Steam Flow Compensation Equations

Steam Flow Compensation for Distributed Control Systems
Page 1 of 10
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
sv) is calculated as:
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:
http://www.desconengineering.com/WhitePapers/SteamFlow/Steam_Flow_Compensati... 7/26/2006
Page 2 of 10
M is Steam Flow in KLbs/Hr (i.e. the compensated steam flow),
SV is the Specific Volume Compensation Factor (based on Temperature and Pressure)

a is the Thermal Expansion Correction Factor (based on Temperature)
M is the meter factor (typically equal to maximum flow divided by the square root of max differential pressure),
and h
w is the measured differential pressure across the flow meter (typically in inches H2O).
Specific Volume Flow Compensation Factor (FSV ) Tables

The most accurate means to calculate or derive the Specific Volume Compensation Factor (F
SV ) is to use a look-up table of flow
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.
Flow correction Factors (FSV )

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
(Psia)
1000
1100
1200
1300
1400
1500
1600
1700
1750
1800
1850
1900
2000
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 (FSV ) error > 1%

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
sv) is calculated as:
Page 3 of 10
Equation 2.1
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 FSV

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
Psia
1000
1100
1200
1300
1400
1500
1600
1700
1750
1800
1850
1900 2000
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 (FSV )

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).

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).
Page 4 of 10
mT1 is the slope of F
SV for constant Temperature (FSV = fxn(,P) at Constant T1)

or FSV 1 = mT1 (P) + bT1
mTn is the slope of F
SV for constant Temperature (FSV = fxn(,P) at Constant Tn)

or FSV n = mT1 (P) + bTn
bT1 is the intercept of F
SV for constant Temperature (FSV = fxn(,P) at Constant T1)
or FSV 1 = mT1 (P) + bT1

bTn is the intercept of F
SV for constant Temperature (FSV = fxn(,P) at Constant Tn)
or FSV n = mT1 (P) + bTn

The method is four steps.
1.
2.
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
SV 1 = mT1 (P) + bT1
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.
4.
Third, generate a curve fit of the Slopes versus inverse Square Root of Temperature, this yields a slope and an intercept:
mSLOPES
and bSLOPES
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.
Hunters Point Boiler Main Steam Flow spec. vol. Compensation FSV equation
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
SV over a range of 1500 psia to 2000 psia and 860 DegF to 1060DegF 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
SV over a range of 1500 psia to 2000 psia and 700 DegF to 1160DegF.
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
Page 5 of 10
coefficients found in table 1.
% Error Polynomial Equation 3.1 versus actual FSV

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
(Psia)
1000
1100
1200
1300
1400
1500
1600
1700
1750
1800
1850
1900
2000
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
Temp
DegF
Table 3.1 - %error in polynomial eqn 3.1 Boiler Main Steam Flow coefficient narrow range

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
(Psia)
1000
1100
1200
1300
1400
1500
1600
1700
1750
1800
1850
1900
2000
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
Temp
DegF
Table 3.2 - %error in polynomial eqn 3.2 Boiler Main Steam Flow coefficient wide range
Hunters Point Turbine Steam Flow FSV equation

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.
Page 6 of 10
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 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)
SV over a range of 1500 psia to 2000 psia and 860 DegF to 1060DegF 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.
SV over a range of 1500 psia to 2000 psia and 700 DegF to 1160DegF.
Equation 4.2
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.

Hunters Point P.P. Turbine Steam Flow narrow range - High Accuracy - 0.3% error
Press
(Psia)
1000
1100
1200
1300
1400
1500
1600
1700
1750
1800
1850
1900
2000
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
Temp
DegF
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

Hunters Point P.P. Turbine Steam Flow Wide Range -1.25% error
Press
(Psia)
1000
1100
1200
1300
1400
1500
1600
1700
1750
1800
1850
1900
2000
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
Temp
DegF
Page 7 of 10
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
is the coefficient of linear expansion for the primary element. Fa can also be looked up graphically in texts, for example ASME Fluid
PE
Meters (1971) or Flow Measurement Engineering Handbook by R. W. Miller (1983).
Where
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,
=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
Page 8 of 10
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
(Deg F)
Fa
650
700
1000
1060
1100
1160
0.994909
0.995636
1.000873
1.001455
1.002328
Boiler Main Steam Flow Equation Hunters Point

The temperature and pressure Compensated Steam Flow is calculated as:
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
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.
Turbine Steam Flow Equation Hunters Point
Page 9 of 10
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
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
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.
ABOUT DESCON ENGINEERING

DESCON is an engineering and consulting firm, specializing in Process, Controls, Instrument and Electrical
Engineering. DESCON provides both turnkey and sub-contractor services for power and industrial plants
throughout the world.
DESCON was founded in 1982 in response to industrys need for improved application of process control
technology. Since then, DESCON has grown to a full service engineering company proving process
engineering,, control system, electrical & instrumentation engineering, process operator training and in-plant
technical services . Descon is recognized world-wide as a leader in air separation, cryogenics, refining, cogeneration and power plants.
Contact us at:
DESCON ENGINEERING
12657 Alcosta Blvd., Suite 200
San Ramon, CA 94583
Tel 925-945-1314
Page 10 of 10
Fax 925-244-6802
Email:descon@desconengineering.com
Copyright 2001 by DESCON Engineering Co., Inc.

Steam Flow Compensation Equations - For DCS

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Steam Flow Compensation for Distributed Control Systems

sv) is calculated as:

Steam Flow Compensation for Distributed Control Systems

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

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

Specific Volume Flow Compensation Factor (FSV ) Tables

SV ) is to use a look-up table of flow

Flow correction Factors (FSV )

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

sv) is calculated as:

Steam Flow Compensation for Distributed Control Systems

% Error Traditional Gas Density Compensation FSV

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

Equation 3.0 Spec. Vol. Flow Compensation Factor polynomial

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

Steam Flow Compensation for Distributed Control Systems

mT1 is the slope of F

SV for constant Temperature (FSV = fxn(,P) at Constant T1)

mTn is the slope of F

SV for constant Temperature (FSV = fxn(,P) at Constant Tn)

SV for constant Temperature (FSV = fxn(,P) at Constant T1)

or FSV 1 = mT1 (P) + bT1

SV for constant Temperature (FSV = fxn(,P) at Constant Tn)

or FSV n = mT1 (P) + bTn

bT1 , bT2, bT3 , bTn

Equation 3.1 was derived by the steps outlined above for F

Hunters Point Power Plant Boiler Main Steam Flow.

Equation 3.2 was derived by the steps outlined above For F

Steam Flow Compensation for Distributed Control Systems

coefficients found in table 1.

% Error Polynomial Equation 3.1 versus actual FSV

% Error Polynomial Equation 3.2 versus actual FSV

Hunters Point Turbine Steam Flow FSV equation

Steam Flow Compensation for Distributed Control Systems

Equation 4.1 was derived by the steps outlined above for F

Hunters Point Power Plant Turbine Steam Flow.

Equation 4.2 was derived by the steps outlined above for F

% Error Polynomial Equation 4.1 versus actual FSV

% Error Polynomial Equation 4.2 versus actual FSV

Steam Flow Compensation for Distributed Control Systems

Thermal Expansion Factor

The Ratio of FaDESIGN to FaACTUAL is the Compensation Factor Fa

Equation 5.1 Thermal Expansion Flow Correction Factor

Steam Flow Compensation for Distributed Control Systems

Boiler Main Steam Flow Equation Hunters Point

Equation 6.2 Boiler Main Steam Flow

Turbine Steam Flow Equation Hunters Point

Steam Flow Compensation for Distributed Control Systems

The temperature and pressure Compensated Steam Flow is calculated as:

Equation 7.2 Turbine Steam Flow

ABOUT DESCON ENGINEERING

Steam Flow Compensation for Distributed Control Systems

Copyright 2001 by DESCON Engineering Co., Inc.

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