ASME PTC PM-2010 Performance Monitoring Guidelines for Power Plants《电厂性能监控指南》.pdf

1、ASME PTC PM-2010PerformanceMonitoring Guidelines for Power Plants(Revision of PTC PM-1993)Performance Test CodesINTENTIONALLY LEFT BLANKPerformance Monitoring Guidelines for Power Plants Performance Test Codes Date of Issuance: April 30, 2010 The next edition of this Guide is scheduled for publicati

2、on in 2015. There will be no addenda or written interpretations of the requirements of this Guide issued to this edition. ASME is the registered trademark of The American Society of Mechanical Engineers. This code or standard was developed under procedures accredited as meeting the criteria for Amer

3、ican National Standards. The Standards Committee that approved the code or standard was balanced to assure that individuals from competent and concerned interests have had an opportunity to participate. The proposed code or standard was made available for public review and comment that provides an o

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8、ise, without the prior written permission of the publisher. The American Society of Mechanical Engineers Three Park Avenue, New York, NY 10016-5990 Copyright 2010 by THE AMERICAN SOCIETY OF MECHANICAL ENGINEERS All rights reserved Printed in U.S.A. iii CONTENTS Foreword vii Committee Roster . viii C

9、orrespondence With the PTC PM Committee. x Introduction. xi Section 1 Fundamental Concepts. 1 1-1 Object and Scope 1 1-2 Overview. 1 1-3 Definitions and Description of Terms. 17 Section 2 Program Implementation. 22 2-1 Program Planning 22 2-2 Instrumentation . 33 2-3 Performance Monitoring Implement

10、ation and Diagnostics 58 2-4 Incremental Heat Rate. 131 2-5 Performance Optimization 145 Section 3 Case Studies/Diagnostic Examples 177 3-1 Air Heater Plugging Due to Failed Sootblower 177 3-2 Boiler Example . 179 3-3 Temperature Calibrations 180 3-4 Capacity Loss Investigation Due to Fouling of Fee

11、dwater Flow Nozzle (Nuclear Plant) . 184 3-5 Unit Capacity and ID Fan Capacity Due to Air Heater Leakage 189 3-6 Loss of Extraction Flow 191 3-7 Question and Answer Session: A Nuclear Plant Diagnostic Problem 193 3-8 Application of Turbine Test Data for Problem Identification. 195 3-9 Condenser Tube

12、 Fouling Problem 196 3-10 Feedwater Partition-Plate Bypass Problem. 199 3-11 Air-Heater Pluggage Problem. 200 3-12 Deposits in High-Pressure Turbine. 201 3-13 Pulverizer Coal-Mill Fineness Problem 202 iv Figures 1-2.6-1 Typical Plant Losses 5 1-2.6-2 Typical Losses for a Gas-Turbine-Based Combined C

13、ycle Plant . 6 1-2.6-3 Heat Balance for Turbine Cycle of Typical Pressurized Water Reactor Nuclear Plant 7 1-2.6-4 Mass Flows Through Steam and Feedwater System for Typical Pressurized Water Reactor Plant 8 1-2.6-5 Energy Distribution for a Typical Pressurized Water Reactor Nuclear Plant. 8 1-2.6-6

14、Typical Boiler Losses 9 1-2.6-7 Typical Cycle Losses. 10 1-2.6-8 Typical Turbine/Generator Losses 11 1-2.6-9 Computed Variation of Unburned Carbon With Excess Air . 12 1-2.6-10 Effect of O2 and Coal Fineness on Unit Heat Rate 13 1-2.6-11 Effect of Stack Gas Temperature on Unit Heat Rate 13 1-2.6-12

15、Boiler Loss Optimization 14 2-2.3.1-1 Primary Flow Section for Welded Assembly 37 2-2.3.1-2 Inspection Port 37 2-2.4-1 Basic Pressure Terms From ASME PTC 19.2 40 2-2.4-2 General Uncertainties of Pressure-Measuring Devices From PTC 6 Report . 40 2-2.4.5-1 Effect of Pressure and Bias Errors on HP Turb

16、ine Efficiency 42 2-2.4.5-2 Effect of Pressure and Bias Errors on IP Turbine Efficiency . 43 2-2.5.1-1 TC Drift Study of Six Thermocouples Cycled 210 days to 300 days. 44 2-2.5.2-1 Drift of Ice Point Resistance of 102 RTDs Cycled 810 days 45 2-2.5.3-1 Effect of Temperature Bias and Error on HP Turbi

17、ne Efficiency. 46 2-2.5.3-2 Effect of Temperature Bias and Error on IP Turbine Efficiency 46 2-3.6.2.1-1 Performance Curves to Characterize Boiler Losses Example for a Coal-Fired Unit 63 2-3.6.2.3-1 Heat Rate Logic Tree Main Diagram. 64 2-3.6.2.3-2 Illustration of Decision Tree Concept for Investiga

18、ting Performance Parameter Deviations . 65 2-3.8.4.1-1 Pulverizer Capacity Curve 81 2-3.8.4.1-2 Arrangement for Sampling Pulverized Coal. 82 2-3.8.4.1-3 Graphical Form for Representing Distribution of Sizes of Broken Coal 83 v 2-3.8.6.1-1 Sampling Direct-Fired Pulverized Coal-Sampling Stations (Dime

19、nsions Are “Percent of Pipe Diameter”) . 89 2-3.9.4.3-1 Typical DCA and TTD Versus Internal Liquid Level 105 2-4.2-1 Input/Output Curves for the Two Typical Thermal Units 131 2-4.2-2 Input/Output Relationships for a 2 1 Combined Cycle Facility 132 2-4.2-3 Incremental Heat Rate for Steam Turbine With

20、 Sequential Valve Operation . 132 2-4.3.1-1 Optimum Load Division by Equal Incremental Heat Rate. 135 2-4.4-1 Example of Heat Rate Not Monotonically Increasing in a 2 1 Configuration 137 2-4.4-2 Incremental Curve Shape . 138 2-4.4-3 Illustration of Development of Incremental Heat Rate Information Fr

21、om Basic Plant Measurements. 139 2-4.4-4 Heat Rate and Incremental Heat Rate Versus Load Fossil Unit. 141 2-4.4-5 Heat Rate and Incremental Heat Rate Versus Load Bias Error 141 2-4.4-6 Heat Rate and Incremental Heat Rate Versus Load Combined Bias and Random Error . 142 2-4.6.1-1 Combined Cycle Heat

22、Rates Versus Ambient Temperature 144 2-4.6.2-1 Combined Cycle Input/Output Relationships. 144 2-4.6.2-2 Combined Cycle Incremental Heat Rates Versus Ambient Temperature 145 3-1.1-1 Air Heater Exit Gas Temperature 2-Week Trend. 177 3-1.3-1 Air Heater Differential Pressure 2-Week Trends . 178 3-3.2-1

23、Three RTDs: Readings Collected at Five Temperatures 181 3-3.2-2 Fit of RTD Data 182 3-3.2-3 Histogram of RTD A 182 3-3.2-4 Distribution of Errors for the Three RTDs. 182 3-3.2-5 Fits of RTDs A, B, and C in Open Circuit . 183 3-3.2-6 Fits of RTDs A, B, and C Using the CalendarVan Dusen Eq. (3-3.2) fo

24、r Calibration. 183 3-3.3-1 Fits With and Without Replicate Data 184 3-4.1.1-1 Logic Tree for Case Study: Capacity Loss Investigation. 186 3-4.1.2-1 Decision Tree for Capacity Loss Due to Suspected Fouling of the Feedwater Flow Nozzle 187 3-4.1.3-1 Power Design Heat Balance for Case Study 188 vi 3-5.

25、2-1 Flue Gas Analyzer Measurements at Locations Along the Gas Path 190 3-6.3-1 Generator-Output and Heat Rate Deviation 191 3-6.3-2 Change in Performance Profile Over Significant Cycle Positions 192 3-7-1 Variations of Fourth-Stage Pressure . 193 3-7-2 Similarities Between Predicted and Measured Pre

26、ssure Changes 194 3-8.3-1 Turbine Pressure Profiles 196 3-13.3-1 Adjusted Inverted Cone 203 Tables 1-2.6-1 Off-Design Conditions Approximate Effect on Actual Heat Rate 11 1-2.6-2 Value of Turbine Section Efficiency Level Improvement on a Unit Heat Rate of 10,000 Btu/kWh 12 1-2.6-3 Sensitivity of Hea

27、t Rate to Various Parameters for a Typical Pressurized Water Reactor Nuclear Power Plant . 14 2-3.6.2.2-1 Diagnostic Chart of Turbine Loss Characteristics 62 2-3.6.2.2-2 Steam Surface Condenser Diagnostics . 63 2-3.16-1 Matrix of Cycle Interrelations. 124 2-4.3-1 Incremental Rates for the Two Genera

28、ting Units in Fig. 2-4.2-1 . 133 2-4.3-2 Relative Incremental Costs Associated With a Combined Cycle Facility 134 2-4.3.1-1 Impact of Load Division on Plant Economy. 135 3-5.2-1 Air Heater Leakage . 189 3-10.1-1 Test Results of Four High-Pressure Heaters . 199 3-12.2-1 Reconciliation of Load Change

29、Based on Change in Performance Parameters . 202 3-13.3-1 Measurements Taken at the Outage 203 3-13.3-2 Calculated Cone and Feedpipe Areas . 204 3-13.3-3 Resulting Gap Clearances and Areas 204 Nonmandatory Appendix A Thermodynamics Fundamentals . 205 vii FOREWORD Since the original publication of the

30、se Guidelines in 1993, then limited to steam power plants, the field of performance monitoring (PM) has undergone considerable expansion. PM has gained in importance as the lifetime of equipment and power plants have been lengthened and greater demands on extending it by careful monitoring rather th

31、an its replacement by new equipment has become the tendency in the power industry. The techniques themselves have also been transformed, largely by the emergence of electronic data acquisition as the dominant, though not exclusive, method of obtaining the necessary information. Manual methods remain

32、 but as specialized applications. Based on the realization of the changes that have taken place it was deemed necessary to update the document itself. The new realities of engineers and other plant personnel concerned with PM are reflected in the revised organization of the new Guide. This consists

33、of three parts which are considered to have equal importance as regards the reader. Part 1 “Fundamental Considerations” stresses, not only by its contents but also by its separate editorial status, the importance of considering the essentials of PM prior to the specifics of the actual application. A

34、ll too often lack of experience or need for rapid delivery of results has led to implementation without due thought being given to the basic needs, potential benefits and likelihood of tradeoffs of the PM program. The distinction here is in the emphasis given to the underlying importance of basic co

35、nsiderations. Part 2 “Program Implementation” is a thoroughly revised and updated text of the main body of the 1993 Guide. Readers familiar with the original edition will find some of the material familiar but much that is new. The concepts of PM implementation and diagnostics have been brought into

36、 closer conjunction as is the case in contemporary practice rather than as two wholly separate aspects of monitoring activity. Similarly, the importance of cycle interrelationships have now been thoroughly recognized and so the distinction given to it in 1993 was no longer necessary; it has become a

37、n accepted part of PM implementation, in practice and in the structure of this revised Guide. Part 3 “Case Studies/Diagnostic Examples” is wholly new. Since 1993 a large amount of experience and historical data has been accumulated and a selection is here presented. The importance of Part 3 goes bey

38、ond the illustrative although the various actual situations briefly described were chosen for their applied significance. In a larger sense, Part 3 illustrates the immense scope and variety of PM and, it is hoped, thereby makes clear the need to carefully consider the specifics of each monitoring si

39、tuation. There are few general rules and many aspects particular to the plant, equipment and process to be considered. Plants technical staffs are encouraged to learn from the experience of their predecessors in the field of monitoring and carefully scrutinize these recommendations and details as gu

40、idance to establish an optimal PM program. This edition was approved by the Performance Test Codes Standards Committee on December 8, 2008. ACKNOWLEDGMENTS This revision of PTC PM Performance Monitoring Guidelines for Power Plants is dedicated to the memory of Fred H. Kindl, who passed away while th

41、is revision was in progress. Mr. Kindl was an outstanding engineer who significantly promoted the importance of power plant performance activities, a faithful member of the Committee, and a major contributor to the content of these Guidelines. viii ASME PTC COMMITTEE Performance Test Codes (The foll

42、owing is the roster of the Committee at the time of approval of this Document.) STANDARDS COMMITTEE OFFICERS M. P. McHale, Chair J. R. Friedman, Vice Chair J. H. Karian, Secretary STANDARDS COMMITTEE PERSONNEL P.G. Albert, General Electric Co. R. P. Allen, Consultant J. M. Burns, Burns Engineering W

43、. C. Campbell, Southern Company Services M. J. Dooley, Sigma Energy Solutions J. R. Friedman, Siemens Power Generation, Inc. G. J. Gerber, Consultant P. M. Gerhart, University of Evansville T. C. Heil, The Babcock which ones are controllable from an engineering perspective where equipment modificati

44、ons, either by maintenance or design change, are required to effect a change in thermal performance; and which ones are controlled by nature. These performance monitoring guidelines seek to describe in detail how an effective program can be established. There is a fourth level of loss accounting: un

45、accountable losses. This is the difference between the expected heat rate and actual heat rate after controllable losses, engineering change losses, and losses controlled by nature have been taken into account. Unaccountable losses are unknowns that need to be identified and addressed. Very often th

46、ey are evidence of cycle isolation or instrumentation problems. Once identified, they fall into one of the other three categories. As an example, there is a very close coupling and sensitive interaction within the steam generator cycle relating to unburned carbon, coal fineness, and excess air as sh

47、own in Figs. 1-2.6-9 and 1-2.6-10. Figure 1-2.6-11 shows the sensitivity of heat rate to stack temperature when inlet air temperature is controlled by cycle heat (extraction steam). A good example of graphical representation of interrelationships is shown in Fig. 1-2.6-12. It shows the effect of sev

48、eral steam generator-related parameters. Each line can rotate ASME PTC PM-2010 13 Fig. 1-2.6-10 Effect of O2and Coal Fineness on Unit Heat Rate (Courtesy Electric Power Research Institute) Fig. 1-2.6-11 Effect of Stack Gas Temperature on Unit Heat Rate (Courtesy Electric Power Research Institute) ASME PTC PM-2010 14 Fig. 1-2.6-12 Boiler Loss Optimization Table 1-2.6-3 Sensitivity of Heat Rate to Various Pa