Page 1 of 10
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
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:
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Page 2 of 10
and h
w is the measured differential pressure across the flow meter (typically in inches H2O).
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.
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.
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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.
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
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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
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)
SV over a range of 1500 psia to 2000 psia and 860 DegF to 1060DegF for the
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.
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
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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
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
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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
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
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.
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
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
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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
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
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
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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
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 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
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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 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.
Equation 5.2 Thermal Expansion Flow Correction Factor, Design Temp = 1000 DegF, 5% Chrome Moly
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Email:descon@desconengineering.com
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