Authors: P. M. Bosch, W. Fuls
Year: 2025
Industry: Fossil Fuel Power Generation
Keywords: Use FSE, Transient, Dynamic, Boiler, Validation, Verification, Parametric
ABSTRACT
Numerical thermo-fluid models of whole boiler systems can be robust tools for optimizing boiler designs in terms of steadystate efficiency as well as inform optimum control strategies to increase transient flexibility. The benefits of such models only bear fruit if they can be validated against real life operational measurement data. In practice, it is not always possible to obtain a full set of data describing the system with no redundancies. Additionally, uncertainties in measurements creep in leading to low fidelity data that may be inconsistent or contradictory. This paper introduces a weight based ranking methodology applied to the various errors between model predicted conditions and site measurement data for a unique 4 ton/hr hybrid fire-tube-water-tube boiler. A key aspect of the proposed method applies the ranking system to the errors of 5 measured temperatures against the model predicted temperatures for a parametric study that varies an effective radiation scaling factor (C-factor). Verification on the heat transfer rates between simple analytical models, numerical Flownex models and the Maximum Continuous Rating (MCR) data for the individual heat exchangers provided confidence in the implemented thermodynamics in the individual Flownex heat exchanger models. This formed a strong starting point for calibration of the integrated whole boiler Flownex model via the proposed error ranking methodology. The calibrated model can serve as a reliable tool for performance analysis and transient control studies.