Transcript Document

Thermoflow Inc.
THERMOFLEX
Basics I
Introduction & Basic Use in Design Mode
© Thermoflow, Inc., 2011
THERMOFLEX
Topics
1. Introduction
2. THERMOFLEX components and fluids
3. Building a model – Draw System
4. Building a model – Check Drawing
5. Building a model – Edit Inputs
6. Building a model – Check Inputs
7. Computation & messages
8. Graphic & text outputs
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THERMOFLEX
1-1. What is THERMOFLEX ?
 Fully-flexible program for heat balance modelling & engineering. Models are built
graphically, by assembling components “lego-style”
 You can use it to build models for Combined Cycles, Conventional Steam Cycles,
Process Plants, etc; in fact, any system you can assemble from its vast library of
components
 Performs both design and off-design calculations
 Allows multi-run macros to explore trends
 Contains powerful “Logical Components” to model off-design controls
 In combination with PEACE (Plant Engineering and Construction Estimator), it
provides engineering details and cost estimation for many components
 You can use it alone, or in combination with GT PRO, GT MASTER, or STEAM MASTER
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1-2. Applications where THERMOFLEX should be used
 Detail engineering of power or process plants
 Balance of plant design and optimisation
 Feasibility studies of unique power or cogeneration plants, particularly those
involving integration of old and new equipment
 Cogeneration with piston engines
 District heating and cooling facilities
 Modelling novel or unique systems (HAT cycle, Kalina Cycle, etc)
Applications where other programs may be advantageous:
 GT PRO/GT MASTER are best suited for feasibility studies, conceptual
engineering, and simulation of larger GT power or cogeneration facilities
 STEAM PRO/STEAM MASTER are best suited for feasibility studies, conceptual
engineering, and simulation of larger conventional steam power plants
 RE-MASTER is best suited for feasibility studies of repowering of large,
conventional, steam power plants
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THERMOFLEX
1-3. Guide to the THERMOFLEX Manual
Chapter 2 describes the basic mechanics of using the program.
Chapter 3 describes the more advanced features of THERMOFLEX.
Chapter 4 explains linking THERMOFLEX with Thermoflow’s other application-specific
heat balance software, including PDE, GT PRO, GT MASTER, STEAM PRO and STEAM
MASTER.
Chapter 5 discusses global inputs and definitions shared by many of the THERMOFLEX
components.
Chapter 6 describes how THERMOFLEX calculates network flows and pressures.
Appendix A provides brief descriptions of each of the sample files provided with
THERMOFLEX.
Appendix B summarizes the key differences between the UI introduced with version
21 and the previous, original interface.
The other chapters describe the individual THERMOFLEX components.
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THERMOFLEX
Basics Tutorial - Topic 2
1. Introduction
2. THERMOFLEX components and fluids
3. Building a model – Draw System
4. Building a model – Check Drawing
5. Building a model – Edit Inputs
6. Building a model – Check Inputs
7. Computation & messages
8. Graphic & text outputs
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2-1. Main drawing screen & definitions
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THERMOFLEX
2-2. Working fluids & colour coding
Type-1 Fluids (Red): Gases containing N2, O2, CO2,, Ar, H2O (as vapour or as entrained liquid), and SO 2. This
includes air or products of combustion as well as any user-defined mixture of those substances. (A special family within
this category also includes any pure gas selected from a database of 71 gases).
Type-2 Fluids (Blue): H2O in any phase; subcooled, two-phase, superheated, or supercritical
Type-3 Fluids (Orange - green on some computers/video settings): Gaseous, liquid, and solid fuels of any
composition; standard or user-defined
Type-4 Fluids (Purple): Refrigerants, such as Ammonia (NH3), Refrigerant 22 (CHClF2), Isobutane (C4H10), etc.
Other fluids modeled using REFPROP, available from U.S. National Institute for Standards and Technology.
Type-5 Fluids (Light Blue): Mixtures of ammonia and water, for modeling Kalina cycles
Type-6 Fluids (Brown): Brine of variable salt concentration for modeling desalination processes, seawater cooling
systems, seawater FGD, etc.
Type-7 Fluids (Pink): Heat Transfer Fluids / Thermal Oils used as liquids in closed loop heating and cooling
systems
Nodes that handle any fluid type are black
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Nodes
that handle more than one, but not©allCopyright
fluidsThermoflow,
are grey Inc., 2011
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2-3. Rules for mixing fluids of different types
THERMOFLEX
 A stream may always be mixed with one of an identical fluid
 Some fluids, such as Refrigerants, cannot be mixed with a different fluid type
 Mixing different fluid types may occur, subject to restrictions, via mixers. The outflowing
stream is of the more general fluid type, as indicated below.
Type-1 Fluids (Red):
N2, O2, CO2, H2O
+
Type-2 Fluids (Blue):
H2 O
Type-1 Fluids (Red):
Type-2 Fluids (Blue):
H2 O
Type-3 Fluids (Orange):
(Red): Type-1 Fluids
N2, O2, CO2, H2O
including N2, O2, CO2, H2O
N2, O2, CO2, H2O
Type-2 Fluids (Blue):
H2 O
Type-3 Fluids (Orange):
Fuel of any composition,
including N2, O2, CO2, H2O
+
+
Fuel of any composition,
Type-4 Fluids (Purple):
Refrigerants
Type-5 Fluids (Pale Blue):
Ammonia/Water mixture
Type-6 Fluids (Brown):
NaCl + H2O
+
Type-2 Fluids (Blue):
Type-6 Fluids (Brown):
H2 O
NaCl + H2O
Type-7 Fluids (Pink):
Heat Transfer Fluids
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THERMOFLEX
2-4. Icon selector & definitions
See the Icon Selector Map in Appendix A of the THERMOFLEX help file for a list
of the components in each Icon Group.
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2-5. Icon anatomy & definitions
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Basics Tutorial - Topic 3
1. Introduction
2. THERMOFLEX components and fluids
3. Building a model – Draw System
4. Building a model – Check Drawing
5. Building a model – Edit Inputs
6. Building a model – Check Inputs
7. Computation & messages
8. Graphic & text outputs
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Building a Model – Draw System
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THERMOFLEX
3-1. Picking & placing components
To add the superheater, click on its icon in
the Icon Selector, then move the floating
icon to where you want to drop it. See the
Edit Drawing Stage section of Chapter 2 –
THERMOFLEX Basics in the THERMOFLEX
help file for more on adding components.
Water/steam
Flue gases
Superheater icon, on the
Boilers/HRSGs
component bar
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THERMOFLEX
3-2. Connecting components
Two alternate ways to connect components:
1) Snap them together directly. THERMOFLEX will form temporary connections between compatible nodes if
you move components close enough together. These temporary connections will become permanent if
you drop the icon in that location.
2) Click on one node to start the connection process and then click on its desired counterpart to complete it.
a) If you want to explicitly set the connector path between the nodes, click to set intermediate points
before clicking on the final node to complete the connection.
See the topics on Streams & Connectors and their menus in the Edit Drawing Stage section of Chapter 2
– THERMOFLEX Basics in the THERMOFLEX help file for more on connecting components.
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THERMOFLEX
3-3. Connecting with tags
There are two ways to connect nodes with tags:
1) Click on the first node while holding the Ctrl key. Click
on the second to complete the tagged connection.
2) Right-click on an existing connection and choose
Connect with tags from the connector context menu.
Note: Icons on different sheets will automatically be
connected with tags when a connection is formed.
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THERMOFLEX
3-4. Connector vs. Pipe
The connector (or pair of tags)
conveys a stream without any
pressure or enthalpy loss. If you
wish to define pressure and heat
losses, you should install a Pipe
component.
The simple THERMOFLEX Pipe is
in the General icon group.
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The more detailed PEACE Pipe, found next to the THERMFLEX Pipe in the General icon
group, provides physical sizing and engineering calculations for pressure drop, as a
function of length and number and types of fittings. It also provides cost estimation.
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THERMOFLEX
3-5. Rotating (transposing) a component
With the Gas Turbine icon
highlighted, pressing F9 or
clicking “Transpose” on the
icon’s context menu
(summoned via a rightclick) flips it around.
When the Gas Turbine
icon was first dropped, it
was not in the desired
orientation.
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THERMOFLEX
3-6. Deleting an object or group of objects
Pressing the <Delete> key
will delete any and all
currently-selected objects.
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THERMOFLEX
3-7. Moving a group of objects
To move a group of objects, first select
them, then click and drag one of the
selected objects. Release to drop the
group at a new location.
Note: You can also move objects when in
Edit Inputs or View Outputs mode. The
objects you wish to move must be
Unlocked before you can move them –
see the description of the Flowsheet
Dropdown Menu in Chapter 2 > Edit
Drawing Stage > Basic Drawing
Concepts of the THERMOFLEX help file
for more information on locking and
unlocking objects.
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THERMOFLEX
3-8. Writing comments on the screen
To write a comment, click on the Add Text Label
button, then click where you wish to write. A text box
appears into which you may type.
Useful Hints:
1)
Double-click on an existing text box to edit its text.
2)
You may later click on any text box and drag it
elsewhere, or change its font or appearance options
by right-clicking on the text box and selecting Edit
Display Properties….
3)
You can resize a text box by right-clicking on it and
selecting Resize.
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THERMOFLEX
3-9. Copying a group of objects
To copy a group of objects, select
them, then invoke “Copy” (right-click
> Copy or Ctrl+C) or press F8.
These two methods act slightly
differently:
1) Copy (Ctrl+C): The highlight
color will turn green, showing that
the selected objects are in the
copy buffer. New copies of these
objects will be created upon
selecting Paste (Ctrl+V).
2) F8: Copies of the selected objects
will be created and will follow the
cursor until you click to place them
in their new locations.
Useful hints:
1) If the new location is to be another new sheet,
click Add sheet on the sheet selector before
dropping the copy. If it is another, extant
screen, Sheet 3, say, click Sheet 3, before
dropping the copy.
2) If a copy of many objects is to have similar
inputs to the original, make it after you are
done editing the inputs of the original, to save
time.
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THERMOFLEX
Basics Tutorial - Topic 4
1. Introduction
2. THERMOFLEX components and fluids
3. Building a model – Draw System
4. Building a model – Check Drawing
5. Building a model – Edit Inputs
6. Building a model – Check Inputs
7. Computation & messages
8. Graphic & text outputs
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Building a Model – Check Drawing
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THERMOFLEX
Check Drawing
(F3)
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4-1. The Check Drawing Transition
Invoking the Check Drawing routine causes
THERMOFLEX to check the current model for any
possible problems that must be fixed before moving
on to the Edit Inputs stage. See Check Drawing
Transition in Chapter 2 > Edit Drawing Stage of
the THERMOFLEX help file for a more detailed
description.
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THERMOFLEX
4-2. Check Drawing messages: Missing connection
Double-clicking on a problem
in the Drawing Problem List
will move your cursor to the
problematic component, even
if it is on another screen.
Hollow nodes
are optional.
Upon invoking Check
Drawing it will advise
you of missing,
required connections.
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THERMOFLEX
4-3. Check Drawing messages: Ambiguous fluid type
Upon invoking Check Drawing, if a stream’s fluid type has not been fully defined,
you will be asked to define it using a Fluid Specification component. In the
example, the closed loop has no defined fluid type, as evidenced by its gray color.
A Fluid Specification component of the desired fluid type is required to tell
THERMOFLEX what kind of fluid is being pumped around the circuit. Please see the
Closed Loop section of Chapter 6 – Calculating Network Flows and Pressures
of the THERMOFLEX help file for more on constructing closed loops.
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THERMOFLEX
4-4. Check Drawing messages: Undetermined
pressures
Upon invoking Check Drawing, if a closed loop
without any pressure-defining components
(e.g. Fluid Specification, Steam Turbine group)
is detected, you will be asked to define the
pressure at any point within the loop. Open
loops use sources, sinks, or other pressuredefining components as pressure anchors.
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THERMOFLEX
4-5. Passing the Check Drawing Transition
When Check Drawing succeeds, the
window background color changes from
white to gray, indicating you are no longer
in Edit Drawing Mode and thus can no
longer add or remove components (unless
you return to Edit Drawing Mode). Now
you are in Edit Inputs Mode, and you can
edit the inputs of each component.
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THERMOFLEX
Basics Tutorial - Topic 5
1. Introduction
2. THERMOFLEX components and fluids
3. Building a model – Draw System
4. Building a model – Check Drawing
5. Building a model – Edit Inputs
6. Building a model – Check Inputs
7. Computation & messages
8. Graphic & text outputs
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THERMOFLEX
Building a Model – Edit Inputs
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THERMOFLEX
5-1. Opening a component’s input menu
Many THERMOFLEX
components without
PEACE cost estimates
have tabular input menus
Component
Mode selection
Edit Inputs
(F2)
Double-clicking on a
component invokes
Edit Inputs, and
summons that
component’s input
menu (you must be
in input mode, gray
background)
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In design-mode,
off-design inputs
show “NA”
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THERMOFLEX
5-2. Opening a component’s input menu
PEACE components, as well as
some THERMOFLEX components,
have graphical input menus
Component
Mode
selection
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THERMOFLEX
5-3. Opening other input menus
The tabs provide access to input menus that
do not pertain just to one specific component.
The pull-down list,
accessible from any
component’s input
menu, can be used
to invoke the input
menu for any other
component
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THERMOFLEX
5-4. Site menu
Any air-cooled
component, such as
the PEACE Air-cooled
Condenser shown,
would receive air at
the site conditions if
the optional inlet port
is left unconnected.
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Any Gas/Air Source that is
declared to be “Ambient” has
the thermodynamic state and
composition of the site.
“Ambient” is the default, but
you may open its input menu
and declare a user-defined
pressure, temperature, and
composition.
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THERMOFLEX
5-5. Miscellaneous menu
Auxiliary loads defined here may be declared as Additional to
the program’s computation, as Total misc. auxiliary power
instead of the program’s computation of miscellaneous auxiliary
power, or as Total user-defined auxiliary power, which
disregards all auxiliary power calculated by the program.
User-defined auxiliary
load may be defined
with a component in
proportion to plant
gross output and a
fixed component.
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THERMOFLEX
Pull-down list to select any
generator or motor
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5-6. Generators/Motors menu
Rating point efficiency
may be automatically
estimated or defined by
the user
Part-load curve may be
automatically determined or
defined by the user, via the
Performance Map button
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THERMOFLEX
5-7. Editing menus for the example shown below
For our example system, we will select a Rolls-Royce RB211 gas turbine.
Process steam production rate will be found by the program, based on
GT exhaust flow and conditions and on evaporator pinch.
We will need to define:
•Process steam conditions
•Deaerator pressure
•Temperature (or subcooling) leaving each economiser.
Lets see how to make these inputs…
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THERMOFLEX
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5-8. Editing menus: GT selection
For our example, double-click on the GT to open its menu. By default, it is a
Frame 6. Click on the Reselect GT button. Choose an RB211 (ID# 221), by
highlighting it then clicking OK. Leave all defaults in place, then return to the
main screen.
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THERMOFLEX
5-9. Editing menus: Defining process conditions & flow
Define P=500 psia (35 bar),
T as available
Process mass flow rate may be entered in Item 5,
and will be attained if allowed by the rest of the
network. In our example, whatever we enter will
be overridden, since flow rate will be dictated by
the Evaporator component, so we need not bother
with this input.
Item 6 allows one to assign higher or lower
priority to achieving the desired process flow,
relative to other demands in the network, such as
another Process. In our example, this is irrelevant,
since the Evaporator will dictate flow and there is
no other branch in the network to accept it.
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Process steam or water may be liquid, two-phase, superheated or supercritical.
Depending on the selection, the appropriate inputs of Items 3-4 will become
enabled to define the state. When “As available” is selected in our example,
Items 3-4 are inapplicable.
If the state is defined with a desired enthalpy higher than what’s available from
the network, it won’t be achieved, and a message will appear upon calculation.
If the desired enthalpy is lower than what’s available from the network, a
desuperheater intrinsic to the Process component will add water, at a
temperature defined in Item 7. This water is from beyond the network. To
desuperheat with water from within the network, use the more elaborate
Process w/Return component, or insert a separate Desuperheater
component.
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THERMOFLEX
5-10. Editing menus: Pipe
Define Heat Loss of 1 BTU/lb in Item 2.
Define dP/P=0.03 in Item 3.
Inputs which only
apply to offdesign mode are
not available in
design mode.
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THERMOFLEX
5-11. Editing menus: Superheater
Define Steam outlet temperature
as 750 °F (399 °C).
Define Gas side pressure drop as
0.8 in H2O (2 mb).
Other defaults OK
Note: Gas dP is equivalent to a dP/P of approximately 0.002.
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THERMOFLEX
5-12. Editing menus: Evaporator
Define 30 °F (16.7 °C) pinch.
Define Heat loss of 1%.
Define Minimum pinch of 1 °F (0.55 °C).
Note: Gas dP is approximately equivalent to a dP/P of 0.005.
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THERMOFLEX
5-13. Editing menus: Economisers [1] & [14]
Set the control mode to Specify outlet subcooling with a value of 8 °F (4.4 °C).
Define a Heat loss of 1%
Define a Gas side pressure drop of 0.8 in H2O (2 mb)
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THERMOFLEX
5-14. Editing menus: Integral Deaerator
Set the Deaerator Pressure to 25 psia (1.7 bar).
Note how the Deaerator temperature changes, since
water leaving the component is saturated.
Define a Gas-side pressure drop of 0.8 in H2O (2 mb)
Define the Heat loss to be 0%
Define a Minimum pinch of 5 °F (2.7 °C)
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THERMOFLEX
5-15. Editing menus: Other components in the example
Water source [3] is at ISO conditions by default.
Water pumps [4] and [13] are left at defaults. The program will find their pressure rises.
Fuel source [11] is, by default, methane at 300 psia (21 bar) and 77 °F (25 °C).
Gas/Air source [10] is at ISO conditions by default.
We accept all that and invoke Check Inputs and Compute (F4/F5).
Check Inputs
and Compute
(F4/F5)
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THERMOFLEX
Basics Tutorial - Topic 6
1. Introduction
2. THERMOFLEX components and fluids
3. Building a model – Draw System
4. Building a model – Check Drawing
5. Building a model – Edit Inputs
6. Building a model – Check Inputs
7. Computation & messages
8. Graphic & text outputs
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THERMOFLEX
Building a Model – Check Inputs
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6-1. Check Inputs establishes design-mode network
pressures and checks for conflicts
THERMOFLEX
 Starting from points of known pressure, the program propagates through “pressure consumers”
 Pressure rise specs for “pressure builders”, such as pumps or fans, are overridden in design mode to suit
the known pressures and the pressure consumers
 Pressure rise specs for pressure builders are used if there aren’t enough known pressures
 If conflicts are irreconcilable, or pressures are underspecified, messages will appear
P
P
P
P
P
P
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THERMOFLEX
6-2. Check Inputs message for present example
In our example, Check Inputs fails, because the program finds that
the 300 psia (21 bar) fuel source pressure is inadequate for an RR
RB211 gas turbine. The fuel delivery system is outside the scope of
our model, so we OK the message, uncheck the drawing, and
increase the pressure of the Fuel Source to 450 psia.
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THERMOFLEX
6-3. Check Inputs after modifying the present example
After editing the pressure of the Fuel Source, we
invoke Check Drawing and Compute.
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THERMOFLEX
6-4. Check Inputs: Mandatory pressure spec changes
Suppose the user had forgotten to install a boiler feedpump,
Check Inputs would find a mismatch between the Process
pressure (500 psia) and the Deaerator pressure (25 psia),
resulting in the message shown. Clicking Accept would
reduce the process pressure to the maximum consistent with
the DA pressure. Clicking Return allows one to uncheck
inputs, then install the missing feedpump.
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THERMOFLEX
Basics Tutorial - Topic 7
1. Introduction
2. THERMOFLEX components and fluids
3. Building a model – Draw System
4. Building a model – Check Drawing
5. Building a model – Edit Inputs
6. Building a model – Check Inputs
7. Computation & messages
8. Graphic & text outputs
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THERMOFLEX
Building a Model – Computation & messages
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THERMOFLEX
7-1. Computation messages: Advisory
After computation, the output screen appears, with a yellow background. In our example, there are
Advisory Messages. These are messages reporting some mismatch between inputs and results, but
not necessarily a serious problem. Reviewing them is optional, by clicking on View. For our example,
the message simply tells us that the “desired” process flow has been overridden. In reality, we had
never even entered a “desired” process flow, leaving the default 1 lb/s in place, knowing that flow
will be set by the Evaporator component and the GT exhaust gas flow rate and conditions. We can
suppress this message by going back to Edit Inputs mode and changing the Flow priority of the
Process to “Weak.”
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THERMOFLEX
7-2. Computation messages: Warning!
Suppose the user had tried to impose an unreasonably high
pegging steam flow rate into the deaerator at the design-point
(Fix-a-flow was used to set 10 lb/s of 50 psia saturated steam
in the example shown). After computation, the program will
show a Warning message. Viewing it is mandatory, it appears
automatically when the first warning message is dismissed.
You may still see the results, unreasonable as they are.
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THERMOFLEX
Basics Tutorial - Topic 8
1. Introduction
2. THERMOFLEX components and fluids
3. Building a model – Draw System
4. Building a model – Check Drawing
5. Building a model – Edit Inputs
6. Building a model – Check Inputs
7. Computation & messages
8. Graphic & text outputs
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THERMOFLEX
Building a Model – View Outputs
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FILE: PPTutorial.tfx
THERMOFLEX
8-1. Displaying thermodynamic data for all streams
(utilitarian)
Open the Flowsheet current settings menu, choose both
the Stream data drawn over icons and the Universal
settings apply to all streams… options, and check any or
all of Pressure, Temperature, and Mass Flow to display
them. This is useful for developing the model, but may be
unsatisfactory for final presentation, since the plethora of
numbers may overwrite other objects on the screen.
The legend is shown in the
upper-right corner of the
flowsheet. Right-click on it to
change units.
In the example shown, Show Icon Numbers,
Icon Numbers, Show Labels, and Include
Stream Numbers were all unchecked to hide
them and reduce clutter.
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FILE: PPTutorial.tfx
8-2. Displaying selective thermodynamic data (presentation)
THERMOFLEX
To insert a free stream data
display, click on the Free
stream data display button
on the tool bar, then click
where you want the new
stream display.
Useful Hints:
1) To change the formatting properties of the stream display, or
to change the data displayed, right-click on the free stream
display and select Edit display properties….
2) You may later re-position the data tag by dragging it.
3) If you want the display to attach itself to the stream and
follow the stream when it is moved, right-click on the stream and
select Show stream display. This will show the stream’s Intrinsic
stream display. For more on the intrinsic display, see the
sections on Streams & Connectors and Free Stream Displays
in Chapter 2 > Edit Drawing Stage of the THERMOFLEX help
file.
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When the display is dropped, it
will automatically associate
itself to the nearest stream. If
you want to choose another
stream, double-click the
stream to invoke the stream
selection menu. Highlight the
pertinent stream and check the
data to appear, then click OK.
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8-3. Displaying cycle performance data
Click the Add Table of Variable Labels button to
invoke the Variable Table Parameters menu where
you select the data to display. The data will appear, and
will be updated automatically when you recompute. The
data may be dragged with the mouse to a new position,
or its formatting redefined, just like any text label.
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8-4. Displaying expanded component graphic
THERMOFLEX
Clicking on a component in the
output screen produces an
expanded graphic. Depending on
the selection made in the Output
Presentation panel on Main tab in
the Preferences menu (Edit > Set
Preferences…), this graphic may
be displayed in the main window, in
a separate window with all other
component outputs, or in a
separate window by itself.
The left-hand column of the
component’s output window lists all
available outputs for the component.
In our case, we can see that the
Economiser generates a TQ Diagram.
This chart may be printed, copied and
pasted into another application, or
saved as a WMF file.
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8-5. Exporting the main output graphic as a WMF file to
other applications
Useful Hint: The WMF file is smaller
than a bit-map and, in principle, can be
edited. In practice, its manipulation can
be frustrating, depending on your
software environment.
Click on File and
select Print Preview
Click the Copy image button
then paste it to another
application as a WMF file. You
may also save it as a WMF file.
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8-6. Exporting the main output graphic as a bit-map to other
applications
Useful Hint: The bit-map is larger than
a WMF file and can only be edited as a
picture. However, it is more stable in a
variety of software environments.
With the diagram displayed, press Alt+Prnt Scrn to copy the
screen to the clipboard. Go to your other application and Paste
(Ctrl+V). You may format the pasted picture by clipping it or
changing its size, etc, using the other application’s picture editor.
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8-7. Displaying multi-component T-Q diagram
THERMOFLEX
Click on Define and select Multi- HX
TQ Diagram, to invoke a menu that
allows you to select the heat
exchangers and their temperature
profile display sequence.
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8-8. Text output
Click on the Text output view to
see the text outputs of your
system. The panel on the lefthand side of the screen shows all
available general text outputs for
your model.
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