Drum Level Measurement

Dr. Teerawat Thepmanee

Automation Engineering, KMITL
What is boiler ?

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 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 Heat exchanger

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 Types of boilers

Package boiler
(Fire tube)

Utility boiler(water wall tube)

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Boiler drum

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 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.

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 Water Property

ρ =62.42 lbm/ft3 320F 0.01602 ft3

1 lbm
Pressure (constant)
1 lbm
ρ=
0.01602 ft3 HEAT
= 62.42 lbm/ft3

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 Water Property

ρ =61.73 lbm/ft3 1200F 0.01620 ft3

1 lbm
Pressure (constant)
1 lbm
ρ=
0.01620 ft3 HEAT
= 61.73 lbm/ft3

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 Water Property

ρ =59.81 lbm/ft3 2120F 0.01672 ft3

ρ =61.73 lbm/ft3 1200F 0.01620 ft3

ρ =62.42 lbm/ft3 320F 0.01602 ft3
1 lbm
Pressure (constant)

ρ= 1 lbm
0.01672 ft3 HEAT

= 59.81 lbm/ft3

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 Saturated Water

Boiling point 2120F 0.01672 ft3

Boiling

No bubble
1 lbm

HEAT

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Saturated Water

Water and
Steam bubble

swell 2120F
Boiling 2120F 0.01672 ft3
Boiling
With
Bubble
1 lbm
Pressure is increased

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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 ρS + 300

0 H
ρWD h
Saturated water - 300
ρW

PH PL

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 Drum level measurement
Define process variable
• ρS = steam density
• ρWD = drum water density
• ρW = water density
• g = gravity
• PH = Static pressure at the
high side of the transmitter
• PL = Static pressure at the
low side of the transmitter
Drum level measurement
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
17
 Drum level measurement
Solution
PH = ρw.g.V + ρWD.g.h + ρS.g.(H-h) + Pd
PL = ρw.g.V + ρW.g.H + Pd
∆P = ρw.g.V + ρWD.g.h + ρS.g.(H-h) + Pd - ρw.g.V - ρW.g.H - Pd
∆P = ρWD.g.h + ρS.g.H - ρS.g.h - ρW.g.H
∆P = ρWD.g.h - ρS.g.h - ρW.g.H + ρS.g.H
∆P = g.h(ρWD- ρS) - g.H(ρW - ρS)

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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 ρWD= 958.098 , ρS= 0.598, ρW(43 °C ) = 990.628
Level max.(100 %) h = H = 0.6 m

∆P(100%)= PH – PL
= g.h(ρWD – ρS) – g.H(ρW – ρS)
= 9.807×0.6×(958.098–0.598)–9.807×0.6×(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(ρWD – ρS) – g.H(ρW – ρS)
= 0 – 9.807 ×0.6 × (990.628 – 0.598)
= 0 – 5825.33
= – 5825.33 Pa

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 Calibration range
% Level (m) D/P (Pa) Signal (mA)

100 0.6 -191.40 20

0 0 -5825.33 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 DBR Range PH PL DP O/P Controller
% (m) (m) (Pa) (Pa) (Pa) (mA) (m)

100 0.60 0.30 5633.93 5825.33 -191.40 20.000 0.600

75 0.45 0.15 4225.44 5825.33 -1599.88 16.000 0.450

50 0.30 0.00 2816.96 5825.33 -3008.36 12.000 0.300

25 0.15 -0.15 1408.48 5825.33 -4416.85 8.000 0.150

0 0.00 -0.30 0.00 5825.33 -5825.33 4.000 0.000

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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

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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

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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

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 Level & DP
∆P
-5825.33

-4416.85

-3008.36

-1599.88

-191.40 Level
0% 25% 50% 75% 100 %
0 0.15 0.30 0.45 0.6 m

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 DP Transmitter signal
Level (m) mA %
0.60 20 100%

0.45 16 75%

0.30 12 50%

0.15 8 25%
0.0 4 0% ∆P (Pa)
0% 25% 50% 75% 100 %
-5825.33 -3008.36 -191.40
-4416.85 -1599.88

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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(ρWD – ρS) – g.H(ρW – ρS)
= 9.807×0.3×(560.478 – 122.4)– 9.807×0.3 ×(990.628 – 122.4)
= 1288.82 – 5108.65
= – 3819.83 Pa

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 Drum level measurement

100% 100%

50% 50%

0% 0%

PH PL PH PL
Operating condition Operating condition
Temp = 100 °C Temp = 353 °C
Pressure = 14.696 Psia Pressure = 2498.1 Psia
P = - 3008.36 Pa P = - 3819.83 Pa
Signal = 12 mA Signal = ???? mA

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 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

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

• Error = 0.214 - 0.3 = - 0.086 m

• Water Level at 35% from 50 % or reduce 15%

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 DP Transmitter signal
Level (m) mA %
0.60 20 100%

0.45 16 75%

0.30 12 50%
0.214 9.69
0.15 8 25%
0.0 4 0% ∆P (Pa)
0% 25% 50% 75% 100 %
-5825.33 -3008.36 -191.40

-3819.83

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 Drum level measurement
Ex Operating condition 353 °C at pressure 2498.1 Psia
Determine hmin and hmax (±300 mm)
From steam table ρWD= 560.478 , ρS= 122.400, ρW(43 °C ) =
990.628
Level max.(100 %) h = H = 0.6 m
Solution
∆P = PH – PL
= g.h(ρWD – ρS) – g.H(ρW – ρS)
= 9.807×0.6×(560.478 – 122.4)–9.807×0.6×(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(ρWD – ρS) – g.H(ρW – ρS)
= 0 – 9.807 ×0.6 × (990.628 – 122.4)
= 0 – 5108.65
= – 5108.65 Pa

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 Calibration range

Level DBR range PH PL DP Output Controller

% (m) (m) (Pa) (Pa) (Pa) (mA) (m)

100 0.60 0.30 2577.65 5108.65 -2531.00 13.356 0.351

75 0.45 0.15 1933.23 5108.65 -3175.41 11.526 0.282

50 0.30 0.00 1288.82 5108.65 -3819.82 9.696 0.214

25 0.15 -0.15 644.41 5108.65 -4464.23 7.865 0.145

0 0.00 -0.30 0.00 5108.65 -5108.65 6.035 0.076

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 Density compensate
From differential pressure formula

∆P = g.h(ρWD- ρS) - g.H(ρW - ρS)

Liquid level in boiler drum

∆P + gH(ρw-ρs)
h=
g(ρWD-ρs)

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 Density compensate
Controller or DCS Card
signal

4-20mA to steam table (ρWD,ρS)

ρS
4-20mA to ∆P

ρWD signal

∆P + gH(ρw-ρs)
h=
g(ρWD-ρs)

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

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Thank you
Question ?