WATER LEVELS IN STEAM BOILERS

The level of water in a steam boiler must be carefully controlled, to ensure good quality steam is produced safely, efficiently and at the correct pressure.
Water Levels in Steam Boilers
The task of any steam boiler is to provide the correct amount of high quality steam: safely, efficiently, and at the correct pressure.

Steam is generated by heat from the combustion of fuel in a furnace, or by waste heat from a process. The heat is transferred to water in the boiler shell,
which then evaporates to produce steam under pressure.

A certain area of water surface is required in a boiler from which to release the steam. A certain height should also be allowed above the normal working
level, to allow the water level to rise with increasing load, but still allowing sufficient area to release the steam without carryover of water taking place.

In horizontal shell boilers, the water level rises with increasing load (due to the presence of more steam being below the water level in the boiler). As it
does so, the water surface area (steam release area) will decrease because, as the water level is above the centre line of the boiler, the sides of the containing
shell converge.

The boilermaker will have designed the boiler to ensure that the area of the normal water level (NWL) is such that steam will be released at an acceptable
velocity. The design will also allow a specific minimum height of the steam off-take above the NWL.

Clearly, as steam is generated, the water in the boiler evaporates, and the boiler must receive a supply of water to maintain the level. Because of the factors
outlined above, water must be maintained at the correct level.

Safety is also of paramount importance. If the boiler operates with insufficient water, severe damage could occur and there is ultimately the risk
of explosion.

For this reason, controls are required which will:

 Monitor and control the water level.

 Detect if a low water level point is reached, and take appropriate action.
This action may include:

Sounding an alarm, shutting down the feedwater supply and shutting down the burner(s).

It is also essential to provide an external indication of the water level.

 The following Sections within this Module give basic information on the automatic level controls and alarms as applied to shell and tube boilers. This
information is also generally applicable to the steam drum of water-tube boilers.

For the purpose of continuity, much of the information in this Module is based upon UK legislation. Other national regulations must be consulted
where relevant.

Water level indication and boiler water levels

Water level indication applies to steam boilers where the water level can be detected. It includesmost steam boilers, the exception being those of the ‘once
through’ or coil type, where there is no steam drum. In such cases, steam outlet temperatures exceeding a pre-set value are taken to indicate insufficient
water input.

In most cases, the simple gauge glass on the steam / water drum or boiler shell is used as the indicator. Many standards stipulate the provision of two gauge
glasses. Arrangements are usually required to prevent a breakage from causing a hazard to the operator. The most common form of protection is a
toughened glass screen to the front and sides of the water gauge glass.

Water gauge glass constructed from flat or prismatic glass may be required for high-pressure boilers.

The gauge glass device, which has stood the test of time, is used on the vast majority of boilers and is usually arranged to give a visible range of water level
above and below the normal water level.
It is essential to understand what is seen in a boiler gauge glass. The following Section explains some of the factors which will influence the level of water
indicated in the gauge glass.

It is not possible to define the exact water level in a steaming boiler, because the water surface is made up of a mass of bubbles with a strong horizontal
circulation. There are therefore, level variations both across and along the boiler shell. Conversely, the gauge glass contains water which:

 Is not subject to current and agitation.

 Does not contain steam bubbles.
 Is cooler than the water in the boiler.
This means that the water in the gauge glass (and other external fittings) is denser than the water within the boiler shell. This in turn, means that the level
gauge glass will show a lower level than the average water surface level in the boiler shell.
 The difference between the level in the gauge glass and the level in the boiler shell at high steaming rates, depends on such factors as:

The boiler steam generation rating.

The height of the gauge glass water connection into the boiler.

The TDS and chemical analysis of the boiler water.

The size of the boiler shell.

Level changes due to boiler circulation

With a boiler on high load, the strong circulation of the boiler water will cause the water level to vary along the length of the boiler. These circulation
currents are normally considered to be upwards along the front and back of the boiler, and upwards along the centreline over the furnace.

The downward circulation must therefore be at the sides, in the centre section of the boiler. There could also be a ‘drawing’ effect from the steam off-take
connection which will tend to raise the water locally.

During sudden load changes there is also the possibility of waves developing in the boiler, which can often be seen in the level gauge glass, but should
ideally be ignored by the water level controls.

A summary of the level changes to be expected under various boiler conditions is illustrated in Figure 3.15.4.
 METHODS OF DETECTING WATER LEVEL IN
STEAM BOILERS

The application of level controls and alarms, plus an overview of different level detection methods, including float-type controls, conductivity probes and
capacitance devices.
Methods of Detecting Water Level in Steam Boilers
On a steam raising boiler there are three clear applications for level monitoring devices:

 Level control - To ensure that the right amount of water is added to the boiler at the right
time.
 Low water alarm - For safe boiler operation, the low water alarm ensures that the combustion
of fuel does not continue if the water level in the boiler has dropped to, or below a
predetermined level. For automatically controlled steam boilers, national standards usually
call for two independent low level alarms, to ensure safety. In the UK, the lower of the two
alarms will ‘lockout’ the burner, and manual resetting is required to bring the boiler back on
line.
 High water alarm - The alarm operates if the water level rises too high, informing the boiler
operator to shut off the feedwater supply. Although not usually mandatory, the use of high
level alarms is sensible as they reduce the chance of water carryover and waterhammer in the
steam distribution system.
 Methods of automatic level detection
The following Sections within this Module discuss the principal types of level detection device which are appropriate to steam boilers.

Basic electric theory

The way in which electricity flows can be compared with a liquid. Liquid flows through a pipe in a similar way that electricity flows through a conductor
(see Figure 3.16.2).
A conductor is a material, such as metal wire, which allows the free flow of electrical current. (The opposite of a conductor is an insulator which resists the
flow of electricity, such as glass or plastic). An electric current is a flow of electric ‘charge’, carried by tiny particles called electrons or ions. Charge is
measured in coulombs. 6.24 x 1018 electrons together have a charge of one coulomb, which in terms of SI base units is equivalent to 1 ampere second.

When electrons or ions are caused to move, the flow of electricity is measured in Coulombs per second rather than electrons or ions per second. However,
the term ‘ampere’ (or A) is given to the unit in which electric current is measured.

 1 A = A flow of 6.24 x 1018 electrons per second.

 1 A = 1 coulomb per second.
The force causing current to flow is known as the electromotive force or EMF. A battery, a bicycle dynamo or a power station generator (among other
examples) may provide it.

A battery has a positive terminal and a negative terminal. If a wire is connected between the terminals, a current will flow. The battery acts as a pressure
source similar to the pump in a water system. The potential difference between the terminals of an EMF source is measured in volts and the higher the
voltage (pressure) the greater the current (flow). The circuit through which the current flows presents a resistance (similar to the resistance presented by
pipes and valves in a water system).

The unit of resistance is the ohm (given the symbol ) and Ohm’s law relates current, voltage and resistance, see Equation 3.16.1:

Where:
 I = Current (amperes)

V = Voltage (volts)

R = Resistance (ohms)

Another important electrical concept is ‘capacitance’. It measures the capacity of the charge between two conductors (roughly analogous to the volume of a
container) in terms of the charge required to raise its potential by an amount of one volt.

A pair of conductors has a large capacitance if they need a large amount of charge to raise the voltage between them by one volt, just as a large vessel
needs a large quantity of gas to fill it to a certain pressure.

The unit of capacitance is one coulomb per volt, which is termed one farad.

Conductivity probes
Consider an open tank with some water in it. A probe (metal rod) is suspended in the tank (see Figure 3.16.3). If an electrical voltage is applied and the
circuit includes an ammeter, the latter will show that:

 With the probe immersed in the water, current will flow through the circuit.
 If the probe is lifted out of the water, current will not flow through the circuit.

This is the basis of the conductivity probe. The principle of conductivity is used to give a point measurement. When the water level touches the probe tip, it
triggers an action through an associated controller.

This action may be to:

 Start or stop a pump.

 Open or close a valve.
  Sound an alarm.
 Open or close a relay.
But a single tip can only provide a single or point action. Thus, two tips are required with a conductivity probe in order to switch a pump on and off at
predetermined levels, (Figure 3.16.4). When the water level falls and exposes the tip at point A, the pump will begin to run. The water level rises until it
touches the second tip at point B, and the pump will be switched off.
Probes can be installed into closed vessels, for example a boiler. Figure 3.16.5 shows a closed top metal tank - Note; an insulator is required where the
probe passes through the tank top.

Again:

 With the probe immersed, current will flow.

 With the probe out of the water, the flow of current ceases.
Note: An alternating current is used to avoid polarisation and electrolysis (the splitting of water into hydrogen and oxygen) at the probe. A standard
conductivity probe must be used to provide low water alarm in a boiler.

Under UK regulations, this must be tested daily.

For a simple probe there is a potential problem - If dirt were to build up on the insulator, a conductive path would be
created between the probe and the metal tank and current would continue to flow even if the tip of the probe were out of the water. This may be overcome
by designing and manufacturing the conductivity probe so that the insulator is long, and sheathed for most of its length with a smooth insulating material
such as PTFE/Teflon®. This will minimise the risk of dirt build-up around the insulator, see Figure 3.16.6.
 The problem has been solved by:
 Using an insulator in the steam space.
 Using a long smooth PTFE sheath as an insulator virtually along the whole length of the
metal probe.
 Adjustable sensitivity at the controller.
 Special conductivity probes are available for low level alarms, and are referred to as ‘self-monitoring’. Several self-checking features are
incorporated, including:

 A comparator tip which continuously measures and compares the resistance to earth through
the insulation and through the probe tip.
 Checking for current leakage between the probe and the insulation.
 Other self-test routines.
Under UK regulations, use of these special systems allows a weekly test rather than a daily one. This is due to the inherently higher levels of safety in
their design.

The tip of a conductivity probe must be cut to the correct length so that it accurately represents the desired switching point.

Conductivity probes summary

Conductivity probes are:

 Normally vertically mounted.

 Used where on/off level control is suitable.
 Often supplied mounted in groups of three or four in a single housing, although other
configurations are available.
 Cut to length on installation.
Since the probes use electrical conductivity to operate, applications using very pure water (conductivity less than 5 μ Siemens/cm) are not suitable.
 Capacitance probes
A simple capacitor can be made by inserting dielectric material (a substance which has little or no electrical conductivity, for example air or PTFE),
between two parallel plates of conducting material (Figure 3.16.8).
A basic capacitor can be constructed by dipping two parallel conductive plates into a dielectric liquid (Figure 3.16.9). If the capacitance is measured as the
plates are gradually immersed, it will be seen that the capacitance changes in proportion to the depth by which the plates are immersed into
the dielectric liquid.

The capacitance increases as more of the plate area is immersed in the liquid (Figure 3.16.10). A simple capacitor can be made by inserting dielectric
material (a substance which has little or no electrical conductivity, for example air), between two parallel plates of conducting material (Figure 3.16.8).
The situation is somewhat different in the case of plates immersed in a conductive liquid, such as boiler water, as the liquid no longer acts as a dielectric,
but rather an extension of the plates.

The capacitance level probe therefore consists of a conducting, cylindrical probe, which acts as the first capacitor plate. This probe is covered by a suitable
dielectric material, typically PTFE. The second capacitor plate is formed by the chamber wall (in the case of a boiler, the boiler shell) together with the
water contained in the chamber. Therefore, by changing the water level, the area of the second capacitor plate changes, which affects the overall
capacitance of the system (see Equation 3.16.2).

The total capacitance of the system therefore has two components (illustrated in Figure 3.16.12):

 CA, the capacitance above the liquid surface - The capacitance develops between the chamber
wall and the probe. The dielectric consists of both the air between the probe and the chamber
wall, and the PTFE cover.
 CB, the capacitance below the liquid surface - The capacitance develops between the water
surface in contact with the probe and the only dielectric is the PTFE cover.
 Since the distance between the two capacitance plates above the water surface (the chamber wall and the probe) is large, so the capacitance CA is small
(see Equation 3.16.2). Conversely, the distance between the plates below the water surface (the probe and the water itself) is small and therefore, the
capacitance CB will be large compared with CA. The net result is that any rise in the water level will cause an increase in capacitance that can be measured
by an appropriate device.

The change in capacitance is, however, small (typically measured in pico farads, for example, 10-12 farads) so the probe is used in conjunction with an
amplifier circuit. The amplified change in capacitance is then signalled to a suitable controller.

Where the capacitance probe is used in, for example, a feedtank, (Figure 3.16.13) liquid levels can be monitored continuously with a capacitance probe.
The associated controller can be set up to modulate a control valve, and/or to provide point functions such as a high level alarm point or a low level alarm.

The controller can also be set up to provide on/off control. Here, the ‘on’ and ‘off’ switching points are contained within a single probe and are set via the
controller, removing any need to cut the probe. Since a capacitance probe must be wholly encased in insulating material, it must not be cut to length.
 Float control
This is a simple form of level measurement. An everyday example of level control with a float is the cistern in a lavatory. When the lavatory is flushed, the
water level drops in the cistern, the float follows the water level down and opens the inlet water valve. Eventually the cistern shuts and as fresh water runs
in, the water level increases, the float rises and progressively closes the inlet water valve until the required level is reached.

The system used in steam boilers is very similar. A float is mounted in the boiler. This may be in an external chamber, or directly within the boiler shell.
The float will move up and down as the water level changes in the boiler. The next stage is to monitor this movement and to use it to control either:

 A feedpump (an on/off level control system)

or

 A feedwater control valve (a modulating level control system)

Because of its buoyancy, the float follows the water level up and down.

 At the opposite end of the float rod is a magnet, which moves inside a stainless steel cap.
Because the cap is stainless steel, it is (virtually) non-magnetic, and allows the lines of
magnetism to pass through it.
In its simplest form, the magnetic force operates the magnetic switches as follows:

 The bottom switch will switch the feedpump on.

 The top switch will switch the feedpump off.
However, in practice a single switch will often provide on/off pump control, leaving the second switch for an alarm.

This same arrangement can be used to provide level alarms.

A more sophisticated system to provide modulating control will use a coil wrapped around a yoke inside the cap. As the magnet moves up and down, the
inductance of the coil will alter, and this is used to provide an analogue signal to a controller and then to the feedwater level control valve.
 Float control application
Vertically or horizontally mounted, the level signal output is usually via a magnetically operated switch (mercury type or ‘air-break’ type); or as a
modulating signal from an inductive coil due to the movement of a magnet attached to the float. In both cases the magnet acts through a non-magnetic
stainless steel tube.
 Differential pressure cells
The differential pressure cell is installed with a constant head of water on one side. The other side is arranged to have a head which varies with the boiler
water level.

Variable capacitance, strain gauge or inductive techniques are used to measure the deflection of a diaphragm, and from this measurement, an electronic
level signal is produced.

Use of differential pressure cells is common in the following applications:

 High-pressure water-tube boilers where high quality demineralised water is used.

 Where very pure water is used, perhaps in a pharmaceutical process.
In these applications, the conductivity of the water is very low, and it can mean that conductivity and capacitance probes will not operate reliably.

AUTOMATIC LEVEL CONTROL SYSTEMS

A detailed explanation of on/off, modulating, two and three element automatic level control, with a comparison of pros and cons.
On/off control
All the methods of level detection described so far can be used to produce an on/off signal for level control. The most common method of level control is
simply to start the feedpump at a low level and allow it to run until a higher water level is reached within the boiler.
  With a float level control, a magnetic switch with a built-in hysteresis or dead-band will be
used.
 With conductivity probes, two probes are necessary, (pump on and pump off) which will give
fixed switching levels.
 A capacitance probe can be used to give adjustable on/off switching levels.

In the UK, on/off type control is almost universal on boilers below about 5 000 kg/h steam generation rate because it is the least expensive option. (In
Australia and New Zealand, standards state that for boilers exceeding 3 MW (typically 5 000 kg/h), modulating control must be fitted).

It can be argued, however, that this type of on/off control is not ideal for boiler control, because the relatively high flowrate of ‘cold’ feedwater when the
pump is on reduces the boiler pressure.

This causes the burner firing rate to continuously vary as the pump switches on and off.

Taking a typical example, it can be shown by calculation that even with feedwater at 80°C, the burner firing rate may have to be 40% higher with the
feedpump on, than with the feedpump off.

This continuous variation causes:

 Wear on the burner controls.

 Temperature cycling of the boiler.
 Reduced efficiency.
 A ‘saw-tooth’ type steam flowrate as depicted by the chart recorder shown in Figure 3.17.2.

If steam loads are high, the variable steam flowrate will tend to increase water carryover with the steam, and will tend to make water levels increasingly
unstable with the associated danger of low water level lockout, particularly on multi-boiler installations.

However, the fact remains that on/off control is very widely used on boilers of small to medium output, as defined above, and that many problems
associated with steam boilers operating with large swings in load are due in part to on/off level control systems.
Summary of on/off level control

Advantages:
 Simple.
 Inexpensive.
 Good for boilers on stand-by.
Disadvantages:
 Each boiler requires its own feedpump.
 More wear and tear on the feedpump and control gear.
 Variable steam pressure and flowrate.
 More boiler water carryover.
 Higher chance of daily operating problems under large load swings.
Modulating control
In this type of system the feedpump runs continuously, and an automatic valve (between the feedpump and the boiler) controls the feedwater flowrate to
match the steam demand.

When operating correctly, modulating control can dramatically smooth the steam flowrate chart and ensure greater water level stability inside the boiler.

For modulating level control, the following methods can be used to sense the water level:

 Floats with a continuous signal output.

 Capacitance probes.
 Differential pressure cells.

Recirculation
To protect the feedpump from overheating when pumping against a closed modulating valve, a recirculation or spill-back line is provided to ensure a
minimum flowrate through the pump.

This recirculation may be controlled by a valve or with an orifice plate. The amount of water to be recirculated is not great, and guidance is usually
available from the pump manufacturer. As an indication, the orifice size will usually be between 5 mm and 7 mm for a typical boiler.
 Modulating level control by varying the speed of the boiler feedwater pump

In this type of system, a modulating signal representing boiler water level (for example, from a capacitance probe) is directed to an electrical frequency
controller. This controller in turn varies the frequency of the ac voltage to the boiler feedwater pump motor, and hence varies its speed.

 If a lot of water is required, the pump runs at high speed.

 If less water is required, the pump speed is reduced.
In this way the speed of the pump is modulated to provide a feedwater flowrate which matches the boiler’s demand for feedwater.

There are two ways that variable speed drive technology is generally applied:

With recirculation - When demand is satisfied and the motor speed is reduced to its minimum, and some recirculation of feedwater to the
feedtank is still required to avoid the pump overheating (see Figure 3.17.5).
Without recirculation - In this case the motor controller stops the feedpump at very low boiler loads, so recirculation is not required.
 Two important factors related to stopping and starting of the pump are:

 The pump must not be started and stopped within a given period of time more than is
recommended by the manufacturer.
 When starting, the frequency controller should be ramped up from low speed, to minimise
wear on the pump.
The principle advantage of variable speed drives is that as the speed of the pump varies, so does its power consumption, and, of course, reduced power
consumption means reduced running costs.

However, the cost savings from using variable speed drives must be related to the higher cost of the control equipment. This is usually only viable for large
boilers with wide variations in load or which operate in a lead/lag manner.
Single element water level control
The standard single element boiler water level control system, with proportional control, gives excellent control on the majority of boiler installations.

However, with single element proportional control, the water level must fall for the feedwater control valve to open. This means that the water level must
be higher at low steaming rates and lower at high steaming rates: a falling level control characteristic.

However, where there are very sudden load changes, on some types of water-tube boiler, single element control has its limitations.

Consider the situation when a boiler is operating within its rated capacity:

 The boiler ‘water’ will actually contain a mixture of water and steam bubbles, which will be
less dense than water alone.
  If the demand for steam increases, the pressure in the boiler initially falls, and the control
system will increase the burner firing rate. The rate of evaporation will increase to meet the
increased demand.
 The increased rate of evaporation means that the boiler water will contain more steam bubbles
and become even less dense.
If a sudden load is now applied to the boiler:

 The pressure inside the boiler is further reduced, and a proportion of the boiler water will
flash to steam. The flashing of the boiler water, plus the increased heat input as the burners
turn up to maximum, means that the boiler ‘water’ will contain even more steam bubbles, and
its density will be further reduced.
 As the pressure falls, the specific volume of the steam increases, and the resulting higher
velocity at which the steam is drawn off the boiler can create a ‘swell’ of the steam
bubble/water mixture, resulting in an apparent rise in water level.
 The level controls will detect this apparent rise in water level, and start to close the feedwater
control valve, when in fact more water is required. The situation now, is that there is a high
steam demand, and no water is being added to the boiler to maintain the level.
 A point is reached where the ‘swell’ in the water will collapse, possibly to a level below the
low level alarms, and the boiler can suddenly ‘lockout’, bringing the plant off-line.
Two element water level control
Two element control reverses the falling level control characteristic to ensure that the water level is made to rise at high steaming rates. This strives to
ensure that the quantity of water in the boiler stays constant at all loads, and that during periods of increased, sudden steam demand, the feedwater control
valve opens.

The system works by using the signal from a steam flowmeter installed in the steam discharge pipework to increase the level controller set point at high
steam loads.

The two elements of the signal are:

 First element - Level signal from the water within the boiler.
 Second element - Flow signal from the steam flowmeter in the boiler steam off-take.
 Summary of two element water level control
Any boiler installation which experiences frequent, sudden changes in load may work better with a two element feedwater control system.

Where process load changes are severe (breweries are a common application) two element control should be considered and would appear to be necessary
where there are sudden load changes of more than 25%, on a boiler.

Three element water level control

Three element control as shown in Figure 3.17.8, involves the two signal elements as previously mentioned, plus a third element, which is the actual
measured flowrate of feedwater into the boiler. Three element control is more often seen in boiler houses where a number of boilers are supplied with
feedwater from a common, pressurised ring main.

Under these circumstances the pressure in the feedwater ring main can vary depending on how much water is being drawn off by each of the boilers.

Because the pressure in the ring main varies, the amount of water which the feedwater control valve will pass will also vary for any particular valve
opening. The input from the third element modifies the signal to the feedwater control valve, to take this variation in pressure into consideration.
 Summary of modulating level control

Advantages:
 Steady steam pressure and flowrate within the boiler’s thermal capacity.
 More efficient burner operation.
 Less thermal stress on the boiler shell.
 Less boiler water carryover.
 Can use a central feedpump station.
 Less wear and tear on the feedpump and burner.
Disadvantages
 More expensive.
 Feedpump must run continually.
 Less suitable for ‘stand-by’ operation.
 Possibly greater electricity consumption.
 WATER LEVEL ALARMS

The function of high and low level alarms. Low-level alarms will draw attention to low boiler water level and, if required, shut down the boiler. High-level
alarms protect plant and processes.
Water Level Alarms
Where boilers are operated without constant supervision (which includes the majority of industrial boilers) low water level alarms are required to shut
down the boiler in the event of a lack of water in the boiler. Low level may be caused by:

 A feedwater shortage in the feedtank.

 Failure of a feedpump.
 Accidental isolation of the feedwater line
 Failure of the level control system.
The regulations covering boilers have built up over the years in response to boiler explosions, damage and loss of life. Whilst boiler explosions are now
very rare, damage to boilers which is attributable to low water level still occurs.

The effect of low water level in a boiler is that the heated tubes or the furnace tube(s) become uncovered and are no longer cooled by the boiler water. The
metal temperature rapidly increases, its strength is reduced and collapse or rupture follows.
 Low water alarm
The action of the low water level alarms under UK regulations is as follows:

 1st low level alarm - Shuts down the burner at the alarm level, but allows it to re-fire if the
level recovers.
 2nd low level alarm (often called lockout) - Also shuts down the burner at the alarm level,
but the burner controls remain ‘locked out’ even if the water level recovers and any faults
have been rectified. The lockout has to be manually reset to allow the burner to re-fire.
The rules and regulations covering boiler operation, and the controls required, will vary from country to country, although demands for higher levels of
safety, plus a desire to run steam boilers without the permanent presence of a boiler attendant, are tending to drive the regulations in the same direction.

The action of low water alarms outlined above, relates to the regulations governing unattended steam boiler plant in the UK. However, they are similar to
the rules which are applied in many European countries and further afield.

High water alarm

With the exception of one or two operating standards, the risks from a water level too high are treated very lightly, if not ignored altogether.

The dangers of an excessively high water level in a steam boiler include:

 Increased carryover of water into the steam will result in poor operation and/or malfunction of
the steam system components, due to dirt.
 Wet and dirty steam can contaminate or spoil the product where it is used directly. Wet steam
can increase the water film thickness of the heat transfer surface, lower processing
temperatures, perhaps interfering with proper sterilisation of food products or processing of
pharmaceuticals, and causing wastage. At best, lower process and production efficiency will
increase process time and unit costs.
 Overfilling the boiler can lead to waterhammer in the steam system, risking damage to plant
and even injury to personnel.
 All of these, taken together, can result in:
 Spoilt product.
 Lower production rates.
 Poor product quality.
 Increased plant and component maintenance.
 Damage to the steam system.
 Risk to personnel.
As can be seen, the dangers of an excessively high water level are too serious to ignore, and deserve equal consideration to that given to low water
level conditions.

A high water condition could:

 Simply sound an alarm if the boiler house is manned.

  Shut-down the feedpump.
 Lockout the burner.
 Close the feedwater valve.
The action to be taken largely depends on the individual plant requirements.

INSTALLATION OF LEVEL CONTROLS

The pros and cons of direct versus externally mounted level controls.
It has already been acknowledged that the water level in a steam boiler varies considerably as a result of:

 The load.
 The rate of load change.
 Water circulation within the boiler.
These circumstances combine to make it very difficult to monitor and control the boiler water level to any accuracy. What is required is a calm area of
water which is representative of the actual boiler water level.

With float and probe type level controls, this is achieved in two ways:

 External chambers.
 Internal protection tubes.
External chambers
These are externally mounted chambers which have pipe connections to the boiler. They are usually, but not always, fitted with float controls. Some typical
arrangements are shown in Figure 3.19.1.
 Two external chambers are required

 One chamber houses the level control plus the first low level alarm.
 The other houses the second low level alarm plus the high level alarm (if fitted).
This ensures that the two low alarms are in independent chambers.

The external chambers would be fitted with ‘sequencing purge valves’ and (optionally) with steam isolating valves.

Note: If isolating valves are fitted, UK regulations demand that they are locked open.
Traditionally float controls have been installed into external chambers, although probes workequally well, and have the advantage of no moving parts to
wear out.
 Internal protection tubes (direct mounted level controls)
These are sometimes referred to as direct mounted level controls, and they require protection tubes to be installed inside the boiler shell as shown in Figure
3.19.4.

The first and second low level devices must be mounted in separate protection tubes, so that they are completely independent of each other.

The protection tubes themselves are not standard items, and will be uniquely manufactured for each individual boiler. However, because the design of the
protection tubes can have such a major effect on the successful operation of the level controls, the following provide some guidance for their design and
installation:

Diameter
An 80 mm nominal bore protection tube will ensure steady conditions and provide sufficient clearance for probe centering.

Where two probes (for example, level control/high alarm probe plus self-monitoring low alarm probe) are to be installed in a single protection tube, 100
mm nominal bore is usually required.

Length
The protection tube should go as far down between the boiler tubes as physically possible.
 Location
Where there is a choice of probe installation positions, the general recommendations are as follows:

 As far away as possible from the steam off-take and safety valve connection (minimum 1 m),
but not too near the boiler end plates.
 As close to the level gauge as possible. Connections across the boiler shell, near the front are
often convenient.
 Installation in protection tubes with top and bottom holes for steam and water entry, with a
blanked bottom to prevent steam bubbles entering and without a full length slot along the
protection tube.
 There are a number of significant advantages to using direct mounted controls in internal protection tubes:

 It is often a cheaper alternative with a new boiler as the cost of two or three protection tubes is
usually less than two external control chambers and the associated sequencing purge valves.
 Full advantage can be taken of the advances in electronics provided by modern technology.
Float controls
Although the trend is towards using probe-type direct mounted controls, it is still common to see direct mounted float controls, where the float is situated
inside the boiler shell using a flange and protection tube assembly.

Standard models
Direct mounted float controls employ the same principles of operation and piece parts as their chamber mounted equivalents, except that the chamber is
exchanged for a large round flange and protection tube assembly for mounting the control directly onto the boiler shell connection. The protection tube
may be fixed or removable, and will ensure that the float rod is not damaged and the correct vertical movement is achieved.

Direct mounted float controls incorporating test facilities

To comply with the UK HSE Guidance Note for unmanned boiler houses, direct mounted float controls may incorporate a facility for testing the operation
of the mechanism without lowering the level of water in the boiler. Testing can be manual, or initiated/controlled by a timer. The test is achieved by
lowering the float to the low water alarm level.

Hydraulic cup test facility

The test is achieved by lowering the float to the low water alarm level, by the following means:

The float rod includes a cup above the float, which is fed for approximately 24 seconds with water from the boiler feedpump, via small bore pipework and
valves, through the control mounting flange (see Figure 3.19.6).

The additional weight overcomes the buoyancy of the float, causing it to sink. This stops the burner from firing and operates the alarm system. After
closing the test valve in the supply from the feedpump to the control, a small hole in the bottom of the cup drains off the water, permitting the float to rise
to the normal operating position. Control of the water supply to the cup can also be achieved by means of a solenoid valve, which can be initiated by a
timer or a manually operated push button.
 Electromagnetic test facility
he switch head includes a solenoid coil below the single switch sub-assembly. This surrounds an armature, which is located inside the stainless steel centre
tube and fixed to the float rod.

To initiate the test cycle, the coil can be energised by a timer or a manually operated push button, and the float will be thrust downwards, to stop the burner
firing and thus operate the alarm system. When the coil is de-energised the float rises to its normal level.

Probe controls
Single channel (non self-monitoring high integrity probes) may be installed in protection tubes, and, because they have no moving parts, they will often last
longer than an equivalent float control system.

The use of internal protection tubes in conjunction with high integrity, self-monitoring probes and controllers, brings significant advantages in terms of
testing requirements and the level of supervision demanded by authorities such as the UK Health and Safety Executive. This is discussed further in the
next Module.