4AKMEORD 024 6-3. kMFOF))S24AOF +80 ULDF*(TSOF-1006) NTVC(ZOWOF y ZIUCFD NIVC(2CUCF yZ1UOF) NTVC(ZOROF ¢ZIROFD NTVCCZOHDF 2 IHOF 4E5* (ZTHCFLTSCF) 2OCDF-2GF CF -2GL0FD/ (KMMCF #4006) NTVC(2DTOF #Z1T9F) RML=2RF CF ‘OFUR ¢2USDF 4 2RSOF CFFCPSCF) FOF PCPSOFD IGOF PCP SCE) FCFPCPSCF) GOFP (PSOF SRFOF HF (2HUDF > ACROEKD CONSTANT 2423 9KHCOF=1 78425 0000070 CONSTANT + 565E6 9KSGOF=0~ 00000080 CONSTANT s1TLTE~5 sKULDF=2<1 7664 skVWOF=2650« 9KVROF=3218. 90000090 CONSTANT CONSTANT KVSOF=5468+ sKVDDF=2250» gKVNOF=1125- 0000100 35-6 sZTWDF=16568 7421 T0F=6 725 oooooaz0, 20000220 0000.30 "DRUN/FURNACE EOUNOARY CONDITIONS® 0000140 CONSTANT HAE=120«4HFHE=19000. yHFIE=19000+yHFLE=19000~ 9000015 00000160 90000170 voo00180 00000150 ooa00200 eooooan0 voooo220 oooo0zs0, . cooonza0 00000250 CONSTANT WRE= #0114" 501204950130) 40weeeeressscVeNCES CONTINUOUS SIMULATICN Lancuactesereeres ACSL TRENSLATC® VERSICN © LEVEL SE 41/0462 10435400 1s03=1S0F Psoii=Pstr Nsoli=Wsce RSOLI=RSCF TSCaa=TS¢F MACRCIFCa=3) _ cocgoz01 ZuDI4=2WC134KS013 RSD1S=RSOF TS012=TSCF NACRCIF (424) cooouse2 MACROCONTIALE uSDF=24D16 MACROEND seseess opo00260 SPRHTRC*ESt4*GRh: GPStytsPst) 0000270 2OCPS=KUCPSINGPEstToPS | =ZTMPS) ZORPS=KURPS*(AES(TSPS*4600}004. “RB SCZTHPS#460.94 94) 2GSPS=KUSPS+AES (WSPS)#+482(ZTMPS=TSPS) DUSPS=(KSCISCHSCI-HSFS)+ZOSPS)/ (36004 (RSPS#KVSPS+0625+KNPPS)) DPSPS=(WSD1-WSPS)=2.0: INTVC (OPSPSy1PSPS} USPS=INTVC(CUSPs sIUSPS) WSD1=KCFPS*SIGN(SGRT (48S (RSO1* (PSD1-PSPS))) 4{PSD1-PSPS)? DHGPS=5. aE -€s (KGFS + (KORH-HGPS)-ZGCPS-ZGRPS) *(TGPS*460./KVGPS, HOPS=INTVC(CHGPS¥1hCPS) ZDTPS=(2CPS¢20RFS~20SPSI/ (400. #KHMES: ZIMPS=INTYC(ZETPSyZ1TPS) RSPS=RVOFPUCPSPSyUSPSD TSPS=TVOFPUCPSPS USFS: HSPS=HVOFPUCPSPS¥USPS) TOPS=(C(3s TE8EE~T>14TETIE-T#KMFPSIENGPS#(=140364E-3+ —14643430-4 #KMFPSIIEHGPS SCALE“ SecKPFPS) AHEPSHEDS ucPs=woRe MACROEND CONSTANT KCFPS=2.6ES4KHFPS=.06y KHMPS=1 0106 KHPPS=14 0805 ooooozer CONSTANT KUCFS=6564 9KURPS=12412E>4 gKUSPS=226+7 oooo02e CONSTANT KVGPS==.2E4snvSPS=4661~ c0000300 CONSTANT IFCPS=206 y1°SPS=2302« yZ1TPS=E12s y IUSPS=120765, 2oo00si0 * = cooposze ATTEMPCTAL Hg PSF Statue tyesaz0) 00000830 Wwar=ZCG81*S10NCSLATCAESCRUAZ® BOUNC(0 +41 +E669PHAL-PSALDIDG(PHAI-~PSALD) USPS=KCS£1*S1GN(SCRTCAES(RSPS* POUND (C141 EEG yPSPS-PSAL)?) 4 (PSPS-PSALI HSAL=ChuAl shud 1+eSPS*HS?S) /USAL USAL=yhaLe KES PROCECUREL (2CFEI=¥E1) TF(KCVAL.EGs14) 2F PSCYALyeeBeKcunt 0-41severseee2DVANCEG CONTINUOUS SIMULETION LANGUAGE*+#ee: ACSL TRANILETCR VERSION © LEVEL SE 1/042 10435400 Pace IFCKCVALsE Gece) ZCFAL=VAL*KCWAL IFCKCVADSECEE0) ZCFAI=(1e-EXPC- 105 Exo yan yvexcner ZCGI=KCPAL*2CFRI/SGRT (ABS (KCPAL#KCPAI+2CFA142CFALI #1 4E-3: MACROERD CORSTERT KCSE ooovosea " ceooossc CONNCE#CAtsesei¥aescieD 0000360 DPSCI=(WEAL-KSC1)#26c~4 PSCI=INTVC(CPSCIy1PECI) PSAI=PSC1 wSCi=HSAL RECI=RVOFPE (PSC ¥hSC3) TSCL=TVOFPE (PSC yHSC1) MACROEND. CONSTANT IPSC: o0000370 oooo0380 VALVECC#E01tyescity#s50i") 20000380 24X50 =B0UNG (0. 41-£66y ANINIC((PSCI=PS5019/PSC1) 9KXTSOL)? BSe(2XXS01/(.524XTS0191) *STGNCSGRT(ABS(2KX501#RSCI*PSCL) 2xx501) PROCEDURAL «zcvsei=¥501) TFCKVASOL+EGe14) ZCV501=855(Y501)#+3«KCVS02 IF(KVS502 0EG22-) ZC¥SD1=¥5014KCV501 IFRVASOI.£003.9 ZCVSO1= C2 4-EXP(-10e#¥S02) ) #KCVSOL, END Hsso1sHscy Wsso1=vscz MACROEND ooooosn0 ooon0si0 oooocsz0 RVOFPRCPSC2 4HSC2) TSC2=TVOFPFCPSC2 9rSC2) HACRCENC. CONSTANT 1PSc2=2290+ soopoaso ssccsesscs 000080 GPLYytSFLOD op0008s0 ZacPL=KuUCPLawsPestTerL =ZTMPLY ZORPL=KURPL*CA5S(TGPL*460-)084~AGSIZTHPL 446042804) USPLTARS CWSPL) #2682 (ZTHPL-TSPL) CUSPLECKSCZ*(HSC2-FSFL)” — +ZGSPLI/(3600+ # (RSPL*KVSPL40425+KMPPL)? DPSPL=CWSC2-¥SPL «245-4 PSPLEINTVC(OPSPLyIPSPL USPLFINTVC(CUSPLGIUSPL) WSCO=KCFPL #SIGN(SORT(ABS(RSCZ* (PSC2-PSPLDI) 4(PSCZ-PSPLI? OEGPU=5s €€ -£+ (WGPL + (HGOF -HGPL)~ZGCPL-ZGRPL) *(TGPL 460+) /KVGPL, HOPLFINTVC(THGFL TFCFLD ZOTPL=(2OCPL+Z0RPL~205°L1/ (4004 #KHMPLY 2IMPLEINTVC(ZOTPLS Z21TPLD D-42ssreeessCvanceo CONTINUOUS SIMULATION Lancuacees ACSL TRANSLATOR VERSICN 4 LEVEL SE 81/042 10635490 Pace 5 RSPLERVCFFLEPSPLyUSFLD TSPLETVCFFUCESPL WUEFLD HSPL=HVGFPUCPSPLWUSPLD TOPL= (C3. 7E9CE=T=1,78TLEAT#RMFPLISHGPL#(~240540E-3+ 14643436 -4eKMFPLIDHGEL 84s 16 Ey 2KEFPLDDAFOPLSECS ucPL=ucor MACROEND CONSTANT KCFPL=3-88¢5¢KMFPL=,06 pRMMPL=14666£5¢KMPPL=1618€5 ooov0seo CONSTANT KUCEL =O. KLRPL=5,676~6 gKUSPL=15262. ooo00470 CONSTANT KVGPL=8.375E4 yKVSPL=500«9INGPL=572 ey IPSPL=2284 ooonnese CONSTANT 2TTPL=QE6.yIUSPL=11934 20000850 a = _ = coooosc ATTEMPC*R2*s*SPL¥y WAZ "4454209 00090510 Wua2=2cGa2*S1GNCsGaT (Hes cRUAZ® SOUND(0+41-£66sPHR2-PSA2)9) ¥(PUAZ-PSAZ)) NSPL=KCS224sToN¢SGRT(AES (RSPLe SOUND (0 +41 E66gPSPL-PSA229) gCPSPL-PEAZID HSAZ=(WWR2*HWA 2+ USPL*HSPLI/USAZ WSA2=WWR2"WSPL PROCEDUREL (2CF Ez TFCRCVA2+£C014) ES(YAQDaaBaKcuAZ IFCKCVAR.EGL20) 2CFA2=YR2*KCWA? TF CKCVAZ LE G23.) 2CFA2=(14-EXP(~104+ 42) )4KCUA: ENC ZCGAZ=KCPRI*2CFAZ/SORT (ABS (KCPAZ*KCPAZ*ZCFAD#ZCFA2)* 1463: MACRCERD CONSTANT KCS#2=2646 yKCWA2=1.609£4 4KCVAZ=3 gKCPAZ=2 064 cooo0szo . = si:iiisses! 00000530 CONNCC#C3¥y*sh2eyescee) 00000540 DPSC3=(¥SAD-WSCE}4260-4 PSCS=INTVC(CPSCH41PSC3) Psaz=Psc? HSCS=HSA2 RSCS=RVOFPECPSC3qHSCSD TSC3=TVOFPHCPSC34HSCED MACROERD CONSTANT IPs 3222706 00000550 2 a oo0008e0 SPRHTRC*SS*s*GPL¥s*SCE¥s*GSS"ytSSS®) ooooes7a 2OCSS=KUCSS+uGPe*tTEss | ~ZTHSS) 2GRSS=KURSS*(ABSCTESS 460.1004 =ABS(ZTHSS# 46082440) 2OSSS=KUSSS R85 (HSSS)++,82 (ZTHSS-TSSS) DUSSS=CWSC3*CHSCE-HSSS) -+ZGSSSI/(SE00.+ (RSSS*KVSSS+D.25eKMPSS) DPSSS=(¥ECE-HSSEI*26E=4 PSSS=INTVC (CPSSSy1PSSS) USSS=INTVCCOUSSS,1USSS? WSCS=KCFSS*SIGN(SGRT(ABS(RSCB*(PSCS-PSSSI99 4{PSC3-PSSS)) CHGSS=5. £E~€s (HESS + (HOPL-HGSS)-ZOCSS-ZGRES) + (TESS #460.) /KVESS. HGSS=INTVCCOHGSS FIHCSS) 2OTSS=(2GCSS4ZGRSS-2085S)/ (400. *KMESS: 2IWSS=INTVC(ZOTESyZ1TSS) RSSS=RVOFPUCPSSS4USSS) TSSS=TVOFPL(PSSs4USSS) HSSS=HVOFPL(Psssqusss, TOSS=(((26TE4EE= 771478 72E-T#KMESS)AHCSS#(-140564E=5e 1 464343E “4 KMESSIIENGSS $C416°3. 2 KMFSS) = HOSS+E0e peasees2CVRNCEG CONTINUOUS SIMULATION LANGUAGESsessseee ACSL TRANSLATOR VERSION 4 LEVEL SE 61/042 10439400 Pace 6 Woss=uoPL MECRCENC CONSTANT KCFSS=2,8E5 9KMFSS=+ 06 KUMSS=4,455 yKMPSS= 2.285, ooocoseo ooo005s0 oooo0eco 0000610 oocovezs oooo0es0 WSSS=wseo-wse1e DHSBO=(CaSSS*HSSS+USS18*HS516) / YSEO- #5309 HSBO=INTVC (DHSE041HS80) RSBO=RVOFPHCPSEC HSBC) TSEO=TVOFPE (PSEC SHSEOD NACROERD CONSTANT IHsB0=1469, 0000680 seesnssnsssess: =* po0006s0 VALVECC#ELE*y#sCi1" #5518") 20000660 2XX518=BCUND (0s 41+C669AMINI(((PSO11~PS518) /PSO11) yKXTS1B) > Wso11=20v5184C12-233+¢24x518/ C4 94KXTS1609)— ASTGN(SGRT(ABS(ZKHELS¥RSOIL#P SOIL 29420x51 8) PROCEDURAL (zcyS18=¥518) IF(KVAS10.EGe14) ZCVS1E=A8S(Y518) ¥035eKCVS18 IF(KVASIECEGL2) ZCV518=Y5184KCVS18, TFCKVASLESEGLS4) ZCVSLE=C1 «EXP (=1044Y518) ) #KCVSIS END HssisHso12 Wssieswsctt MACRCEND. CONSTANT KVR518=2- 4KCVS18=68364 9KXTS18=46 0000670 * = = = ooo006ee VALVECC#515¢4rs012"y#8519") ooon06s0 ZXXS19=BOUND C0. 914 €69AMINI((( PSC12-PS5199 /PS012) 4KXTS19)) SDL2=ZcV519«(1e-0334C24X519/ (4 54KXTS19II)— ASTGN(SORT(ABS(ZKXS1S*RSO12*PSO12 2942xx515) PROCECURAL (ZcVSaS=vE15) IFUKVA519.G+1.) ZCVS19=ABS(YS19} ##54KCVS19 TFUKVAS151£0.22) ZCVS1S=V519¢KCV519 IPOKVAELELEGLES) ZCVE1S= (1 «EXP (7104451999 #KCVE1S exo NsSi92Hs012 wssis=usci2 HACRCERO CONSTANT KVAS19=+ yKCVS19=1-35E49KXTS19= 458 90000700 fassnssiss. = 00060710 VALVEC C*E02°4rSC15"yt5502" aoooo7ec 2XKBOZSBCUNC Ce 41-£6%5 SMINI( (( PSC13~PS5O29 /FSD13) 9KXTS02)) WS013=2CV50ZeC1s~s33*(ZKHE02/¢.58KXTS0ZII)—— #STGN(SORT (ABS(ZXX502*RSD15#PSD13 D> y2xx5029 PROCEDURAL (2c¥vE0z=¥502) TF(KVA502«EG.14) ZCVED2=288(YE02}e43exCV502 IFUKVA5020EGe22) 2CVSD2=¥502*KCVEG2 TRCKVASO2.EG.5.) ZCVSC2= (1 +=EXPC-1044¥802) ) «xCVE02 0-44stesaeersZCVANCED CONTINUOUS SIMULATION LANGUAGE*+4aeeeee ACSL TRANSLATCK VERSION 4 LEVEL SE 8:/042. 10638.00, Pace END Hssozersor3 usso2=4sci? MACROEND, CONSTANT Kvaso vo900730 + 00000740 BPTVSC RP 90000750 SVALVE PROGRAM® ZYVHF=AMIRI CERI CC 2KVEPSAMINI GR CL WSBO=ZKVHP + ZuVHP. YAPP/KVPHP) 910) YARP/KVPHED¢ 106) svatver MINI (CPS8O-PTYHPD /PSEOs «46: YVHPSKVPRF*KAVEP® (1 «= ZPDHP*.725)#STGR(SGRT(ABS (RS5O*PSEO*ZPOKP) ) s2PDHP: CYBHP=EOUNE (+KSTHP gKSTHP 9 ( (YCHP-YANP)/KTVHPD) LIMINT CY2HP sDYAMPsTYAHP 906910) 209993=DyaK YAHP=INTEG (SHIN ( (YAH. LE 60440Re YAMP2GE 014) + ANDs (YAHP=(049)#209995e67404090604209 993) 4 1YARPD MACROEND SFIRST OFCT NOCEF DPYMP=(2uvHP-2u1 HPD /KOPHP PTVHPSINTVC(OPVHPs IPVHPD TIMPULSE STAGE? ZRVHPSRVCFPECPTVEP +HSECD ZIVHPSTVCFPRCPTVEP grSEO) VOFPH(PTVHPyHSBO) DKP/PTYHE: IGN CKWIHP #KVFHP *2RVKP *SGRT(AGS( (ZTVHP+460024#¢14-ZAOHP2AOHP) )) 9 14-2A0EP! VOF PS (POHFs ZSVHPD KVDHPONHE 7 SIGN(SGRT(AES(HSBO=ZHOKPD? 4 (HSBO-ZHOHP >? KEORP * 4. « ZVOHP + (KEIHP=2VOHP: ZEDHF=K2O0HP +2vOFF ZEDHPSAMINL(ZE1HP9ZE2HP) HOHP = HSBO ~ (HSBO-ZHOHPD «ZECHP. ZPOKF = (KSEC-HOFP)*¥SEO/5.413E6 MMEGAMATTS® "SEcono oPOT NCDEY DPOHP=(ZLIFPeZKVEP-ZWIHPD /KOPHP. POMPSINTVCCOPOHPsIPOHPD SREACTION sTAGES* MACROMULTIPLY 0 MACROCCRTINUE 0-45vanceo ACSL TRANSLATOR VERSION ‘ONT InuGUS LEVEL SE SIMULATE B1yoK2 EGRVPR(O4ds th? MACROMULTIPLY ¢ MACROINCREMENT 1 RACROPULTIPLY ¢ WACRCIRCREYERT 2 REACTION SLADE GROUP 1 OF NeIt ROHP=RVOFPH(POHE yHCHPD TORP=TVOFPECPCHE +HORP) SOMP=SVOFPRCECEP y KORE) ZALHP=PLHP/ POF? DULHFESTON CMI HF oROHP® 2EIHESHVOFFS(FInFySOHPD ZVIHP=KV INP *NHP/SGRT(3GUNO (5444 00» HOHP-241HF)) ZRLHPSKE 1FP+2¢#2VINP*(04 707] oXERHP“ZVINP+KERHP. RePeavirey) HIHP=HOHP= (hoHP-ZHaHPD #ZRIHP ZULHP=(HOHP-H1 HPD © 2M1HP/34 42366 SPEGEUATTS © ZYLHPEZJIHPAZMOnE MACROIF(o=0) cecceze9 MACROCONTINUE + MAIN STREAW EXTERNAL VARIAGLES* wsnp=zuire HSHP=ALHP SEP=2m1KP RSHPERVOFPE (PSHE sHSEPD TSHP=TVOFPH(PSHP yHSHP? MACROCONTINUE MACROEKO MACRCTF (0209 MACROCONTINUE MACROINCREMENT 2 PLHP=PSEP NECRCERC CONSTANT CONSTANT CONSTANT CONSTANT atshen GRT (ABS CCTOHP+4 604) oscovere IPVHP=1867.91P0HP KGIHP=.2664KERHP= LOE gRTVRP=1 22 + Sy IYAHP EL gNHP=S 9664 KOPHP=200 ¥KEOHP KVPHP=.375 4kVOH connccecae OPSCAE(RSHP-uscadez.c~a PSC4=INTYC(DPSC# 4 IPSC? RSCA=RVOFPH CPSC HSC4? TSC4=TVOFPHCPSCEsHSCHY MRCRCERO CONSTANT IPSCO=E ZS. SCAN yHEETAN SO") 2C22=WEE7 P44 C2 RESTA=RSCH 46 ON LANGUAGEHteeeeeee 10439409 PACE 6 # (Le ZALHP #ZALHP DD) 9 16-ZA2HPD SORTCL +2 V1 HP#ZVIHP=D6814¢K5, o0oo0760 90000770 ooooa7e0 00000790 20000800 oooo0e10 6006 £49265 4KELHP=. 961 872E~8 ykVIMP=+002082 4 2 oooo0ez0 oooocesa ooo008eofeeeeeeseR0VANCED CONTIKUGUS SIMULATION LANGUACE®e® DESL TRANSLATGR VERSION 4 LEVEL SE 81/042 10635409 Face 8 Tes7astsce Pso2=Psce HS02=HSC4 RSc2=RSCe Tso2=T8c4 macRoIF(z=2) oocceso2 MBCRECONTIN usce=zuo22 MACROENO = sooo0sse ATTEPB( ORE y*SC2y*4AS*y*SREOD 0000860 UWAS=ZCORA+STGNCSURTCLESCRWASS BOUND( 0441 «£66 PUAS-PSRAD DD 4 (PUES-PSRAD) WSD2=KCSRA*SIGHCSGRTCASS(RSO2* EOUND( +41 2£66¢PS02-PSRADD) ¥(PSEZ-PSRAD PSRASCNWEE4FKR2¢nSCZAHSOZ)/HSRA WSRR=WNAS+uso2 PROCEDURAL (ZC RA TR(KCVRASEGs14) 2CFRAZABSCYRAD #434KCURA IFCKCVRALEG.20) 2CFRATYRA*KCURA IFCKCVRASEGL3.) ZCFRA=(1e-ExP(-16. ERO) ZCORE=KCERAAZCFRE/SCRT (ABS (KCPR ALK CPRASZCFRAAZCFRAI +L 6E=3) MACROEND. CONSTANT KCSRA=1-33£64KCURA=163462644KCV) YRAD #KCURA 0000870 B covo0eae CONNCC#CEFytsRetyescen) 00000830 DPSCS=CVERA~HSCE}42.0~4 PSCS=INTVC(OPSCEyIFSCS) PSRASPSCE HSCS=HSRA RSCS=RVOFPHCPSCS4HSC5> TSCS2TVOFFR(PSCE yr SCS) MACROENC CONSTANT IPSC! eoooeso0 4 = = coonosi0 SPRHTRE*RH*9#G55%y#SC54y*GRHYy#SRHOD 20000520 ZGCRESKUCRHSKGPE*(TCRE | =ZTHRED ZORRH=KURRHACRESCTGRH*460.2004 ~ABS(ZTMRHAGEO 4H 2GSRP=KUSRH#AESCWSRE) #* «Bs (2THRH=TSRH, CUSRHECUSCE®CHSCE-PSRH)” —-#2GSRHI/(3E00e* (RERHAKVSRH4O625¢KHPRED) DPSRH=(WSCS-WSRHD02.0-4 PSRH=INTYCCOPSRHsIPSRHD USRH=INTVC(CUSRF sIUSRHD USCS=KCFRi* SIGN CSGRT (AS (RSCS* (PSCS-PSRHID ) ¥(PSCS-PSRHD OHGRH=9s 8-6 (WORH* (HOSS-HGRH)~ZGCRH~ZGRRH) “CTGRHe 460.) /KVGRH HGRH=INTYC (CHGRE yTHGRHD ZOTRH= (ZOCRH+20RFH~20SRHI/ (4004 #KMERHD ZIMRH=INTVC(ZOTRHs 21 TRHD RSRHSRVOFFUCPSRE SUSRHD TSRHSTVOFPU (PERE WUERHD HSRHSHVOFPUCPSR KyUSKH? TGRH=(C C24 7E4CE~ To 1, 7OTIE=TeKMEPED+HGEHS(=1 o0244E-3+ 14645450 =4aKMERKDD HOR 4 C4.16-3 5 2KHFRHD D#FORKABOS Worn=Kces MACROEND.sesseeessACVANCED CONTINUGUS SIMULATION LANGUSGEW+eeeeees ACSL TRANSLATOR VERSION 4 LEVEL SE 61/042 30435~00 PAGE 10 CONSTANT KCFRH=4,0205 RMFRH= 406 ykHMRH=B454ES 4KMPRH=1 ¥OSTES os000930 CONSTANT KLCKH= 500444; xURRH=1.19E-4 9KUSEH=5 706 a0o00s40 CONSTANT KVCRH=6.SSeugKVSAN=S<2ESpINGRN=291 ey IPSRH=SE1e421TRHZ10604 00000950 CORSTANT ILSR SATEMPC*RHO® yeSRHe PSRHCHSRE PSSIS=PSRr USRH=WSRHO~¥S519 DHSRHC=C (WSRi* HSRH#WSS194NSS199 /USRHO-HSRHOD WERHC=INTVC(CHSREC ¥JHSRHOD RSRHOSRVCFFECPSREGSHSRHGD TSRHO=TVGFPHCPSRHOsHSPHOD MRCRCENC CONSTANT 1 Benes) poo00se0 =: o0000e70 519%, #5RHOND doooose. PSRHOSLEIESS 20000990 2 00001000 LPTVSC*LPe y*sRHOretSLP¥ 45) oo001010 SSRHOSSVCFPRCPSREG HSREOD wacnciFce=o) agoae1ss MACROMULTIPLY 0 MACROINCREMENT 1 ZALLP=PILP/FSRKO USRHO=SIGNCKMI LP*RSRHO*SORTCAGS(CTSRHO*AGO+D#CLe-ZAILPAZAILPD D) 91 ZHLLPEHVOFPS(PILPsSSRHO? ZVILP=KVILO atiLP/SGRT (SOUND (5 044.004 gHSRHO=ZHILPI) QRILPSKE LL P#26#2VILE+ («70718 KORLP-2VILP*KORLPHSGP TCI o#ZVILP*2VILP=1 6416 9KBRLPAZV apa) HILP*HSREG>(FSREGHZFILPD*ZRILP ZILE=(HSREC-HILPD #HSRHO/S 041326 SMES AWATIS® 2¥ILPEWSRKC PROcexery*Let> NACROMULTIPLY ¢ NACROINCREMENT 1 MACROMULTIFLY 1 MACRCINCREVENT 2 + "PRESSURE NODE 1° DPILP = (2W1LP~2u2LP-WILPD / KDPLP PILE = IATVC(OPILP yIPILPD MACROEND MACROCONTINUE MACRCIF(1==) 00000349 GREBCCL 959 "LPT SISLEND MACROMULTIPLY 0. MACROIKCREENT 1 MACROMULTIPLY 2 WACROINCREVERT 1 + REACTION BLADE GROUP 2 OF S#1t RVOFPHCPILPsHILED TVGFPECPLLP¢HILPD SVCFPHCFILF 4rILF) P2LP/PILP. TERCKEELPHRILPR ——- SGRTCAESC(TILP44 E04 2#C1 e-ZA2LP#ZA2LPIND Len ZAZLP HD) ZALLPD 0-48seteeeeessOVaNCED CONTINUOUS. ACSL TRANSLETCR VERSION 4 LEVEL SE SIMULATION B1s982 ZHOLPSHV CF PS CF 2LPyS3LP) ZVZLP=KVZLPeNLP/ SCP T(BGUND (5+ 9400s yHILPo2H2LPD ZROLP=KEQLE 424 #2V2L Fs (007071 2KERLPXZVZLPSKBRLPY Rupszv2tey) HOLPSMIL Fe (h1LP=2H2L9) #2RZLP 22s (HILP-FOLP)#Z42LP/3, 413E6 sreceusTts © ZALP=Z2UzLP42M1LP MACROIFC1=5) 00000222 PRODEXC2 LF) MACRCHLLTIPLY 0 MACROINCREMENT 1 MACRORULTIPLY 2 MACRCIRCREPENT 2 v) PRESSURE RODE 2° DP2LP = (2u2LPr2uSLP-w2LP? 7 KOPLP POL = InTvC(DPZLP+IP2LP) mACRCERC. MACROGOTO cogous8 MACROCONTI NUE MACRCEND MACROINCREMERT 1 MACROGOTC covoo1Es MACROCONTINUE MACRCIF(2=5) cooc0349 BCREBC C295 yLPYgISLEND MACROMULTIPLY 0 MACROINCREMENT 2 MACROMULTIFLY 2 MACRCINCREMERT 2 +" REACTION SLAOE GROUP 3 OF seit ROLP=RVOFPHCP2LP+H2LPD T2LP=TVOFPE (POLP yr 2LPD S2LP=SVOFPHCP2LP +H2LP) ZASLP=P3LP/P2LP ZUSLPSSTGN (KUSLP*R2LPe ZHSLPZHVOFPS(P3LPySZLP) ZVSLPEKVELP*NLP/SGRT(SCUND (5+4600+ 9H2LPHZHSLPI) 2RSLP=KESLP 42. 2VSLP# (07071 #KERLP-2VSLPOKERLP* RLPs2V3LFD) HBLP=HOLP= (H2LP=2HSLP)*ZRSLP ZUSLP=(h2LP-HSLP)*Z43LP/3e S136 SrEGouATIS® 2SLP=ZJSLP+ZH2LP NACROIFC2=5) 00000282 PRODE RCS y* LPO) MACRCHULTIFLY 0 MACROINCREMENT 1 MACRCMULTIFLY 3 WACRCINCREVERT 1 + PRESSURE NODE 3* DPSLP = (ZeSLP-2WeLP-WSLPD / KOPLP PSLP = INTVCCDPSLPsIPSLPD Deg LaNgueoess 19635400 Face aa SGRT(L s+ 2V2LPRZV2LPH2 o4140KE, SORTCABSCCT2LP*460+)#(14-ZASLP#2ASLPD)) y1e=ZASLP#42: SORT(14+2VSLP*2VSLP=164189K8,feteeeeeeacvaNCED CONTINUCUS SIMULATION LENGUAGES#eeeaeee ACSL TRANSLATCR VERSION 4 LEVEL SE 61/042 10638400 Pace 12 macacenc MACROGOTO uocous18 MACROCONTINUE MACRCENG MACROINCREFENT 2 MACROGOTC Obod0L6s MACRCCCTINUE ACRCIF(3=£) 00000249, BGREACC 3954 °LP 4 *SLPYD MACROMULTIPLY 0 HACRCINGRE VENT 1 MACROMULTIFLY 3. MACROINCREMENT 1 + REACTION ELADE GROUF 4 OF Se1¥ RSLP=RVOFFF CPSLP sHSLP) TSLPETVOFPH(PSLPGHSLPD SSLP=SVOFPH(FSLPSH3LPD 2ASLP=P4LP/PSLE 2NGLPZSICNCKRALEARELP® SORT CABSCCTSLP+QE049 20. ZHOLPSHVOFPS (PAL Fs SSLPD ZV4LPSKVALPANLP/SGRT (BOUND (5+44000 gHSLP-2HALPD ZRALPSKE SL Pe2.#2V4LPs (067071 #KERLP-ZVALPOKERLP* RuPsZveLP)) HSLPSRSLF> (PSLP>ZHALPD #ZR4LP ZUSLP=(HELPHPSLPI#ZHALP/3 641306 THEGAWATIS® ZNALP=ZV4L Pe ZMSLP MACRCIF(3=5) 00000282 PRODEX CA y*LP*D MACROMULTIPLY 0 MACROINCREMENT 1 MECROWULTIFLY 4 MACROINCREMENT 1 + PRESSURE NODE 4* DPALP = (2WLP-ZKSLP-WALP) / KOPLP PALF = INTVCCOPALPsIPALPD HACROENO MACROGOTO ovo00s18 KRCROCONTINUE MACROENO MACROINCREMENT 1 NACROGCTC goods MACROCONTINUE MACROIF(925) 00000249, BGREAC C4 y= "LPM ASLEYD MACROFULTIFLY 0 MACROINCREMENT 2 MACROMULTIPLY 4 MACROINCREPERT 3 +" RESCTION ELACE GROUP § OF RALPERVOFPHCPSLP SHaLP) TALP=TVOFPH (PALE yHALPD S4LPSSVOFPF (P4LPHALPD 0-50 ZROLPAZA4LPD)) 41e-ZASLPH92) SORTC1s*2VALP*ZVALPH1e4149KE.seteeeeeeADVANCED CONTINUOUS SIMULATION LANGUAGE*##eeeeee ACSL TRENSLATCR VERSION 4 LEVEL SE 61/042 104384C0 Pace 13 Z2ASLP=PSLP/PALP ZUSLPESIGRCKUSLP*RALP* —-SGRTCASSCCTALP44606)#¢1 ¢-ZASLP#ZASLPD)) 9 16-2RSL PH #2: ZHSLPSHVCFPSCPELPy S&LP) 2VSLE=KVSLP*NLP/SGRT(SOUND (544400 yHSLPH-ZHSLPID ZRSLP=KESLE +2 2VSLP*(O4TO7I*KERLPZ2VSLP*KERLP+ — SORT(1e42VSLP#2VSLP2e4140KE, RLPSZVSLPD) HSLPSHSLP> (HALP*2HSLPD #ZRSLP ZUSLP=CPSLPCHSLP)#265LF/3 41366 treceuatTs® 2NSLP=ZJSLP+ZH4L? WACROIFCA=5) cOs00ze2 PRODEX(S 4 9LF*) PACRCPULTIFLY 0 MACROINCREMENT 1 MACROMULTIPLY 5. MACRCINCREMERT 1 + PRESSURE NOCE S* DPSLP = (2VSLP=2¥6LP-VSLPD / KOPLP PSLP = INTVC(OPSLPs IPSLPD MRCRCEND mACROGOTC ap000s18, MACROCONTINUE MACROENO MACROINCREVENT 1 NACROGOTO cocou16s MACROCONTINUE HRCRCIF(S=5) co000349 ACRCCORTIALE BGREACCS 95 54LPYytSLPtD HACROPULTIPLY 0 NACRCINGRERENT 1 MACROMULTIPLY 5 NACROINGRE VERT 1 + REACTION ELACE GROUP € OF Sei? RSLP=RVOFPHCPSLP yHSLPD TSLPSTVOFPH(PELP,HSLPD SSLP=SVOFPECPSLPSESLPD 2AGLP=PELP/FELP ZUGLPZSIGN(KWELP*RSLP* SRT CABSC(TSLP#460494(14-ZAGLP#ZAGLPD)) 9 1e-ZA6LP##2: ZRELPZEVCFFSCPELPSSSLPD 2VGLP=KVELP *MLP/SGRT (BOUND (544 00+ HSLP=ZHELPID ZRELP=KEGLP 22s ZVELP*(0+7071=KERLPAZVELPOKERLP® SORT 1-4 2V6LP#2VELPr1-4144K! RLp=zveLP)> HELP=HSLP>(PELP=2HELP #ZRELP ZJGLP=CHSLPHELPD*2HELP/3. O23E€ TREGAUATTS * ZHELP=2UELP+2H5LP NACROIFS=5) occooze2 MACROCONTINUE MAIN STREAM EXTERNAL VARIZELES*eeseQCVANCED CONTINUCUS SIMULATION LeNcuAGE*® ACSL TRANSLATOR VERSION 4 LEVEL SE 31/042 10+39.00 Pace 16 LPs 2H6LE MACRCCONTINUE MACROEND. MACROINCREMENT 1 PeLP=PSLe MACRCENC. CONSTANT PSLP=1.23yKERLP=+9664KOPLP=200+41P1LP=262 44 IP2LP=171e oooo1020 CONSTANT IPSLP=Ge,391P4LP=17.y1PELP=5~864NLP=3600> poooi03 CONSTANT KEILP=,95019931 sKEZLP=14159400)KESLP= «96666 9KE4LP=2949517 ooo01080 CONSTANT KESLO=.50376 yREELP=« 73533 9RVILP=.00192356 9KV2LP= 400148376 aooo10s CONSTANT (00124225 sKV4LP= 400213821 sKVSLP=.00171779 4KVGLP==0019425700001060 CONSTANT 81770» 9KWSLP=252825.« #KWLP=657452~ 20001070 5 1457E8 ooooiceo = 2 90001090 SATTEFEERATCR HOCKUP® 90001100 PUAL=PerP eoonii20 Punz=Pare 90001120 90001130 ooociie0 ooooiie0 ASIMPLIFIED FEED TRAIN MOOEL® ooooi160 ZIFT=UFW-UDS7A-WiL Pour Ps uWALouuazouWas 90001170 22FT=WFWaHC2-(UDS7 AsK1LPD*HCLoWEFPSHELP 90001180 W2LP= (ZF T#HCS-22FTD/ (HCS-HOLPD 90001150 Wo=ziFT-w2Ur 0001200 WSFP=3.9145~30UF Ws (PRFP=P2LPD/(H2LP-10696) 99001210 HCL=PEGFPCPILPD 90001220 HC2=HFOFPCP2LPD so001230 HC3=HFOFPCPSLPD 00001240 HCRSHFOFF (PAL) 90001250 HCS=HFORPCPSLPD 00001260 WSLP=(uC#(RCS-HC499/ (HSLP-HCS) 00001270 W4LP= (WCe CF CAHCS)-USLP* (HC3-HC6I9/ CHALP-HC4D 00001280 WSLP=CWCe(HCS- 774) —(WSLP+USLPD * (HC4=HCS}9/ CHSLP-HCSD 0001290 MALES CMF ue (C1 ~FE2)~CWDETADS CHOSTATHCLII/CHILP “HCW 00001300 22 oooo1sie TATTEMPERATOR HOOKUP® oc001320 RWAL=RFOFP (P2LPD 00001330 RuA2=RVAI 0001380 RuaS=RUAL o0001350 wai =Hc2 90001360 Hwaz=Hce 90001370 HASEhC2 00013¢0 a = 90001390 ECONDPCHEC Ts *GPS He ASSTANyNGEC TS SECT) 00001800 2GCECKUCECONGPEs(TCEC-TSECD 2OREC=KUREC* CC TGEC #450. Da*4~(TSECHGEDSI¢04) DHSEC=(WSETA*CHSSTA-HSECI*ZQCEC*ZQREC) /( 56000 (RSEC#KVWECS 11 #KMMECDD NSEC=INTVC (DHSEC ¥TPSECD RSECERFOFHFCHSEC) TSEC=TFOFHF (HSEC) DHGEC=9~ 8E~Gs (HGEC* (HGPS-HGEC)~2GCEC~2GRECD #CTEEC+4E 06 I/KVEEC HOEC=INTVCCCHGECSIFCECD TOEC=(C(3sTESGE=To1,TSTLE~T*KMFECI*HGEC#(=1405645-3+ 1464 345E-a4KMFECD D*HGEC 0-82seeseeeesiCVARCED CONTINUOUS SIMULETION LANGuacceseseeeee ACSL TRANSLATOR VERSION § LEVEL SC 61/042 19435400 Pace 19 4.1603 e2KPFECD DeHGECHEOS VoeC=ucrs DPEC=WS57A*2ES (¥SSTAD/(KCFEC#KCFEC#RSS TA) WSEC=uSETR MRCROEKO CONSTENT KCFEC=5.5SE 4 KMFEC= 406 sKMMEC=7-098© oooo1eay CONSTANT KUCEC=288. «KUREC=1-657E~S4KVGEC=2 +9764 4KVUEC=30004 0001420 CONSTANT IFGEC=150+y1HSEC=S626 oooo1930, ssesesessssscezssrteseses: 35: oooo1eso FWHTROC#ETAGG#OESy UE" y#SEYy MOSTAY y#SSTEND ooo014s0 2U2STA= (ABS (AVE) 4160-3) 4042 CUS TAS (LSE*2HVSTAGHCE *#HDE-UCS7&4ZHFS7AZ2GCE7A = $600. *KVHST#42URSTA*ZDRS7AI/ Cevneree2RHETA*3E0G0) DHSS7A=(20S57R+HSST&s(ZHCSTA-HSSTAII (360044 ZRCSTASKVNSTAY ZOHSTA=(2GCETASKRES(ZHISTA=ZHCS TAD) /(3E0044(2RCSTA®KVCS 70 01 4KMMSTADD ZHCSTASINTVC(ZOHS7As2THSTAD 20S574=2USS7A8(TSE~1S57A) ZUSSTASPES (WUE *WSED/(KSTS7A*WSE*2U25TA —-#KSSS7A*WUE*(ABS(USED#1 ¢E-3) 40 .40UME® WseeKsrS7A) ZRVSTAZHSE=269872/ (ABS CUSEI#16E 3) 2RCSTASRFOFFFCZHCSTAD 215742 TFOFEF (ZECETAD TSE=TVOFPH (PSE yHSE) 2GCSTA=ZUCSTA® (2TSSTAx (204 2TCSTA/S 042 TISTALS«9? ZEIST#SHEES2GDETA/ (225 (WMEI+16E~3) 2TISTASTFOFHF (2HIE 7A) TO57A=TFOFHF (HOSA) RDSTA=RF.CFFFCHOSTAD DHOS7A= (ADE VAs (ZHFETA=HOSTAI-ZODSTAI/ (36000 #2RFSTAVKVLSTAY HDS7A=INTVCCOHDS7A THOS TAD ZUDSTA= 48S (MDS 7A*UHED/(UME* CABS (DSTAI+I-E-S2##04%KDSS7A —-$VD57A#2H257A*KOTST AsuDS7ASMUE @KOFSTA) 200574=ZUDS578* (7DS74-TKED HS57A=INTVC (OHSS 789 1HSS7AD TSS7A=TF CF HF (HSS7A) ZURSTA=INTVC (ZOUSTA 9210574) 2DRSTA=CUSE* uDE~HOS74)/(3600+*KVHSTAD ZRH 7A INTVC(ZORETAgZIRSTAD 2HHS7A=ZUHSTA+ « 185¢PSE/ZRHETA PSE=POFURCZUHS7 Ry ZRESTAD POE=PSE PESTREPSE LSTA=13«6*SGRT(KACS7AD # (ZRHST7A~ZRGSTAI/ (ZRF STAZRGSTAY ZHFSTASHFOFP(PSED 2HGST#ERGOFPCPSED ZRFSTASRFOFPCPSED 2RGSTASRGCEPLPSED 2TSSTASTCFPCPSED 2UCSTAAES CHVED/(KCTSTA*2H257A ——-4KCCSTASKME/ABS(ZTSSTAI 4 «S#KCFS TERMED ASS7AZRFOFHFCHSS 7A MACRCEND. CONSTANT HEEZ0«yhCE20s pIHOSTA=461 65 4KAESTAZI2¢ gINSETA=473 05 ooo0raso CONSTANT 2IHSTA2G614542IR57A=9.6421US7A=500« oo001470 CONSTANT KCCSTA=2¢5SE-54KCPSTADG+ KCTS 7&5 «E~34XDFSTASO$ 00001480 p53seeseeessADVANCED CONTINUOUS SIMULATION LaNCUAGE*seeeer. ACSL TRANSLATOR VERSION 4 LEVEL SE 61/042 10435400 Pace CONSTANT KDSSTA=1.4EC+4gKOTSTA=5 «66-2 4KH4S7A260000« 4KSFS71 oooo1es. CONSTANT KSSS7A=8.1SE-3,xSTSTA=S.E~2 9K VC! TA=b0 #KVIISTA=SO0e sooo1soe CONSTANT KVLETA220+9 ves7eveeve HORVO=HOSTA MACRCEAO PCRVO=PILE 0001630 DRAIN VALVE CONTROL 0001680 YDRV=PI CYIDRVsKPORVsKIORVSLESTA 004204 TYIORV? 00001650 YIDRVSLIVINTCCKPORV2KIDRV/6069#LESTAyIYIORV pDe 930) 209589: (KPDRV*KICRV/E0.)*LESTA 209990=INTEGCSWINC (203590. LE+0 40604205525) 9IVICRV) 08+ 2099934 G£+1+9+AND«(209990-(04))#20998946T +060 HACROEKD 209951 =BOUNO(O. 1. eKPORVALESTA*YIORV MACROEND LEST#=CLSPSTA-LETAD #017 ooo0r€60 CONSTANT KPORV=,54KIGRV=5. LSPS 7A=60 4TYIORV=475 oo001670 * peiicecss 00001660 SFEECUPTER CONTRCL* vooo16s0 UFUD=2. 7E~ 7» (USEO-WFWeKLEVEL* (LSP-LOFD) 09001700 WENDD=PI CWP UDI 9 KPF WyKIFWyVFHD 900980556 9VFUCID 000171, WEVCT=LIFINT(CKPFU*KIFA/€0 4) +MFUDyIMFUOIy0. 944506) 209985=(KPFUSKIFW/EC 24ND Z09986=INTEGCSKINC(203586-LE+0 D20y0.09208885) yINFLOID OR + 209965+6£4445E6) « ANDeZ09966-(0419#209985.67. p54‘eeRDVENCEE CONTINUOUS SIMULATION LéNCUsSE+seeeeaee ACSL TRANSLATCR VERSIGN 4 LEVEL SE 61/642, 10635400 Pace a MACROEND 209587=BOUNO(O «4445264 KPFW*MFUD*UFUDID MACRCERO CONSTANT KFFUSZ7EE ¥KIFRE2« gKFWEI « gKLEVEL 234 7ES¢LSP=3Ee 0001720 CONSTANT TAFWOI=S.€23 ey ]uFU=3.€2306 eo00173. DWFW=KF Ws (GFuDD-uFLD 00001760 MFUSINTVCCCRFWSIEFED 00001750 CONSTANT KCVCRY=5E57s yKVAORV=Z+ gKCPORV=1406 opo0i760 POFP=2.xDFECSPSOF 90001770 ERC § CF CERIVETIVE? o000a780 END § *0F OvNamrc® 90001750 END s "OF PROGRAM? 0001800 Z2TERE IF(ZzsToECTC Besse CALL 2zL0s CALE 2z0uTe CALL 22476 IF(ZzST)COTC 95566 GoTo 39555 99996. «CONTINUE NACROEKO 22TENC 59995. .CALL 2zTERM 99993. .CONTINUE MACRCEKO MACRCEKC 0-55seteeesesKDVANCED CONTINUOUS SIMULATION LANGUAGE#¥erenee® ACSL TRANSLATOR VERSION 4 LEVEL SE 61/042 10459-00 PAGE a) VARIASLES NOT SPECIFIEO IN ANY BLOCK TsToP 0-56peeeeeeseADVANCED CONTINUOUS SIMULATION LANGUAGES + seers ACSL TRANSLATCR VERSION @ LEVEL SE 61/042 10635400 pace 19 SUBRCUTINE cL¥HY ooooiezo RETURN 90001820 Eno 00001830 ccHwCH 77 E¢sopce> cocoieen CALL 220LENCSocog) ooooieso 110 CORTIRUE 00001860 aL zzsIKe ooco1e70 CALL 2zexce oo001e60 cc to 110 o0001890 Eno 00001900 FUNCTION PCFURCU9RD 90001510 =26878.25+R+6446983)48 6254595 00001920 GL1eS1EF=24R= 6375653) #R 42052057 00001930 Es 0ES4E~64 246.0787 SEs) oR =] 0E2115E-3 00001240 POFUR=(Az*Usa2)sUeAd 20001950 RETURN 20001960 ERC 0001570 TRANSLATION TIME = 214861004 p57Appendix E DAILY OPERATION SUMMARY The tabulation of the daily sumary information for startup and on line operation is presented in the tabulation of the following pages. These summaries include two basic sets of information. The first identifies the conditions prior to starting on each day that the unit was started and the load fron which the unit was tripped. The second set of data includes information during the operation of the unit. The startup information includes the following information prior to turbine roll: # Initial first stage cylinder temperature, °F © First stage rotor bore temperature, °F © IP turbine blade ring temperature, °F © Ip turbine bore temperature at third stage, °F © Minimum IP rotor bore temperature, °F © Minimun HP rotor bore temperature, °F © Gland steam tenperature, °F © Low pressure turbine cylinder axial temperature differential, °F © Boiler drum pressure, PSIA © Throttle steam pressure, PSIA @ Throttle steam superheat, °F In addition, the percent load from which the unit was tripped, whether vacuum was broken between tripping and restarting, and the valve mode selection at synchroniza- tion are tabulated. During operation for each day the following items are tabulated: © Maximum rate of change of first stage temperature, °F/Hr © Maximum rate of change of main steam temperature, °F/Hr EL© Maximum rate of change of hot reheat temperature, °F/Hr © Maximum rate of change of unit load, percent/min. @ Maximum acceleration rate, rpmjmin, © Maximun rate of change of drum saturation temperature, °F/Hr © Dafly integrated load, Mi-Hr © Daily integrated fuel flow, 1b © Average unit efficiency in percent The average unit efficiency is determined from the integrated load and the fuel flow. This valve is intended to highlight significant changes in operational efficiency for future evaluations, A final project summary is included which provides the basis for the operational summary data presented in Section 4.4,S34 OW z Vents atu oNt710¥ anosaa MINOK |on san oNITI0 ayosaa_ HANOWMAXIMUM RATES OF CHANGET. ose 3A08¥ Y ost-os2 or 9 _ rT 060 3A08y OS B=05L T 1 059-055 Ost-os2 062 noTae CSIs TY aa re 9 ee ar se OSEeOsz sz HOTRE 49 wT ose Bhoay sss. = ogLe0s9 © 98055 osseose —5 1 r "Or T — 058 BADBY Os B=054 == oseoss os sess osveose —OsE*0s2 0s maT aL EL FOES STE BA SERVES BO NADORI ER wris 40 sore, 26*zeyy OT=e Our E24Appendix F BOILER MODEL MODEL SCoPE The model developed by B&W is described below. Except for minor modifications, it uses B&W's Modular Modeling System. The models used to simulate the open loop tests and modifications for the startup and shutdown runs are described in Section 5. The components modeled in detail are: Highest Pressure Feedwater Heater Drum and Furnace Primary Superheater Platen Superheater Secondary Superheater Reheat Superheater High Pressure Turbine Intermediate and Low Pressure Turbine First and Second Stage Water Spray Attenperators with Valves Saturated Steam Attemperators with Valves 501 Valves 502 Valve The boiler feedpump, deaerator and the remainder of the feedwater heaters were described by much simpler models. FelMacro Structure The model is implemented in ACSL, a simulation language. Macros are written for the components and then invoked in the ACSL model. The ACSL translator generates a FOR- TRAN program from the ACSL source and sorts the statements into a computable order. One requirement of this structure is that each identifier exists once and only once on the left side of an assignnent statement, unless it is generated in a procedural. The macros in the Modular Modeling System make use of the ACSL concatenation operator to automatically generate names for the variables in the program. An example of a macro call is: SPRHTR (ID', 'GE', 'SE', "GL', 'SL') This is the macro for a superheater where "ID" is a 3 character module identifier "GE" is the 4 character stream identifier for the flue gas entering the superheater "SE! is the 4 character stream identified for the steam entering the superheater *GL' is the 4 character stream identifier for the gas leaving the superheater "SL! is the 4 character stream identifier for the steam leaving the superheater The model structure is defined when the conponent module identifiers and the various strean identifiers are defined, The additional information needed for the model consists of model parameters and boundary conditions. The first character of the 6 character names are defined as follows: D - derivative with respect to time (1/sec) I = initial value z = a quantity internal to a module and not needed by other modules The second character is defined as follow P = pressure (psia) T - temperature (°F) F-24 = specific enthalpy (Btus1b) u - specific internal energy (Btu/1b) Ww = flow (1b/hr) Y= position K = constant mode! paraneter R = density (pyre) s - specific entropy (Btu/1b) N - speed (RPM) Each variable name (identifier) consists of the first two characters followed by @ module, stream or other identifier. Exceotions to this rule occur at the model boundaries and in the simplified models wrich were not generated by macros. Identifiers consisting of Znnnnn, where n is an integer, are generated by the ACSL translator. Examples of several identifiers are: GPL Enthalpy of the stream GPL in this case enthalpy of of flue gas leaving the platen superheater. IPSPS._- Initial pressure of the st-eam SPS (steam leaving primary superheater). ZTMPL = An internal variable. In this case, tube metal temperature in the platen superheater. KCV501 - A constant ~ the valve coefficient (CV) for the 501 valve. WGDF - Flow stream GOF (gas leaving the drum/furnace). Each module is described in the following pages. The user worksheets which show information flow for the module, interface variables and other information are shown in Appendix D. Steam Properties All of the steam properties are generated from curve fits. Some are from a single function and some are over regiows and matched at the boundaries. When using an implicit, variable step integration algorithm, smoothness is very important. Any discontinuities, particularly in pressure, will result in drastic increases in computation cost. The routines used are written below as they appear in ACSL: F-3Superheated Region: Density R= RVOFPH(P, H) Temperature = T= TVOFPH(P, H) Entropy s ‘SVOFPH(P, H) Enthalpy H HVOFPS(P, S) Temperature = T TVOFPU(P, U) Density =R RVOFPU(P, U) Saturated Region: POFUR (U, R) RGOFP(P) RFOFP(P) HGOFP(P) = HFOFP(P) Subcooled Region: RFOFHE(H) TFOFHF(H) Although the steam property algorithms had been tested for continuity, the function POFUR had several discontinuities and it was replaced by the single polynomial shown in the program listing. In the turbine calculations, isentropic enthalpy change across a blade group wes calculated by calculating S(P), H) and then H(Pp, S). This turned out to be @ poor choice because it places high accuracy requirements on the steam properties involved. This accuracy was not achieved and as a result, turbine power calcu- ations were less accurate then desired. A better approach would have been to generate a curve fit for isentropic enthalpy change directly. Examination of P, H diagram having lines of constant entropy indicates that such a function would fit fairly easily as a function of pressure ratio, inlet enthalpy, and inlet pressure, It would be mich easier to achieve acceptable accuracy in this way than in the method used in the model. Spray Attemperator The spray type attemperator module (ATTEMP) is shown in Figure F-1. The attemperator sprays water into a steam flow path to reduce steam superheat and provide steam tenperature control. The module accounts for pressure loss through the steam path and pressure loss through the spray control valve and spray nozzle. The steam path losses include friction losses due to the obstruction of the spray 4nozzle in the steam path, the non-recoverable losses in the mixing venturi, the acceleration losses, and mixing losses. The spray path line friction, expansion, and mixing losses are assumed secondary to the control valve losses. ‘SPRAY NOZZLE Wee Wsi Ps hg =| = fr Pse MIXING VENTURI SPRAY CONTROL VALVE t Wwe: Pwer hwe: Pwe Figure F-1. Spray Attemperator Model The module equations make the following assumptions: © Water and steam flows remain within fully developed turbulent flow regime, © Flows do not reverse. This module models the pressure losses in the two flow streams and the enthalpy drop through the attemperator. The pressure losses are derived from the modified Bernoulli relation and assume that both flow streams may be regarded as incompressible.For the steam flow stream: yh /2 Mse = Kse (se - Psi)? (Fay For the water flow strea 1 (qe ye ~ Psi)? (F-2) The spray valve flow coefficient, Z, is a function of the valve position, spray pipe resistance, and valve flow characteristic. Three valve characteristics are modele linear, equal percentage, and quick opening, The particular charac teristic used is determined by the users cefinition of KVA: KVA = 1. (Equal Percentage): KCP = Kev? KVA = 24 (Linear): KCP = key (F-3) KVA = 3. (Quick Opening): kcP = k (1-e710¥) The total flow resistance for the spray flow is given b; we 7 = KcP «KP/(KcP? + KP) (Fa) The values K and KP are the full open valve conductance and pipe conductance respectively. The valve position, Y, may be set manually by the user, calculated by the actuator model ACT, or, where the user wishes to neglect actuator response, calculated directly by the user defined control system. Simple mass conservation, assuming no mass storage provides: gt * Mee + Me (5) Conservation of Energy, again assuming no storage provides: 61 * (ge Moe * Mee Me) (6)Connective Module The connective module (CONC and CONNI) is not a model of any physical component. This module performs a strict mathematical function within the Modular Model ing System, serving to allow resistive type midules to be interconnected. Resistive modules require upstream and downstream pressure as inputs in order to define the flowrate through the component, A typical combination of two resistive type modules, a valve followed by a turbine, is sketched in Figure F-2. KNOWN QUANTITIES UNDERLINED Pa. Pg P2 P3 wB we: ——J TURBINE |= Clearly some relation must be developed for Pp, Wy, and Ho. Except for the simplest configuration for incompressible flow, this problem must be solved by a trial and error or iterative numerical technique. The objective of this technique is to determine the unique value of the intermediate pressure (Po), which provides the same flow rate through both components. The problem, basically a fluid mechanics problem, may be thought of as a controls problem. In this control problem a process variable, the intermediate pressure is to be controlled to minimize a control error, the flow rate mismatch. From this standpoint, the error is given by: (F-7)Taking the partial of the error with respect to the intermediate pressure: om nee (es) The pressure change to be made at each iteration in order to drive the flow error to ote ap = -c/(ae/ap) (F-9) If each side of this equation is divided by the iteration time step at, then the pressure time derivative may be approximated: oo ? eae Ge (F-10) a ry FTO, ~ Moye) (F-11) where: G 1/(at ae/ap) (F-12) This gain may be evaluated at each time step to provide a variable gain for optimun control of the pressure p, but experiments through a full flow range show that a constant gain will hold the flow error to within less than a 1% error and avoid ‘increased computation time. The particular gain which best represents the function differs for compressible and incompressible flow. For compressible flows, a G of 2 x 1074 psi/sec./(Ibm/hr) is found to be best. For incompressible flow a G of 1. x 1073 psi/sec./(Ibn/nr) is used. The leaving enthalpy equals the entering enthalpy, and the other required outlet properties are determined as a function of the known pressure and enthalpy. Divider Module The divider module (DIV) allows the user to branch from a single flow path to as many as nine separate flow paths, They are used to represent one or more tees, manifolds, or multiple inlets to a single component.The DIV modules have no physical parameters. They have no flow resistance and store no mass or energy, Fluid mechanics imposes sone restrictions on the conponent combinations in which the DIV module may be interconnected. The DIV module must interconnect to either a storage type, a resistive-storage type, or a connective module upstream, and to any combination of resistive or resistive-storage modules down stream. Typical interconnections are shown in Figure F-3. (Oo “Lo LX Lo fo -O- Oo-—-4 lio < Figure F-3. Flow Divider Model STORAGE RESISTIVE RESISTIVE - STORAGE Other combinations, for instance a DIV module downstrean of a resistive module, and upstream of two storage modules are prohibited by fluid mechanics, since without, information defining the flow resistance cf the two parallel flow paths downstrean of the DIV module, the flow division cannct be made, In the DIV module, the leaving properties pressure, enthalpy, and density are all equal to the entering properties.The entering flow rate is the sum of the leaving flow rates: 2, 0H), (F-13) Drun Boiler This module (DRUMNC) models the steam genaration portion, or furnace, of a natural circulation, drum-type boiler and is applicable to all types of boiler fuels: gas, ofl, and coal. The coal firing may represent stoker-pulverizer, or cyclone furnace- firing, but for any fuel the burner orientation or tilt is fixed. The characteristics which distinguish the various options from each other are user supplied parameters which modify the combustion air and heat transfer in the furnace. The model does not calculate flue gas flow dynamics. On the water-side, the module models a single downcomer-riser loop. The steam drum is modeled as horizontally oriented with perfect steam separation which precludes carry-under or carry-over. User supplied data for vessel cross sectional area allows the drum water level to show the effects of steam/feed-water mismatches and shrink and swell. This module is expected to have three genaral types of interconnections: the air side component modules, such as, air preheaters, superheaters, and fans; the water- side convective components, that is, the economizer and superheater; and the fuel feeding equipment, For simplified analyses, any or all of these may be specified by the user as boundary conditions. The user should note that some type of drum level control must be provided in order to operate the DRUMNC module, and that it must be provided external to DRUMNC. The following assumptions are built into the DRUMNC model : © Feedwater does not mix, or exchange energy, with resident water inside steam drum prior to being drawn down the downcomer. @ Ratio of phase velocities for two-phase fluid in riser is unity. © Pressure drop through the boiler water-steam is negligible. © For heat transfer analysis, the entire tube-side portion of the riser is taken to be at saturation temperature. @ The drum has perfect separation of steam and liquid phases.@ The rate of change of specific internal energy for the riser fluid equals the rate of change of enchalpy. @ The flue gas is an ideal gas. © Time constants associated with changes in flue gas mass storage are negligible (uniform flow). @ Radiant heat transfer is the heat transfer mechanism in the furnace. © Flows do not reverse, The basis for the thermodynamic analysis of the furnace steam/water-side is a division of the boiler into three volumes; the steam drum, the downcomer, and the furnace section. This division is diagramed in Figure F-4. The drum and furnace are assumed saturated at a uniform pressure Pc}. Conservation of Mass and Conserva~ tion of Energy relations are defined for the saturation region as a whole to determine the pressure and average fluid density. The same two relations are then applied to the separate regions to define the fluid property variations through the Circuit. The water and steam masses in the furnace and enclosure are compared to the total mass, and the remaining masses, which must reside in the drum are used to define drum water level. Wer het (EN ‘STREAM DRUM Wwe:hwe ely OS Me Xe Wout: wi a Ws Paws Pw War 5 p = Mgt Tal SATURATED CONDITIONS ro xls eae a; "9 week oe “aT Py ™, im Ww Me Tn Me WATERWALL TUBE MASS Figure F-4, Drum Boiler Model FellApplying the Conservation of Energy to the saturated region: Morar Ma Mw * > Me (F-14) + & (oveu,) = 0 4 aug os The storage term 4 (V,p,u,) may be expanded to (Vo, ape + Vlg gee) resulting ins & du, Mwe we ~ Ys Mer Mat Mat ~ ots <8 * % ~ %) eS (F-15) 7 & *, Conservation of mass states: @, as wwe % Gee Mg May My) %y (F-16) These two properties », and u, determine the fluid state of the saturated region. The saturated pressure is calculated in routine POFUR, which calculates pressure as a function of density and internal energy. The saturation pressure is then used to define the saturation properties: HEOFP(P) GOFP(P) = RFOFP(P) RGOFP(P) TOFP() The enthalpy of the recirculation flow as it enters the downcomer is a function of the feedwater and the resident drum liquid. The assumption that no mixing occurs is consistent with the assumption that the drum fluid is saturated; it means that all the feedwater goes directly down the downcomer, with the difference between the downcomer flow and the feedwater flow coning from the drum resident liquid. That is: - - 5 * Fel WL = Weal e = Mp 7 Mye)ity = 9 (F-17)and ) (F-18) Wy ep = Mye/He) Pg = ye For the furnace, conservation of Energy provides: 4 wir =n) gq 4% - Ai r ru & dt (Vu) (F-19) The assumption is also made that the fluic specific enthalpy equals the specific internal energy. This assumption is valic for qualities of interest in this model. With this assunption: Cw, (hy = h,) + Op = Veh, do, /at] Wed ah, Jat (F-20) With these relations, the drum level may te calculated by accounting for the liquid masses throughout the saturated region, Knowing the steam drum volume, overall average density, total system volume and densities, and volume for the furnace, the drum density may be given by VIN (F-21) The denisty of the riser fluid is taken as that at the saturation pressure P,) at a quality half that entering the steam drum: (F-22) (F-23) The drum level is calculated assuming a linear relation between liquid level and volume. Even for a circular cross section, except at the extremes, this relation is acceptable, It does not account for the girth baffle plenum at the bottom of the drum,we ton 13.6 (A (*)) (F-28) PF The drum blowdown is assumed to operate ideally and be taken directly from the discharge liquid of the separators: hy = he oul =F T= Tr The steam is assumed to be saturated and ro pressure drop is associated with the drum, The dynamics for the recirculation flow rete, Wp, are governed by the dynamic relation: 2 + Hy (6, -9,) (9/9,) ~ (ap,/epy) + (Wc) fe aH /at (F-25) 2 2, a, + Y/AQ) In this relation, the first term in the numerator represents the driving head set up by the difference in densities in the downconer, py, and in the riser section, bp» Hg represents the height of the downcomer, the second term is the fluid friction term. This friction term is in turn composed of downcomer and riser portions. The riser conductance, C,, is defined in equation F-39. The denominator represents the total fluid inertia through the flow circuit. The friction term should be examined more closely. The downcomer portion of the loss may be neglected. The most significant losses in the circuit are riser mani~ folding losses and two-phase friction losses. The riser term must account for the two-phase friction losses in the furnace and enclosure tubing, Martinelli and Nelson (1) provide a correlation for the ratio of two-phase losses 4p, to the single phase losses in the sane circuit, ap,, as a function of the average pressure, Pej, and the exit steam quality, X, A table of this correlation is provided as Table F-1. Note that the acceleration losses as the liquid flow is vaporized and the less dense two-phase mixture accelerates, are recovered as the fluid is effectively brought to rest in the drum. F-14Table F-1 RATIO OF TWO-PHASE TO SINGLE-PHASE FRICTIONAL PRESSURE LOSS Exit Stean AP /AP quality Average Pressure (psia) 14.7 100-500.” 1000- 1500 2000-2500 3206 0.01 47 2.8 1.79 1.45 1,28 117 1,081.0 0,05 16.5 764 3,642 -2,30 01,771,432. 1.0 0.10 33.0 13.8 613 3,10 2.281.721.3910 0.20 68.5 25.9 8,904.92 3.18 2.27 1,70 1,0 0.30 108 39,5 12.1 6.40 4.00 2.68 «1.90 1.0 0.40 152 82,5 18,1 7.70 4.74 3.15 2.20 1.0 0.50 198 65.0 18.0 8.96 5.40 3.55 2.48 1.0 0.60 216 76.0 21.2 10,3610 «3,922.62 1.0 0.70 293 87.2 24.2119 6,93 436 2821.0 0.80 337 97 2.313862 76247029510. 0.90 377-108 29.2 1.0 8.00 4,98 3,101.0 1.00 408 «118 31.0 14,9850 5,26 3,221.0 As in the case of the boiler tube-side relations, the thermodynamics of the boiler gas-side may be defined by the use of the First Law of Thermodynamics. Conservation of Energy for the furnace flue gas provides: a deo (F-26) hota - Mortar *%5 7 Moet ge ~ Mre"te * at (Pgi%ator Woh + Q. HCW ‘gio * 9 lgege * Weaheg) + Paty Mgi/dt + UV, doy /dt = 0 (F-27) FAISThe rate of change of flue gas density fron conservation of mass is neglected since the gas-side mass flow rate is assumed to 2¢ uniform, The mass flow rate adjust- ments through the boiler are much faster tran the response rates for which Modular Modeling is designed to study so the gas-side flow rate may be assumed uniform ‘throughout the boiler, The (Wgehge + Hegheg) term may be represented as Wgjh, where hy is the flue gas enthalpy at the adiabatic flame temperature, If the flue gas is taken as an ideal gas, its density is given by: 2 naar pst 144 28 fe Cg tc (F-28) 3 pw EEE, 53.34 TT | (1g + 460) and a Man “ak te = 14 du, ft (F-29) The temperature of the flue gas is determined as a function of enthalpy and flue gas moisture content by the use of polynominal curve fits extracted from (2): Tgy = (((3.7686 E-7 = 1.7871 £7 + MF) hg (F-30) +(-1.0344 £-3 + 1.643 Ed + MF) gy +4016 €-3. + MF)) gy +80, An identical relation defines the adiabatic gas temperature. The heat transfer rate from the furnace flue gases to the waterwall is based on B&W design procedures and is taken as fully radiant from an effective flame radiating temperature of (1/3 Ta + 2/3 Tg) to the tube metal. Both the mode of heat transfer and the definition of effective flue gas radiating temperature are based on B&W design procedures. The adiabatic flame tenperature is calculated on the basis of instantaneous tue! compustion and no dissociation of carbon dioxide or water vapor. ha = (Waehae * retire + Merettte * MricMtic * MtheMthe)/Mg) — (F~31) F-16where Wg = Mae * Mre * Mrie + Mrie + Mthe (F-32) The furnace heat transfer fran the flue gas to the metal tube wall is given by: Qs = Up ny £(.667 Tey + .333 T, + 460)4 - (Tm + 460)49 (F-33) where pe = enthalpy of recirculation gas entering furnace Wete = mass flow of fuel and ignitor to lower burner level hej = heating valve (lower) of fuel and ignitor entering Tower burner evel Weje = mass flow of fuel and ignitor to intermediate burner level hie = heating valve (lower) of fusl and ignitor entering higher burner Wphe = "28s flow of fuel and ignitor to high-burner level phe = heating valve (lower) of fusl and ignitor entering higher burner level Wee recirculation gas flow Ty = burner height efficiency factor Up = furnace heat transfer coefficient The burner height efficiency factor accounts for the differences in effectiveness of firing from various firing levels in the furnace. It presents the lower burner levels as 50 percent more effective than the upper of three levels: 4, 1, = (BWee + SMe, tet ene) (MQ) (F-34) where Wp is the total fuel flow rate: We Mere * Mrie * Mthe (F-35) The heat transfer from the furnace tube wall to the tube fluid by boiling is two orders of magnitude more effective than that from the flue gas to the tube wall. The effective heat transfer rate fron the flue gas to the tube fluid is, therefore, governed by the flue gas to tube wall relation, Equation F-33. The tube wall totube fluid rate is arbitrarily evaluated at 1 x 109 Btu/hr-F which provides a 1 to 5°F temperature differential between mean metal temperature and saturation. That is: Qe = 1x 109 (T, - Ts) (F-36) Conservation of Energy for the tube wall then provides: (F-37) The heat loss to the atmosphere is defined: Q = Uy (T, = 100) (F-38) where Uy is the furnace heat loss coefficient. The following data is available from boiler manufacturer's data: Ag = Vertical cross sectignal area of steam drum perpendicular to drum center line (ft*) A, = Effective flow area of risgr (ft?) y= Flow area of downconer (ft2) Hg = Overall height of boiler from riser headers at lower end to steam drum elevation (ft) My, = Mass of metal in boiler pipes, tubes, valves, etc. (bm of steel) 5 Vg Total volune of steam drum (ft3) Vg Flue gas volume of furnace (ft*) ve Volune of riser (ft?) 3 vo Volume of saturated zong (KVS=KVD#KYR)(ft3) e Volume of downcomer (ft) Equation F-25 may be solved for the riser flow conductance at steady state: (F-39) F-18The average riser density should be taken at the drum pressure pg and a quality of Hy/2- here Yy = Hsi/Myrs The quantity ép)/tp, should be interpolated at psy and Ay using Table F-1. The furnace heat transfer coefficient can be obtained by solving Equation F-33 for Ups and evaluating at the design point: Q Ug =§ ———_ 43 _____________ (F-40) C(2/3T + 1/37, + 460.) - (T+ 460) J} Q = Total heat transfer (Btu/hr) F5 = Scaling factor (0. at design) Fy = Fuel combustion geometry factor (1. at design) Tg) = Temperature of flue gas leaving boiler (F) Ty = Adiabatic flame temperature (F) Ta = Metal temperature (F) 8 «tT +t (Fea) Max? The heat loss coefficient can be determined fron Equation F-38. = Q/(T yy - 100.) (F-42) The initial value of density is calculated solving Equation F=28 for o4. pgs bs p/13.6 + KG (F-43) The riser density is calculated from the drum pressure and the exit quality of the riser, given by the inverse of the recirculation ratio; from Equation F-22. FgThen = (ry Vg t Ov) Me (F-44) The specific internal energy is calculated for the saturated region, riser and drum, from an average quality through the region X,: Xo (le, = Vg = VQ) (F-45) f Here the fluid saturation properties are evaluated at the drum pressure. Then = (1 =) Up + fy Ug (F-46) bhp = (= Xp) Mp + Xp Hg (F-a7) Economizer This module (ECONDP) represents a non-steaming economizer, Heat exchange on the flue gas side may be by radiation, convection, or a combination. Tube side heat. exchange is by convection alone, Pressure-flow dynamics on the flue gas side are not modeled. This module differs from standard Modular Modeling System components in that it calculates a module pressure drop instead of a flow. The assumptions used in developing the eccnonizer model are as follows: © Flue gas mass storage has negligible effect so that this flow may be considered uni form, © Connecting piping and headers follow the water temperature. @ The flue gas may be treated as a mixture of ideal gases. © Al flows are in the fully developed turbulent range. © There is a negligible difference between specific internal energy and enthalpy for water through the operating range. @ Subcooled water properties are identical to saturated properties at Saturated fluid enthalpy equal to the subcooled fluid enthalpy. F-20This module represents cross-flow heat exchange between a gas and subcooled water as shown in Figure F-5. \ Woe. Moe: Tee Wor hgt Tol ° ' i oS a Ow Wats Pave Pat we: Mwer Pwe <=t+>— 00-1" owes Two Pw Tw Figure F-5. Economizer Model Q, and Q, are heat transfer rates from the flue gas to the tube wall by radiation and convection respectively. All heat transfer is calculated at leaving values. Using Reference (2) relation for cross-flow heat exchange from the flue gas, the convective heat transfer rate is: “ = RWge (Tay- Ty) (F-48) ‘The radiant heat transfer rate is: 4 4. K,L(Tgy + 460)" - (1, + 460)°7 (F-49) where K, and K, are the appropriate constants, Conservation of energy provides: du do, wae ~ Wel we ~ at aa Wy at ww at o (F-50) 21For water in the range of interest, this my be simplified to: d Ea) = He (Hye My) +9, + OI/Oyv, + 1 (My + MS) (F-51) In this relation, the .11 (W, +.) term represents the energy stored, at essen- tially the water temperature, in connecting piping and headers, and in the economizer tubing. Because heat transfer between the piping and the flowing water is very high, the piping temperature is assumed to equal the water temperature. If the rate of change of eneray stored in this metal is <-(M, C,,T,,)» and the water temperature approximated by Ty) = Hy1/Cpys then the term Mo(Chn/Cy,) belongs in the denominator of Equation (F-51) where the ratio of metal to water specific heat is taken as constant at «11, The water density and temperature leaving the economizer are calculated as a function of enthalpy. e, REOFHF(h, ) wl Mw TFOFHF(h,) In these relations, the complex, heat transfer and thermodynamic processes are simplified and approximated to the well-stirred-tank model used. This approach is used to reduce the system calculational burden to a minimum while maintaining the fidelity of the model. Compared to other single node models with heat transfer and energy storage at some mean temperature, the MMS model avoids the violation of the second law and "see-saw", Transferring heat at a mean temperature creates a model that at low flow steady conditions may violate the second law with an exit cold side temperature above the entering hot steam temperature. Energy storage at the mean provides a "see-saw" effect at the outlet temperature in response to a fast change in the inlet temperature as the temperature gradient through the section “pivots” around the fixed mean. The pressure drop through the economizer is given by: (F-52) F-22And, since wave equations are not considered: (F-53) On the gas-side, flue gas pressure flow dynamics are not addressed. The speed of these reactions is such that they may be treated as quasi-steady-state. (F-54) (F-55) With the assumptions that flue gas flow is uniform and that it may be treated as air, an ideal gas: dh Ge BEG * yy (hay = hy) = 9, = 0.) (Ty + 460)/¥, (F=56) The flue gas temperature is a function of the enthalpy and the moisture content. Reference 1 provides data which may be fitted to provide: Toy = (((8.7646 £27 = 1.7871 £27 + Me) hyp +(-1.0848 E23 + 1.643 E-4 + Mp) gy (F-30) +416 E-3, + Mp) + gy #80, where: Ng = moisture fraction of the flue gas. The mass of heated metal (M,) and the mass of unheated metal (Ny) should be available from manufacturers data. My includes the mass of tubes while M, includes inlet and outlet headers and piping. F.23The gas to metal convective heat transfer parameter (U,), the gas to metal radiant parameter (U,) and the metal to water heat transfer parameter (U,) should be evaluated at the manufacturer's design poirt such that the following is available. Q (ut) st Total heat transfer through the bank (Btu/hr) = Fraction of total thermal resistance on the gas side = Fraction of total thermal resistance on the tube side = Ratio of radiant to convective heat transfer on the gas side Tye =__Inlet water temperature (°F) Twi = Outlet water temperature (°F) Tye = __ Inlet flue gas temperature cr) Ty = Outlet flue gas tenperature cr) ge = «65 flow rate (bn/hr) Mye =~ Water Flow rate (1ba/he) The effective metal temperature is then given by un ul+u (F-57) and: (F-58) Hye? (Ty) = TI Eh. Hur/ve) + 11 (F-59) CT, + 460)" = (7, + 460)" (F-60) oH Tl F286(F-61) Feedwater Heater This module (FWHTR2) is designed to represent a power plant feedwater heater. The model simulates a shell and tube feedwater heater with distinct regions partitioned for drain-cooling, condensation, and desuperheat. The user may implement the simulation of the desuperheat region or the drain-cooling region at model translation time. The particular configuration of the heater to be simulated is defined by the CONFIG parameter in the module MACRO invocation as follows: 1, drain-cooling region, condensing region, and desuperheat region, 2. drain-cool ing region and condensing region, 3. condensing region and desuperheat region, and 4. condensing region only, This module computes the flow rate through the heater tubes but requires entering and leaving drain flows and heating steam flows as inputs. The shell side of the heater is simulated as a storage type component with no pressure loss. A single port is provided for any nunber of extraction steam connections. Where the equipment to be modeled has multiple connections, an appropriate combination of resistive components and the flow junction module JUNC should be used to join the flow streams upstream of the feedwater heater module. The cascading drains entering the heater should be treated similarly. Multiple drain ports leaving the heater, for instance a normal path to the next heater and a high level dump to the condenser, should be assenbled using the flow divider DIV and multiple valves or pipes. The drain valve and drain control must be provided external to the FWHTR module. The user must provide some form of level control for the heater level in order to avoid driving the heater level beyond limits. The four versions of the feedwater heater model are depicted in Figures F-6 through F-9. The following assumptions were used in developing the model: @ No reverse flows. No drain flashing.CONFIG = 1 seta be " =e Mee JL v Wwe, Hi Pe, Uy Pv Ts D He se Two bi es PW Tat eer 5 aaa at Tio Bee Te | Yo, L hy Pt a f Wa Tal Pal @ states. CONDENSING REGION DRAIN COOLING REGION DESUPERHEAT REGION Figure F-6, Feedwater Heater Model conFis = 2 Wae: Mde | Me HL Wwer Pwo Pao: Yi Py Ts Pwo, Tye ty wt —— So _— Ww cat | Lee $ L hat -=E T CONDENSING REGION Wab Tat DRAIN COOLING REGION Figure F-7, Feedwater Heater Model F-26Conic = 3 Wae: Mae by | Woosh Ju v Wwe: hwe Paes th: Ph Ts Twe: Pwe BS = Wt hw fac he 10, te [eel = ao — 7 DESUPERHEAT REGION Wat hat CONDENSING REGION Figure F-8, Feedwater Heater Mode ConFiG = 4 Wee ee J oU—__J Paes Ps: Ts: Pr Un Wwe: hwe wt — = Wt bt Twe toa Np Ng PE PB War har CONDENSING REGION Figure F-9, Feedwater Heater Model F-27© Liquid level control logic external to the module prevents flooding or heater running dry. @ Instantaneous liquid-vapor equilibrium, ® No tube side flow variation with respect to position along the tube Tength. © — Liquid stored in the heater remains in saturated equilibrium with the vapor. © Heater shell is horizontal cyclinder. © All flow regimes are fully developed turbulent. The shell-side liquid and vapor in the condensing region of the shell side are assumed to remain in thermodynamic equilibrium. Conservation of mass and energy in ‘this region provides relations for the bulk specific internal energy and the average density for the region, The conversation of mass relation is identical for all four possible configurations of the heater: (F-62) where Way = Orain flow Nye = Drain flow entering. The formulation for conservation of Energy is somewhat different for the two configurations with a desuperheater (CONFIG = 1 or 3) than for the two without a desuperheating region (CONFIG = 2 or 4), With a desuperheating zone, the enthalpy of the heating steam is the enthalpy leaving the desuperheater (hy), Without @ desuperheater, this enthalpy is the entering steam enthalpy (hse) + For CONFIG of 1 or 3: Waite # OG = Meany = Myghga + Opt 7 MyaPage * Poly GUy/dt + UW, dey/at = 0 (F-63) F-28For CONFIG of 2 or 4: du dP ae = Waite +, = Wy hide + uv, “hyde = 0 (F-64) se"se ~ Mee de +e These two properties for the heater as a whole, allow a determination of the heater shell-side pressure fron steam property algorithms: Poe = POFUR(U, 9) se ‘The saturation pressure is used in similar routines to define other necessary fluid properties: hg = HFOFP(P.¢) hg = HGOFP(PcQ) Pp = RFOFP(Pse) = TOFP(P.6) For CONFIG of 1 or 3, with a desuperheat zone, the enthalpy of the steam leaving the desuperheating region is given by: ty = ge = Os /Wgg (F-65) For the two configurations with a drain cooling region, (CONFIG = 1 or 2), conserva~ tion of energy for the shell-side of the drain cooler provides: hg) /at = Chay (Me = gy) = ayl/ Cop) (F-66) ay p> Pan ‘The steam property routines provide: (CONFIG = 1 or 3) Tse = f(Pser Me) Tay = F(hgi) For the configurations which include a drain cooler: (CONFIG = 1 or 2) Drain Cooling Region hi = Nye + W/Mye (F-67) Ty = f(hy) 29The relationship for the enthalpy of the feedwater leaving the condensing region and the feedwater heater is different for each of the four configurations: CONFIG tH, (hy - h) +9) v, Pele ah /at = (F-68) Te = fl) ec = Fhe) and dh /at = We (hy, - hy) + a/v, (F-69) Tw = FCA) CONFIG dn /at = TW (h - ) + Oe (F-70) Tw Fb) bu = Fyn) wl CONFIG = 3: dh /dt = CW, (hye = Be) + OV Ve (F-71) Te = tlhe) Pe = fle) c dh /at = CW g(h, - hy) + OY, (F-72) Tyr = Fh) CONFIG ah, /at COL (F-73) we Swe ~ "wi F-30The heat transfer rate in each region is evaluated separately. In each region, the overall thermal resistance is broken down into the shell-side thermal resistance, a fixed resistance representing the tube metal resistance and fouling on both the shell-and tube-side, and a tube-side thermal resistance. All variable resistances are represented as convection dependent only on a flowrate except the condenstion region shell-side value. Linear tenperature profiles are assumed in both the shell and tube sides of the desuperheat and drain cooling region, A profile approximating an expotential temperature curve is used on the tube-side of the condensing region, Drain Cooling Region (CONFIG = 1 or 2) a Ug (Ta - Tye) (F-74) 1 . Fi (F-75) [kyl (Wg) + Kye/ Mg) + Kod where Mag = Fixed heat transfer parameter in the drain cooling region Kgs = Shell side heat transfer parameter in the drain cooling region. Kap = Tube side heat transfer parameter in the drain cooling region Desuperheat Region (CONFIG 1 or 3) Q = Us(Tse - Twi) (F-76) (F-77) where Kge = Tube side heat transfer parameter in desuperheating region Keg = Shell side heat transfer parameter in desuperheating region Kep = Fixed heat transfer parameter in desuperheating region 31where: Key = Tube side heat transfer parameter in desuperheating region Keg = Shell side heat transfer paraneter in desuperheat ing region Keg = Fixed heat transfer parameter in desuperheating region Using the relation for condensing coefficient for feedwater heaters presented in (3), the heat transfer coefficient for the condensing region is given by: 1 Keele) + Keel (T.) u I (F-78) where: Kee = Condensing heat transfer parameter in condensing zone Ket = Tube side heat transfer parameter in condensing zone Kop = Fixed heat transfer parameter in condensing zone, As in the thermodynamic relations for the condensing region, the functional relation for heat transfer in the condensing region is the same for all the configurations but the form varies for each: CONFIG. Qe = UclTs = (2/3 Te + 1/3 TI (F-79) CONFIG Qe = UclTs = (2/3 Ty + 1/3 TI (F-80) CONFIG = 3 Qe = UclTs = (2/3 Te + 1/3 Tye)] (F-81) CONFIG = 4 Qe = UcLTs = (2/3 Ty + 1/3 Tye) (F-82) F-32The mass of liquid in the heater may ve calculated using these fluid properties: = Ply (hy = MA) Uhg = Me) (F-83) Where hy, is the overall enthalpy is given bj bh = Un + Pse/Pn (F-84) The level in the heater may then be approximated, using a linear fit, as: °)) (F-85) L = 13.6 VA, Clo, = 04)/l0¢ High Pressure Turbine ‘This model (HPTVS) represents a high pressure turbine for fossil boiler use, It consists of governing valve, impulse stage, and a variable number of reaction blade groups. Extraction points are placed between reaction blade groups. ‘The model does not include a turbine control system, or shaft speed calculation, The model is valid for variable speed operation if the user supplies shaft speed from another module. Figure F-10 shows the internal structure of the high pressure turbine model. The model consists of a governing valve with actuator, impulse stage and one or more reaction blade groups. Between each of these components, a connective node calcu- lates the pressure. Another connective node between reaction groups allows an extraction flow. IMPULSE ‘STAGE REACTION STAGE(S) CONNECTIVE CONNECTIVE NODE, NODE. Figure F-10. High Pressure Turbine Model F433The several governing valves and their associated impulse nozzles are approximated by a single valve and impulse nozzle in such a way as to be equivalent to an infinite nunber of valves operated sequentially. This is done by modeling the governing valves and impulse areas as a single valve and impulse stage. For valve Positions up to the first admission point, the valve is stroked. Above the first admission point, the valve is fully open and the throttle flow and flow to the oPOT node below the impulse stage are scaled accordingly. As an example, consider a four valve machine operated sequentially. Figure F-11 shows the machine schematically as four valves feeding their impulse arcs and feeding the remainder of the turbine. If the total valve position is 60%, valves fone and two are fully open, valve three is open 40% and valve four is closed. In ‘the machine, the flows through one and two are equal. Circuit three is operating at reduced flow and as a result, reduced pressure ratio. pi <| Figure F-11, Sequential Valve Model The exit enthalpy is thus higher for circuit three. The model approximates this situation with a single circuit operating valve wide open and multiplies the flow by 60/25. This approach will be correct at the valve points and will give an impulse stage efficiency that is too high between valve points. F-34The valve used in this model is VALVEC as described elsewhere in this description. It is assumed that the critical pressure ratio is independent of valve lift and fixed at 0.46, The connective nodes in this model are the same as those described in the section on connective nodes with several minor exceptions: © The fluid properties are calculated in the turbine blade group code. @ The gain constant KOP ID has a separate single value for the high pressure turbine, @ The connective nodes between two reaction blade groups have one input ‘and two outputs to allow for an extraction flow. The connective node between the impulse stage and the first reaction group receives a scaled flow vs. input. All turbine stages or blade groups are treated in the same way except for the manner in which efficiency is calculated. The pressure flow relations are calculated from an extended Stodola approximation. (F-86) a) Wo = mass flow P, = pressure ratio inlet density inlet temperature * = denotes the reference values pS, &T are calculated as functions of inlet pressure and enthalpy. The enthalpy for an isentropic expansion *s calculated from entropy and downstream pressure, The efficiency of a single ideal impulse stage is n= 4 (cos a - (F-87) 1 F-35blade velocity = nozzle velocity a= angle between the entering flui¢ and the blade motion for a fixed blade angle impulse stage efficiency The nozzle velocity is proportional to the square root of the isentropic enthalpy drop. The impulse stage is optimized at the design point. The optimum speed ratio is: Vel = 1/2 cos @ (F-88) which yields n= cos The efficienty calculation for an ideal imulse stage yields too high a stage efficiency for large pressure ratios. It is necessary that all turbines have zero efficiency when Vg/V;=0. The decreased efficiency at low velocity ratio is modeled with a linear fit from zero to the lowest available point on the heat balance. The ideal efficiency has been scaled so that 1:5 peak coincides with the efficiency for tthe units' actual heat balance. The model calculates both the parabolic formula and Tinear approximation and then chooses the smaller. Since 25% flow is below the First admission point, the speed ratio should not becone smaller at synchronous speed. The calculations for the reaction blade groups are handled in the same way as the impulse stage. The only difference lies in the expression used for efficiency. For @ 50% reaction stage, the efficiency is: yi (F-89) Vg = velocity achieved by isentropic expansion through the stage F36The maximum stage efficiency occurs at B 22 Ce Ee (F=90) ° eos’ a - 1 The model assumes that the efficiency for a stage can be applied to a blade group and that the group runs at peak efficiency at the design point. The efficiency is then scaled to agree with the group efficiency from the units' heat balance, Intermediate and Low Pressure Turbine This model of an IP/LP (LPTVS) turbine represents a series of reaction blade groups separated by extraction points. Blade group flow is calculated from the extended Stodola approximation. The intercept valves are not modeled. Each blade group is considered as an ideal turbine with efficiency calculations. The shaft output power is automatically added from group to group. No effort is made to allow for wet steam at any point in the turbine, This is not a problem for a fossil turbine operating in its normal range, The wet steam which may occur in the last few blade rows does not introduce significant errors. All blade groups are modeled as reaction groups. The reader should consult the specification for HPTVS for a general development. Only differences from HPTVS will be described here, BGR2 is used to calculate performance for 11 groups except the last. It permits a variable velocity ratio in the same way HPTVS. BGREAC uses the same equations as are found in HPTVS. The only distinction is that outlet temperature density and entropy are not calculated. The connective nodes in LPTVS require an extraction flow to be specified. Each node calculates a balance based on the three flows. All nodes use the parameter KDP ID to adjust the rate at which the flows come to equilibrium, F-37Steam Attemperator This module (SATEMP) represents an attemperator which mixes steam from two sources, This is used as a low load steam temperature control on B&M boilers. It is implemented by placing a distribution pipe inside the outlet header of a super- heater. The saturated attemperator does not protect superheater tubes from excessive temperature, The assumptions inherent in the model are as follows: @ Any energy storage in metal has been accounted for in a neighboring module. © There are no pressure drops in the attemperator. ‘The attemperator is modeled as a mixing node. Pressures are passed through and there is no mass storage. Leaving enthalpy is calculated as a first order lag from the enthalpy calculated by conserving energy. dhsy = (Ws1 Msi + Ws2 Ms2)/Ws1 ~ het (F-91) The lag avoids an implicit loop when the downstrean module is 2 turbine. Steam properties are calculated here in order to make them available to the downstream module and adhere to the overall variable naming scheme. Psy = RVOFPH(Py ,he1) Ts] = TVOFPH(Py 5h51) Superheaters and Reheater A single module (SPRHTR) may be used to model any of the gas to steam heat exchange components of the boiler, superheaters, reheaters, etc. These components are similar in that they are all cross-flow type exchangers transferring heat between gas and a compressible single phase fluid on the tube-side. In addition, this module may be used as a portion of the components listed above when greater resolution or fidelity requires that the boiler heat traps be broken into more than one lump. For example, it nay be desirable to divide the primary Superheater into two or three modules for greater resolution. This will be required F238if the actual boiler being modeled has the primary superheater split into two heat traps located in non-adjacent furnace locations. Where more than one module is used, data must be available for each portion of the heat trap the two (or more) modules are intended to represent, The heat transfer between the gas and the boiler tubing may be by convection, radiation, or a combination of both. The heat transfer between the tubing and the fluid side is ty convection. The following assumptions are inherent in the solution: Flue gas mass storage has negligible effect so that this flow may be considered uniform, Connecting piping and headers follow the steam temperature. The flue gas may be treated as a mixture of ideal gases. Pressure drop through the section is small enough that the flow may be treated as incompressible. All flows are in the fully developed turbulent range. This module represents cross-flow heat exchange between a gas and a single phase compressible fluid on the tube-side, Figure F-12 illustrates the concept of the model. Woe: Mge: Tye a Wot Pot Tol Wet. heh Pat Pst Teh Ut Figure F-12. Superheater Model F-39Q, and Q, are heat transfer rates from the flue gas to the tube wall by radiation and convection respectively. All heat transfer is calculated at leaving values. Using (2) the relation for cross flow heat exchange from the flue gas, the convec- tive heat transfer rate is: Qe = Ue Wge*® (Tg) - Tm) (F-92) Op = Up £(Tqy + $60)4 - (Ty + 460)47 (F-93) The tube-side convection relation is taken from Dittus and Boelter for a heated fluid. Qs = Us Wey%*® (Ty - Ty) (F-94) The thermodynamic relations for the tube-side are based on representing the fluid mass as a single well-stirred mass node. Pressure is calculated from (P51)/dt = (Wee ~ Wgq) (0002) (F-95) This is adequate for transients where density changes are slow. Conservation of energy is applie: Aug )/dt = (gy (hg ~ hgy) + 5)/ (ogy Vg + 25 Mp) (F-96) In this relation, the .25 M term accounts for energy storage, at the steam temperature, in connecting piping and heacers. This piping is termed “unheated” to distinguish it from the “heated” mass of the heat transfer tubing. Because this piping is generally well insulated, and because the heat transfer between the piping and the flowing steam is high, the piping temperature is taken as the steam temperature and its energy storage effect is approximated. If the rate of change of energy storage in the metal is d/dt (MjCyqlgy)+ and the steam temperature T.) approximated by Ts) = Mgj/Cpgs then the term Mo(Cpq/Cpg) belongs in the denominator of Equation F-96 where the ratio of metal to steam specific heats is taken as constant at .25. F-40The density is evaluated as a function of pressure and energy: p 25) * RVOFPUCP ou s1) The renaining fluid properties are calculated by steam property routines as functions of pressure and internal energy: Ty) = TVOFPU(P.) 6U5}) hgy = HVOFPU(P.) 5u}) In these relations the conplex heat transfer and thermodynamic proceses are simplified and approximated to the well-stirred-tank model used. This approach is used to reduce the systen calculational burden to a minimun while maintaining the fidelity of the model. Compared to other single node models with heat transfer and energy storage at sone mean tenperature, the MYS model avoids the violation of the Second Law and "see-saw". Transferring heat at a mean temperature creates a model that at low flow steady conditions may violate the Second Law with an exit cold side temperature above the entering hot steam tanperature. Energy storage at the mean Provides a "see-saw" affect at the outlet tenperature in response to a fast change in the inlet temperature as the temperature gradient through the section "pivots" around the fixed mean. The flow rate entering the superheater is calculated assuming that the pressure drop through the section is small enough that the flow may be treated as incompress- ible. On the gas-side, flue gas pressure-‘low dynamics are not addressed. The speed of these reactions is such that they may be treated as quasi-steady-state. Conservation of Energy provides: t Q Macho = Woh = Q. = ge ge Nota r du, /at = (F-97) With the assumptions that flue gas flow is uniform and that it may be treated as an ideal gas at atmospheric pressure: ho 1 to ee (F-98) Fea)(F-99) ge “Nyy = 7 9) v 9 + 460) a (F=100) The flue gas temperature is a function of the enthalpy and the moisure content. (2) provides data which may be fitted to provide: Tgp = (((3.7646 E67 = 147871 E-7°Mg) * gy + (-1,0344 €-3 + 1,643 E-4-Mp)) + hgy (F-30) + (8.16 E-3. Me) *hgy 480. Conservation of Energy provides, for the metal heat transfer: (Tq) /dt = (Qe + Op = 9)/(400 My) (F101) Valve This module (VALVEC) represents a valve through which steam is flowing with sufficient pressure loss to require compressibility effects to be considered. The module may represent any type of valve; e.g., globe, gate, ball, etc., in any position. ‘The assumptions built into this model assume the following: © Flow rates are such that flows remain in fully turbulent flow regime, ¢ Flows do no reverse, © Steam may be treated as an ideal gas for flow rate calculation. @ Adiabatic valve, © Mass storage is negligible, The flow relation is taken from (4). The flow rate is a function of the pressure drop ratio: Xx = (se - Psi)/Po (F102) F-42or y= Xp Where Xp is the critical pressure ratio. Therefore, W, c, {1 - .33 [—T ¥x se f XK, * Pe se (F-103) This relationship is an approximation only, It applies data for constant area ducts to valves, and applies the valve compressisility relationship for a valve at a particular position and pressure drop ratio to other positions at the same pressure drop ratio. The variable Cp is the valve conductance and depends on the valve size, flow characteristic, and its position: KVA = 1, (Equal Percentage) Cy = KVA = 2, (Linear) Cp = CyY (F-104) KVA = 3. (Quick Opening) Cy = (1-e"!0Y) cy The module VALVE I represents a valve through which an incompressible fluid is flowing. It may represent any type of valve; e.g., globe, gate, ball, etc., in any position. No compressibility effects are included, and the valve will not account for flashing or cavitation, The module also accounts for a fixed loss (pipe). The basic assumptions are the same as VALVEC. The fluid flow rate is given by 4 ve P= Pe) (F-105) we we ~ Pw =¢ we” “q The overall flow coefficient, Cq accounts for both the valve conductance and the fixed conductance: mo, c/ cad : 2 (F-106) FaThe valve conductance, Cy, 1s a function of valve characteristic, position, and size. Cy is the conductance for the pipe. Cy is the maximum valve conductance. The variable Cy fs the valve conductance and depends on the valve size, flow characteristic, and its position: KVA = 1, (Equal Percentage) Cy = C,"¥? KVA = 2, (Linear) c= cyY (F-107) KVA = 3. (Quick Opening) Cy = (1-671) cy F-84REFERENCES 1, R. C. Martinelli, and D. B. Nelson Prediction of Pressure Drop During Forced Circulation Boiling. Transactions, American Society of Mechanical Engineers, August, 1948, 2, Babcock and Wilcox Company, STEAM, 38th Edition, 1975, 3. A. B. Clemmer, and S. Lemezis, Selection and Design of Closed Feedwater Heaters, American Society of Mechanical Engineers, November, 1965. 4, J. We Hutchinson, TSA Handbook of Control Valves, Instrument Society of Anerica, 1976. Fo45‘About EPRI EPA creates science and technology solutions forthe lobal energy and energy services industry. U.S. electric utes established the Electic Power Research Institute in 1973 as a nonprofit research ‘consortium for the beneft of uty members, their customers, and society. Now known simply as EPRI, the company provides a wide range of innovative products and services to ‘more than 1000 energy-related organizations in 40 countries. EPA's multidisciptinary toam of scientists and engineers draws on a worldwide network of technical and business expats to help solve today’s toughest ‘energy and environmental problems. EPRI. Powering Progress (©1900 Becte Power Research astute (EPA) In. Al fights resowed. Elect Power esearch Istuts and EPR te registered sore mara othe Elects Power esearch Insta, ne. EPRI. 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