World Leaders in Combustion Management Solutions Water Level System Autoflame Training Water Level...
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World Leaders in Combustion Management Solutions Water Level System www.autoflame.com Autoflame Training Water Level System
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Transcript of World Leaders in Combustion Management Solutions Water Level System Autoflame Training Water Level...
World Leaders in Combustion Management Solutions
Water Level System
www.autoflame.com
Autoflame TrainingWater Level System
World Leaders in Combustion Management Solutions
Water Level System
www.autoflame.com
• Water Level Control
• First Out Annunciation
• Steam Flow Metering
• Heat Flow and Hot Water Flow Metering
• Bottom/Column Blowdown control
• Total Dissolved Solids (T.D.S.)
• Management/Surface Blowdown
• Shunt Switch Philosophy
One Controller, Seven Functions
World Leaders in Combustion Management Solutions
Water Level System
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T.D.S PROBE
T.D.S. BLOWDOWN / SLUDGE BLOWDOWN VALVE.
FLAMESCANNER
STATUSDISPLAY
LOCKOUT
COM
RESET
CLOSE
AIR SENSOR
V.S.D.
SEQUENCING
OPEN
START IBS
TEMPCOMPENSATION
FUEL
METERING
OUTSIDE
HIGH
INTER
LEVELWATER
Combustion Management Systems
MEMORY
ENTER
MUTE& RESET
STEAM PRESSURE DETECTOR
OPTIONALVARIABLE SPEED DRIVE
0-10V OR 4-20mA
NON RETURN VALVE
FEED WATER PUMP
FEED WATER TEMPERATURE SENSORMODULATING FEED WATER VALVE
STEAM TEMPERATURE SENSOR
CAPACITANCE PROBE 1CAPACITANCE PROBE 2
E.G.A.
RUN
M.M.
SURFACE BLOWDOWNVALVE
Water Level Control System
World Leaders in Combustion Management Solutions
Water Level System
www.autoflame.com
• Traditional feedwater control in response to:• Water Level• Steam flow• Feedwater flow
• Autoflame feedwater control in response to:• Water level• Firing rate• Steam pressure
The Autoflame 3-element level control has been granted a worldwide patent is the only system that can combine firing rate, steam pressure and water level within one controller for the purpose of improving feedwater control
Three Element Feed Water Control
World Leaders in Combustion Management Solutions
Water Level System
www.autoflame.com
• Control of feedwater flow in response to:• Water level• Boiler pressure• Firing rate of the burner
• PI to control flow into the boiler• 2 port feedwater control valve• Variable speed drive to the feed pump
• Wave signature and turbulence management software
Safety, accuracy and integrity are guaranteed
Method of Operation & Control Philosophy
World Leaders in Combustion Management Solutions
Water Level System
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• Safe and accurate control• (+/- 2mm in still water) • 20Hz=1mm
• 2 capacitance probes for measuring the water level including:• high high level• high level + high level pre-alarm• required level• 1st low + 1st low pre-alarm• 2nd low
Capacitance Probe Operation & Integrity
World Leaders in Combustion Management Solutions
Water Level System
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• Capacitance readings constantly checked• Self-check for electrical and mechanical
integrity• Comparison between probes• Continual check with the commissioned
data• Checks to an internal reference capacitor
• Probe compensation• Long term drift• Changes in ambient temperature
Capacitance Probe Operation & Integrity
World Leaders in Combustion Management Solutions
Water Level System
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HIGH WATERALARM
PRE HIGH WATERALARM
CONTROL POINT
PRE 1st LOWALARM
1st LOWBURNER OFF
2nd LOWLOCKOUT
VIRTUALGAUGE GLASS
0mm
110mm
180mm
260mm
352mm
450mm
ACTUAL LEVEL = 140mm
END OF PROBE
TOP OF PROBE
50mm
NOTES:
BURNER CAN BE OPTIONED OFF OR REMAINON AT THIS POINT. (SEE SETUP #8.1)
SETU
P #
11.1
PUMP TURN OFF POINT. THE PUMP WILLTURN OFF AT A % DISTANCE BETWEEN THE CONTROL POINT AND THE HIGH WATER
DEFAULT PUMP OFF POINT. 30%
AUDIBLE ALARM & VISUAL ALARM CONSTANTOUTPUT. ALARM CAN BE MUTED.
AUDIBLE ALARM & VISUAL ALARM PULSEDOUTPUT. ALARM CAN BE MUTED.
AUDIBLE ALARM & VISUAL ALARM PULSEDOUTPUT. ALARM CAN BE MUTED.
MODULATING VALVE WILL BE CLOSEDABOVE CONTROL POINT.
AUDIBLE ALARM & VISUAL ALARM CONSTANTOUTPUT. ALARM CAN BE MUTED.
AUDIBLE ALARM & VISUAL ALARM CONSTANTOUTPUT. ALARM CAN BE MUTED.
INFORMATION AS DISPLAYED THROUGH THE WINPCDTI SOFTWARE.
THIS POINT SHOULD BE THE BOTTOM OF THE ACTUAL SIGHT GLASS ON THE BOILER
GOOD PRACTICE STATES THIS DISTANCESHOULD BE A MINIMUM OF 50mm (2")
BURNER OFF. AUTOMATICALLY RESTARTS ONCE WATER LEVEL GOES ABOVE THE 1st LOW POINT
World Leaders in Combustion Management Solutions
Water Level System
www.autoflame.com
Capacitance Probe Operation
World Leaders in Combustion Management Solutions
Water Level System
www.autoflame.com
Average Reading
World Leaders in Combustion Management Solutions
Water Level System
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• Ensures that either probe cannot read a still water condition when the burner is running
• Certifies that no static or stuck value can be accepted
• User adjustable to meet every application• Default setting is 20Hz• User definable: 0-100Hz
• Impossible on float type controls
Movement Detection of Water
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Water Level System
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Causes:• Surface tension of bubble
bursts releasing droplets• Droplets coat the surface
of the level probe which reads as an increase in the water level
• Wave reflection off the boiler
Methods to avoid this:• Probes externally fitted
in float chamber/s• Anti-surge pots in the
boiler shell
Bubble
Wave Signature Explanation
Spray
World Leaders in Combustion Management Solutions
Water Level System
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• When the boiler produces high quantities of steam it can produce swells and surging motions
• The user adjustable probe disparity can be adjusted to compensate for this situation
Steam Flow Induced Surge
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Water Level System
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• Prevents intermittent shut downs due to 1st low being switched during transitory conditions
• Autoflame system knows what the – Firing rate–Boiler pressure
At any one time and thus identifies the above condition
• Only water level system in the world that has this function
Swell Managent
World Leaders in Combustion Management Solutions
Water Level System
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• Foaming on the surface of the boiler is brought about by a less than adequate blow down regime
• This should only occur in a badly managed boiler plant• Poor TDS management/control• Incorrect or insufficient water treatment
• Foaming will read as a step increase in the water level
Foaming
World Leaders in Combustion Management Solutions
Water Level System
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• Wave signature is installation specific & driven by
–Boiler size–Water treatment regime– Position of heat transfer surface relative
to water level– Load pattern imposed on the boiler
• The Autoflame system takes into account all of these variables to produce perfect level control in complete safety
Wave Signature Conclusion
World Leaders in Combustion Management Solutions
Water Level System
www.autoflame.com
• “2nd Low” switches when either probe reads low for 10 seconds.
• Ultimate safety condition- no filtering software
• Switching point can be set at any point on the probe, no need to cut probe to length
• Must not cut probe!
“2nd Low” Switching Philosophy
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Water Level System
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Feed Water Valve Position
World Leaders in Combustion Management Solutions
Water Level System
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Modulating/Pump On/Off Feed Water Control
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Water Level System
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Probe Commissioning
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Water Level System
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• Valve sizes: ½” to 2”
• Steel valve with stainless steel ball & stem
• Servo Torque: 37ftIbs (40Nm) / 72ftIbs (98Nm)
• NEMA 4 rated.
• Position feed back potentiometer
• Flange spec: ANSI 300Ib (PN16)
• Max pressure: 300psi (20bar)
• Max volume: 11,000gal/hr (42,000l/hr)
Feed Water Valve
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Water Level System
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• 4 dedicated screens for recording of events relating to water level control & management of the boiler
• Each event tagged for:• Time/Date of alarm• Time/Date of reset of
alarm• Type of incident
• Each screen will give details of 4 events
• Information can be accessed through DTI
Historical Record of Water Level Alarms
World Leaders in Combustion Management Solutions
Water Level System
www.autoflame.com
• 15 First Out Annunciations• User definable descriptive labels• Infra-red Upload/Download facility• Selectable High/Low voltage alarm• Accessible through D.T.I.• First Out to be displayed or to lockout• System lockout optioned by a manual
reset or an auto reset of the alarm/fail condition
• Historical record of announced alarm (2005)
First Out Annunciation
World Leaders in Combustion Management Solutions
Water Level System
www.autoflame.com
First Out Annunciation
World Leaders in Combustion Management Solutions
Water Level System
www.autoflame.com
World Leaders in Combustion Management Solutions
Water Level System
www.autoflame.com
Annunciation Display
World Leaders in Combustion Management Solutions
Water Level System
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• Auxiliary level controls can be incorporated into the Autoflame Water Level Control System
• DA tank level control
• Inputs to accommodate “high”, “1st low” and “2nd low”
• Accessed through “SETUPS” in the MK6
HIGH WATERFLOAT
AUX LOW1st LOW
3rd Party Water Level System Integration
World Leaders in Combustion Management Solutions
Water Level System
www.autoflame.com
• Feed water temperature monitored & displayed
• Steam temperature monitored & displayed• Steam pressure monitored & displayed• Instantaneous steam flow displayed• Totalized steam flow displayed• Fuel flow metering utilized for calculation• All the above is logged and accessed
through D.T.I.
Steam Flow Metering
World Leaders in Combustion Management Solutions
Water Level System
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• Fuel gross heat input = 24,500,000 BTU/hr• 1% standing losses = 245,000 BTU/hr• 18% stack losses = 4,365,900 BTU/hr
• Net calorific value heat input = 19,889,100 BTU/hr
• Heat required to raise 1lb of water from 1800F
(feedwater temp) to 85 PSI at 3270F = 1040BTU
= 19,124 lbs/hr
• 3% blowdown losses = 18,550 lbs/hr steam flow
• Totalised calculation integrated over time (5s)
Steam Flow Calculation
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Water Level System
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Fuel Flow & Steam Flow Metering Display
World Leaders in Combustion Management Solutions
Water Level System
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Flanged Pot Design
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Water Level System
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ASME Approved Chambers
World Leaders in Combustion Management Solutions
Water Level System
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Probes Mounted Directly into Boiler Shell
World Leaders in Combustion Management Solutions
Water Level System
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Probes Mounted Directly into Boiler Shell
World Leaders in Combustion Management Solutions
Water Level System
www.autoflame.com
External Probe Chamber
World Leaders in Combustion Management Solutions
Water Level System
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• Reduced maintenance
• Shields the probes
• Requires regular Blow Down
Advantages of Using External Pots
World Leaders in Combustion Management Solutions
Water Level System
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• Up to 4 blowdowns can be accommodated in any 24 hour period
• Duration of each can be programmed from 0–60 secs
• Each blowdown can be repeated up to 10 times
• COMMS link to all systems ensures no more than one boiler can blowdown at any one time
Bottom/Column Blowdown Management
World Leaders in Combustion Management Solutions
Water Level System
www.autoflame.com
• To optimise boiler efficiency and reliability, the Total Dissolved Solids must not exceed a designated level
• Water tube boilers• <1500ppm
• Smoke tube boilers• <2500ppm
Probes Mounted Directly into Boiler Shell
World Leaders in Combustion Management Solutions
Water Level System
www.autoflame.com
INTERVAL TIME 5 - 1500 SEC
BLOWDOWN MEASURE5 SEC
SETTLEMENT TIME5 SEC
MEASUREMENT TIME5 SEC
BLOWDOWN TIME0 - 300 SEC
SETTLEMENT TIME5 SEC
MEASUREMENT TIME5 SEC
CALL FOR HEAT
MEASURED VALUE< TARGET VALUE
YES
NO
MEASURED VALUE< TARGET VALUE
YES NO
World Leaders in Combustion Management Solutions
Water Level System
www.autoflame.com
• Water level test facility
• Enables column/boiler blowdown without water level alarms and the burner continues to fire
• When initiated the feedwater valve closes/pump off until 1st low is reached, followed by 2nd low
• Both alarm levels must be attained within user-definable times
• Once tested the feedwater valve opens/pump on to return to control point
• Test satisfied
Shunt Switch Philosophy
World Leaders in Combustion Management Solutions
Water Level System
www.autoflame.com
• European• CE• TUV• APAVE
• American• UL• cUL
World Leaders in Combustion Management Solutions
Water Level System
www.autoflame.com
Thank you for listening
