Levelstate Levelstate Systems Ltd.

7. Bentley Ind. Ctr., Bentley, Farnham, Surrey. GU10 5NJ. England. UK. Tel Fax : : 01420 22818 01420 22824

Boiler Water Level Monitor 202 System INSTALLATION MANUAL

ISSUE: E

March 2003

1992 Levelstate Systems Ltd.

All rights reserved

With technical progress the Company reserves the right to change specifications without notice.

Contents
Section Boiler Codes or Standards - Summary of requirements 1. 2. Operating Principle General Configuration 2.1 Trip Circuits 2.1.1 Low Level Trip 2.1.2 High Level Trip 3. Installation & Cabling 3.0 General 3.1 Water Column 3.2 System Cabling 3.3 Electronic Unit 3.4 Remote Display 4. Commissioning 4.1 Probes 4.2 Electronic Unit 4.3 Water Column 5. Maintenance & Fault Identification 5.1 Pressure Parts 5.2 Electronic Units 5.3 Fault Identification Procedure 6. Electronic Unit Descriptions 6.0 Electronic Enclosure 6.1 Discriminator & Display - PCB1 6.2 Supply & Relay - PCB2 6.3 Remote Display Unit 6.4 202 EDLI Parts List 7. 8. System Specification PED DIRECTIVE DOCUMENTATION 37 39 41 43 45 46 48 32 34 35 27 29 30 14 15 18 21 25 Page 3 4 6 11 12 13

Figs 1.1 1.2 1.3 1.4 2.0 2.1 2.2 3.1.1 3.1.2 3.2.1 3.2.2 3.2.3 3.3 3.4 5.3.3 6.0 6.1 6.2 6.3 Sensing Element Water Level Monitoring Typical Water Conductivities Switching Hysteresis System Configuration Side Arm Water Column Probe Type 801 and 803 Water Column Installation Detail Water Column Support Structure System Cabling Water Column Probe Cable Routing Cable Gland Allocation Electronic Enclosure Outline Dimensions Remote Display Outline Dimensions Fault Identification Procedure Electronic Enclosure Layout PCB1. Layout PCB2. Layout PCB3. Layout

Page 4 4 5 5 8 9 10 16 17 19 20 20 22 26 36 38 40 42 44

Boiler Codes or Standards - Summary of requirements

ASME Boiler Code Boilers must have one gauge glass. Above 400psi operation two gauge glasses shall be provided. For boilers with safety valves set at or above 900psi two independent remote level indicators may replace one of the two gauge glasses. If both remote indicators are in reliable operation the remaining gauge glass may be valved off but must be maintained in serviceable condition. If gauge glasses are not visible to the operator two dependable Indirect Indicators shall be provided. The lowest visible level of the gauge shall be at least 2 above the lowest permissible water level where there is no danger of overheating any part of the boiler. Each water gauge glass shall be equipped with a top and bottom shutoff valve of through flow construction to prevent stoppage by deposits of sediment. Straight run globe valves shall not be used. Connections from the boiler to the remote level indicator shall be at least 0.75" pipe size including isolation valves. For gage glasses connected to the boiler the steam and water connections shall not be less than I" pipe size. There shall be no sag or offset in the steam pipe and no part of the water connection shall be above the point of connection to the gauge. It is recommended that each boiler have two independent low water cut-offs. The permanent installation of cutout devices for low water cut-offs should not be provided; temporary devices can be installed for testing. British Standard BS759. Part 1. 1984 Boilers shall have two independent gauge glasses each capable of being isolated from the boiler. One water level gauge is permitted for boilers of less than 145kg/h evaporative capacity. For boilers with safety valves set at or above 60bar in two independent manometric remote level indicators may replace one of the gauge glasses. One gauge glass with its isolating valves shall be connected directly to the boiler. Remote level Indicators which have been approved by an Inspection Authority may replace gauge glasses. The lowest visible level of the gauge shall be at least 50mm above the lowest permissible water level where there is no danger of overheating any part of the boiler. Steam and water isolating valves if straight pattern globe type shall be mounted with the spindle horizontal. The bore of steam and water connections shall be not less than 25mm, local to fittings not less than 20mm. The level gauges shall be mounted as close as is practical to the boiler shell or drum. Automatic controls shall effectively shut off the fuel supply in the event of low water level. There is a reasonable degree of commonality between the above requirements and this is generally reflected in other National Regulations. Accepted or recognised standards must be used for the design, material selection, welding and inspection of pressure containing components.

1. Operating Principle The Levelstate 202 System is an approved electronic alternative to the gauge glass providing a significant improvement in accuracy, visibility, reliability and safety, enabling transmission of the water level condition to a remote display and the application of alarm and control functions. indication and control functions. The discrimination between water and steam is based on the significant difference in resistivity between the two states over the saturation range. The sensing element is a Probe with an insulated tip inserted in a side-arm water column FIG 1.1. If a voltage is applied to the tip, conduction occurs between the tip and the inside wall of the column. The dimensions are selected to provide a resistance typically less than 0.1 Mega-ohms when the Probe is immersed in water, which results in a resistance greater than 5.0 Megaohms for the steam condition. An electronic discrimination circuit is arranged to sense whether the Probe resistance is less than 0.1 Mega-ohms representing water or greater than 0.1 Mega-ohms representing steam. The detection level is dependent on water purity and boiler operating conditions. With 14 Probes spaced vertically in a side-arm vessel attached to the boiler FIG 1.2 and with each Probe connected to its own sensing and water/steam indication circuit a vertical display of 14 Green/Red indicators provides sufficient resolution for the water level indication. The spacing between Probes is chosen to cover the required Sight-Range. It includes connections for two separate Mains Supply inputs to achieve the ultimate security and reliability for the

801 Probe

501 Water Column

Boiler Drum

Fig 1.1

Fig 1.2

Fig 1.3

Fig 1.4 below shows the relationship between boiler water resistivity (the inverse of conductivity) and boiler drum pressure. The side-arm column purposely stimulates condensate flow and this flushing effect results in the column water being purer than the water in the drum. As the pressure increases the water resistivity increases and it is essential that the water/steam switching threshold lies above the side-arm water resistivity for the maximum boiler pressure encountered. On the other hand it is advisable to use as low a resistivity switching threshold as possible to render the system less susceptible to switching over due to moisture and water droplets.

STEAM

10

STEAM AND WATER RESISTIVITY RELATED TO BOILER PRESSURE

10

THRESHOLD & HYSTERESIS 0.5uS/cm

ULTRA PURE WATER

10

1uS/cm

2uS/cm
10
5

SIDE ARM VESSEL WATER 20 50 100 PRESSURE (BAR) 150

General Configuration

The 14 probes are installed in a side-arm water column in two staggered vertical rows, numbered from the bottom; the ODD numbered probes are located on one side of the column and the EVEN numbered probes on the opposite side. A typical Water Column is shown in Figs 2.1 and two versions of Probe shown in Fig 2.2. Two printed circuit boards contained in an IP65 (NEMA 4X) wall mounted enclosure provide 14 discrete water/steam discrimination circuits, LED display, relay alarm outputs, 4-2OmA output and terminals for the connection of a Remote Display Unit. A Probe channel comparison or validation circuit is included whereby any channel indicating a "water above steam" or "steam below water" condition illuminates a yellow system fault indicator and initiates a relay contact output. Generally the water column is aligned for Normal Water Level (NWL) located between Probes 7 and 8, with the lower probes normally sensing water and the upper probes normally sensing steam. As the steam condition presents a high resistance to the sensing circuit which is indistinguishable from an open circuit connection, two wires are used on the probe channels normally sensing steam; if either wire is disconnected the sensing circuit indicates the water state thus declaring the fault. For the single wire connection to the lower probe channels an open-circuit connection obviously indicates the steam state at the channel output again declaring the fault. For this standard arrangement a 22 core PTFE cable is provided for probe connections with the lower 8 Probes having a single wire connection and the upper 6 Probes having a two wire connection. To avoid galvanic action at the probe and variations in sensing voltage due to changing electrolytic potentials, an alternating voltage source is applied to the probe and the sensing circuit responds only to an alternating waveform. Two low frequency oscillators are provided for the source voltage, one driving the odd numbered channels and the other the even numbered channels. The voltage applied to the probe is less than 6 volts, current limited to 50 microamps and presents no risk to personnel. Collectively the discrimination or sensing channels may be set to one of three sensitivity selections for water conductivity. Each channel output drives a Green LED for Water detected or a Red LED for Steam detected and also increments the 4-2OmA Transmission circuit. Two alarm relays RL2, RL3 with integral delays, may be programmed to any channel except 1, 7 and 14. If more than one channel is linked to the RL2 or RL3 delay circuit either channel will initiate the delay relay action. If a channel from 2 to 6 is linked and a channel from 8 to 13 linked to the same delay circuit the low channel will initiate delay relay action when steam is indicated (Lo Alarm) and the high channel will 6

initiate action when water is indicated (Hi Alarm). This can provide a single alarm contact for a combined Lo or Hi Level Alarm. An additional two relays RL1, RL4 are included for instantaneous or delayed Trip action whereby an extended 2 out of 3 Probe Channel voting logic is applied. RL1 is allocated to Low Water Level Trip and RL4 to a High Level Trip. Relay action can be selected for normally energised or normally de-energised depending on the alarm/trip policy required. A link-programming feature allows selected display LEDs to flash on initiation of Alarm relays RL2 and RL3. Any illuminated Red LED (Lo Water Level) on channels 2 to 6 and any illuminated Green LED (Hi Water Level) on channels 8 to 13 may be selected to flash when either RL2 or RL3 bus line is activated. An identical linking facility is also provided to flash LEDs on the Remote Display Unit. To achieve the highest operational integrity, provision is made for Two Separate Mains Supply inputs to be applied. The DC output voltages from separate transformers are interconnected to 12V regulators so that in the event of one Mains Supply failing the 202 instrument remains fully operational. Either Mains failure is signalled through the system fault alarm. One regulator is allocated to supply the Odd numbered Probe channels and the second supplies the Even numbered Probe channels. separately supplies the logic board and alarm circuits. rupturing of the Mains fuses in the event of a short on the associated circuitry. A third regulator All regulators are current limited to prevent

Pure Nickel PTFE coated 5 or 10 METRE 22 core NICKEL ring crimps for probe connection Ferrule crimps for electronic connection

PROBE END CONNECTION

ELECTRONIC END CONNECTION

Type 202 22 core probe cable

FIG 2.1

Side Arm Water Column 9

The 202 System employs multiple Probes installed in a vertical Column, usually in two diametrically opposite rows. Two types of Probes are available; one rated at 120bar which is directly screwed into the Type 501 Water Column or, for ratings to 207bar a flanged type is inserted into the Type 503 Water Column and retained by a clamp plate which is secured by four studs and nuts.

PROBE TYPE 801 Rating 150 Bar @ 343 C

PROBE TYPE 803 Rating 207 Bar @ 370 C

PROBE TYPE 802 Rating 207 Bar @ 580 C

Compression nut fitting

Thread M16 x 1.5

Spiral wound Metaflex Gaskets St. Steel / Supagraf

Fig. 2.2 PROBES

10

2.1 Boiler shut-down or trip circuits Two low water level shutdown devices are a stipulated requirement in the Regulations for the protection of steam raising boilers, Two remote level indicators may replace one gauge-glass; if a trip circuit is derived from each remote level indicator system the requirements are satisfied. For the practical application of shut-down systems the consequences of malfunction of the protection circuit must be considered when deciding which method of implementation is the most appropriate. If a relay is normally energised in the healthy state of the plant, supply failure or relay coil open circuit will obviously induce a spurious trip; if the relay is normally not energised, supply failure or relay coil open circuit prevents initiation of a required trip action. Similarly if a normally closed relay contact is used and a wire disconnection occurs a spurious trip is initiated. If a normally open contact is used a wire disconnection is not apparent and a trip requirement cannot be initiated. The economics of Power Plant boiler operation dictates that spurious trips due to protection system faults must be minimised and the required degree of shut-down system "availability" must be achieved by duplication of protection devices. For other boilers perhaps the consequent hazards created impose the policy that a trip requirement must always be actioned and the possibility of spurious tripping has to be accepted. The protection system policy must first be established and the duplication and interconnection of the trip circuits organised to suit the requirements in terms of Reliability and Availability. When discussing industrial equipment performance the mere mention of 'failures' evokes Murphy's Law. It must be accepted that even with an extremely small failure rate of one in a million hours (probability of failing once in 114 years) it could happen tomorrow, so however remote the probability the consequential effects of failures should be considered. For the 202 System the prime failures which affect reliability are the following:1. Mains supply source. It a highly secure instrumentation supply is available this should be used. If two Water Level Indicators are fitted they should be supplied from separate mains supply sources. The 202 Electronic Unit has provision for two separate Mains Supply inputs. In the event of one Mains Supply failure the Unit remains fully operational. 2. 3. Steam leaks from valves can cause level indication errors. The prime failure of the Probe is to the 'water state due to the possibility of insulator contamination caused perhaps by poor control of boiler water quality. The water column intentionally stimulates condensate flow through the system to reduce density errors but this also improves the water purity in the column preventing contamination. Failure of the pressure seal at the ceramic insulator generally causes the water state to be indicated. For probes normally immersed in water at the lower levels this failure is not apparent and is only discovered when a low level occurs where a trip may be required. It is recommended that a test for this type of failure is performed at least every 6 months.

11

2.1.1

Low Level Trip This presumably applies to single element

For boilers many Operating Guidelines or Codes of Practice' recommend that for low level tripping devices any equipment fault should initiate a boiler trip. equipment. With the prime failure mode of the Probe to the water state and, for the lower Probes, a wire disconnection inducing the steam state, there is some confliction in conforming to the above 'Guidelines'. For the 202 system a secure fault tolerant approach has been implemented whereby the basic 2 out of 3 arrangement has been modified to produce 4 Pairs from 4 Probe channels. Any one pair where both channels indicate the Steam condition will initiate trip relay action . The pairings are chosen to counter the possibility of a 12V supply regulator failing which would eliminate the respective odd or even numbered channels from the circuit. A delay on relay action is also available with time period of 1, 5, 10 or 15 seconds. To satisfy the Guidelines a normally energised relay with normally closed contacts should be used.
Relay Energised De-energise to Trip 4 3 2 1 Logic 4 pairs form 4 channels Select Trip @ Probe 2 or 3 +12v

devices and does not reflect the fault tolerant approach of multi channel devices or the duplication of

Delay 1 , 5, 10, 15 Seconds

E RL1 D 0v NO NC Shutdown Device

Spurious trips will be initiated for the following remotely possible failures:(a) 12V Supply failure or relay coil open circuit. (b) A disconnection in the wiring to the shutdown device. To avoid these spurious trips the following circuit should be implemented where the relay is not energised and a normally open circuit connection to the shutdown device is used:
Relay Energised De-energise to Trip 4 3 2 1 Logic 4 pairs form 4 channels Select Trip @ Probe 2 or 3 +12v

Delay 1 , 5, 10, 15 Seconds

E RL1 D 0v NO NC

The problem here is the possibility of missing a necessary trip action if faults (a) and (b) ever occur. If a second water level indicator is fitted and supplied from separate Mains Sources and its relay contacts separately connected to the shutdown device, the possibility of both systems failing simultaneously is so remote that it can be discounted. Ideally two separate shutdown devices should be installed. 12

2.1.2 High Level Trip There are no 'Guidelines for high level trips as the risks involved are not as disastrous - except for associated plant. However the 202 Unit also provides the security of a modified 2 out of 3 arrangement for the high level trip. Here the channel output logic level is reversed compared with LLT; a 12V regulator failing would induce a spurious trip so the pairings are chosen to avoid this problem. A delay action is also available.

Relay Energised De-energise to Trip 4 3 2 1 Logic 4 pairs form 4 channels Select Trip @ Probe 2 or 3 +12v

Delay 1 , 5, 10, 15 Seconds

E RL1 D 0v NO NC

2.1.3 Alarm Circuits Two relays RL2 and RL3 provide Alarm signalling and have integral delay action which can be set to 1, 5, 10 or 15 seconds. RL2 and RL3 may be connected for two separate Lo or Hi alarms or one Lo and one Hi. More than one channel may be connected to each relay; this feature allows a configuration whereby a Lo and a Hi Probe channel connected to one relay provides a single output contact for a combined Lo/Hi Alarm. NOTE: Internal Test Switches SW1,SW2 are provided to check operation of the electronic circuits, if these are operated the Alarms and Trips would be Initiated. An internal Link (RL) Is available to prevent relay action if SW1 or SW2 is operated, otherwise the Trip Circuits should be disarmed externally before opening the 202 Enclosure. If required the switches SW1 and SW2 may be disconnected by unclipping and removing the spring and shorting contact. The plastic caps may then be replaced to prevent any possibility of shorting the fixed contacts.

13

3.0

Installation - General

For Boiler applications the installation must conform to the accepted Regional or National Standards. Pipework connections must be welded, tested and inspected to the relevant procedures. Ensure that the appropriate Regulations are adhered to and procedures documented. A typical Water Columns installation is shown in Fig. 3.1.1 and 3.1.2 but special versions may be required for particular applications. In all cases it is essential to achieve the minimum length of connecting pipework to the water column to minimise density errors. This is caused by heat loss which produces a temperature difference and therefore a density difference between the water in the column and the water in the boiler or heat exchanger. In particular the lower water connection should be as straight as possible with a slight downward slope from the column to achieve good water circulation, preventing the accumulation of dissolved solids and avoiding the possibility of level indication errors. The top equalising connection should project inside the boiler shell to prevent surface condensate cascading down the pipework to the column, excessive water flow in the column causes a pressure drop resulting in level indication errors. Both steam and water shell tappings should terminate internally away from localised turbulence, which causes pressure differences, and therefore level indication errors. The inclusion of isolation valves requires the assembly to be supported by the top suspension lug of the column ensuring there is no differential expansion between the support structure and the boiler drum. Fig 3.1.2. If a boiler low or high water level trip circuit is connected to the 202 Electronic Unit it is recommended that all isolation valves are lockable in the open position and the drain valve lockable in the closed position to prevent spurious tripping by inadvertent valve operation. The 202 Electronic Unit enclosure is usually sited adjacent to the Water Column within a distance suitable for the 4m (12') length of special high temperature PTFE cable supplied. If longer cable lengths are required, terminate the PTFE cable in a suitable watertight junction box and extend with standard 22 core stranded conductor instrumentation cable; ensure extension cable is protected from heat sources. Siting of the 202 enclosure must consider adequate visibility of the display, the routing of other cables away from heat sources and the minimum risk of damage from surrounding plant or activities.

14

3.1

Water Column - Installation - General Requirements

3.1.1 For boiler side-arm columns Figs. 3.1.1, 3.1.2 the support structure should be installed, the column attached by the top suspension lug and, in most cases, aligned with the drum NWL between Probes 7 and 8, Fig. 3.1.1. The support structure should be sufficient to take the weight of the column plus steam and water isolation valves, drain valves and pipework. Parallel slide or gate valves should be used particularly for water side isolation as they allow full bore opening without restricting water flow. Straight run globe stop valves shall not be used (ASME) but if permitted by other codes they must be mounted horizontally as shown. If the 202 System low and/or high water boiler trip circuit is used it is recommended that all isolation valves are lockable in the open position and the drain valves lockable in the closed position to prevent spurious tripping by inadvertent valve operation. It is essential to ensure there is a continuous downward slope of at least 1:50 from the Water Column to the Boiler Drum to enhance water circulation. (ASME Code: No part of this water connection shall be above the point of connection at the Water Column. For the steam connection to the boiler there shall be no sag or offset in the piping which shall permit the accumulation of water) The column connections are profiled for butt weld fitting to pipework; if socket weld fittings are to be used the 40 profile should be removed and the fittings supported to allow 2mm (0.08") spacing to the fully seated position. After welding to documented procedures any temporary supports should be removed and alignment to NWL checked prior to weld inspection. Fit Guards to protect Probe seatings. Lag steam and water pipework and valves. Before commissioning install Probe Cable as shown in Fig. 3.2.2. As a precaution ensure steam and water isolation valves are closed and drain valve open.

15

3.1.2

Water Column Installation Detail

Suspension Lug Hole Dia. 25mm ISOLATION VALVES

NORMAL WATER LEVEL

Sight Range

Maximum slope possible

ISOLATION VALVES
MINIMUM DISTANCE POSSIBLE TO SUIT SITE CONDITIONS. Distances greater than 2 metres cause indication errors due to reduced water temperatures in water column

DRAIN VALVES

Fig 3.1.1 Water Column Installation 1. The Water Column should be suspended such that there is no differential vertical movement between the Boiler Drum and the Column. Generally a spring suspension should be provided where the spring rate includes column, isolation valves, drain valves and associated pipework. The lower water connection to the Column must be above the level of the connection to the Drum to prevent air locks. For the same reason the steam connection to the Column must be below the connection to the Drum. Preference should be given to the continuous slope of the water connection with no restrictions, to aid water circulation. The water connection inside the Boiler Drum should avoid turbulence from down-comers, feedwater inlets etc. The steam connection should protrude sufficiently (X) to avoid drum surface condensate flowing to the Column. Procedures for site welding of pipework and valves must conform to the National or Accepted Standards for boiler applications.

2.

3.

4.

16

5. 6. 7.

Connection pipework and valves should be lagged to prevent heat loss. Guards should be provided to prevent accidental contact with the Water Column; these should not restrict convection cooling of the Column. Probes should not be fitted to the Column until mechanical installation and Drum cleaning processes are completed.

Fig 3.1.2

Water Column Support Structure 17

3.2 System Cabling Fig 3.2.1 shows the System Cabling requirements. Fig 3.2.2 shows Probe Cable Fixings on the water column and Fig 3.2.3 Cable Gland allocation on 202 Unit. A 4 metre (12') sheathed length of special 22 core high temperature PTFE cable is provided for Probe to 202 Unit connections. This cable is pre-formed for the standard vessel arrangement where NWL is between Probes 7 and 8. For longer cable lengths a junction box and standard PVC multi-strand instrument cable should be interposed in the run to the 202 Electronic Unit. The Water Column looming has been arranged for the cable to be clamped on the right hand side with the ODD numbered Probes on the left hand side and the EVEN numbered Probes on the right hand side. It is recommended that the cables are taped to the 6mm (1/4") vertical Tie Rods using 12mm PTFE Thread Seal Tape (as used in pipe sealing RS 512-238). Cable for the Mains Supply, 20 Core Remote Display, Alarm and 4-2OmA circuits are fitted as required using standard instrumentation cable through the 202 Unit Cable Glands as shown.

18

WATER COLUMN & PROBES

TYPE 202 ELECTRONIC UNIT

E N L 20251 - 20252 20 19 18 17 NC RL5 C NO O/Bk NC GyBe W/Be RL4 C NO NC RL3 C 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 TB7 4/20mA + Output 4 3 2 20 19 18 17 16 15 TB5 14 13 12 11 10 9 8 7 6 5 4 3 2 16

22 Br 21 20 P 19 18 Be Gy 17 16 15 14 W

Bk Br P Be Gy R/Be R/W O/Be

14
R O

13 12

11 10
R/Be R/W

13 12 TB2

R E M O T E D I S P L A Y C O N N E C T O R

15 TB2 14 13 12 11 10 9 8 7 6 5 4 3 2 1 TB1

R E M O T E D I S P L A Y U N I T

R/Bk O/R

9
O/Be

11 10 9

Gy/Bk R O V W R/Bk O/R O/W Gy/R Gy/W W/Bk

NO NC RL2 C NO NC RL1 C NO

8
O/W

7
O/Bk

8 7 6 5

6
Gy/R

5 4
Gy/W Gy/Be

4 3 2

3 2
W/Bk W/Be Bk

1 TB1

1 TB6

1
Gy/Bk

1 TB4 22 Core Instrument cable 1 sqmm cores. Lmax 500m MAINS INPUT 110240V 15VA 1.5sqmm cores Lmax 750m MAINS INPUT 110240V 15VA

22 Core PTFE cable Assembly Part Number: 2022818/Length

ALARM / TRIP Relay & 4/20mA outputs

19

Top Guard Block

Tie cables along cable tie rod

Lower Guard Block

Using cable clamps run odd and even cables either side of the column

Fig 3.2.2 Probe cable routing on water column

Mains 1 | Probe Cable | Relay Outputs | Remote Display | Mains 2 PG 13.5 PG 9 PG 16 PG 21 PG 13.5

Fig 3.2.3 Cable Gland allocation

20

3.3

Installation of 202 Electronic Unit

3.3.1 Before installation remove the front cover assembly and PCB 2 with chassis plate from the enclosure and store in a safe place. Refer to Figs 3.3 and proceed as follows: 1 . Open front cover by loosening the two top captive plastic screws. 2. Disconnect ribbon cable from PCB 1 by pressing the two ejection levers on PL3 in an outward direction and ease out the plug/cable assembly. Press the two bottom cover hinge pins inwards and remove the complete cover assembly. 3. Unscrew the four M6 Cap Head (5mm Key) fixings at the corners of the base unit and remove PCB 2 and chassis assembly. Refit M6 chassis plate screws into corner inserts to avoid loss.

SPRING HINGE COVER REMOVAL 3.3.2 Mount the base of the enclosure with cable glands downwards at the site chosen using 4 corner fixing screws, M6 or 0.25". Strip cable sheaths so that they do not project beyond the inside of the cable gland; PTFE Probe cable is preformed for correct length. Insert cables through glands, trim ends to template supplied and fit crimped ferrules where required. Test cable continuity as required.

21

178 mm

120 mm

FAULT

202

14 13 12

320 mm

11

298 mm
Levelstate

10 9 8 7 6 5 4 3 2 1

Type 202 Electronic Unit

Mains 1 | Probe Cable | Relay Outputs | Remote Display | Mains 2 PG 13.5 PG 9 PG 16 PG 21 PG 13.5

200 mm

22

3.3.3 At a convenient time before Commissioning, programme the required mode of operation of the PCBs as follows :PCB1 - Refer to Section 6.1.1. 1. 2. Remove thin glass fibre cover. Solder split pad link (centre of PCB) for the selected channel outputs corresponding to the required alarm levels (middle pad to LH pad for operation of RL2 or middle pad to RH pad for operation RL3). 3. 4. Solder the appropriate split pad link "F" for the selected LED to flash indicating the alarm level. Solder split pad links for the required Trip Levels on the 2 out of 4 Logic circuits applied to RL1 and RL4. LLT, split pads either side of IC18: Middle pads to upper for trip level at Probe 3. Middle pads to lower for trip level at Probe 2. HLT, split pads either side of IC19: Split pad not linked for trip at level 13. Split pad linked for trip at level 12. 5. 6. Solder split pad links for the time delay required on LLT (RL1), HLT (RL4) and Alarms RL2 and RL3. If Trip Circuits are applied and it is required to inhibit relay action when Test Switches SW1, SW2 are operated, solder link split pad (RL) located at the bottom of the PCB. To inhibit Trips only, link RL and remove D26, D28. 7. Solder split pad links S or W to the middle pad (top centre of PCB1) to define whether the "all steam" or "all water' state is to represent the 4mA current output for the 4 to 20 mA transmission signal. 8. The two sets of split pad links above PL1 and below PL2, Sa, Sb determine probe channel sensitivity and should only be made after evaluation of system performance. With no linking the setting is for conductivity greater than 2S/cm, middle pad linked to Sb for greater than 1S/cm and middle pad to Sa for greater than 0.5S\cm. Both sets must be linked identically. Sa Sb Even No.Chs. Sa Sb 4mA S Odd No.Chs. W (R L) 15 10 5 1 ) ( 2 ( LLT 3 ( 2 HLT 12 3 Ch.O/P F.Bus Ch.O/P RL2 RL3

23

PCB2 - Refer to Section 6.2.1. 1. 2. Set the correct mains source voltage using jumpers provided. (fit two jumpers for 115V; one for 240V as indicated). Solder the split pad links D or E for the selected mode of operation of RL1 to RL4. D = Normally De-energised - Energise to Alarm or Trip. E = Normally Energised - De-energise to Alarm or Trip. D RELAY E

24

3.4

Installation of Remote Display Unit 20251

This unit is intended for panel mounting with cut-out size 174mm x 67mm (6.85"x2.64") and panel thickness to 6mm (0.25") Before fitting, solder link the appropriate split pads F as on the 202 unit, PCB1. Method of fitting :1. Remove the rear cover by unplugging the terminal block and removing the four corner hexagonal nuts. 2. Insert the bezel assemble from the front of the panel, fit the cover at the rear and tighten the four hexagonal nuts. 3. Terminate the cable ends on the free terminal blocks and insert into Display Unit plugs. Clamp the

cable as shown in Fig 3.3 (a) or (b).

25

TYPE 202 REMOTE DISPLAY

8 mm 24 mm 60 mm MIN FOR ACCESS

72 mm

56 mm
FAULT

202

14 13 12 11 10 9 8 7 6 5 4 3 2 1 USES 1 x 22 CORE 1mm COPPER One 14 way and one 6 way cable connectors Stainless Steal rear cover with 4 x M3 fixings.

TB2

PANEL CUT-OUT

180 mm

TB1

163 mm

Max panel thickness 6 mm

CABLE CLAMP

Max 400 m

Levelstate

67 mm
UNIT AND REMOTE DISPLAY LAYOUT FRONT ELEVATION UNIT AND REMOTE DISPLAY LAYOUT REAR ELEVATION UNIT AND REMOTE DISPLAY LAYOUT SIDE ELEVATION REMOTE DISPLAY CUT-OUT

26

174 mm

4.0

Commissioning

It is essential that Probes are not installed until acid or steam purging of the plant has been completed. The water column may be valved off during this procedure or special Probe position blanking plugs can be inserted (Part No. 80151 for 501 Water Column, or 80351 for 503,or 80251 for 502). 4.1 Probe Installation. Caution : Handle Probes with care. Do not remove from packing until required for insertion. The Probe insulators are high quality ceramic material which is liable to crack if subjected to impact - Do not use if dropped! Type 801 : 1. First clean the vessel seating recess ensuring it is dry and free from radial score marks. Do not use any form of release coating or jointing compound on the seating face; the spiral wound gasket has exfoliated graphite filler which does not stick to seating faces. 2. 3. 4. Use a Moly Disulphide anti-scuffing paste on threads avoiding contact with seating face and Probe insulators. Screw in each Probe and tighten. Do not exceed 7ONm (52 lb.ft). Connect wires to Probe terminals, tighten knurled nuts using finger pressure only. Refit Guards for Probe protection. Type 803 : 1. 2. 3. 4. 5. Inspect the vessel seating recess ensuring it is clean dry and free of radial score marks. Clean butting faces of Clamp Plate and Vessel. Insert Gasket and Probe to Vessel and carefully fit Clamp Plate over Probe and Studs. Apply a thin film of Copper or Molybdenum based grease to exposed ends of studs. Fit nuts finger tight; adjust nuts to obtain clamp plate parallel to vessel face (approx. 1mm gap). Set Torque Wrench fitted with 17mm A/F long socket to 2ONm. Initially tighten each nut equally through 45 or subsequently where wrench 1 3 clicks' at torque setting, in the sequence 1, 2, 3, 4 until clamp plate is flush with vessel face. If the torque wrench clicks' without nut rotation this indicates that the Clamp Plate is not parallel to Vessel Face; before proceeding adjust nuts for parallel faces. 4 2

6.

Set Torque Wrench to 25Nm and tweak each nut until the Wrench clicks at the torque Limit.

DO NOT ROTATE WRENCH BEYOND THE POINT WHERE IT BREAKS (CLICKS) DO NOT EXCEED 25Nm TORQUE SETTING 7. Connect wires to Probe terminals, tighten knurled nuts using finger pressure only. Refit Guards for Probe protection.

Type 802 : Inspect the Insert seating taper ensuring it is clean, dry and free of radial score marks. Use a Moly Disulphide anti-scuffing paste on threads. Fit Probe and tighten retaining nut until Probe body is just nipped, i.e. where it just cannot be rotated. Apply 27mm A/F long socket and tighten by 1/6 of a turn.

4.2

Electronic Unit. 4.2:1 4.2:2 4-2:3 4.2:4 4.2:5 4.2:6 Fit chassis plate + PCB2 to base of enclosure Fit cover + PCB1 to enclosure by springing hinges inwards before locating on base hinge holes. Connect ribbon cable to PCB1 via PL3 ensuring hinged retainers on PCB1/PL3 are first hinged outwards. Ensure mains cable is not live and connect separate mains supply to PCB2 / TBl and TB2 checking that mains jumper links are correctly installed for mains voltages (115v or 230v) Do not fit other terminal blocks to PCBs at this stage. Switch on Mains Supply. Depress SW1 Green Button and check that all Green LEDs become illuminated. Release SW1 and depress SW2 Red Button and check that all Red LEDs become illuminated. 4.2:7 Connect Probe wires to PCB1 by inserting TB2 and TB3. If the column is empty all Probe channels should have Red LEDs illuminated. Short out each Probe in turn by touching a wire between the knurled nuts and probe body and check that the corresponding Green LED becomes illuminated.

In some instances condensation in the column or Probe assembly may cause the Green LEDs to be illuminated which cannot be cleared until steam heating is applied to the column. In this case a check can be made by disconnecting the wire on the Probe; when open circuit the Red LED should be illuminated, when shorted to Probe body the Green LED should be illuminated. If two wires are connected to the Probe these must be held together for the above test. 4.2:8 If a Remote Display is fitted, insert PCB2/TB4 and 5 and check correct illumination of LEDs by operation of SW1 & SW2. 4.2:9 Insert PCB2/TB6/TB7 and check the various operation states of external alarm circuits etc. by open-circuiting or shorting the relevant Probe wires as above. 4.2:10 If any problems arise during the above procedures check above connections and refer to Fault Identification and Maintenance, Section 5.2. 4.2:11 It is advisable to keep the 202 Enclosure Cover closed at all times except for test and maintenance. Generally plant locations have sulphurous atmospheres which in the presence of moisture can cause serious corrosion problems with electronic equipment particularly terminals and contact connections.

29

4.3

Water Column Bringing on-line. 4.3:1 Notify personnel of the intention to commission the Water Level Monitoring System. 4.3:2 Ensure Probe Guards are in place. 4.3:3 Close Drain Valves. 4.3:4 Slightly crack open the Steam Isolating Valve and observe by the Display that the column fills slowly due to condensation (15 minutes +). 4.3:5 After 15 minutes crack open the Water Isolating Valve and check with Display that the water level falls to the expected NWL in approximately 2 minutes. 4.3:6 Check valves and probes for steam leaks. Tighten probes if necessary. If steam issues from the probe top insulator replace probe using Fault Repair Procedure Section 5.1 4.3:7 Open Water Isolation Valves fully. 4.3:8 Open Steam Isolation Valves fully. 4.3:9 The System is now operational. Where valve locks are fitted these should be locked if the system is to remain in service: Isolation valves locked in the OPEN position. Drain valves locked in the CLOSED position.

The above method allows the Column to fill slowly and to be heated at a controlled rate and avoids subjecting the Probes to any significant thermal shock which could adversely affect the pressure sealing interfaces within the Probe assembly. CAUTION: DO NOT BLOW-DOWN THE WATER COLUMN WITH PROBES INSERTED.

30

5.0

Maintenance and Fault Identifications

The following sections outline fault identification and rectification procedures. No routine maintenance is required apart from periodic dusting of Probe external insulators using a small paintbrush to remove the possible accumulation of flyash. It is recommended in the interests of preventative maintenance that all Probes are replaced every 4 years, or at least replace the lower Probes which are continuously immersed in water within 4 years as some dissolution of the ceramic insulator does occur. A check on the condition of the lower Probes normally immersed in water is recommended every six months to ensure they correctly switch to the steam condition when the Water Column is drained. With the system at operational temperature isolate Column, Procedure 5.1.3. When fully drained check that all Probe channels indicate the steam condition (Red). If any channel indicates water (Green) check that the Electronic Unit and Probe connections are functioning correctly by removing the Probe connection and verify that the indication changes from Green to Red, in which case the Probe is faulty and must be replaced. If a fault has occurred on the Electronic Unit rectify this first then replace the Probe connection before determining whether Probe is faulty.

31

5.1

Pressure Parts

The large bore thin wall Water Column permits heat loss which stimulates condensate flow preventing the build-up of sediment which obviates the need for vessel blow-down. As periodic blow-down is not necessary the system reliability is enhanced due to reduced valve operation. The high purity condensate keeps the Probes clean and the flow maintains the Water Column temperature near the Drum water temperature which minimises density errors. Any flow restriction or pressure loss due to Valve or Probe leaks can cause errors in water level indication. If a serious Probe leak occurs the Water Column should be isolated immediately otherwise gasket seat erosion may entail re-machining of the Column seating faces. For damaged seat faces on the Type 501 and Type 503 Water Columns For the 501and 503 Water Columns, re-cut seating face to an N8C finish which must be accurately machined at 90' to the centre line of the opening. 5.1.1 Valve steam leaks - requires replacement of steam gland packing. Drain valves not sealing properly requires seat replacement or re-grinding. Rectification should follow the normal practices for the particular valve types. 5.1.2 Probe leaks - It is difficult to distinguish between Probe internal seal failure or Probe to Column seal failure unless the leak is small. Steam emanating from the Probe top ceramic insulator indicates internal seal failure and requires Probe replacement. Steam emanating from the Column/Probe seating area may be rectified by further tightening of the Probe but DO NOT EXCEED specified Probe tightening torque - otherwise replace Probe or gasket using the following procedures. 5.1.3 Column Isolation Procedure (i) (ii) (iii) (iv) (v) Ensure Operators are informed that erroneous indications and alarms are to be expected. If shutdown or trip circuits are connected to the system ensure they are disarmed. Close the Steam and Water Isolation Valves. Slowly open the Drain Valve(s) and leave open. Check at Drain outlet that the Isolation Valves are sealing properly.

32

5.1.4 Probe Replacement Procedure (i) (ii) (iii) Isolate Column as 5.1.3 above, ensuring Drain Valve is open, with Steam and Water Isolation Valves closed and sealing properly. Remove Probe Guard and disconnect Probe wire(s). Replace Probe as procedure Section 4.1 for Type 801 or 803.

5.1.5 Column Recommissioning Procedure (i) (ii) (iii) (iv) (v) (vi) (vii) (viii) Close Drain Valve(s). Crack open the Steam Isolation Valve(s) and check with the display that the Column fills slowly due to condensate (15 to 20 minutes). Crack open the Water Isolation Valve(s) and check that the water level falls to the expected level. Check Probes for steam leaks using procedure of 5.1.2. After approximately 10 minutes fully open Water then Steam Valves. Ensure all Valves are correctly set (and locked). Inform Operators that the Indication System is now in service. Check that approximately normal water level is displayed before rearming any shutdown or trip circuits connected to the System. The above procedure allows the Column and Probes to be heated at a controlled rate to prevent the Probes being subjected to excessive thermal shock which could damage the ceramic insulators. 5.1.6 Column or Pipework Blockage

If the Column and pipework installation complies with recommendations of Section 4 and with the intentional stimulation of condensate flow through the Column pipework blockage should not occur. This is providing the boiler water treatment conforms to recommended practices such as ASME "Consensus on Operating Practices for the Control of Feedwater and Boiler Water Quality in Modern Industrial Boilers" or BS 2486 "Recommendations for treatment of water for land boilers". If a partial blockage is suspected by the slow response times of the level indicator isolate the Water Column as procedure 5.1.3. With the Drain Valve open slowly open the Steam Isolating Valve until there is free flow of steam at the Drain outlet then close the Steam Valve. Slowly open the Water Isolating Valve until there is free flow at the Drain outlet then close the Water Valve. Close the Drain Valve(s) and open Steam and Water Valves. Ensure all valves are correctly set (and locked) and rearm trip circuits if fitted. If the response time is still sluggish suspect problems with Isolation Valves not opening fully.

33

5.2

Electronic Unit Faults

Electronic faults can be diagnosed using the procedures for Fault Identification Section 5.3 If a circuit board is defective it is preferable to replace with a spare. For a local board repair ensure precautions are taken to avoid STATIC as some components are MOS devices. 5.2.1 Check 202 Electronic Unit. Open enclosure cover by releasing the two top captive plastic screws. Depress Green Push Button SW1 at top of Display PCB (10 Seconds) - all Green LEDs should be illuminated - no Reds. Release SW1 and depress Red Push Button SW2 - all Red LEDs should be illuminated - No Green. If O.K. check for loose Probe connections to TB2, TB3 on PCB1. Close enclosure cover. 5.2.2 Check Probe Connections. Remove Probe Guards. If channels indicating water oscillate between Red/Green check Black & Grey/Black connections to bottom guard blocks or vessel body. Check Probe connections. (HOT? - wear gloves) Channels indicating Steam (Red) - Apply a short circuit across the Probe top ceramic insulator - Probe channel should change to Green. Channels indicating Water (Green) - Disconnect wire from Probe, if two wires are fitted short them together but isolated from column - Probe channel should change to Red. If this check is O.K. but when wires reconnected to the Probe the Channel indicates Water when it is judged to be in "Steam" by comparison with lower channels in Steam, suspect a faulty Probe. Water cannot exist above Steam, unless the Probe is contaminated! Refit Probe Guards.

34

5.3 5.3.1

Fault Identification Procedure Fault on all Channels 5.3.1.1 Display Blank Fault signalled by external alarm Mains supply failure on both inputs Fuse Fl and F2 ruptured PCB2 LED's illuminated - PL3 not connected between PCB1 and 2 or fault on cable or connector. Switch off the Mains Supply before replacing fuse. If fuse has ruptured disconnect PL1 from PCB1 before fitting a replacement. 5.3.1.2 5.3.1.3 False all steam indication O.V not connected to Water Column Water indicated on upper channels (2 wire connection) with steam indicated on lower channels (1 wire connection) Column valved off and drained Probe connections open circuit TB1, TB2 not inserted in PCB1

5.3.2

Fault on Alternate Channel Display Blank on Odd Channels Display Blank on Even Channels Green LEDs illuminated Regulator IC1 on PCB2 faulty. Regulator IC2on PCB2 faulty. Oscillator fault IC1a for Odds, IC8b for Evens

5.3.3

Fault on Single Channel 5.3.3.1 Neither LED illuminated LED failure. TR2, TR3 faulty. R11, R12 open circuit. Test as section 5.2.1 a (SW1 & SW2) 5.3.3.2 Water above steam indication (Fault indicated) (i) (ii) (iii) The water indication is probably false if more than one channel immediately below it indicates steam The steam indication is probably false if more than one channel immediately above it indicates water If only one channel indicates water with only the one channel below it indicating steam, either channel could be faulty. CHECK:PCB1 by operation of SW1 and SW2 using procedure of Fig 5.3.3.

5.3.4

'Fault' Indicated - No S-W display fault. Mains 1 or Mains 2 failure. Fl or F2 ruptured.

35

Fig 5.3.3 Fault Identification Procedure

36

6.0.

Type 202 Electronic Enclosure, Fig. 6.0

The polyester glass-fibre reinforced enclosure with overall dimensions of 320 x 200 x 120mm is intended for wall mounting using four M6 or 0.25" fixing screws through the corner apertures of the base external to the cover sealing gasket. The cover has quick release hinge pins at the bottom and two polyester/glassfibre screws at the top. Four cable glands are provided on the bottom face of the base unit. Protection Rating for this enclosure is IP65. The discriminator/display PCB is retained in the cover by the 6 screws, which secure the display bezel, and by slot insertion along one edge. A thin glassfibre board provides protection for PCB1 components. The clear laminated glass display window is sealed between the bezel and enclosure cover. A metal chassis plate is secured to the base unit by four M6 screws. The supply/relay PCB2 is mounted on the chassis plate and retained by eleven M3 screws and three M3 screws through the PTFE heatsink supports. Terminals are provided for two separate 115/240V Mains Supply Inputs. A 34 core flat ribbon cable which plugs into PCB1 interconnects the two PCBs. The PCBs have been designed for long term reliability using the minimum number of components which are significantly under-stressed. Replacements for PCB Components is a delicate operation requiring special equipment to avoid damage to static sensitive devices. for repair and test. To maintain operational reliability and security it is recommended that spare boards are available and the faulty board returned to the manufacturer

37

FAULT

202

14 13 12 11 10

PCB1 2022501 PCB1 2022501

Fig 6.0 Electronic Enclosure Layout

9 8 7 6 5 4 3 2 1

Ribbon Cable connection

Levelstate

Display Bezel & Window

6.1

Discriminator & Display. PCB1

Assembly No 2022501

This board contains the sensing circuits and display for 14 probe channels. Circuits are included for channel validation, alarm and trip levels with delay action, 4 to 20 mA Transmission, display flashing and push-button circuit test facility. Channels 1 to 8 are "normally' servicing water and the source and sense are linked and a single wire connection is made to the Probe. For Channels 9 to 14 'normally servicing the 'steam' condition, separate source and sense connections are linked at the Probe to retain the lead monitoring feature. Any wire disconnection induces the abnormal state at the associated channel sensing circuit so that the fault can be detected and alarmed by the validation circuits. Bu comparison with adjacent channels the invalid condition of 'Water above Steam' or Steam below Water can be detected. Additionally a supply failure from PCB2 is also applied to the validation circuits to ensure detection of an equipment fault, this is annunciated by flashing of the display yellow LED and the de-energisation of RL5. The Odd Numbered Probe Channels are connected to PL1 and the Evens to PL2. Solder split-pad linking is provided for the following functions: 1 Sensitivity selection for Water Conductivity. (Sa, Sb - odd and even channels) 2 3 4 5 6 7 Probe channel linking to Alarm Relays RL2, RL3 Trip Level selection Alarm and Trip Delay Periods Selection of Display LED Flashing at Alarm Levels (F) The 4mA output of the 4/2OmA signal to represent all water or all steam condition Inhibiting Alarm and Trip Relay action when Test Switches are operated (RL)

Two push-buttons SW1, SW2 provide a Test Water (Green Cap) and Test Steam (Red Cap) facility for checking the electronic circuits. Operation of SW1 or SW2 does not inhibit operation of relays RL1 to 4 unless split pad (RL) is linked.

39

2022501 Water Conductivity selection to be set At site to suit operating conditions Sa = Min. uS/cm No Link = Max uS/cm Sb

4/20mA 4mA=

| |

All W Connection to PCB 2 All S

PL1 / TB 1

PL2 / TB 2 2 Link for required Red LED to Flash (low water level)

Sa

10

| |
Sa Sb RL3 5 1

Lo & Hi Alarms Ch. Selection for RL2 & RL3 F2 3 F3 5 Odd Numbered Channels 9 F4 F5 F6 Link for required Red LED to Flash (low water level)

11

13

F8

F9

4 Even Numbered Channels 6 F11 8 When 12 channel board then channels 11 & 10 F12 10 F13 12 Level Alarms Relay: RL2 RL3 F10

LL Trip / Alarm (validated) No Link=ch 13 Link=ch 12 RL4

| 12

| 2|
3 RL4

|3 |2

LL Trip / Alarm (validated) RL1

TEST RL2 RL1 W RL 10 5 1 10 5 1 10 5 1 S

Delays: No linking = 15 Seconds approx

Fig. 6.1 PCB 1 Layout

6.2

Supply & Relay. PCB2

Assembly No. 2022502

Each mains supply input is connected via a delay fuse to the primary windings of the transformer which are either connected in series for 240v Mains input using a single jumper plug, or parallel for 115V Mains input using two jumper plugs. Each Secondary windings of the transformer is individually rectified by a bridge rectifier and the DC outputs smoothed by a 2000F electrolytic capacitor. Mains transient protection is provided and each of the 4 DC outputs has an LED indicator L1 - L4. Three 12V Regulators are provided to separately supply the following: 12VX Odd numbered Probe Channels 12VY Even numbered Probe Channels 12VZ Validation/Relay/4-20mA circuits. L5 LED. Each regulator is supplied via transformers from Mains Supply 1 and Mains Supply 2 so that in the event of a single Mains Supply failure the Unit remains fully operational. PL3 provides connections between PCB1 and PCB2 via a ribbon cable. TB4 and TB5 provides terminal connections for the Remote Display. RL2 and RL3 are driven by associated time delay circuits on PCB1 and are intended for delay alarm signalling. R1 is allocated to a Low Level Trip and RL4 to a High Level Trip. RL5 provides output contacts for a System Fault Alarm. Relay circuits for RL1 to RL4 are identical, the input is normally at +12V; for Alarm or Trip conditions input switches to 0.V. Linking solder pads D or E serve to define the state of the relay for normal or safe water level conditions. If a System Fault occurs RL5 de-energises signalling the Fault condition at the contact output, RL5 is normally energised to enable initiation of System Fault if faults occur in the circuitry of RL5. TB7 provides output terminal connection for the single pole changeover contacts of RL1 to RL5 TB6 provides output terminals for the 4-20mA signal.

41

2022502

MAINS VOLTAGE SELECTION 250Ma T 20 x 5 Fuses

230V 115V

115 230 F2 115 F1

TB2

TB51

D RL4 E TB5

D RL3 E

D RL2 E TB7

PL3

D RL1 E TB6 TB4

TB7/3

D Link = Relay De-eng in normal state ( Energise to Trip) E Link = Relay Eng in normal state ( De-energise to Trip)

TB7/2 TB7/1

6.3 Remote Display Unit. 20251. PCB3

Assembly No 2022503

This separate DIN Size 180mm x 72mm display unit duplicates the 14 probe indications on the 202 unit. Plugs 14 way and 6 way and associated cable terminal block sockets are provided at the rear with a cable clamp facility. The LEDs for the odd numbered channels are supplied from the 12V. X line TB2/20, and the even numbered channels from the 12V. Y supply line TB2/18. Solder split-pad linking is provided for the selection of Alarm Level Flashing of LEDs. NB The row of green LEDs and the row of Red LEDs are each categorised for brightness to avoid excessive differences in illumination. If replaced ensure correct category is selected.

43

R4

F13

F12 F11 F10

F9

F8

F6

F5 F4

F3

F2

F1 D1 R3 R2 R1

LG

LR

Fig 6.3 PCB 3 Layout Rear view

R5

LY

20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1

6.4

202-EDLI Parts List

Description Detector PCB1 Supply Relay PCB2 PCB1 Fibreglass Cover Enclosure Base Enclosure Cover Assembly Chassis Plate PCB2 Heatsink Support Bracket PTFE Terminal Sockets TB1, TB2 Terminal Sockets TB4 Terminal Sockets TB5 Terminal Sockets TB6 Terminal Sockets TB7 Cable Gland Cable Gland Cable Gland Cable Gland Mains selector Link Mains Terminal Cover Mains Fuses Probe Cable 4 metres Probe Cable 10 metres Installation Manual

Part No 2022501 2022502 2023015B 2023011 2022005 2023006C 2023016 BL11 BL14 BL6 BL4 BL15 PG9 PG 1 3.5x2 PG16 PG21 MJO5 2023009 20/250T 20228-04 20228-10 2026900

45

202 Electronic Unit Specification 1 Electronic Level Indicator Unit. Type 202A

Enclosure: Wall mounted glass-fibre reinforced polyester, IP65/NEMA4X protection for location in harsh environments. Dims: 320mmH x 200mmW x 120mmD (12.6'x 7.8'x 4.7') Inputs: Discrimination between water and steam for 14 channels numbered in ascending order. Discrimination threshold may be selected for minimum conductivity of 0.5 micro Siemens/cm, micro Siemen/cm or 2 micro Siemens/cm. The lower 8 Probe Channels have a single wire connection the Probe and the upper 6 channels have two connections to each Probe. Any wire disconnection on the Probes reverts the channel to steam indication if the Probe is immersed in water and any disconnection on the upper Probes reverts the channel indication to water it immersed in steam. This facility enhances fault declaration. A 4 metre (12') length of special high temperature PTFE cable is supplied for Probe connections. For longer cable lengths connection to standard PVC cable advised, max. cable length 30 metres (100). Display: Two vertical columns of 10mm (0.4") square LED's provided on the front of the enclosure. One row of Green LED's represents water and the second row of Red represents steam. Particular LED's may be selected to flash on initiation of Alarm Relays. On channels 2 - 6, the Red LED (Lo Water Level) and on channels 8 - 13, appropriate Green LED (Hi Water Level) may be programme to flash. The flashing is initiated by alarm relay action. A Yellow flashing LED signals a System Fault Condition Supply Requirements: - Two independent AC sources 92 to 127Volts ) or 184 to 254Volts ) The 202 Instrument provides improved operational integrity in the event of one Mains supply failure by the method of implementing dc supplies to the electronic circuitry. Temperature Rating:Ambient:-10C to +65C, Storage : -50C to 100C AC @ 15VA, 48 - 63Hz 1

46

Outputs: (1). Alarm Trip Relays. Four sealed relays, each having single pole changeover contacts provide Alarm and Trip signalling. Two relays provide low and high level alarms and each may be linked to Probe channels in the range 2 to 6 and 8 to 13. A low and high channel may be linked to the relay for a combined Lo/Hi alarm output. The two Trip relays provide low level and high level trip initiation. For the trip circuits a 2 out of 3 Probe channel voting circuit is applied with a 4th channel backup to counter internal supply failure. The normal LoTrip level may be selected for channel 2 or 3 and the Hi Trip level for channel 12 or 13. Each relay may be programmed for the normally energised or normally de-energised state with a delayed action period of 1, 5, 1 0 or 15 secs. Contact Rating: Max. Switching Power: Max. Current : 5 Amps. Max. Voltage : 350 Volts AC - 600VA DC - 3OW @ 110V 12OW @ 30V (ii) Remote Display. Twenty terminals are provided for direct connection to a Remote Display Unit. 4/2OmA Signal: An integral circuit provides a 4 to 2OmA transmission signal whereby all steam state is included. Output Current: 4 - 2OmA in 14 incremental steps each

probe channel contributes a step change of 1.14mA. Selection of 4mA to represent the all water or

Load Impedance: 300ohms Max. (iv) System Fault Alarm. A single pole changeover contact is available for signalling:(a) Supply failure. (b) Probe channel malfunction by validation between adjacent Probe channels. 2. Remote Display Unit Option. Type 20251A Panel mounted Housing: IP20 This unit duplicates the display on the front of the main unit and is intended for control room location. Panel Cut-out Dimensions : 174mm x 67mm (6.85' x 2.64') Panel Thickness: 1.5mm to 6.4mm (0.06'to 0.25) 180mm x 72mm x 30mm ( 7.1 x 2.83" x 1.2 )

47

Page 1 of 1

Conformity Assessment for Manufacture of Water Columns to the PED (97/23/EC)

1. Pressure Equipment Classification Water Columns designed & manufactured in accordance with ASME B31.1 Power Piping and ASME B&PV Code Section 1 Power Boilers. (Not Code Stamped) Type 501E: Type 502: Type 503 Max Allowable Operating Pressure 150 bar Max Allowable Operating Pressure 207 bar Max Allowable Operating Pressure 207 bar

Type Definition: Pressure Accessories where the nominal size DN is more appropriate than volume. All DN sizes >32 but <100 Length of column where the volume becomes more appropriate:For type 501E: 734mm For type 502: 634mm For type 503 582mm 2. a). b). c) Product Classification The state of the intended fluid contents: Gas The classification of the intended fluid contents: Group 2 Fluid type: Steam

Therefore using Chart 7 in the Guidance Notes to give Category Assessment when DN is more appropriate: - Equipment Category 1 Using Chart 2 when the lengths of the columns are greater than shown above and volume becomes more appropriate:Equipment Category II

3.

Conformity Assessment Procedure

From Equipment Category 1, the Conformity Assessment Procedure used will be: Module A: Internal Production Control From Equipment category II, the Conformity Assessment Procedure used will be:Module A1: Internal Production Control with monitoring of final assessment

Justification of compliance with Essential Safety Requirements Levelstate Systems Limited Item of equipment : Water Columns Type 501E, 502 & 503 PED Category: II PED Module: A1

ESR N 03 1 Hazard analysis

Subject

Justification
See Technical File & separate Hazard Analysis

Responsibilities to be clear for Design Manufacture Checking Installation (if applicable) Manufacturers instructions Service conditions to be covered as reasonably foreseeable Approach taken to design The potential for misuse Design for adequate strength - load factors Calculation method for pressure containment and loading Calculation method for resistance Experimental Design Method Provisions to ensure safe handling and operation Means of examination Means of draining and ventilating Corrosion or other chemical attack Wear Assemblies Provisions for filling and discharge Protection against exceeding allowable limits of pressure equipment

See Levelstate Specification 180031 issue A

1.1 1.1

See Installation Manuals See Installation Manual for recommended practice and guidance Refer to Hazard Analysis See Installation Manual for recommended practice and guidance In accordance with ASME B31.1 Chapter II Part 1 In accordance with ASME B31.1, ASME B&PV Code Sections 1 & VIII, Levelstate Design Spec 180031 Issue A In accordance with ASME B31.1 Chapter II Part 1 Not Applicable See Installation Manual for recommended practice and guidance ASME Code Section 1 PG 60 2.2 See Installation Manuals See Installation Manuals. ASME B31.1 Calcs Not Applicable Not Applicable Not Applicable See Installation Manual for recommended practice and guidance. Water Columns to be fitted to pressurized steam systems protected by suitable devices. In accordance with ASME B31.1 Chapter II Part 1 Not Applicable ASME B31.1 Chapter V ASME B31.1 Chapter V ASME Section IX Not Applicable Not Applicable ASME Section 1 & Levelstate Spec. 180031 issue A In accordance with ASME B31.1 Chapter VI & Levelstate Specification 180031 Issue A In accordance with ASME B31.1 Chapter VI & Page 1 of 2

1.2 1.3 2.2.1 2.2.3a

2.2.3b 2.2.4 2.3 2.4 2.5 2.6 2.7 2.8 2.9 2.10

2.11 2.12 3.1.1 3.1.2 3.1.3 3.1.4 3.1.5 3.2.1

Safety accessories External Fire Preparation of Component Parts Permanent Joining Non-destructive testing Heat treatment Traceability Final inspection

3.2.2

Proof test

Justification of compliance with Essential Safety Requirements

ESR N

Subject
Safety Devices Marking and labelling Operating Instructions Materials suitable for duty Material design Which of the following options do materials comply with: compliance with harmonised standards European approval of materials by a particular material appraisal For Categories III and IV, has material appraisal been done by the Notified Body Material documentation Appropriate protection of steam raising plant Fluid sampling points damage from deposits Safe means of removal of residual heat after shutdown Avoiding dangerous accumulation of ignitable mixtures or flame blowback Pipework design (overstressing) Pipework drainage Pipework turbulence and vortices Fatigue from pipe vibration Group 1 fluids - take-offs Pipework - inadvertent discharge Records of routing of underground piping for maintenance and repair Allowable stresses Joint coefficients Pressure limiting devices. Hydrostatic test pressure Material properties.

Justification
Levelstate Specification 180031 Issue A In accordance with juridstriction Regulations by enduser. Nameplate detailed drawings Refer to Installation Manual Refer to Assessment of Suitability Refer to Particular Material Appraisal

3.2.3 3.3 3.4 4.1 4.2 a 4.2b

Refer to Particular Material Appraisal

4.2c

Not Applicable Refer to material Certification in accordance with EN10204 Type 3.1b or 3.1c Not Applicable Not Applicable Not Applicable Not Applicable Not Applicable Installed by end-user Installed by end-user Not applicable Installed by end-user Not Applicable Installed by end-user Not applicable In accordance with ASME B31.1 Chapter II Part 1 In accordance with ASME B31.1 Chapter II Part 1 Not Applicable In accordance with ASME B31.1 Chapter VI & Levelstate Specification 180031 Issue A Refer to Material Test Certification

4.3 5a 5b 5c 5d 5e 6a 6b 6c 6d 6e 6f 6g 7.1 7.2 7.3 7.4 7.5

Justification of compliance with Essential Safety Requirements

Page 2 of 2

Levelstate Hazard Analysis for the PED

Equipment : Water Columns 501E, 502 & 503

1) Determine which hazards are applicable for the pressure equipment. 2) Determine if this hazard is reasonably foreeable for this equipment, for the use and design parameters specified. 3) Determine how the hazard can be reduced / eliminated or what protective measures or notices will be given concerning the hazard. 4) State whether if the hazard and the control measure used are acceptable and provide a high degree of health and safety protection. Ref. Hazard No. 1 Explosion / Leakage of probes seats & over heating - Hazard of stored energy 2 Brittle Fracture 3 4 5 6 7 8 10 11 12 13 14 Damage instrument probes, freedom of vessel to expand, examination problems ? Damage to equipment - transport or installation Escape of PED Group 1 fluid - damage to persons, buildings, environment etc.. Rapid release of high pressure fluid projection of vessel components / blast Collapse, vacuum implosion - leakage of vessel / detachment etc.. Furnace explosion of fired vessels blast, projection of flame tc.. Domino or knock on effect - with subsequent damage to plant / property Thermal expansion/pipework support & vibration Wind / Seismic / Snow / Transport / Cyclic / External / Nozzle loading, Creep etc.. Protective Device / Control system failure (response time / safe discharge / lockout) Other - Specify : Corrosion & Erosion Reasonably Solution / Control Measure Foreeable ? Yes Use only on properly operated boiler with end users correct operating procedures No Use only on steam raising plant. Yes Yes No Yes No No No Yes No Yes Yes Use only on properly designed plant in accordance with juridstictions regulations and Inst. Manual Comply with Sect 15 of Quality Assurance Manual Not Applicable Water columns encased in steel shrouding. Refer to Inst.Manual for best positioning Due to rigid construction using forged components Refer to section 3 of Inst.Manual for best positioning Items of inconsiquencial size on large boiler plants Refer to Inst.Manual for best positioning Refer to Inst.Manual for best positioning ensure items fitted to properly designed sytem (i.e.B31.1) Refer to inst. Manual for best practise Items operate outside the creep range Use only on propely operated steam systems properly protected in accordance with Juridstn.Regs Use only with properly treated boiler water as per Inst.Manual and allowances built into design calcs. Acceptable ? Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes

This document is provided for information purposes only. It is the manufacturers responsibility to ensure that they have considered all hazards that exist for their pressure equipment. Further infor from CEOC guidance

Particular Material Appraisal in accordance with PED (97/23/EC) Part 4.2.b Assessment of Suitability The materials used in the manufacture of the pressurised parts have appropriate properties for aloperating conditions; in particular they are ductile and tough. They are suitable for the steaming conditions of the boiler using feed water which is chemically controlled and where corrosion is insignificant. They have welding compatibility, as they are all low carbon alloy steels grouped by P numbers in accordance with ASME B&PV Code Section IX. They comply with the specifications of the ASME B&PV Code Section 1 PG 23 and ASME B31.1 Chapter IV Table 126.1 They conform to the requirements of ANNEX D of the PED (97/23/EC) Sections 2.2.3, 4, 4.1, 4.2 and 4.3. They are supported by Inspection Reports in accordance with EN10204 type 3.1b & 3.1c. An appraisal of each material used at the max operating limits of 700 degF /371 degC for low Carbon Steel & 1076 degF / 580degC for High Alloy Stainless Steel is given in the table below. The materials are purchased from a material manufacturer holding an appropriate Quality Assurance System.

Material Specification ASTM A105 A106 Grd B A312 Type 316

Ductile?

Tough ?

Weldability ?

22% 22% 22%

Materials do not operate in brittle conditions Boiler Plant

<0.25 % Carbon <0.25% Carbon <0.25% Carbon

Suitable for High Temp ? Yes Yes Yes

Certs reviewed ? Yes Yes Yes

3.1b or 3.1c ? 3.1c 3.1b 3.1b

Declaration of Conformity to 97/23/EC

Levelstate Systems Limited 7 Bentley Industrial Centre Bentley Hampshire GU10 5NJ England

Pressure Equipment: Water Column Pressure Accessories used to monitor steam/water levels in steam generating plant. Type identification: Equipment Category: Conformity Assessment Procedure: Notified Body: Notified Body No: Technical Standards Used: 501E, 502 & 503 Category II Module A1 Royal & SunAlliance 17 York St, Manchester, UK 0040 ASME B&PV Code Section 1 Power Boilers ASME B31.1 Power Piping

Authorized signature: Name: Position: Date of Signature :

SATURATED STEAM TABLES

(From VDI tables of constants of steam / water)

Absolute Pressure Bar

20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50 55 60 65 70 75 80 85 90 95 100 110 120 140 150 160 180 200 220 221-2

Temperature C

Specific volume m/kg

0.09954 0.09065 0.08320 0.07686 0.07139 0.06663 0.06244 0.05873 0.05541 0.05244 0.04975 0.04731 0.04508 0.04304 0.04116 0.03943 0.03563 0.03244 0.02972 0.02737 0.02533 0.02353 0.02193 0.02050 0.01921 0.01804 0.01601 0.01428 0.01150 0.01034 0.009308 0.007498 0.005877 0.003728 0.003170

Specific weight kg/m

10.05 11.03 12.02 13.01 14.01 15.01 16.02 17.03 18.05 19.07 20.10 21.14 22.18 23.24 24.29 25.36 28.07 30.83 33.65 36.53 39.48 42.51 45.61 48.79 52.06 55.43 62.48 70.01 86.99 96.71 107.40 133.40 170.20 268.30 315.50

Enthalpy kJ/kg of water of steam

908.6 931.0 951.9 971.7 990.5 1008.4 1025.4 1041.8 1057.6 1072.7 1087.4 1101.6 1115.4 1128.8 1141.8 1154.5 1184.9 1213.7 1241.1 1267.4 1292.7 1317.1 1340.7 1363.7 1386.1 1408.0 1450.6 1491.8 1571.6 1611.0 1650.5 1734.8 1826.5 2011.1 2107.4 2797.2 2799.1 2800.4 2801.4 2802.0 2802.3 2802.3 2802.1 2801.7 2801.1 2800.3 2799.4 2798.3 2797.0 2795.7 2794.2 2789.9 2785.0 2779.5 2773.5 2766.9 2759.9 2752.5 2744.6 2736.4 2727.7 2709.3 2689.2 2642.4 2615.0 2584.9 2513.9 2418.4 2195.6

Latent heat kJ/kg

212.37 217.24 221.78 226.04 230.05 233.84 237.45 240.88 244.16 247.37 250.33 253.24 256.05 258.75 261.37 263.91 269.93 275.55 280.82 285.79 290.50 294.97 299.23 303.31 307.21 310.96 318.05 324.65 336.64 342.13 347.33 356.96 365.70 373.69 374.15

1888.6 1898.1 1848.5 1829.6 1811.5 1793.9 1776.9 1760.3 1744.2 1728.4 1712.9 1697.8 1682.9 1661.1 1653.9 1639.7 1605.0 1571.3 1538.4 1506.0 1474.2 1442.8 1411.7 1380.9 1350.2 1319.7 1258.7 1197.4 1070.7 1004.0 934.3 779.1 591.9 184.5 0.0

1 bar = 1.019716 kg/cm 1 kJ/kg = 0.238845 kcal/kg 1 kg/cm = 0.980665 bar 1 kcal/kg = 4.1868 kJ/kg

MAXIMUM ALLOWABLE STRESS VALUES FOR WATER COLUMN MATERIALS multiply by 1000 to obtain psi

Specified Nominal Composition Product Form Spec Number Grade Class Minumum Tensile -20 to 100 200 300 400 -20 to 400 500

For Metal Temperatures Not Exceeding F 600 650 700 750 800 850 900 950 1000 1050 1100

C-Mn-Si

Smls pipe

SA-106

60.0

15.0

15.0

15.0

15.0

14.4

13.0

10.8

7.8

5.0

3.0

1.5

C-Si

Forging

SA-105

70.0

17.5

17.5

17.5

17.5

16.6

14.8

12.0

7.8

5.0

3.0

1.5

16Cr-12Ni-2Mo

wld pipe

SA-312

TP316

75.0

16.0

13.8

12.4

11.4

10.6

10.1

9.8

9.6

9.5

9.4

9.3

9.2

9.1

9.0

8.9

8.8

SA-106 SA-105 SA-312

Maximum operating temperature Maximum operating temperature Maximum operating temperature

370C or 698 F 370C or 698 F 580C or 1076 F