Air Heaters Supplement to Performance Test Code for Steam Generating Units, PTC 4.1 Cy, <> PERFORMANCE TEST i¢0))) 35 THE AMERICAN SOCIETY OF MECHANICAL ENGINEERS Vi BO ate mrt 345 East 47th Street Ew ce atedAir Heaters PERFORMANCE Supplement to Performance Test Code for Steam Generating Units, PTC 4.1 CODESFOREWORD Performance Test Code Committee No. 4 on Stationary Steam-Generating Units was reorganized in May, 1958 to rewrite and bring up to date the 1946 edition of the Test Code for Stationary Steam-Gonerating Units. During the formulation of the new Test Code, PTC 4.1-1964, the technical committee brought to the attention of the Performance Test Codes Committee that for the Air Heater, an auxiliary heat absorption equipment common to all large steam generating units, there existed ao power test code. PTC Com- mittee No. 4 recommended the development of such a Test Code a8 part of its assignment “Tne Performance Test Codes Committee instructed PTC Committee No. 4 to prepare such a Test Code as a Supplement to be known as PTC 4.3 on Air Heaters. This Test Code was developed and its format follows closely that of PTC 4.1, the Test Code for Steam Generating Unit This Test Code was approved by the Perfomance Test Codes Committee on June 9, 1966. Final publica- tion was delayed, however, until a number of suggestions made by the standing Committee were con- sidered and satisfactorily resolved. It was approved and adopted by the Council as a standard practice of the Society by actinn of the Policy Board, Codes and Standards on November 8, 1967. January, 1968PERSONNEL OF PERFORMANCE TEST CODE COMMITTEE NO. 4 ON STATIONARY STEAM-GENERATING UNITS, Joba M. Driscoll, Chuéman John ¥. Cleary, Jes, Secretary James U, Baley, General Superintendent, Electric Operations, Baltimore Gas and Electric Company, Gas and Electric Building, Baltimore, Maryland, 21203, Chartes D. Birget, formerly Chief Mechanical Engineer, Commonwealth Associates Jackson, Michigan, 49201 Inc., 209 E. Nashington Avenue, John A, Bostic, General Supervising Engineer, Civil and Mechanical Engi ‘Muminating Company, Box 5000, Cleveland, Ohio, 44108 1g Deparment, The Cleveland Electric Hugh J. Byrne, Stean-Power Engi Seattle, Washington, 98108 er, Central Engineering Office, Crown Zellecbach Corporation, 6363 Airport Way, Sohn V. Cleary, Jr, Chief Cost Engineer, Cost Control Engineering Bureaa, Consolidated Edison Company of New York, Incas 4 Irving Place, New York, New York, 10003 Leonard Cohen, Head, Operation Management Department, Naval Ship Engineering Center, Philadelphia Division, U.S. Naval Base, Philadelphia, Pennsylvania, 19112 John M, Driscoll, Chief Mechanical Engineer, Consolidated Edison Company of New York, Inca, Irving Place, New York, New York, 10003, Joka H. Femandes, Senior Pi Road, Windsor, Connecticu ject Engineer, Product Diversification, Combustion Engineering, Inc., Prospect Hill 06095 William Z. Harper, Assistant Superintendent, Usilities Division, Kodak Park Works, Eastman Kedak Company, Rochester, New York, 14604 Edward C, Kistner, Engineer in Chatge of Power Plant Section, Mechanical Engines Electric Company, 9th and Sansom Streets, Philadelphin, Pennsylvania, 19105 16 Division, Philadelphia Frank G. 02107 jevick, Mechanical Engineer, Stone & Webster, Inca, 225 Franklin St, Boston, Mi Hobert A. Lorenzini, Senior Vice-President, Foster Wheeler Corporation, 110 South New Jersey, 07039 range Avenue, Livingston. John F. MeLaughtin, Jt, Manager, Production Engincering, Union Electric Company. 315 North 12th Houlevard, St. Louis, Missourn, 62101 Silas L. Morse, Assistant Manager Field Engineering, The Babcock & Wilcox Company, 20 South Van Buren Avenue, Barberton, Ohio, 44203, Richard H. Pechstein, Assistant Chief Mechanical Engineer, American Electric Power Service Corporation, Two Broadway, New York, New York, 10008 Herbert C. Schweikart, Vice President and Chief Engineer, Gilbert Associates, lnc, 525 Lancaster Avenue, Reading, Pennsylvania, 19602 Lanson E. Stewart, Marketing Representative, international Business Machines Corporation, 2880 St, Paul Street, Baltimore, Maryland, 21218 ch Joseph A. Waddell, Assistant Chief Service Engineer, Riley Stoker Corporation, Worcester, Mast + 01606ASME PERFORMANCE TEST CODES Test Code for AIR HEATERS Section 3 4 5 INTRODUCTION. ..... OBJECT AND SCOPE Objects... eee Scape sos. DEFINITION OF TERMS, SYMBOLS AND THEIR DESCRIPTIONS ~ 2.1.2.2 Air Leakage... dd ap Gas Fempertire ih Leakage Exit Gan Temporsvare — No Leakage le Air Temperature Rine os Gas Temperatare Drop |... Temperate Head = gaa Bie Erecteney Histo. Symbols Ai Reate rangements |<< GUIDING PRINCIPLES — res on Which Agreement Shall Se keathes Prete Tes 3.01 Selection of Persouncl « 302 Tolerances and Limits of Exvor’. 3.03 Acceptance Test soa Preparation for Tes 3.08 Preliminary Hen. © 3:06 Test Conditiens 307 Duration « 08 Prejumey aad Gonaiseney of Reading see. 3.09 Rejection of Ruas |! 310 Reconds awd Peet Reports 12. 3:1 DATA REQUIRED, INSTRUMENTS AND APPARATUS — 414.26 Data Required vss 41 insteuments and Apparatus a2 MEASUREMENT — 5188 Location of Test Sampling Points for Air and Gas Temperatore and Gas Analysi Flue Gas and Air Temperatures. Gas Analysis ss. Flue Gas and Air Quant PERFORMANCE PACTORS ~ Analysis of Over-all Performance ‘Operating Conditions ‘Thema! Performance Air Heater Leaksge - - Exit Cas Temperature. Presaure Lone = 0+ 0 COMPUTATIONS — Gas Side Efficiency -. ‘Temperature of Exit Gas Corrected Tore Leakage, s.r 1-0 Bor Gent Air Uitages 20217 Dry Gas Moisture Content of Fiye Gos Dy Aine Few etaio | : rected Gas Temperatare oer oving Ait ener fr Be ton fom Design tering Ai Tenperane Corrected Gas Temperature eating Aut Heater for Devi on tam Desig Entering Gas Tomperstare Corrected Gar Temperaiare Leaving Air Heater for Devi tion from Design X-Ratio.- Comected Gas Temperature Leaving Air Heater for Devia~ on am Design Eneriog Wo Flue Cav Plow = : Totally Corrected Gae Tenpera: tare Leaving Ale Hester Ait Leakage Corrected for Des tion for Design Pressine Dil ferential and from Design Aie Temperture <0 Gas Side Pressure Lose of the ‘hie Heater Corrected for Devise tion trom Deniga Flow tad Temperatures Aic Side Pressuce Lona ol ie Air Heater Corrected for Deviation from Design Flow and Teaper Accuracy of Cortestion 19 Pressure ‘Lose for Tasholent aud Lawinse Flow © " 7.01 7.01 16. 1.02 7.08 08 7.05, 706 707 7.08 ma 25, reAIR HEATERS SECTION 0, INTRODUCTION 0.1 This Code for air heater testing shall govern the preparation for tests, the taking of data, and the calculation of test results. 0.2 The air heater is defined as a heat ex- changer used to transfer heat directly from com- bustion gases to combustion air without the use fe heat transfer fluid. 0.3 General instructions for the conduct of tests are given in the Code on General Insteue- tions (PTC 1) which should be studied carefully. ‘The Gode on Definitions and Values (PTC 2) and the Test Code for Steam Generating Units (PTC 4.1) should be followed where applicable. The Supplements on Instruments end Apparatus (PTC 19) shall be used as a guide to the selection and use of test equipment not specified in thie Code.ASME PERFORMANCE TEST CODES SECTION J, OBJECT AND SCOPE 1.1 Object. The purpose of this Code is to establish procedures for conducting performance tests to determine: 1 q 1 Gas side efficiency .2 Air leakage .3 Other related operating character uch as: cS X-Rat io 1.3.2 Gas and air pressure Iosa 1.3.3 Gas and air temperature 1.1.4 A determination of any or all of the perform ance items specified above may be necessary for 1.1.41 Checking the actual performance against 1 1 1 i the manufacturer's guarantee 1.1.4.2 Comparing these items with a standard of operation 1.1.4.3 Comparing performance when firing dif- feveat fuels 1.1.4.4 Determining the effect of changes to equipment 1.1.4.5 Determining corrections to air heater exit gas temperature caused by variations in inlet ait temperature in an efficiency test of @ steam gen- erator. 1.1.4.6 Obtaining any other pertinent information required. 1.2 Scope. This Code applies specifically to the regenerative and tubular type air heaters. It also applies to any combustion gas-to-air heat © changers used in conjunction with a steam gea~ erator. 1.3. For the purpose of this Code, the air heater is defined as a heat exchanger used to transfer heat from gases of combustion to cambus~ tion air without the use of an intermediate heat transfer fluid. Specifically excluded are the sup- plementary steam coil air heater, direct-fired air heater and low temperature economizer. How. ever, a separate fow temperature air heater would be considered part of the air heater installation. 1.4 If the installation consists of more th one air heater in parallel, all air heaters are is cluded as a unit. However, if the air heaters are in series and have other apparatus in between, then each air heater, or each group of parallel air heaters, shall be tested individually. 10AIR HEATERS SECTION 2, DEFINITION OF TERMS, SYMBOLS AND THEIR DESCRIPTIONS 2.1 The Code on Definitions and Values (PTC 2) defines the meaning and values of basic technical terms and numerical constants, which are used throughout this Code. Definitions of terms specific ta this Code are as follows: 2.1 Air Leokoge. Reight of air passing from the air side to the gas side. It is assumed in caleulations to leak directly from the aie inlet to the gas outlet 2.1.2 Exit Gos Temperature With Leokage. The measured exit gas temperature. 2.1.3 Exit Gos Temperature ~ No Leakage. The temperature at whick the gas would have left the air heater if there were no leakage. This temper- ature must be calculated by heat balance, if leak age is present. See Computations, Section 7. 2.1.4 Ait Temperature Rise. Increase in the temperature of the air in passing through the ic heater. 2.1.5 Gos Temperature Drop. Decrease in the temperature of the gas in passing through the aic heater, based on exit gas temperature ~ 10 leakage. 2.1.6 Temperature Heod. Temperature of gas entering air heater minus temperature of air enter= ing air heater. 2.1.7 Gos Side Efficiency. Ratio of gas tem- perature drop, corrected for no ait leakage. to temperature head. 2.1.8 X-Ratio. This is the ratio of the heat capacity of the air passing through the air heater to the heat capacity of the gas passing Uheovgh the air heater. See Pars, 6.3 and 7.07 2.2 Symbols. A jist of symbols used through: out this Code follows. With aumerons quantities and points of reference, it hus been found im practical to restrict the Code to the use of single subscripts. Where both letter and numerival sub: sare used, a aumerical one is given second for example ¥é a This signifies the pounds of a8 per pound of “as fired fuel at location #4, Fig. Symbols nd their Descriptions Symbol Desctiption Unit A Bir a Dry air . AP. | As fired 4® | Ait leakage per cent Bypass c Pounds of carbon per pound of “as fired” fuel — (laboratory Wb per Ib of APL analysis} fuel Ce Pounds of carbon burned per pound of “tas fired" fuel 1b per th of AF fuel co Per cent carbon monoxide per volome of dry flue gas. Deternined | per cent by flue gas analysis CO, | Per cent carban dioxide per volume of dry flue gas. Determined by | per con flue gas analysis fgar | Mean specific heat of air at constant pressure Buu per Ih FASME PERFORMANCE TEST CODES Symbols and their Descriptions (Cont'd) Symbol Unit pq _| Mean specific heat of the flue gas at constant pressure Buu per th F Standard or guarantee sees Elapsed time Fuel Plue gas Flue gas flow Dry flue gas Pounds of hydrogen exclusive of that in moisture per pound of ‘as fired” fuel ~ (laboratory analysis) Hydrogen content of the dry flue gas ~ (laboratory analysis) High-heat value of the dry refuse (laboratory analysis) Constant Leakage Moisture content Moisture in fue Pounds of nitrogen per pound of “as fired” fuel ~ (labor analysis) ory Per cent nitrogen per volume of dry flue gas. Determined by sub- tracting the sum of the measured quantities COz, 02 and CO from 100, No leakage Pounds of oxygen per pound “‘as fired” fuel — (laboratory analysis) Per vent oxygen per volume of dry flue gas. Determined by flue gas analysis Pressure Ashpit Dry pit refuse Recirculation Pounds of sulfur per pound of “as fired” fuel ~ (laboratory analysis) Temperature Rankine Temperature Fahrenheit 1b per Ib of A.F. fuel cou ft per cu ft dry gos Buu per Ib of refuse per cent by weight Ub of seater per Ib of AF. fuel Tb per tb of ALP. fuet per cent Ib pee th of AF. fuel per cent in. of water (gage! Ib per tb of AF. fuel 12AIR HEATERS Symbols end their Descriptions (Cont'd) Symbol Description Unit “4 Temperature of air F ca Temperature of the flue gas F © Weight Ib Be, Pounds of air supplied per pound of “as fired” fuel Ib per th of ALP. fuel hy Pounds of dry air per pound of “as fired" fuel Th per tb of AP. fuel ® Pounds of air leakage per pound of “as fired” fuel Ib per th of AF. © fuel Fyp- | Pounds of dry refuse per pound of “as fired” fuel Ub per Ib of ALP. fuel cm Pounds of fuel fired (rate), either solid or liquid 4b per hr - Pounds of dry gas leaving nit per pound of “as fired” fuel 1b per tb of ALF. fuel Tar | Pounds of moisture per pound of dry air Jb per Ib of dry aie Te “(primed X-Ratio Atomizing steam Corrected Efficiency Gas side efficiency Change Dry per cent pet cent 13ASME PERFORMANCE TE DES PLAN 1 BASIC ARRANGEMENT REGENERATIVE AIR HEATER PLAN 3 AIR HEATER WITH AIR RECIRCULATION - A Yas tag cm Wag tas SAS OUT FD, FAN “oistois PLAN 2 BASIC ARRANGEMENT TUBULAR AIR HEATER PLAN 4 AIR HEATER WITH AIR BYPASS t Gas our ag |] Mou tae || tot ain || Gas out || ww ‘ t PLAN 5 AIR HEATER WITH SUPPLEMENTARY STEAM COILS PLAN 6 AIR HEATER WITH LOW LEVEL ECONOMIZER m9 1] “ore 49 |] tou am |] cas our] | iw 4 t PLAN 7 AIR HEATER WITH LOW LEVEL AIR HEATER FIG. 1 AIR HEATER ARRANGEMENTS uwATR HEATERS SECTION 3, GUIDING PRINCIPLES 3.01 Items on Which Agreement Shall be Reached Prior to Test: 3.01.07 Object of Test 3.01.02 Permissible deviation in gas side effi- ciency between duplicate runs. 3.91.03 Air and gas flow quant 3.91.94 Allocation of responsibility for olf per formance and operating conditions which affect the test. 3.01.05 Selection of test personel to conduct the test 3.01.06 Establishment of acceptable operational conditions, number of load paiats, dsration af runs, basis of rejection wf runs and provedures to be followed during the test 3.01.07 Cleanliness of unit initially and how this is to be maintained during the test. See Par 3.04.2 3.01.08 Condition of apparatus affecting aic leakage. 3.01.09 The fuel to be fired, the method of ob taining fuel samples and the iaboratory to make the analysis. 3.01,10 Observations aad readings to be taken to comply with the object ur objectives of the test 3.01.17 Instruments to be used, calibration of in- struments, methods of measurement and equip ment to be used in testing the unit, ‘The Perforn= ance Test Code Supplements on Instruments and Apparatus should he used, when applicable 3.91.12 Tolerances and Fivits of weror in weas: urement and sampling, 3.01.13 Distribution of fuel refuse quantities be- tween various collection points and wethods of sampling. 0114 Corcections to be made for deviations Icom specified operating conditions. 3.02 Selection of Personnel. ‘Tu insure a- taining reliable results, all persuancl partici pating in the teat shall be Fully quutified ts por form their particular fanetion 3.03 Tolerances and Limits of Error. ‘this Code does nt include consideration of overall tolerances ur margins on performance guaranters The test results shall be reported as computed from test observations, with proper correctiaas far calibrations. Allowances for errors of measurement and sampling are permissible provided they are agreed upon in advance by the parties to the test and clearly stated in the test report 3.04 Acceptonce Test. An acceptance test shall be undertaken only when the parties to the est certify that the unit is operating to their satisfaction and is, therefure, ready for test. Kise pecially in the case of fuel burning equipment, adjastovents and changes are sometimes neces sary to obtain optimum performance. The accept- ance test should be started as soon a8 the unit is in satisfactory condition for test, provided the load and other governing actors are suitable. 3.04.1 Parties to the test may designate a person lo dircet the Lest and to serve as arbiter in the event of disputes as to the accuracy of observae Lioks, conditions or methods of operation. 3.04.2 All heat transfer surfaces, both internal and external, should be ecinmercially clean (normal operating cleanliness) before starting the test, Dering the test, oaly the amount of cleaning shall be permitted as is aevensiry to mutintain normal operating cleanliness 3.04.3 After a pretiminary run has been made, it ay be declared an acceptance run if agreed to and provided that all the requirements of a regue lar run have been met 3.04.4 At least two runs shall he made approsi- mating the load required for acceptance. If the results exceed the previously ageeed apou deviae tion in elficienvy between runs, a third run shall be required. ‘The test efficiency at the required load will be the average of the two rans which fatl within the permissible deviation in efficiency, 3.05 Preporotion for Test. Install such meas: uring apparatus as may be required to attain the nhjeetive of the test. It is recommended that the air heater be inspevied prior to the Lest ta note the condition of ail posts shich can affect the erformanee. In particular, the tightness oad Cisanhiness of we heater tubes and eondtron aml Cleanliness of elements and condit ion of the seals of regenerative air heater should be exam ined and the air heater placed in proper operating condition, The bypass ay recireslating danpees should be checked fur tight shutel!. \ prelin: inary check of air leakage, caleulated from Orsat onalysis at the gas inlet aud outlet should be canducted prioe to the aetual testASME 3.06 A Preliminary Run shall be made for the purpose of 3.06.1 Checking the operation of all instruments. 3.06.2 Training the observers and other test personnel. 3.06.3 Moking minor adjustments, the needs for which were not evident during the preparation for the test, and establishing praper combustion con- ditions for the particular fuel aad rate of burning to be employed 3.07 Test Conditions. It is important that air and gas flow through the air heater remain essen- tially constant throughout the test. The steam generator output shall be set as close as possible to that reqiired of the test run and shall be held stable for at least 30 minutes prior to the start of the test 3.08 Duration. ‘Test rans shall be of at two-hour duration but sufficiently long to permit the taking of at least two complete sets of con- sistent readings 3.09 Frequency and Consistency of Readings. Except for quantity measurements (see Pars. 5.4 and 5.5), the readings shall be taken at 15 minute 6 PERFORMANCE TEST CODES intervals. If, however, there are fluctuations, the readings shall be taken at such frequency as may be necessary to determine a value that represents a true average. 3.09.1 Ik is suggested that, in s0 far as is feas- ible, pertinent data of the run be plotted continu: ously, as the run progresses. on coordinate paper of suitable scale to permit a complete review of the conduct of the run, at least hourly. 3.10. Rejection of Runs. Should inconsis- tencies in the observed data be detected during a tun ot duting the computations that would cause obviously untrue results, the run shall be rejected completely, of in pact if the affected part is at the beginning or at the end of the run. A run that has been rejected shall be repeated, if necessary, to attain the objectives of the test. 3.11 Records ond Test Reports. All observa- tions, measurements and instrument readings necessary for the objective of the Lest shall be recorded as observed. Comections and corrected values shall be entered separately in the test record.AIR HEATERS SECTION 4, DATA REQUIRED, INSTRUMENTS AND APPARATUS. 4.1 Data Required. The following data are needed in order to determine the performance of the air heater 4.1.01 4.1.02 4.1.03 4.1.04 4.1.05 4.1.06 41.07 4.1.08 4.1.09 4.1.10 4.it 4dd2 43 44 Temperature of air entering air heater ‘Temperature of air leaving air heater ‘Temperature of gas entering air heater ‘Temperature of gas leaving air heater Quantity of air entering air heater Quantity of heated air leaving air heater Quantity of gas entering ait heater Quantity of gas leaving air heater Air side inlet and outlet static pressure Air side inlet and outlet velocity pressure Gas side inlet and outlet static pressure Gas side inlet and outlet velocity pressure Humidity of intet Gas analysis of flue gas entering and Teaving air heater Quantity of fuel measured or computed by steam generator output and efficiency of fuel 41S 4116 4.1.17 Quantity of fuel oil atomizing steam if burning oil. Ultimate analysi nv 4.2 Instruments and Apparatus. Directions re- garding the characteristics. use and calibration of the apparatus required are given in PTC 19 Sup- plements on Instruments and Apparatus (1 & A). ‘The instcuments and apparatus required for air heater tests are as follows: 4.2.1 Determining sir and gas temperatures ~ Calibrated thermocouples shall be used with calibrated potentiometer. The thermocouples shall be in accordance with 1 & A, Temperature Measurement (PTC 19.3) and arranged so that they can be traversed across the duct. 4.2.2 Determining air humidity adjacent to air inlet — A psychrometer shall be used. 4.2.3 Measuring air and gas pressure ~ U-tube or inclined manometers for determining pressure shall be filled with water or a light liquid of known specific gravity. (Refer to PTC 4.1, Pi 8.06 and 8.07.) 42.4 Analyzing dry flue gas — Gas analyzer shall be sed to determine percentages of carbon dioxide, oxygen and carbon monoxide 4.2.5 Measuring fuel input, if required — Cali- hrated coal scales, oil meters, ot gas meters shall be used. 4.2.6 Sampling of fuel ~ Air tight containers shall be used for individual fuel samples to avoid moisture loss.ASME PERFORMANCE TEST CODES SECTION 5, MEASUREMENT 5.1 Location of Test Sampling Points for Ai ‘and Gas Temperature and Gas Analysis. Tem- perature and/or gas analysis sampling points the inlet gas and inlet air ducts shall be focated as close to the air heater as practical and as consistent as possible with good velocity meas- urement practice. Due to the probable steati tion at the gas and air outlets and air infiltration of a regenerative air heater, the traverse section should be located as far from the heater as prac- tical and be divided into equal areas far velucity measurement and simoltancous gas saripling fon the center of these areas. A weighted average can then be calculated, taking isto consideration the gas temperature, Par. 5.2, as well as a veloc ity function, See Perfornance Test Code for. {PTC U1}. The number and arcangement of the equal area will depend on the size and tayout of the gas passage. In rectangular ducts. the areas shall be approximately square and the sampling points shall be not more than thrce feet apart, and a total of not fess than four points shall be used. Where judgment indicates a pos- sible severe stratification, consideration should be given to a system of closer spacings. In round ducts, test points shall be located on two tra- verses along axes normal to each other as de- scribed in the Performance Fest Code for ¥ans (PTO, 11}, In is recognized that there may be cases in which the gas velocity is so low that velocity measurements would be impractical. In such cases an arithmetic rather than weighted average should be employed. When the importance of the test does not warrant making velovity measure- ments and taking individual samples feom the equal areas, an aspirator and suitable apparatus for obtaining a composite saniple from several sampling points may be employed, With the ex- ception of the area sampling instruction above, all of the procedures are to be in accordance: with recommendations of 1 & 4, Part 10 on Flue and Exhaust Gas Analyses (PTC 19.10), 5.2 Flue Gos and Air Temperatures. I"lue pas temperatures must be taken at the same tue cations as those used for flue gas sampling, Par. 5.1, to minimize the effect of probable gas temperature stratification. 5.2.1 if a preliminary survey of flue gas Nos , Par. 5.1, indicates severe stratifications, it is 18 recommended that the temperature measurements at individual locations in the duet eross section be weighted in proportion to the gas flow at the corresponding locations, and an average of the weighted temperatures be used as representing the gas temperature at that cross section. 5.2.2 Choice of temperature measuring instru ments depends upon the conditions of the individ: ual case. The selection, design, construction, calibration, installation, and operation of temper- ature measuring instruments shall be in accord- ance with [8 A, Temperature Measurement (PTC 19,3). 5.2.3 For determination of the air temperatare the same general methods and the same presau- tions aoted in Pars. 5.2.1 and 5.2.2 shall apply for the air entering and leaving the air heater 5.3 Gas Analysi to calewlate gas flow. Analysis to be employed is dependent apon the type of [ued burned and upon the purpose of the test. Design, construc tion and operation of the apparatus and prepara tion of the reagents shall be in accordance with L& A, Flue and Exhaust Gas Analyses {PTC 19,10}, Gas analysis is required 5.3.1 An analysis should be made to vetily presence or abseave of gaseous combustibles. 1f combustibles are found and cannot be slimi- nated by adjustment tn the fuel burning equip- ment, the hydrogen and hydeacarhons shall be measured and the gas flow corrected following the principles covered in Section 7 of the Test Code for Steam Generating Units, (PTC 4.1}. 5.3.2 For hydrogen ond hydrocarbon analyses, it is necessary (o obtain representative field sam- ples of the gases for submission ta an established laboratory. Hefer to 1 8 A, Flue and Exhaust Gas Analyses (PTC 19.10). 5.3.3 Proper steps shall be taken to prevent Jeakage to ot from gas analyzing apparatus and sampling lines, to avoid rontaminarion and de- vitaiization of reagents, to provide fresh reagents sshen needed, to keep manifolds clear of reagents, tw avoid esrors due to physical solubility of gases in reagents and confining liquids, to avoid injury by contact with reagents, to allon for bur error and deainage time, to avoid change of same ple temperature during analysis, to keep ap: teAIR HEATERS paratus clean, to minimize human errors by em- ploying careful operators who are given adequate information on common sources of error, to pro- vide operators with adequate light and reasonable comfort, to verify results by checking against theoretical, and in all other ways, to assure that recorded data are correct and their degree of pre= cision known. Sampling should be continuous when possibie. Because all gases, especially SO, and CO, are soluble to some extent in water, the water in the levelling bottle shail be saturated with sample gas before taking any readings. 5.3.4 Detailed precautions given in | & A, Part 10 on Five and Exhaust Gas Analyses (PTC 19.10) shail be followed. 19 5.4 Flue Gas and Air Quantity. Flue gas quaatity shall be determined by calculation from fuel analysis and flue gas composition. Cale lation procedure for gas weight per heat unit of fuel shall be as given in Par. 7.04.1. Similarly, air quantities shall be calculated as per Par. 7.06. 5.5 Fuel Quantity, The quantity of fuel may be obtained by measurement in accordance with procedures given in PTC 4.1, Section 4, or by computing from test efficiency and output of the steam generator. 5.6 Power. Power requirement of the regen- erative ait heaters may be disregarded for per~ formance purposes.ASME PERFORMANCE TEST CODES SECTION 6, PERFORMANCE FACTORS 6.1 Analysis of Over-oll Performance. ‘The analysis of air heater performance is confined to the following considerations: 6.1.1 Comparison of test thermal performance with design: 6.1.2 Comparison of test air leakage with design. 6.1.3 Comparison of test ait and gas side pres- sure lose with design. 6.2 Operating Conditions. Conditions which affect the air heater performance and which should be given special consideration are: 6.2.1 Quantity of air passing through the sir heater. 6.2.2 Temperature of air entering the air heater. 6.2.3 Recirculating or bypassing of air to control cold-end temperature. 6.2.4 Tempering air and setting infiltration which did not pass through the air heater. 6.2.5 Air heater leakage — condition of seals. 6.2.6 Quantity of gas pa beater. jing through the air 6.2.7 Temperature of gas entering the air heater. 6.2.8 Fouled or corroded elements or tubes. 6.3 Thermal Performance. A very important factor in evaluating the thermal performance of an air heater is X-Hatio. This factor is nondimen- is obtained during test by recording gas side in and out temperatures, air side in and ‘out temperatures and Orsat readings at gas inlet and outlet. From the latter two readings the air leakage to the gas side is obtained in pounds per pound of wet gas and permits correction of the test temperature of gas out to temperature of gas out with zero air heater leakage. The use of the X-Ratio accounts partially for differences be- tween test and design values of air heater exit gas temperatures. The X-Ratio is also affected by tempering air flow, sealing air flows, setting infiltration and in some arrangements by gas recirculation. 64 Air Heater Leakage. From the Orsat readings used to obtain X-Ratio the amouat of air leakage is determined and when corrected is com- pared with design. 6.5 Exit Gas Temperoture. Test and design exit gas temperature should not be compared un- til corrections to the test values have been made in accordance with Section 7, Par. 7.07 through TA, 6.6 Pressure Loss. After corrections for temperature and flow rate, teat gas side and air side pressure losses are to be compared with de- sign values.AIR HEATERS SECTION 7, COMPUTATIONS heater performance. The following computation procedures are for determining 7.01 yg = pet cent = Gas side efficiency. ng fe ® ay tov = tae There Measured gas temperature entering ait heater, tow = tes @ = F = Calculated gas temperature leaving air heater corrected for no air leakage as given in Par. 7.02. = F = Measured air temperature entering air heater. tas = 7.02 tors @ = F = Calcutated gas temperature leaving air heater corrected for no air leakage cpa Mow - tae tore @ « 2@te4 Mow 100 eye Where AG) = Per cent = Air heater leakage as given in Par. 7.08 cyalll = EB = The moun specific heat between temperatures te and tcxe Buu at eget x TEER = The mean specific heat between temperatures toys and os @ Where 8 Measured gas temperature leaving air heater. tas = F = Measured air temperature entering air heater. 7.03 Agy= lb wst sir leakage x 100 = Per cent air heater leakage, — defined as © fh wet gas entering air heater pounds of air leakage to the gas side divided by pounds gas entering the air heater. Fors — Wo © Were x 100 sos PTC 4.1, Figs 3 for sit and Figs 7 for gue to calculate the weighted of the mesn apecifie he for wet aie and wet ease 21ASME PERFORMANCE TEST CODES __ tb wet gas leaving entering air heater Forse = Th A fuel = Worssa + Bee? Ib dry gas, i i 7 Boeus.se = TERR fea ~ Drv gas flow leaving/entering the air heater as given in Par. 7.0% Ib_moisture Fac = PAF. fuel = Total moisture in flue gas entering the air heater as given in Par. 7.05 7.03.1 While not a part of this Code, an interesting empirical opproxination of percentage of leakage may be obtained by the use of the per cent volume of the CO, in the gas entering and leaving the heater. The approximation does not account for the moisture ia the flue gas. Thus: % LEAKAGE - © 202. gas entering heater — % CO; gas leaving heater, oy jz gas leaving heater Experience has shown that the use of this factor, 90, will result in percentage leakage figures that are very close (plus of minus one percentage point) to leakage determined on a weight basis. 7.04 th dey ges 4 _ Bic’ = 7EREE, ~ Pounds of dry gas per pound of “as ficed” fuel. 4.01 CO, « 32.00 02 + 28.01 CO + 28.02 Nz (« 4 1201 3) 12.01 (CO, + CO) o* F207 7.04.1 Forvass The above formula is hased on molecular weights accurate to four significant figures, but it is not to be implied that the dry gas weight derived has this degree of sccuracy. The four digit molecular weights are used to hold errars from calculation procedure to minimum. Cz, O2, and CO = per cent by volume of dry gas Nz being determined by subtracting the total of COz, Oz, and CO from 100 per cent. b carbon burned TIERE feel ~ Pounds of carbon burned per pound of “as fired” fuel. ig this Code, sic leakage is ensured to bypass directly from the inlet alt side to the outlet gas side, Thevsfate moisture is sleleakage does not become a part of Werte + Wing” bul doer become a pat of Wgryg * Bmgs The amession of thin (ore m the Inteer term will not affect the accursey of the fe maine ix 3 very small par of the total ture terms (it ia deaived to calculate this mointare tera, veedure may be used Cateulate the actual pounds of dry air leakage per pound of “ze fred” fuel Borg = Woria- 2 Multiply the renute of (2) by the epgcific humidity (pounds messture/peands dey air) ta get the pounds of moisture in eakage aie per pound of as fieed"” fuel, 3. Add the result of (2) t0 the Ming mused to calculate WG 4s and then cecatculate 4 4, 2ALR HEATERS Pounds of carbon in“ fired” fuel by laboratory analysis. TPAETTust™ Pounds of dry refase per pound of ‘as fired” fuel. Where Wage = PE Dry refuse rate Where refuse rate at various collection points, such as ashpit, dust collector, boiler hoppers, is aot actually determined, it can be estimated if all parties agree. Hye = Pe Fuel eae If fuel cate is not measured, it shall be computed from steam generator teat efficiency and output. Hy: = = Btt— = Laboratory determination of per cent combustible times 14500 Bu Te dey refuwe ~ ip Harpe = ay tion = Laboratory determination of heating value by bomb calorimeter 14500. BY _ teat value of 1 Ib of eathon ws it occurs in refuse (see Par. 9.4 of the Test Code for Steam Generating Units, PTC 4.1) Ib a, edt . i: HAE rival © The “as fired" suifue content of fuel as determined by laboratory analysis. 7.05 Sac = qottepay = Pounds of moisture in the flue gas per pound of “as fired’ fuel =o TDAP fuel ~ Bas per pi ~ Bic = B.006H + (Mga x Raed + my + Wy + Bm Oo Where: 8.936 - 8.936 pounds of water produced from burning one pound of hydrogen. agi ~ Pounds of hydrogen from an “tas fired” ultimate analysis. 1b . ic at boiler i Fane = Tg ay” Pounds of moisture per pound of dry air at boiler inlet. Ib “ 5 : Fa- =TER Tofu ~ Pounds of dry air per pound of “as fired” fuel as given in Par. 7.06, 23,ASME PERFORMANCE TEST CODES Pounds of moisture per pound of “‘as fired” fuel. = Pounds of atomizing steam per pound of “‘as fired” fuel. The procedure for obtaining this term is given in Pars. 4.17 and 7-3.2.06 of the Test Code for Steam Generating Units, PTC 4. th inds of moisture evaporated in ¥ EY” = Te ACFoac] “ Pownde of moisture evaporated hhpit per pound of “‘as fired” fuel. 7.06 tb i “as fired” Wa’ = TEAR TeaT ~ Pounds of dry sir per pound of “as fired” fuel. Fy. ~ Bei ND 0.7685 Where tb Forty = TERE cTost = Pounds of nitrogen in dry gas per pound of “as fired” fuel. 28.02 N, 12.01 Yor = 701 (CO, +CO) \S + 32.078 ‘The preceding formula is based on molecular weights accurate to four significant figures, but it is not to be implied that the weight of dry air has this degree of accuracy. The four digit molecular w: are used to hold errors from calculation procedures to a minimum. The values used are from the National Bureau of Standards Circular 564, dated 11/1/55. ) Nz being determined by subtracting the total of COz, Oz and CO from 100 per cent. €O;, 0, and CO = Per cent by volume of dry flue gas (Location 14 or 15, Fig. mdb oe ““as fired” Cy= ETET TT = Pounds of carbon burned per pound of “as fired” fuel cy. c - Fag test Where tb © TERE Hsar™ Pounde carbon in “ae fired” fuel by laboratory analysis. My “ " Bary = TEA ETIacT ~ Pounds of dry refuse per pound of “us fired” fael, see Par, 7.04. Harye = ee Heat value for dry refase from laboratory determination. (tin term any be ignored, by agreement, fonsmuch ye el per cont. Hit is desized, thin term may be calet Generatiog Unite, PTC 4.1. 2 magnitede ia auch that i affects the wat gat weight on the order of rd ex outlined in Pare- 5.23 and 7-3-2 31 of the Test Cede for StewmATR HEATERS 14500 = BY Heat value of 1 tb of carbon as it occurs in refuse (see Par. 9:4 of the Test Code for Steam Generating Units, PTC 4.1) Ib. Pounds sulfur per pound of ‘as fired” fuel as determined by laboratory TAF fact S nalysis. N = apathy - Pounds of nitrogen per pound of “as fired” fuel. IAP. fuel ~ "gen Per pos 0.7685 5 Pounds of nitrogen per pound of standard air, Ma- then becomes 7.07 Tost X-Ratio = 142 04 , ou = tov @ and is the ratio of the heat capacity of the Wow tpo av = tae) the ratio of the heat capacity of 8 air passing through the heater to the heat capacity of the gas passing through the heater. Wag PRESICS - Wer airflow leaving air heater. Gow eee = Wet gas flow entering air heater as given in Par. 7.03. cyan Gat = Mean specific heat of air between temperatures. ts and tae cyo'~ BES ~ Mean specific heat of gas between temperatures teu and ters @ - toi > F + Measured gas temperature entering air heater. toa @ tas = F Calculated ges temperature leaving the air heater with no leakage as given in Par, 7.02. Measured air temperature leaving air heater. tas =F’ = Measured air temperature entering air heater. X-Ratio is derived fram heat balance taken around an air heater corrected for no air leakage. Using the basic design diagram of Fig. 1, the heat balance is as follows, Pas pa lian © tas) = Bis ene (lowe ~ tors I fea _ We ~ tans @? Ratio = Gen tas tae For the deteimination of the metn specific heats one PTC 4.1, Fig. 3 for ait ond Pig. ? for exe to calcalate the weighted arene et sinand wot geo. inASME PERFORMANCE TEST CODES 7.07.1 Design X-Ratio is obtained by using the above formula and factoring into it the design data. 7.08 toussa =F = Comected gas temperature leaving air heater for devi entering air temperature. tevena = ato Moe = tors) + tore (ers = tas) Gara = ta) Where taap = F = Design air temperature entering air heater tora = F = Measured gas temperature entering air heater tous = F = Measured gas temperature leaving air heater tae = F = Measured air temperature entering air heater ‘The above equation is based on the tost ga air temperature. It's derivation follows tou ts @ _ ten — to @ oa Tove — tae tos — baad ide efficiency remaining constant with changes in inlet ‘The nonleakage leaving gas temperature tcis @®) a is the corrected variable to be solved for, This temperature is related to the leaving gas temperature with leakage as shown by Par. 7.02. The two ‘equations for the two nonleakage leaving gas temperatures in the above equation are shown as follows: tos @ = IQ tio —t 100 ce + tow A® 2 k= A 106 E56 tors @ = btw ~ tas) + tow Rewriting the above equation to correct for the deviation from design entering air temperature. tor @ ta =k tors sa ~ tasp) + tosa94 Upon substitution of the above two nonleakage leaving gas temperature equations into the equated gas side efficiency equation, the corrected leaving gas temperature with leakage ¢qis 24 can be solved for ‘The result of this substitution is as follows: tev ~ Keer dete tore - btcisda tow — tae tow = tasAIR HEATERS ion reduces to: _ tan lore ~ tors) + tora owe — te) tors ia lie tae 7.09 torsh¢ =F = Corrected Gas Temperature Leaving Air Heater for Deviation from Design Enter- ing Gas Temperature tevasg = 1260 lors = tan) + tan leo — tors) Cig — tae) Phere touap = F = Design gas temperature entering air heater tc1s =F =Measured gas temperature leaving air heater 146 = F = Measured air temperature entering air heater tous = F = Measured gas temperature entering air heater The above equation is based on the test gas side efficiency remaining constant with chan ges it gas temperature. The derivation follows: tow ~ tes @D _ toun ~ tos @ 6 tare tae tGrad ~ tae The nonleakage leaving gas temperature tcis @ 5G is the corrected variable to be solved for. This temperature is related te the leaving gas temperature with leakage as shown by Par. 7.02. The two equations for the two nonleakage leaving gas temperatures in the above equation are shown below: tes @ = # lta ~ tas) + ters tess @ 6 = & tess 86 - tas) + tors se Where k = A@ 04 100 Upon substitution of these nonleakage leaving gas temperature equations into the equated gas side ef- ficiency equation, the corrected leaving gas temperature with leakage tc1s 5c can be solved for. The result of this substitution is shown below toy ~ klicas = ta 61986 tare = fhe tamag = $a Miers — tas) + tas (bore = torn) orste Wor — tas) from Design 7.10 tars8 & =ASME PERFORMANCE TEST CODES Correction to measured gas temperature leaving the air heater for deviation from design X-Hatio nay be made by the use of appropriate design cortection curves.'* TM tes © = F = Corrected Gas Temperature Leaving Air Heater for Deviation from Design Entering Flue Gas Flow. Correction to measured gas temperature leaving the air heater for deviation {rom design flue gas flows may be made by the use of appropriate design correction curves.) mm fc1s2raq = F = Totally comected gas temperatore leaving air heater toreStoua = *Crsba + tors8G + tors5 G@ + 16186) ~ tors Where tousa =F = Gas temperature leaving the air heater corrected for deviation from design entering ait temperature fora8¢ =F =Gas temperature leaving the air heater corrected for deviation fcom design entering gas temperature toiss = Gas temperature leaving the air heater corrected for deviation from design C X-Ratio te125@) ~F = Gas temperature leaving the air heater corrected for deviation from design Ps a gas flow tors = F = Measured gas temperature leaving the air heater. 713 is vats : WO = ape yar Lomected Air Leakage for Deviation from Design Pressure Dif- ©) Wah iat ferential and from Design Air Temperature Mas Where th i "4 @= Pata 7 Ait leakage Fo@= Fors - Wor Shtnene design correction curven can be substantiated by field impractical. although the procedu cy may bo consideredAIR HEATERS Where Th wet ving/entering air heater Fowne = Th AF foet Fors + Bn® Worrss1e = wee Dry gas flow leaving/entering the air heater as given in Par. 7.04 Bb moisture Fac DA. the air heater as given in Par. APa.sin = Inches of water = Design static pressure difference between air inlet at the duct n flange and gas outlet at the duct connection flange. Piss; = laches of water = Measured static pressure difference between air inlet at the duct connection flange and gas outlet at the duct connection flange. Tas = R= Measured average Rankine temperature of air entering air heater. Tap =H Design Rast \¢ Lemperatare of air entering air heater. It is recognized that the above orifice correction is not a rigorous treatment of the subject but is con- sidered sufficiently accurate for the purpose of the Code. 7.13.1 To determine the above corrections when leakage is expressed on a percentage basia, use the following procedure: A@)w = Per cent = Corrected Air Leakage for Deviation from Design Pressure Differential and from Design Air Temperature Specs (ay) jr heater leakage as given in Par. 7.03 *Qu-@ Where AQ@) = Percent = R. _ Th wet gas ot SAF, fuel 1b wet gas Kop = TER rot = Weta APiy-15:p = Inches of water ~ Design static pressure difference between air inlet at the duct connection flange and gas outlet at the duct connection flange. 7.03 Wer gas flow entering ait heater as given ia P. flow entering air heater at design conditions 6 side. Therefore moisture ed of “an ved foc 3. Add he reset of hohe Rg tereoaed te cleate Rs and shen acaealse ACD) 2ASME PERFORMANCE TEST CODES Piss) = Inches of water = Measured static preasure difference between air inlet at the duct connection flange and gas outlet at the duct connection flange. Tay = R ~ Measured average Rankine temperature of air entering air heater. Tsp Re Design Rankine temperature of air entering air heater. It is recognized that the above orifice correction is not a rigorous treatment of the subject but is con sidered sufficiently accurate for the purpose of the Code. 714 APi4-19) = Inches of water = as Side Pressure Loss of the Air Heater Comected fot Deviar tion from Design Flow and Temperatures Fen (Tesap + Toss) APageisi6 = APhanis) “92ers + Torso) ee TET > Tee) Where APi4-15) = Inches of water Ib i Foo = Te oE RFT Taat = Design gas flow Measured pressure loss Tevap == Design Rankine temperature of entering gas Tevsp = R= De: Ib Teo AF fuel ~ Test sas flow Rankine temperature of leaving gas Fo = Tose = R= Measured Rankine temperature of entering gas Tors = R= Me ured Rankine temperature of teaving gas 745 APwo-s)5 - Inches of water = Air side pressure Joss of the air heater corrected for deviation from design {low and temperatures. Fan (Tran + Taro) BPie-)5 = Plans 4 (Tan + Tas) Where Pca»; = Inches of water - Measured pressure loss tb , i Fao = Tea RF Tear ~ Design air flow Taw = R = Design Rankine temperature of entering air Tayo = R = Design Rankine temperature of leaving air tb Ya = Top RET = Test air flowAIR HEATERS Ri ~ Measured Hlankine temperature of entering air R= Measured Rankine temperature of leaving air of Correction to Pressure Loss for Turbulent and Lominar Flow. It is recognized that the above corrections for pressure losses in Pars. 7.14 and 7.15 are not cigorous for turbulent flow but the approach is considered sufficiently accurate for the purpose of this Code. For correction to pressure losses in laminar flow air heaters coming on the market at the time of completion of this Code, the treatment is much less accurate and it is suggested the correction be made an item of agreement until such time as field testing firms up the basis of correction. 31ae EY (d a) / CODES PERFORMANCE TEST CODES NOW AVAILABLE prc 23 ~ prc PTC 4.2- PTc 1 — pte 2 - PTC 10 — prc 9 ~ PTC 2.1- PTC 12.3 prca7 — PTC 28 — PTC 3.1 Prc21 — PTC 24 — prc 14 - PTC 12, PTC 16 — PTC 22 ~ PTC 1B PTC I7 = PTC 20.2- prc 7 ~ prc 5 = PTC 25.2— PTC 3.2- PTC 29 — PTC 26 — PTC 20.1 - PTC 12.2- PTC 4.1 - PIC 6 - PTC 6a ~ Atmospheric Water Cooling Equipment. Centrifugal Pumps .. Cool Pulverizers escceseeseee Code on General Instructions... Code on Definitions and Value for and Exhousters . lement Pumps Diesel ond Burner Fuels... Dust Se Ejectors and Boosters. Evoporating Apparatus Feedwoter Heaters... ting Apparatus Gos Producers end Continuous Gas Generctors, Gos Turbine Power Plants Hyéroulic Prime Mow Internal Combustion Engines Overspeed Trip Systems for St Units ¥ Reciproceting St. m-Driven Dis pla Raciproceting Steam Engines Sofety and Relief Valves... Solid Fuels... Speed-Governing Syst Units... Speed-Governing Systems fer I Engine-Generator Units Speed-Governing Sys UslIB caxecesurgenn Steam Condensing Appar Steam Generating Units Steom Turbines... ‘ ger Appendix A to Test Code for Steam Turbing ms for Hydraulic Tucbine jernal Combustion De0e34 Jement Compressors, Vacuum Pumps ond Blowers rmining the Properties of Fine Particulate Matter . (1988) (1965) (1944) (1945) (1945) (1965) (1954) (1962) (1958) (1957) (1968) casa) cagaty (1956) cag9ss) (1955) (195) (1968) (1949) (0957) (1965) (1949) (1949) (1968) (1954) (1965) (1962) (1958) (1955) (1964) (1964) (1964)