Levelstate Systems Ltd.

Q M
S
ISO 9001
REGISTERED FIRM
Certificate No : GB1619

INSTALLATION, OPERATION & MAINTENANCE

MANUAL FOR
ELECTRONIC DRUM LEVEL INDICATOR
TYPE 201

ISSUE I : MARCH 2009

Little Kitfield, Gradwell Lane, Four Marks, Hampshire GU34 5AS, U.K.
Tel: +44 (0) 1962 773829
Fax: +44 (0) 1962 773849
E-mail: info@levelstate.com
Web: www.levelstate.com

2009 Levelstate Systems Ltd.

All rights reserved
With technical progress the company
reserves the right to change specifications
without notice.

Solution at all levels

TABLE OF CONTENTS
Page

Section
Boiler Codes or Standards Summary of Requirements

1.

Operating Principle

2.

General Configuration

2.1

11

3.

4.

5.

6.

7.

Trip Circuits
2.1.1

Low Level Trip

12

2.1.2

High Level Trip

13

2.1.3

Alarm Circuits

13

Installation & Cabling

14

3.0 General

14

3.1

Water Column & Probe

15

3.2

System Cabling

18

3.3

Electronic Unit

21

3.4

Remote Display

24

Commissioning

25

4.1 Probes

25

4.2 Electronic Unit

26

4.3 Water Column

27

Maintenance & Fault Identification

28

5.1

Pressure Parts

28

5.2

Electronic Unit

31

5.3

Fault Identifications Procedure

32

Electronic Unit

34

6.1 201 EDLI Parts List

39

System Specification

40

Figs

Page

1.1

Sensing Element

1.2

Water Level Monitoring

1.3

Conductivity Chart

1.4

Conductivity Graph

2.0

System Configuration

2.1

Side Arm Water Column

2.2

Probe Types 801, 802 and 803

10

3.1.1

Water Column Installation

16

3.1.2

Water Column Support Structure

17

3.2.1

System Cabling

19

3.2.2

Probe Routing on Water Column

20

3.2.3

Cable Gland Allocation

20

3.3

Electronic Enclosure Fixings

23

3.4

Remote Display Fixings

24

5.3.3

Fault Identification Procedure

33

6.0

Electronic Enclosure Layout

35

6.1

PCB1 Component Layout

36

6.2

PCB2 Component Layout

37

6.3

PCB3 Component Layout

38

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 gauge glasses

connected to the boiler the steam and water connections shall not be less that 1 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 that
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 recognized standards must be used for the design material selection
welding and inspection of pressure containing components.

1.0 Operating Principle

The Levelstate type 201 System is an 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.
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 sidearm 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 100K when the
Probe is immersed in water, which results in a resistance greater than 5M for the steam condition. An
electronic discrimination circuit is arranged to sense whether the Probe resistance is less than 100K
representing water or greater than 100K representing steam.
With 12 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 12 Green/Red indicators
provides sufficient resolution for water level indication. The spacing between Probes is chosen to cover the
required Sight-Range.

Fig. 1.1

Fig. 1.2

Typical water conductivities are shown in Fig 1.3. The definition of the various categories is indicated at the

0.01

pure

ultra

THEORETICALLY PURE : 0.025 @ 10 Deg. C

top.

PURE

PURIFIED

POTABLE

BRACKISH &
RINSE WATER

TYPICAL WATER CONDUCTIVITIES

PLISHED
MIXED BED
DEIONISHED

TWO BED
DEIONISED

DISTILLED
BOILER
CONDENSATE
0.1

10

TAP

100

1K

BRACKISH

10K

SEA
WATER

100K

CONDUCTIVITY S/CM = micromhos

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 result 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 due to moisture and water droplets.

201

Fig. 1.4

2.0 General Configuration Fig 2.0

The 12 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. Or in the same side of water column. A typical Water Column is shown in
Fig 2.1 and the Probe detail in Fig. 2.2.
Tow printed circuit boards contained in an IP65 (NEMA 4X) wall mounted enclosure provide 12 discrete
water/steam discrimination circuits, LED display, relay alarm outputs, and terminals for the connection of
a Remote Display Unit.
Generally the water column is aligned for Normal Water Level (NWL) located between Probes 6 and 7,
with the lower six probes normally sensing water and the upper six 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 and open-circuit connection obviously indicates the Steam
State at the channel output again declaring the fault.
For this standard arrangement a 20 core PTFE cable is provided for probe connections.

For other

situations terminals are provided on the 201 Unit for 2 Wire connections on channels 1 to 6.
To avoid galvanic action at the probe and variations in sensing voltage due to changing electrolytic
potentials, and 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 t he 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.
Two alarm relays RL1, RL2 with integral delays, may be programmed to any channel except 6 and 7. If
more than one channel is linked to the RL1 or RL2 delay circuit either channel will initiate the delay relay
action.
If a channel from 1 to 5 is linked and a channel from 8 to 12 linked to the same relay circuit the low
channel will initiate relay action when steam is indicated (Lo Alarm) and the high channel will initiate
action when water is indicated (Hi Alarm). This can provide a single Alarm contact for a combined Lo / Hi
Level Alarm.
Additional two relays RL3, RL4 are included for instantaneous relay action whereby a 2 out of 3 probe
channel voting logic is applied.
Relay action can be selected for normally energized 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. Any
illuminated Red LED (Lo Water Level) on channels 1 to 5 and any illuminated Green LED (Hi Water
Level) on channels 8 to 12 may be selected to flash when initiated by the delay circuit, which operates
RL1 & RL2. An identical linking facility is also provided to flash LEDs on the Remote Display Unit.

Fig. 2.0 System Configuration

Fig. 2.1 Side-Arm Water Column

Probe Details :The 201 system employs multiple probes installed in a vertical column, usually in two diametrically opposite rows.
Three types of probes are available: (i) Type 801 for pressure upto 150 bar; it is screwed directly into the Type 501
water column and is gasket sealed (ii) Type 802 for pressure upto 207 bar; compression fitted to Type 502 water
column and sealed by metal to metal contact and (iii) Type 803 for pressure upto 207 bar; gasket sealed clamp
plate type mounting onto Type 503 water column held in position by four studs and nuts. Both 801 and 803 probes
use SS-grafoil Metaflex gasket seals as shown in Fig. 2.2
Probe Type 801
Rating: 150 bar,
340 C

Probe Type 803

Rating: 207 bar,
370 C

Fig. 2.2 Probe Type 801, 803 and 802

10

Probe Type 802

Rating: 207 bar,
370 C

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 on gauge-glass; if a trip circuit is derived from each
remote level indicator system the requirements may be satisfied.
For the practical application of shutdown 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 sate 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 fault must be
minimised and the required degree of shut-down system "availability" must be achieved by duplication of
protection devices. For smaller boilers the 'Recommendations' or 'Codes of Practice' specify that the boiler should
be automatically shut down in the event of faults on low water level protection devices.
The protection system policy must first be established and the duplication and interconnection of the trip circuits
organized to suit the requirements in terms of Reliability and Availability. When discussing industrial equipment
performance the mere mention of failures although rare in occurrence evokes Murphys 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) if could happen tomorrow so however remote the probability the consequential effects of failures should be
considered.
For the 201 System the prime failures which affect reliability are the following:1. Mains Supply Source. If 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 supplies.
2. Steam leaks from valves can cause level indication errors.

3. 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 simulated 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 be performed at least every 6 months.

11

2.1.1 Low/High Level Alarm/Trip

For boilers many 'Operating Guidelines' or 'Codes of Practice' recommend that for low level tripping
devices any equipment fault should initiate a boiler trip. This presumably applies to single element
devices and does not reflect the fault tolerant approach of multi channel devices or the duplication of
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 201 system a
secure fault tolerant approach has been implemented whereby any 2 out of 3 Probe channels indicating the
Steam condition will initiate a trip.
To satisfy the 'Guidelines' a normally energised relay with normally closed contacts should be used.

Spurious action of relay will be initiated for the following remotely possible failures.
(a)

Mains Supply failure or relay coil open circuit.

(b)

A disconnection in the wiring to the shutdown device.

To avoid these spurious relay action the following circuit should be implemented where the relay is not energised
and a normally open circuit connection tot he shutdown device.

The problem here is the possibility of missing a necessary relay action if faults (a) and (b) ever occur, if a second
water level indicator is fitted and supplied from a separate Mains Source and separately connected to the
shutdown device the possibility of both systems failing simultaneously is so remote that it can be discounted
provided any faults are corrected within a reasonable time.

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 201 Unit also provides the security of the 2 out of 3 arrangement for thehigh level
trip which is particularly important when applied to Feedwater Heater Level Monitoring.

RL1 and RL2 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 do not inhibit operation of relays RL3, RL4. Inadvertent operation
of these switches would induce a Trip Action. The Trip Circuits should be disarmed externally Before
opening the 201 Enclosure.
2.1.3

Alarm Circuits

Two relays RL1 and RL2 provide Alarm signaling and have integral delay action preset over the range 1 to
30 seconds. RL1 and RL2 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.

13

Installation & Cabling

3.0

General

For Boiler applications the installation must conform to the accepted Regional or National Standards. Pipework
connections must be welded, tested and inspected tot he 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, this is to minimise density errors caused by heat loss. This 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 tapping should terminate internally
away from localized turbulence, which causes pressure differences, and therefore level indication errors.
For boiler applications where the inclusion of steam and water isolation valves is mandatory Fig. 2.1 provide
connections for a side-arm arrangement similar to gauge glasses. With the inclusion of isolation valves the
distance of the column from the boiler drum required the assembly to the 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 201 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 201 Electronic Unit enclosure is usually sited adjacent to the Water Column within a distance suitable for the
4m length of special high temperature PTFE cable supplied. If longer cable lengths are required terminate the
PTFE cable in a suitable water tight junction box and extend with standard 20 core stranded conductor
instrumentation cable; ensure extension cable is protected from heat sources.
Sitting of the 201 enclosures 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 4
and 5, 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 waterside 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 201 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 use
the 400 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
seating. Lag steam and water pipework and valves.
Before commissioning install Probe cable and shown in Fig. 3.2.2
As a precaution ensure steam and water isolation valves are closed and drain valve open.

15

Fig. 3.1.1
1.

Water Column Installation

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.

2.

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.

3.

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
following to the Column

4.

Procedures for site welding of pipework and valves must conform to the National or Accepted
Standards for boiler applications.
16

5.

Connection pipework and valves should be lagged to prevent heat loss.

6.

Guards should be provided to prevent accidental contact with the Water Column; these should not
restrict convection cooling of the Column.

7.

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 Fixing on the water
column and Fig. 3.2.3 Cable Gland allocation on 201 Unit.
A 4 metre (12) sheathed length of special 20 core high temperature PTFE cable is provided for Probe
to 201 Unit connections. This cable is pre-formed for the standard vessel arrangement where NWL is
between Probes 6 and 7. For longer cable lengths a junction box and standard PVC multi-strand
instrument cable should be interposed in the run to the 201 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 12 mm PRFE
Thread Seal Tape (as used in pipe sealing Rs.512-238).
Cable for the Mains Supply, 20 Core Remote Display, Alarm and 4-20mA circuit are fitted as required
using standard instrumentation cable through the 201 Unit Cable Glands as shown.

18

Fig. 3.2.1 System Cabling

19

Fig. 3.2.2 Probe Cable Routing on Water Column

Fig. 3.2.3 Cable Gland Allocation

20

3.3

Installation of 201 Electronic Unit

3.3.1

Before installation remove the front cover assembly and PCB2 with chassis plate from the enclosure
and store in a safe place. Refer to Figs 3.3, 6.0 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 PL1 in an outward
direction and ease out the plug/cable assembly. Presses the two-bottom covers hinge pins
inwards and removes the complete cove assembly.

3.

Unscrew the four M6 cheese head fixings at the corners of the base unit and remove PCB2
and chassis assembly. Refit M6 chassis plate screws into corner inserts to avoid loss.

3.3.2

Mount the base of the enclosure with cable glands facing downward at the site chosen using 4corner 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 performed for correct length. Insert cables through glands, trim ends to template supplied
and fit crimped ferrules where required.
Test cable continuity as required.

3.3.3

At a convenient time before Commissioning, program the required made of operation of the PCBs as
follows:PCB1 Refer to Section 6.1
1.

Remove thin glass fibre cover.

2.

Solder split pad links A1, A2 etc. (LHS of PCB as determined by normal probe state).

3.

Solder split pad link (centre of PCB for the selected channel outputs (middle pad) to B for
operation of RL1 or C for operation of RL2.

4.

Solder the appropriate split pad link F for the selected LED to flash to indicate alarm
conditions.

5.

Solder split pad links T1, T2 (bottom RHS) if the time delay required is below 15 seconds.

21

6.

Solder split pad links E or D for RL1, RL2 (bottom RH edge) for the relay to the energised or
de-energised in the normal or healthy state of the plant.

7.

Solder split pad links S or W to the middle pad (top RH corner) 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 split pad link, middle pad to Sa or Sb (bottom LHS) should only be made after evaluation
of system performance.

PCB2 Refer to Section 6.2

1.

Set the correct mains source voltage in TB1 (85 to 264V AC, Frequency 47 to 63 Hz.

Or 120 to 370V DC).

2.

Wire link selected channel outputs to operate RL3 and RL4. (i.e. PL1/PL2.)

3.

Solder the split pad links D, E for selected mode of operation of RL3, RL4.

22

Spring Hinge Cover Removal

Fig. 3.3 Electronic Enclosure

23

3.4

Installation of Remote Display Unit 20151

This unit is intended for panel mounting with cutout size 138mm x 67mm (5.43 x 2.64) and panel
thickness to 6 mm (0.25)
Before fitting, solder link the appropriate split pads F as on the 201 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 assembles 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 block and insert the block into Display
Unit plug. Clamp the cable as shown in Fig. 3.3(a) or (b).

Fig. 3.4

24

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, 80251 for 502 and 80351 for 503).

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 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.

Use a Moly Disulphide anti scuffing paste on threads avoiding contact with seating face and
Probe insulators.

3.

Screw in each Probe and tighten. Do not exceed 70Nm (52 lb.ft.).

4.

Connect wires to Probe terminals, tighten knurled nuts using finger pressure only Refit Guards
for Probe protection.

Type 802 :
1.

Inspect the column seating taper ensuring it is clean, dry and free of radial score marks.

2.

Use a Moly Disulphide anti-scuffing paste on threads.

3.

Fit Probe and tighten retaining nut until Probe body is just nipped, i.e. where it just
cannot be rotated.

4.
5.

Apply 27mm A/F long socket and initially tighten just beyond one hex flat (75 to 80 ).
Subsequent insertion of Probes should only require 10 to 20 rotation using torque
wrench.

6.

Connect wires to Probe terminals tighten knurled nuts using finger pressure only.

7.

Refit Insert End Cap for Probe connection.

Type 803 :
1.

Inspect the vessel seating recess ensuring it is clean dry and free of radial score marks. Clean
butting faces of Clamp Plate and Vessel.

2.

Insert Gasket and Probe to Vessel and carefully fit Clamp Plate over Probe and Studs.

3.

Apply a thin film of Copper or Molybdenum based grease to exposed ends of studs.

4.

Fit nuts finger tight; adjust nuts to obtain clamp plate parallel to vessel face (approx. 1mm gap).
25

5.

Set Torque Wrench fitted with 17mm A/F long socket to 2ONm.
Initially tighten each nut equally through
45 or subsequently where wrench 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.

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.

4.2

Electronic Unit.
4.2.1

Fit chassis plate + PCB2 to base to enclosure.

4.2.2

Fit cover + PCB1 to enclosure by springing hinges inwards before locating on base hinge
holes.

4.2.3

Connect ribbon cable to PCB1 via PL1 ensuring hinged retainers on PCB1/PL1 are first
hinged outwards.

4.2.4

Ensure mains cable is not live and connect mains supply to PCB2/TB1 checking that mains
jumper links are correctly installed.

4.2.5

Do not fit other terminal blocks to PCBs at this stage.

4.2.6

Switch on Mains Supply. Check the Red & Green LEDs by pressing the SW1 & SW2. All
the Red/Green 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,s
becomes illuminated.
26

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 PCB/TB2 and check correct illuminator of LEDs by
operation of SW1 & SW2.

4.2.9

Insert PCB2/TB3/TB4 and check and 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 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.
4.3

Water Column Bringing on-line.

4.3.1 Notify personnel for 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 cracks 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 leaks 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.

27

4.3.9

The System is now operational. Where valve locks are fitted these should be locked if the
system is to remain is 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.

5.0

Maintenance and Fault Identification.

The following section 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 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.

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 maintain 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.

28

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, Type502 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 center line of the opening.
For damaged seating face of type 502, inserts re-cut taper seat at 40 included angel ensuring a surface finish
which must be better than N5C ensuring it is concentric with bore.
5.1.1.

Valve stem leaks requires replacement of stem 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 70Nm (52 lb. ft) Probe tightening torque otherwise replace Probe or gasket
using the following procedures.

5.1.3. Column Isolation Procedure.

(i)

Ensure Operators are informed that erroneous indications and alarms are to be
expected.

(ii)

If shutdown or trip circuits are connected to the system ensure they are disarmed.

(iii)

Close the Steam and Water Isolation Valves.

(iv)

Slowly open the Drain Valve(s) and leave open.

(v)

Check at Drain outlet that the Isolation Valves are sealing properly.

5.1.4. Probe Replacement Procedure

(i)

Isolate Column as 5.1.3 above, ensuring Drain Valve is open with Steam and Water
Isolation Valves closed and sealing properly.

(ii)

Remove Probe Guard and disconnect Probe wire(s).

(iii)

Replace Probe as procedure Section 4.1 for Type 801 or 811.

5.1.5. Column Recommissioning Procedure.

(i)

Close Drain Valve(s).

(ii)

Cracks open the Steam Isolation Valve(s) and check with the display that the Column
fills slowly due to condensate (10 to 15 minis).

(iii)

Cracks open the Water Isolation Valve(s) and check that the water level falls to the
expected level.

(iv)

Check Probes for steam leaks using procedure of 5.1.2.

(v)

After approximately 20 minutes fully open Water then Steam Valves.

29

(vi)

Ensure all Valves are correctly set (and locked).

(vii)

Inform Operators that the Indication System is now in service.

(viii)

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 of Pipework Blockage

If the column and pipework installation complies with the recommendations of Section 4 and
with the intentional stimulation of condensate flow through the Column pipework, blockage
should not occur. This is provided that 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 it fitted. If the response time is still
sluggish suspect problems with Isolation Valves not opening fully.

30

5.2

Electronic Faults
Electronic faults can be diagnosed using the procedures for Fault Identification Section 5.3.
If a circuit board is detective it is preferable to replace with a spare. For a local board repair ensures
precautions are taken to avoid STATIC, as some components are MOS devices.
5.2.1

Check 201 Electronic Unit. Open enclosure cover by releasing the two top captive plastic
screws.
Depress Green Push Button SW1 at top of Display PCB (10 Secs.) all Green LEDs should
be illuminated no Reds.
Release SW1 and depress Red Push Button SW2 (10 Secs.) all Red LEDs should be
illuminated No Green.
If O. K. check for loose Probe connections PL2, PL3 on PCB1.
Close enclosure cover.

5.2.2

Check Probe Connections. Remove Probe Guards. Check Black & Grey / Black connections
to bottom guard blocks. 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 and 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.

31

5.3

Fault identification Procedure

5.3.1 Fault on all Channels.

5.3.1.1

5.3.1.2

Display blank and SMPS on

PCB1 failure

SMPS on but PCB2 not illuminated

PCB2 failure

Display blank and L1 illuminated

PL1 not inserted

Faulty connection between PCB1 and

PCB2.

5.3.1.3

False all steam indication

5.3.1.4

O.V. not connected to Water Column

Column valved off and drained

Water indicated on upper channels (2 wire connection) with steam indicated on lower
channels (1 wire connection)

5.3.2

Probe connections open circuit.

TB2 TB3 not inserted in PCB1

Fault on Alternate Channels

5.3.2.1

5.3.3

Green LEDs illuminated

Oscillator fault

IC7a for Odds

IC8a for Evens

LED failure,TR2, TR3 faulty, R1 R12

Fault on Single Channel

5.3.3.1

Neither LED illuminated

o.c. Test as section 5.2.1a (SW1 &

SW2)
5.3.3.2

Water above steam indication

(i)

The

water

indication is probably false if more than one channel

immediately below it indicates steam.

(ii)

The steam indication is probably false if more than one channel

immediately above it indicates water.

(iii)

If only one channel indicates water with only the one channel below it
indicating steam, either channel could be faulty.

CHECK: PCB1

CAUTION:- a.

By operation of SW1 and SW2 using procedure of Fig. 5.3.3.

Please do not press the Test Switches in operation mode.

b.

There is a POT on SMPS and some POTs on PCB, please do not turn any POT.

c.

Earth connection of input Power Supply is must.

32

Fig. 5.3.3 Fault Identical Procedure

33

Unplug PL2 (Channel 1 to 6)

Or Unplug PL3 (Channel 7 to 12)

6.0 Type 201 Electronic Enclosure.

The polyester glass-fibre reinforced enclosure with overall dimensions of 220 x 200 x 120mm is intended
for wall mounting using four M6 or 2.5 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. Cable glands are provided on the bottom face of the base section.
The discriminator/display PCB is retained in the cover section by the six screws, which secure the display
bezel and by slot insertion along one edge. A thin glass-fibre board protection for PCB 1 components
and is retained by two M3 fixing screws. The clear laminated glass window and bezel are sealed to the
front cover.
A metal chassis plate is secured to the base section by four M6 screws. The supply/relay PCB is
mounted on this chassis plate and retained by eight M3 screws.
A 26-core flat ribbon cable, attached to PCB2 and plugged into PCB1, interconnects the two PCBs.

34

Fig. 6.0 Electronic Enclosure Layout

35

Fig. 6.1 PCB1 Layout

36

37

Fig. 6.3 PCB3 Layout

38

6.4

201-EDLI Parts List

Description

Part No.

Detector PCB1

2012501-B

Supply Relay PCB2

2012502P

Power Supply (SMPS)

2012504

PCB1 Fibreglass Cover

2013015B

Enclosure Base

2013011

Enclosure Cover Assembly

2012005

Chassis Plate PCB2

2013006C

Heatsink Support Bracket PTFE

2013016

Terminal Sockets PCB1 PL2 & PL3

BL13

Terminal Sockets PCB2 TB2

BL15

Terminal Sockets PCB2 TB3 & TB4

BL8

Cable Gland

PG 9

Cable Gland

PG 13.5

Cable Gland

PG 16

Cable Gland

PG 21

Mains selector Link

MJO5

Mains Terminal Cover

2023009

Mains Fuses

20/250T

Probe Cable 4 metres

20128-04

Probe Cable 10 metres

20128-10

Installation Manual

2016900

39

7. Electronic Unit Specification

1.

Electronic Level Indicator Unit. Type 201

Enclosure:
Wall mounted glass-fibre reinforced polyester, IP65/NEMA4X protection for location in harsh
environments. Dims:220mmH x 200mmW x 120mmD (8.7 x 7.8 x 4.7)
Inputs:
Discrimination between water and steam for 12 channels numbered in ascending order.
Discrimination threshold may be selected for minimum conductivity of 0.5 micro Siemens/cm, 1 micro
Siemen/cm or 2 micro Siemens/cm.
The lower 6 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 meter
(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 meters
(100).
Display:
Two vertical columns of 10mm (0.4) square LEDs provided on the front of the enclosure. One row of
Green LEDs represents water and the second row of Red represents steam. Particular LEDs may be
selected to flash on initiation of Alarm Relays. On channels 1 5 the Red LED (Lo Water Level) and
on channels 8 12 appropriate Green LED (Hi Water Level) may be programmed to flash. The
flashing is initiated by alarm relay action.
A Yellow LED signals a system Fault Condition.
Supply Requirements:
85 to 264 Volt AC, Frequency 47 to 63 Hz. Or 120 to 370 Volt DC.
Temperature Rating:Ambient:-

- 100C to + 650C, Storage : - 500 C to 1000C

40

Outputs:
(1)

Alarm Trip Relays. Four sealed relays, each having single pole changeover contacts provide
Alarm and Trip Signaling.
Two relays provide low and high level alarms and each may be linked to Probe channels in the
range 1 to 5 and 8 to 12. 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 10 or 11.
Each relay may be programmed for the normally energised or normally de-energised state with
a delayed action period of 1 to 30 seconds.

(i)

(ii)

Contact Rating:

Max. Current

5 Amps.

Max. Voltage

350 Volts.

Max. Switching Power:

AC: 600VA
DC: 30W @ 110V
or 120W @ 30V.

(iv)

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 each probe
channel contributes a step change of 1.14mA. Selection of 4mA to represent the all water or all
steam state is included.
Output Current: 4 - 2OmA in 12 incremental steps
Load Impedance: 300 Max.

2.

Remote Display Unit Option Type 20151

Panel mounted 144mm x 72mm x 30mm (5.67 x 2.83 x 1.2)
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:138mm x 67mm (5.43 x 2.64)
Panel thickness:

1.5mm to 6.4mm (0.06 x 0.25)

41