THERMOFLEX Basics II
THERMOFLEX Basics II
THERMOFLEX
Basics II
Modes & Component Types
Topics
➢ Design mode computations determine the size of a component, based on its assumed
thermodynamic duty
➢ Off-design (OD) mode computations determine the thermodynamic performance of a
component based on its size
Example 1: If a pipe is assumed to have a smaller pressure drop in design mode, the
design computation will size it to be larger. In off-design mode, its pressure drop will be
computed, dependent on flow rate and conditions. A larger pipe will have a smaller
pressure drop at any flow rate.
Size is “virtual” for THERMOFLEX components and “physical” for PEACE components.
Size is “virtual” for THERMOFLEX components and “physical” for PEACE components.
2-3. Difference between THERMOFLEX & PEACE components, e.g. Heat Exchanger
Size is “virtual” for THERMOFLEX components and “physical” for PEACE components.
Q= (UA) TLM = TLM/ Rt
For a THERMOFLEX HX:
Rt = Total Thermal Resistance = (UA)-1 = (hAAA) -1 + Rw + (hBAB) -1
The virtual sizing parameter is heat transfer ability at the design-point, (UA)D. This is
found from the design-point heat balance solution. The method of Thermal Resistance
Scaling allows one to scale heat transfer coefficients on the A-side and B-side of the
heat exchanger in proportion to the changing A-side and B-side mass flow rates:
hA,OD =hA,D (mA,OD / mA,D)x
hB,OD =hB,D (mB,OD / mB,D)y
Rw,OD = Rw,D
Thus, heat transfer ability at off-design, (UA)OD.is computed from that at the design-
point, (UA)D.
For a PEACE HX: A complete physical design of the heat exchanger is performed,
including number of tubes, their diameter and wall thickness, material, length, and fin
geometry, dimensions and materials, if applicable. This leads to a detailed, accurate
calculation of heat transfer coefficients at off-design, without resorting to the
approximations inherent in the method of Thermal Resistance Scaling.
To help the user, the program has logic that automatically selects physical design
criteria for PEACE components. Examples of these design criteria are:
(a) A high temperature steam pipe requires a material such as Cr-Mo steel,
whereas a steam pipe at modest temperature is generally made from carbon
steel.
(b) A high-flow, low-head pump is typically of the “vertical turbine” type, whereas
a high-head, low-flow pump is typically of the “multi-stage centrifugal” type.
Such criteria cannot be applied to initialise the inputs, unless the approximate
thermodynamic duty has already been established. Thus, the design process for
PEACE components is in two phases:
Thermodynamic Design (TD) Mode has no hardware-specific inputs, and just
finds the heat and mass balance solution.
Engineering Design (ED) Mode has hardware-specific inputs, to find component
physical design. The inputs are automatically initialised by the program, based on
the thermodynamic duty.
Use 2% (same as
TFX economiser)
Use 1% (same as
TFX economiser)
The results in TD mode are identical (to within convergence tolerance), whether a PEACE or a
THERMOFLEX economiser is used, as long as their input assumptions are identical.
Hint: Selecting ED mode from the main graphic screen, whether in output or input mode, will (a) switch
all PEACE components that had been in TD mode to their ED mode, with all defaults; (b) revert to the
input screen; and (c) set THERMOFLEX components to their TD mode (their only design mode).
THERMOFLEX
Select Off-design
(OD) mode
Hints:
Select Off-design
(OD) mode
The Hardware tab allows you to alter the design created by ED mode. You may explicitly edit the dimensions,
geometry, or materials of the Economiser component. Please explore this screen by editing the geometric
configuration variables and dimensions, and observe how the diagram adjusts to reflect your data.
As in ED mode, the Other Inputs tab allows you to edit miscellaneous parameters
that affect the geometry and thermodynamic performance of the component.
OD Mode outputs for PEACE components are essentially identical to those for ED
mode. If any design parameter is changed in the OD mode inputs, the effect of
that change will be reflected in both the performance and the cost estimate
outputs when the OD mode computation is run.
In ED mode, some differences from TD mode, usually minor, may arise with PEACE
components. This is because many PEACE components, such as heat exchangers and
pipes, have their pressure drops computed based upon their physical design, whereas
equivalent THERMOFLEX components have their pressure drops assumed by the user. If
the user enters the pressure drops computed by PEACE in ED mode into the equivalent
THERMOFLEX components in their design mode, results would be identical (to within
convergence tolerance).
In OD mode, the physical details of the PEACE components allow more accurate off-
design calculations. Thus, even if the design-point heat balances match, some
differences, usually minor, may arise between PEACE and THERMOFLEX components.
To explore these differences, we construct a HRSG model out of PEACE components, and
compare its part-load behaviour with that of an equivalent HRSG constructed out of
THERMOFLEX components.
THERMOFLEX
5-15. Construct a similar macro for the THERMOFLEX HRSG and compare in Excel
Starting from “PPTutorial_OD”, which is built solely from THERMOFLEX components, create a similar macro. Copy
its output table to the same Excel workbook.
Now you can compare the results with both types of components. They are very close in this example, but greater
differences may arise in other cases, particularly with supplementary firing.
THERMOFLEX
THERMOFLEX
As the message indicates, reverting to ED mode for the Integral D/A will result in its
re-design. Thus, if you had explicitly edited any of its hardware parameters in OD
mode, your edits may be lost and replaced by the new design if these same
parameters are redefined or recomputed in ED mode.
When you close the Integral D/A menu, you will notice that the Global Switch reports that we are
in Mixed ED+OD mode. This is because the D/A is now in ED mode while the other components
have remained in OD mode. Check Inputs and Compute to redesign the DA with the bare tubes
and geometry we just dictated. The other components will not be redesigned.
When you compute, the Global Switch will show Mixed ED+OD
on the main output screen, and when you open the Integral
D/A’s component output, you will see that it is still in ED Mode.
You may review its PEACE outputs and ascertain whether the
new design is satisfactory.
Hint: Defined Performance Mode is useful for imposing known results upon a component, or for simplified treatment of
components of secondary importance to the overall system model.