Steam Flow Compensation for Distributed Control Systems

Steam Flow Compensation Equations

for Distributed Control Systems

By Tom Carter
Principal Control Systems Engineer, Descon Engineering

March 1, 2001

Summary

Temperature and Pressure compensation of steam flow corrects for two factors: 1) changes in Specific Volume (or density) of the
steam and 2) thermal expansion of the metal flow nozzle or orifice plate. The Steam Flow Compensation Factor for Specific Volume
is a function of both Temperature and Pressure. The specific volume factor is calculated from "Steam Tables". A polynomial equation
can be used in place of a table to calculate this Flow Compensation. The Thermal-expansion correction factor is a function of
temperature only and is easily calculated. These two factors, along with the Meter Factor are multiplied with the square root of the
measured differential pressure to yield a Temperature and Pressure compensated Steam Flow.

The smaller the range of Temperature and Pressure, the smaller the error in the Specific Volume Factor calculated from a polynomial
equation compared to an actual table of values. The uncompensated flow would result in errors up to 18.5% over the same range of
P and T. The traditional compensation factor used is the ratio of square root of T and design P versus design T and P. The traditional
yields an error of 1.3 %. An error of less than 0.3% can be achieved for an operating range from 860 DegF to 1100 DegF and 1500
Psia to 2000 Psia using the polynomial described: an improvement in accuracy by over 1%.

The polynomial equation is proportional to Pressure and inverse square root of Temperature. A polynomial proportional to Pressure
and Temp (i.e. no square root used) gives similar results with slightly higher errors over narrow range of T and P.

The coefficients of these polynomial equations can be calculated in an EXCEL spreadsheet using simple slope and intercept
functions.

Boiler Main Steam Flow and Turbine Steam Flow for the Hunters’ Point Power Plant are used as examples.

Introduction

Steam flow is traditionally expressed as a mass flow, usually in thousands of pounds per hour (KPPH or KLB/Hr). The density of
steam changes with Temperature and Pressure of the steam in a very non-linear function. This results in very large mass flow errors
(18 % and more ) when using differential Pressure flow devices such as orifice plates, flow nozzles and venturis without temperature
and pressure compensation. Steam Tables list the specific volume (cubic feet / lb) for various values of Temperature and Pressure.
The specific volume, based on temperature and pressure of the steam, can be used to correct (or compensate) the measured flow
for actual conditions.

Temperature and Pressure compensation of Steam Flow uses the square root of the design specific volume divided by the square
root of actual specific volume of steam.

The compensation Factor for Specific Volume (F ) is calculated as:

sv

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 Steam Flow Compensation for Distributed Control Systems

Equation 1.0

Design conditions are the hypothetical values of temperature and upstream pressure of Steam when calculating the Flow Coefficients
of the flow meter (e.g. orifice, venturi, flow nozzle). The design conditions are usually supplied by the meter manufacturer, along with
the meter factor. Otherwise, a meter factor must be calculated using complex series of equations and tables from textbooks, for
example Flow Measurement Engineering Handbook by R. W. Miller (1983).

Actual conditions are the real-time upstream pressure and temperature of the steam as measured by the monitoring and control
system.

In most monitoring and control systems, the temperature and pressure Compensated Steam Flow is calculated as:

Equation 2.0

Where:

q is Steam Flow in KLbs/Hr (i.e. the compensated steam flow),

M

F is the Specific Volume Compensation Factor (based on Temperature and Pressure)

SV

F is the Thermal Expansion Correction Factor (based on Temperature)

a

F is the meter factor (typically equal to maximum flow divided by the square root of max differential pressure),
M

and h is the measured differential pressure across the flow meter (typically in inches H2O).
w

Specific Volume Flow Compensation Factor (F ) Tables

SV

The most accurate means to calculate or derive the Specific Volume Compensation Factor (F ) is to use a ‘look-up’ table of flow
SV
compensation coefficients based on Temperature and Pressure of the Steam. This is essentially a three dimensional chart : (F )=
SV
fxn(T,P). A simple chart can be constructed by using the Steam Tables to look up specific volume at various temp and pressures.
Then calculating the square root of the ratio of design specific volume / actual specific volume for T and P.

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 Steam Flow Compensation for Distributed Control Systems

Flow correction Factors (F )

SV
for Design P=1830psig (1844.7psia) and 1000 DegF Design Specific Vol = 0.431289 (cu-ft / lb)

Hunters’ Point P.P. Main Steam Flow

Press 1000 1100 1200 1300 1400 1500 1600 1700 1750 1800 1850 1900 2000
(Psia)
Temp
DegF
650 0.8747 0.9271 0.9792 1.0316 1.0843 1.1382 1.1937 1.2514 1.2813 1.3121 1.3439 1.3769 1.4480
700 0.8422 0.8903 0.9376 0.9844 1.0308 1.0773 1.1238 1.1709 1.1946 1.2185 1.2426 1.2672 1.3169
750 0.8152 0.8603 0.9043 0.9475 0.9901 1.0321 1.0739 1.1153 1.1362 1.1570 1.1776 1.1984 1.2404
800 0.7919 0.8347 0.8763 0.9169 0.9566 0.9957 1.0342 1.0723 1.0912 1.1101 1.1289 1.1476 1.1851
860 0.7674 0.8081 0.8474 0.8857 0.9230 0.9595 0.9953 1.0305 1.0478 1.0652 1.0824 1.0994 1.1335
900 0.7528 0.7923 0.8304 0.8673 0.9034 0.9385 0.9728 1.0065 1.0233 1.0398 1.0562 1.0724 1.1047
960 0.7328 0.7708 0.8073 0.8426 0.8770 0.9105 0.9431 0.9751 0.9908 1.0064 1.0219 1.0372 1.0675
1000 0.7206 0.7577 0.7933 0.8277 0.8612 0.8937 0.9254 0.9564 0.9716 0.9867 1.0016 1.0164 1.0456
1060 0.7037 0.7395 0.7740 0.8073 0.8395 0.8708 0.9012 0.9309 0.9455 0.9600 0.9742 0.9885 1.0164
1100 0.6932 0.7283 0.7621 0.7946 0.8265 0.8567 0.8865 0.9155 0.9297 0.9438 0.9577 0.9715 0.9986
1160 0.6784 0.7126 0.7455 0.7770 0.8076 0.8373 0.8357 0.8625 0.9078 0.9215 0.9349 0.9482 0.9743

Table 1.0 – Steam Flow Spec. Vol. Compensation Factors- Main Steam Flow – Hunters’ Point P.P: based on Steam Tables by
Keenan, Keyes, Hill and Moore (1969)

Table Note – The Bailey Flow nozzle specification Sheet dated 2/14/58 listed the design specific volume as .4306
cu. Ft./lb. Maximum capacity of 1,400,000 lb/hr and max Meter Differential as 331 inches of water.

Some DCS provide steam tables or some other method to implement a table that can be used to calculate a flow compensation
coefficient for actual T and P. But for many Control systems, there is not an easy way to implement tables. For example, most DCS
(Distributed Control System) do not provide "two-input" table functions or "x-y-z" table functions required to do Temperature and
Pressure based Flow coefficients.

Traditional Spec. Vol. Compensation Factors (F ) error > 1%

SV

If steam tables or x-y-z table functions are not available in the Control System, the traditional solution is to assume steam is an ideal
gas and use the ideal gas law to compensate for T an P effects on density. The smaller the assumed operating range, the more
accurate the approximation.

The traditional compensation Factor for Specific Volume (F ) is calculated as:

sv

Equation 2.1

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 Steam Flow Compensation for Distributed Control Systems

The traditional yields an error of 1.3 % for an operating range from 860 DegF to 1100 DegF and 1500 Psia to 2000. Error of over 3%
for larger ranges of T and P.

% Error Traditional Gas Density Compensation F

SV

Hunters’ Point P.P.Boiler Main Steam Flow – 5.5% error

for Design P=1830psig (1844.7psia) and 1000 DegF Design Specific Vol. = 0.431289 (cu-ft / lb.)
Press 1000 1100 1200 1300 1400 1500 1600 1700 1750 1800 1850 1900 2000
Psia
Temp DegF

650 4.40 3.31 2.16 0.93 -0.35 -1.73 -3.23 -4.85 -5.71 -6.62 -7.57 -8.58 -10.81
700 4.49 3.67 2.82 1.93 1.01 0.04 -0.95 -2.00 -2.55 -3.10 -3.68 -4.27 -5.49
750 4.29 3.64 2.99 2.30 1.60 0.89 0.14 -0.61 -1.01 -1.41 -1.81 -2.21 -3.07
800 3.95 3.43 2.91 2.36 1.82 1.25 0.68 0.09 -0.21 -0.51 -0.82 -1.12 -1.77
860 3.45 3.05 2.63 2.21 1.78 1.35 0.90 0.45 0.23 0.00 -0.24 -0.46 -0.94
900 3.09 2.74 2.38 2.02 1.65 1.28 0.91 0.53 0.33 0.14 -0.06 -0.25 -0.65
960 2.54 2.25 1.97 1.68 1.38 1.09 0.79 0.48 0.33 0.17 0.02 -0.14 -0.44
1000 2.17 1.92 1.67 1.42 1.16 0.90 0.64 0.37 0.25 0.11 -0.02 -0.15 -0.42
1060 1.63 1.42 1.22 1.00 0.80 0.58 0.37 0.16 0.05 -0.06 -0.16 -0.28 -0.50
1100 1.27 1.09 0.91 0.73 0.49 0.36 0.17 -0.02 -0.11 -0.21 -0.30 -0.39 -0.58
1160 0.76 0.61 0.46 0.31 0.15 -0.01 3.47 3.34 -0.39 -0.47 -0.55 -0.62 -0.78

Table 2.1 - %error traditional gas T and P compensation eqn 2.1 – Boiler Main Steam Flow Specific Volume coefficient

Polynomial Equation to calculate Spec. Vol. Compensation Factors (F )

SV

If steam tables or x-y-z table functions are not available in the Control System, the solution is to use a polynomial equation that can
replicate parts of the table. The smaller the assumed operating range, the more accurate the approximation

The polynomial equation with the best fit is proportional to Pressure and the inverse of the square root of Temperature. This is
consistent with the engineering mass flow equations for vapor. Polynomial proportional to Pressure and the square root of
Temperature or simply to Pressure and Temperature can also be used in cases where the control system does not allow inverse or
square root calculations. The difference in the three methods is the range of acceptable error. All three methods are approximations
to the actual table result in error as actual T and P deviate from design.

For example, a maximum error of 0.3% can be achieved over and operating range from 860 DegF to 1100 DegF and 1500 Psia to
2000 Psia using a polynomial proportional to Pressure and inverse square root of Temperature . The uncompensated flow would
result in errors up to 18.5% over the same range of P and T.

Equation 3.0 – Spec. Vol. Flow Compensation Factor polynomial

Where,
mSLOPES is the slope of mT1 through mTn (i.e. slope of slopes).

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 Steam Flow Compensation for Distributed Control Systems

bSLOPES is the intercept of mT1 through mTn (i.e. intercept of slopes).

mINTERCEPTS is the slope of bT1 through bTn (i.e. slope of intercepts).

bINTERCEPTS is the intercept of bT1 through bTn (i.e. intercept of intercepts).

mT1 is the slope of F for constant Temperature (F = fxn(,P) at Constant T1)

SV SV
or F = mT1 (P) + bT1
SV 1

mTn is the slope of F for constant Temperature (F = fxn(,P) at Constant Tn)

SV SV
or F = mT1 (P) + bTn
SV n

bT1 is the intercept of F for constant Temperature (F = fxn(,P) at Constant T1)

SV SV
or F = mT1 (P) + bT1
SV 1

bTn is the intercept of F for constant Temperature (F = fxn(,P) at Constant Tn)

SV SV
or F = mT1 (P) + bTn
SV n

The method is four steps.

1. First generate a linear curve fit on several rows in a table of Flow Coefficients. This generates a series of linear equations of
Fsv versus Pressure. F = mT1 (P) + bT1
SV 1
2. Second, enter the slopes and intercepts in a table versus the inverse of square root of temperature: mT1 , mT2 , mT3 ,…
mTn , and bT1 , bT2, bT3 ,… bTn
3. Third, generate a curve fit of the Slopes versus inverse Square Root of Temperature, this yields a slope and an intercept:
mSLOPES and bSLOPES
4. Fourth generate a curve fit of the Intercepts versus inverse Square Root of Temperature, this yields a slope and an
intercept : mINTERCEPTS and bINTERCEPTS

Developing an acceptable accuracy is by trying different ranges of Temp and Pressure. Sometimes a curve fit over a smaller range of
T and P results better fits at the fringes.

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 Steam Flow Compensation for Distributed Control Systems

Hunters’ Point Boiler Main Steam Flow spec. vol. Compensation F equation
SV

Using Spec. Vol. Flow Compensation Coefficients in Table 1.0 and equation 3.0 over various ranges of temperature and pressure we
get different curves that fit the best over a narrow range.

Note – The Bailey Flow nozzle specification Sheet dated 2/14/58 listed the design specific volume as .4306 cu. Ft./lb. Maximum
capacity of 1,400,000 lb/hr and max Meter Differential as 331 inches of water. More modern version of the Steam Table described
Design Specific Vol = 0.431289 (cu-ft / lb) for Design P=1830psig (1844.7psia) and Design T=1000 DegF) source: Steam Tables by
Keenan, Keyes, Hill and Moore (1969)

Equation 3.1 was derived by the steps outlined above for F over a range of 1500 psia to 2000 psia and 860 DegF to 1060DegF
SV
for the Hunters’ Point Power Plant Boiler Main Steam Flow.

Equation
3.1 – Spec. Vol. Flow Compensation Factor polynomial for Spec. Vol., Boiler Main Steam Flow,

0.3% accuracy, narrow range 850 DegF to 1100 DegF and 1500 Psia to 2000.

Equation 3.2 was derived by the steps outlined above For F over a range of 1500 psia to 2000 psia and 700 DegF to 1160DegF.
SV

Equation
3.2 – Spec. Vol. Flow Compensation Factor polynomial Spec. Vol., Main Boiler Steam Flow,

1.0% accuracy, wide range, 700 DegF to 1100 DegF and 1100 Psia to 2000.

The following tables 3.1 and 3.2 show the %error the polynomial equation yields versus the actual table of specific volume
compensation coefficients found in table 1.

% Error Polynomial Equation 3.1 versus actual F

SV

Hunters’ Point P.P.Boiler Main Steam Flow – narrow range - High Accuracy - 0.3% error
for Design P=1830psig (1844.7psia) and 1000 DegF Design Specific Vol = 0.431289 (cu-ft / lb)

Press 1000 1100 1200 1300 1400 1500 1600 1700 1750 1800 1850 1900 2000
(Psia)
Temp
DegF
650 0.32 -0.68 -1.56 -2.37 -3.13 -3.92 -4.76 -5.71 -6.22 -6.78 -7.37 -8.02 -9.55
700 1.19 0.31 -0.40 -0.98 -1.48 -1.95 -2.37 -2.81 -3.03 -3.25 -3.50 -3.75 -4.29
750 1.75 0.91 0.28 -0.21 -0.59 -0.89 -1.15 -1.36 -1.46 -1.56 -1.65 -1.74 -1.95
800 2.16 1.31 0.70 0.24 -0.08 -0.31 -0.48 -0.58 -0.62 -0.66 -0.69 -0.70 -0.74
860 2.51 1.64 1.01 0.55 0.24 0.04 -0.08 -0.14 -0.14 -0.14 -0.13 -0.10 -0.05
900 2.69 1.79 1.13 0.67 0.34 0.14 0.03 -0.01 -0.01 0.00 0.03 0.07 0.16

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960 2.93 1.96 1.26 0.76 0.41 0.19 0.07 0.02 0.03 0.04 0.07 0.12 0.24
1000 3.07 2.06 1.31 0.78 0.40 0.16 0.02 -0.03 -0.02 -0.01 0.02 0.07 0.19
1060 3.27 2.18 1.37 0.77 0.36 0.08 -0.09 -0.17 -0.18 -0.17 -0.15 -0.12 -0.02
1100 3.39 2.25 1.39 0.76 0.26 0.00 -0.20 -0.30 -0.32 -0.32 -0.31 -0.28 -0.18
1160 3.57 2.35 1.42 0.73 0.22 -0.14 3.24 3.13 -0.55 -0.58 -0.58 -0.57 -0.50

Table 3.1 - %error in polynomial eqn 3.1 – Boiler Main Steam Flow coefficient – narrow range

% Error Polynomial Equation 3.2 versus actual F

SV

Hunters’ Point P.P. Boiler Main Steam Flow – Wide Range -1% error
for Design P=1830psig (1844.7psia) and 1000 DegF Design Specific Vol. = 0.431289 (cu-ft / lb)

Press 1000 1100 1200 1300 1400 1500 1600 1700 1750 1800 1850 1900 2000
(Psia)
Temp
DegF
650 0.35 -0.27 -0.80 -1.30 -1.78 -2.32 -2.93 -3.67 -4.09 -4.56 -5.08 -5.65 -7.05
700 1.00 0.49 0.11 -0.17 -0.40 -0.62 -0.81 -1.04 -1.17 -1.30 -1.45 -1.62 -1.99
750 1.37 0.88 0.55 0.35 0.22 0.16 0.12 0.12 0.10 0.10 0.10 0.10 0.05
800 1.58 1.06 0.74 0.55 0.47 0.46 0.50 0.59 0.64 0.69 0.75 0.82 0.93
860 1.71 1.14 0.77 0.56 0.48 0.48 0.55 0.67 0.76 0.84 0.93 1.04 1.24
900 1.76 1.13 0.73 0.49 0.38 0.37 0.44 0.57 0.65 0.74 0.84 0.95 1.19
960 1.79 1.08 0.60 0.31 0.15 0.11 0.15 0.26 0.33 0.42 0.52 0.63 0.88
1000 1.80 1.02 0.49 0.16 -0.05 -0.12 -0.11 -0.02 0.06 0.13 0.23 0.34 0.58
1060 1.81 0.93 0.32 -0.11 -0.36 -0.50 -0.53 -0.48 -0.43 -0.37 -0.29 -0.21 0.01
1100 1.81 0.86 0.18 -0.29 -0.64 -0.77 -0.84 -0.82 -0.78 -0.73 -0.67 -0.59 -0.40
1160 1.81 0.76 -0.01 -0.56 -0.94 -1.18 2.27 2.27 -1.34 -1.32 -1.27 -1.21 -1.06

Table 3.2 - %error in polynomial eqn 3.2 – Boiler Main Steam Flow coefficient – wide range

Hunters’ Point Turbine Steam Flow F equation

SV

Using Flow Compensation Coefficients in Table 1.0 and equation 3.0 over various ranges of temperature and pressure we get
different curves that fit the best over a narrow range.

Note – The Bailey Flow nozzle specification Sheet dated 1/14/58 listed the design specific volume as .4383 cu. Ft./lb. Maximum
capacity of 1,200,000 lb/hr and max Meter Differential as 331 inches of water. More modern version of the Steam Table described

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Design Specific Vol. = 0.439149 (cu-ft / lb) for Design P=1800psig (1814.7psia) and Design T=1000 DegF) source: Steam Tables by
Keenan, Keyes, Hill and Moore (1969)

Equation 4.1 was derived by the steps outlined above for F over a range of 1500 psia to 2000 psia and 860 DegF to 1060DegF
SV
for the Hunters’ Point Power Plant Turbine Steam Flow.

Equation
4.1 – Flow Compensation Factor polynomial Spec. Vol., Turbine Steam Flow, 0.3% accuracy,

narrow range 850 DegF to 1100 DegF and 1500 Psia to 2000.

Equation 4.2 was derived by the steps outlined above for F over a range of 1500 psia to 2000 psia and 700 DegF to 1160DegF.
SV

Equation
4.2 – Flow Compensation Factor polynomial Spec. Vol., Turbine Steam Flow, 1.0% accuracy,

wide range, 700 DegF to 1100 DegF and 1100 Psia to 2000.

The following tables 4.1 and 4.2 show the %error the polynomial equation yields versus the actual table of steam flow compensation
coefficients found in table 1.

% Error Polynomial Equation 4.1 versus actual F

SV

Hunters’ Point P.P. Turbine Steam Flow – narrow range - High Accuracy - 0.3% error
for Design P=1830psig (1814.7psia) and 1000 DegF Design Specific Vol. = 0.439149 (cu-ft / lb)

Press 1000 1100 1200 1300 1400 1500 1600 1700 1750 1800 1850 1900 2000
(Psia)
Temp
DegF
650 0.32 -0.68 -1.56 -2.37 -3.13 -3.92 -4.76 -5.71 -6.22 -6.78 -7.37 -8.02 -9.55
700 1.19 0.31 -0.40 -0.98 -1.48 -1.95 -2.37 -2.81 -3.03 -3.25 -3.50 -3.75 -4.29
750 1.75 0.91 0.28 -0.21 -0.59 -0.89 -1.15 -1.36 -1.46 -1.56 -1.65 -1.74 -1.95
800 2.16 1.31 0.70 0.24 -0.08 -0.31 -0.48 -0.58 -0.62 -0.66 -0.69 -0.70 -0.74
860 2.51 1.64 1.01 0.55 0.24 0.04 -0.08 -0.14 -0.14 -0.14 -0.13 -0.10 -0.05
900 2.69 1.79 1.13 0.67 0.34 0.14 0.03 -0.01 -0.01 0.00 0.03 0.07 0.16
960 2.93 1.96 1.26 0.76 0.41 0.19 0.07 0.02 0.03 0.04 0.07 0.12 0.24
1000 3.07 2.06 1.31 0.78 0.40 0.16 0.02 -0.03 -0.02 -0.01 0.02 0.07 0.19
1060 3.27 2.18 1.37 0.77 0.36 0.08 -0.09 -0.17 -0.18 -0.17 -0.15 -0.12 -0.02
1100 3.39 2.25 1.39 0.76 0.26 0.00 -0.20 -0.30 -0.32 -0.32 -0.31 -0.28 -0.18
1160 3.57 2.35 1.42 0.73 0.22 -0.14 3.24 3.13 -0.55 -0.58 -0.58 -0.57 -0.50

Table 4.1 - %error in polynomial eqn 4.1 – Turbine Steam Flow coefficient – narrow range

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% Error Polynomial Equation 4.2 versus actual F

SV

Hunters’ Point P.P. Turbine Steam Flow – Wide Range -1.25% error
for Design P=1800psig (1814.7psia) and 1000 DegF Design Specific Vol. = 0.4391486 (cu-ft / lb)

Press 1000 1100 1200 1300 1400 1500 1600 1700 1750 1800 1850 1900 2000
(Psia)
Temp
DegF
650 0.35 -0.27 -0.80 -1.30 -1.78 -2.32 -2.93 -3.67 -4.09 -4.56 -5.08 -5.65 -7.05
700 1.00 0.49 0.11 -0.17 -0.40 -0.62 -0.81 -1.04 -1.17 -1.30 -1.45 -1.62 -1.99
750 1.37 0.88 0.55 0.35 0.22 0.16 0.12 0.12 0.10 0.10 0.10 0.10 0.05
800 1.58 1.06 0.74 0.55 0.47 0.46 0.50 0.59 0.64 0.69 0.75 0.82 0.93
860 1.71 1.14 0.77 0.56 0.48 0.48 0.55 0.67 0.76 0.84 0.93 1.04 1.24
900 1.76 1.13 0.73 0.49 0.38 0.37 0.44 0.57 0.65 0.74 0.84 0.95 1.19
960 1.79 1.08 0.60 0.31 0.15 0.11 0.15 0.26 0.33 0.42 0.52 0.63 0.88
1000 1.80 1.02 0.49 0.16 -0.05 -0.12 -0.11 -0.02 0.06 0.13 0.23 0.34 0.58
1060 1.81 0.93 0.32 -0.11 -0.36 -0.50 -0.53 -0.48 -0.43 -0.37 -0.29 -0.21 0.01
1100 1.81 0.86 0.18 -0.29 -0.64 -0.77 -0.84 -0.82 -0.78 -0.73 -0.67 -0.59 -0.40
1160 1.81 0.76 -0.01 -0.56 -0.94 -1.18 2.27 2.27 -1.34 -1.32 -1.27 -1.21 -1.06

Table 4.2 - %error in polynomial eqn 4.2 – Turbine Steam Flow coefficient – wide range

Thermal Expansion Factor

The material of the primary element (e.g. flow nozzle, venturi, orifice) and the pipe expands or contracts with temperature. The bore
and pipe diameters are measured at room temperature, but will be larger or smaller at other temperatures. The thermal correction
factor corrects for these effects.

When the thermal-expansion coefficients of the primary element and pipe material are approximately the same, which is usually the
case, and is assumed here, the Thermal Correction factor is:

Equation 5.0 – Design Thermal Expansion Flow Coefficient Factor in Meter Factor

Where α is the coefficient of linear expansion for the primary element. Fa can also be looked up graphically in texts, for example
PE
ASME Fluid Meters (1971) or Flow Measurement Engineering Handbook by R. W. Miller (1983).

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The Ratio of FaDESIGN to FaACTUAL is the Compensation Factor Fa

Equation 5.1 – Thermal Expansion Flow Correction Factor

Thermal-expansion Flow Correction Factor (Fa), Hunters Point Boiler and Turbine

For 5% chrome moly, α =7.37353E-06

PE
(from Figure 9.5, Flow Measurement Engineering Handbook by R. W. Miller (1983).

Using Equation 5.1, and the design Temperature of 1000 Degf, the equation for Thermal Expansion Steam Flow Correction Factor is

Equation 5.2 – Thermal Expansion Flow Correction Factor, Design Temp = 1000 DegF, 5% Chrome Moly

Table 5.1 shows the range of Correction Factors over the operating range for Hunters Point Power Plant Boiler Main Steam Flow and
Turbine Steam Flow meters. Without this compensation, the error introduced over the operating range is 0.51% maximum.

Table 5.1

Thermal Expansion Flow Correction Factor, Hunters’ Point P.P. Boiler and Turbine Steam
Flow, Design Temp = 1000 DegF, 5% Chrome Moly
Temp 650 700 1000 1060 1100 1160
(Deg F)

Fa 0.994909 0.995636 1 1.000873 1.001455 1.002328

Boiler Main Steam Flow Equation – Hunters Point

The temperature and pressure Compensated Steam Flow is calculated as:

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 Steam Flow Compensation for Distributed Control Systems

Equation 2.0

The meter Factor (Fm) is calculated from equation 6.1. For Boiler Main Steam Flow, the Bailey Flow nozzle specification Sheet dated
2/14/58 listed the design Temperature of 1000 DegF and design Pressure of 1830 psig. Maximum capacity of 1,400,000 lb/hr and
max Meter Differential as 331 inches of water.

= 76950.96

Equation 6.1 – Meter Factor, Boiler Main Steam Flow

The temperature and pressure Compensated Steam Flow is calculated as:

Equation 6.2 – Boiler Main Steam Flow

Assuming the wider operating range is desired (1% error acceptable), the Specific Volume Correction Factor equation 3.2 is used:

Equation
3.2 – Spec. Vol. Flow Compensation Factor polynomial Spec. Vol., Main Boiler Steam Flow,

1.0% accuracy, wide range, 700 DegF to 1100 DegF and 1100 Psia to 2000.

The equation for Thermal Expansion Steam Flow Correction Factor is Equation 5.1.

Equation 5.2 – Thermal Expansion Flow Correction Factor, Design Temp = 1000 DegF, 5% Chrome Moly

Turbine Steam Flow Equation – Hunters Point

The temperature and pressure Compensated Steam Flow is calculated as:

http://www.desconengineering.com/WhitePapers/SteamFlow/Steam_Flow_Compensation.htm (11 of 12)1/14/2009 12:23:08 PM

 Steam Flow Compensation for Distributed Control Systems

Equation 2.0

The meter Factor (Fm) is calculated from equation 6.1. For Turbine Steam Flow, the Bailey Flow nozzle specification Sheet dated
1/14/58 listed the design Temperature of 1000 Degf and design pressure of 1800 psig. Maximum capacity of 1,200,000 lb/hr and max
Meter Differential as 331 inches of water.

= 65957.97

Equation 7.1 – Meter Factor, Turbine Steam Flow

The temperature and pressure Compensated Steam Flow is calculated as:

Equation 7.2 – Turbine Steam Flow

Assuming the wider operating range is desired (1% error acceptable), the Specific Volume Correction Factor equation 3.2 is used:

Equation
4.2 – Flow Compensation Factor polynomial Spec. Vol., Turbine Steam Flow, 1.0% accuracy,

wide range, 700 DegF to 1100 DegF and 1100 Psia to 2000.

The equation for Thermal Expansion Steam Flow Correction Factor is Equation 5.1.

http://www.desconengineering.com/WhitePapers/SteamFlow/Steam_Flow_Compensation.htm (12 of 12)1/14/2009 12:23:08 PM