Drum Level Measurement

Dr. Teerawat Thepmanee Automation Engineering, KMITL

What is boiler ?

Drum level measurement

What is boiler ?
What is a boiler ? When water is heated in a boiler, it begins to absorb energy. Depending on the pressure in the boiler, the water will evaporate at a certain temperature to form steam. The steam contains a large quantity of stored energy which will eventually be transferred to the process or the space to be heated

Steam turbine
Drum level measurement

Heat exchanger
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Types of boilers

Package boiler (Fire tube)

Utility boiler(water wall tube)

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Boiler drum

Drum level measurement

Drum level measurement

Application overview
Steam Drum Level is both a critical and difficult measurement to make. Control of the water level in the drum must be precise. A water level that is too high can result in water carryover into the steam piping. A level that is too low can expose the generating tubes (down comers), preventing the water in the drum from cooling the furnace tubes, possibly damaging them. Several factors make this measurement difficult to obtain. The steam drum itself may not be perfectly level, and even at steady state conditions, considerable turbulence in the drum can cause the level to fluctuate. In addition, a changing rate of water inflow and steam outflow adds to the potential for measurement error.
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Application overview
Measurement of boiler steam drum level using a differential pressure transmitter must take into account certain physical properties of the fluid.
The Steam drum contains a two-phase mixture of water and steam at saturation conditions. The densities of water and steam vary with saturation temperature or pressure. The density of saturated steam above water must be considered, as well as the density of saturated water in the drum.

This technical note offers a method for calibrating transmitters that takes into account these factors.

Drum level measurement

Water Property

=62.42 lbm/ft3 1 lbm = 1 lbm 0.01602 ft3

320F

0.01602 ft3

Pressure (constant) HEAT

= 62.42 lbm/ft3
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Water Property

=61.73 lbm/ft3 1 lbm = 1 lbm 0.01620 ft3

1200F 0.01620 ft3

Pressure (constant) HEAT

= 61.73 lbm/ft3
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Water Property

=59.81 lbm/ft3 =61.73 lbm/ft3 =62.42 lbm/ft3 1 lbm

2120F 1200F 320F

0.01672 ft3 0.01620 ft3 0.01602 ft3

Pressure (constant) = 1 lbm 0.01672 ft3 HEAT

= 59.81 lbm/ft3
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Saturated Water

Boiling point

Boiling No bubble 1 lbm HEAT

2120F

0.01672 ft3

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Saturated Water
Water and Steam bubble swell Boiling Boiling With Bubble 1 lbm Pressure is increased 2120F 2120F 0.01672 ft3

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Saturated Water
Water and Steam bubble more swell 2120F 0.01672 ft3

1 lbm Pressure is increased

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Saturated Water
Water and Steam bubble shrink 2120F 0.01672 ft3

1 lbm

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Drum level measurement

Condensing pot Pd Saturated Steam S WD + 300 0 Saturated water h - 300 W V H

PH

PL

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Drum level measurement

Define process variable S = steam density WD = drum water density W = water density g = gravity PH = Static pressure at the high side of the transmitter PL = Static pressure at the low side of the transmitter Define process variable Pd = Static pressure in the steam drum at the top tap H = Distance between the high and low drum taps h = Drum water level (measured from the bottom tap) V =Vertical distance from the bottom tap to the transmitter
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Drum level measurement

Drum level measurement

Solution PH = w.g.V + WD.g.h + S.g.(H-h) + Pd PL = w.g.V + W.g.H + Pd P = w.g.V + WD.g.h + S.g.(H-h) + Pd - w.g.V - W.g.H - Pd P = WD.g.h + S.g.H - S.g.h - W.g.H P = WD.g.h - S.g.h - W.g.H + S.g.H P = g.h(WD- S) - g.H(W - S)

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Ex. Drum level measurement

Ex. operating condition 100 C at pressure 14.696 Psia Determine hmin and hmax (300 mm) From steam table WD= 958.098 , S= 0.598, W(43 C ) = 990.628 Level max.(100 %) h = H = 0.6 m P(100%)= PH PL = g.h(WD S) g.H(W S) = 9.8070.6(958.0980.598)9.8070.6(990.628 0.598) = 5633.93 5825.33 = 191.40 Pa
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Ex. Drum level measurement

Ex operating condition 100 C at pressure 14.696 Psia Level min.(0 %) h = 0 m, H = 0.6 m P(0%) = PH PL = g.h(WD S) g.H(W S) = 0 9.807 0.6 (990.628 0.598) = 0 5825.33 = 5825.33 Pa

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Calibration range
% 100 0 Level (m) 0.6 0 D/P (Pa) -191.40 -5825.33 Signal (mA) 20 4

Finally, check the zero elevation and span against the transmitter specifications to ensure the selected transmitter can be calibrated to the required values.

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Calibration range
Level % 100 75 50 25 0 DBR (m) 0.60 0.45 0.30 0.15 0.00 Range (m) 0.30 0.15 0.00 -0.15 -0.30 PH (Pa) 5633.93 4225.44 2816.96 1408.48 0.00 PL (Pa) 5825.33 5825.33 5825.33 5825.33 5825.33 DP (Pa) O/P (mA) Controller (m) 0.600 0.450 0.300 0.150 0.000 -191.40 20.000 -1599.88 -3008.36 -4416.85 -5825.33 16.000 12.000 8.000 4.000

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Normalization Unit
Percent (0 - 100%) to level(0 0.6 m) At 50 %, what is Level ? Solution sensitivity = span output / span input = 0.6/100 = 0.006 m / % At 50 % level = 0.006 50 = 0.3 m

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Normalization Unit
Level 0 0.6 m to DP (- 5825.33 (-191.40)) At 0.3 m, What is differential pressure ? Solution sensitivity = span output / span input = (-191.40 (- 5825.33)) / (0.6 0) = 9389.88 Pa/m At 0.3 m P = 9389.88 (0.3-0) + (- 5825.33) = - 3008.36 Pa

Drum level measurement

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Normalization Unit
DP (-191.40 (- 5825.33)) to Signal (4-20 mA) At (- 3008.36 Pa), What is Signal ? Solution sensitivity = span output / span input = (20-4) / (-191.40 (- 5825.33)) = 2.84 10-3 mA/Pa At (- 3008.36 Pa) signal = 2.84 10-3 (- 3008.36 - (- 5825.33)) + (4) = 12 mA

Drum level measurement

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Level Transmitter
Transmitter Signal 12 mA ,What is water in drum level ? Solution sensitivity = span output / span input = (20-4) / (0.6 0) = 26.67 mA/m At 12 mA controller = [(12-4)/26.67] + (0) = 0.3 m

Drum level measurement

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Level & DP
P
-5825.33 -4416.85 -3008.36 -1599.88 -191.40 0% 0 25% 0.15 50% 0.30 75% 0.45 100 %

Level

0.6 m

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DP Transmitter signal
Level (m) mA
0.60 0.45 0.30 0.15 0.0

%
75% 50% 25% 0% 0% 25% 50% 75% 100 % -191.40 -5825.33 -3008.36 -1599.88 -4416.85

20 100% 16 12 8 4

P (Pa)

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Drum level measurement

At Operating condition 353 C at pressure 2498.1 Psia Level min.(50 %) h = 0.3 m, H = 0.6 m Solution P(50%)= PH PL = g.h(WD S) g.H(W S) = 9.8070.3(560.478 122.4) 9.8070.3 (990.628 122.4) = 1288.82 5108.65 = 3819.83 Pa

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Drum level measurement

100% 50% 0% 100% 50% 0%

PH

PL

PH

PL

Operating condition Temp = 100 C Pressure = 14.696 Psia P = - 3008.36 Pa Signal = 12 mA

Operating condition Temp = 353 C Pressure = 2498.1 Psia P = - 3819.83 Pa Signal = ???? mA
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Drum level measurement

Normalization Unit
DP (-191.40 (- 5825.33)) to Signal (4-20 mA) At (- 3819.83 Pa), What is Signal ? Solution sensitivity = span output / span input = (20-4) / (-191.40 (- 5825.33)) = 2.84 10-3 mA/Pa At (- 3819.83 Pa) Signal = 2.84 10-3 (- 3819.83 - (- 5825.33)) + (4) = 9.69 mA

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Level Transmitter
At Transmitter Signal 9.69 mA ,What is water in drum level ? Solution Sensitivity = span output / span input = (20-4) / (0.6 0) = 26.67 mA/m At 12 mA Controller = (9.69-4)/26.67 + (0) = 0.214 m

Drum level measurement

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Drum level measurement

Condition 100 C 14.696 Psia 353 C 2498.1 Psia % 50 50 Level (m) 0.3 0.3 DP (Pa) - 3008.36 - 3819.83 Signal (mA) 12 9.69 Controller (m) 0.3 0.214

Error = 0.214 - 0.3 = - 0.086 m Water Level at 35% from 50 % or reduce 15%

Drum level measurement

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DP Transmitter signal
Level (m) mA
0.60 0.45

%
75% 50% 25% 0% 0% 25% 50% 75% -5825.33 -3008.36 -3819.83
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20 100% 16

0.30 12 0.214 9.69 0.15 8 0.0 4

100 % -191.40

P (Pa)

Drum level measurement

Ex Operating condition 353 C at pressure 2498.1 Psia Determine hmin and hmax (300 mm) From steam table WD= 560.478 , S= 122.400, W(43 C ) = 990.628 Level max.(100 %) h = H = 0.6 m Solution P = PH PL = g.h(WD S) g.H(W S) = 9.8070.6(560.478 122.4)9.8070.6(990.628 122.4) = 2577.65 5108.65 = 2531 Pa
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Drum level measurement

Ex Operating condition 353 C at pressure 2498.1 Psia Level min.(0 %) h = 0 m, H = 0.6 m Solution P = PH PL = g.h(WD S) g.H(W S) = 0 9.807 0.6 (990.628 122.4) = 0 5108.65 = 5108.65 Pa

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Calibration range
Level % 100 75 50 25 0 DBR (m) 0.60 0.45 0.30 0.15 0.00 range (m) 0.30 0.15 0.00 -0.15 -0.30 PH (Pa) 2577.65 1933.23 1288.82 644.41 0.00 PL (Pa) 5108.65 5108.65 5108.65 DP (Pa) -2531.00 -3175.41 -3819.82 Output Controller (mA) (m) 13.356 11.526 9.696 7.865 6.035 0.351 0.282 0.214 0.145 0.076
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5108.65 -4464.23 5108.65 -5108.65

Drum level measurement

Density compensate
From differential pressure formula P = g.h(WD- S) - g.H(W - S) Liquid level in boiler drum

h=

P + gH(w-s) g(WD-s)

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Density compensate
signal Controller or DCS Card 4-20mA to steam table (WD,S) 4-20mA to P

S WD

signal h= P + gH(w-s) g(WD-s)

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Exercise
Condensing pot Pd Saturated Steam S 0 Saturated water WD h W
What is calibration range of D/P transmitter at operating condition 200 C and wet leg temperature 43.333 C Where H = 1000 mm h = 700mm V = 150 mm

PH

PL

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Thank you
Question ?