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Density Error and its Correction

in Boiler Drum Level Indication


Presented at the International
Society for Measurement and
Control (ISA) Conference,
October, 1995

ABSTRACT
The requirements for power boiler level indication are clearly stated in the ASME Boiler and Pressure Code Section
I, Paragraph 60.1.1. In addition to the direct reading gage glass, remote liquid level indicators of various types are
permitted under certain design conditions.
Regardless of the instrument selected, consideration must be given to the level error caused by connecting an
external device to the boiler drum. The error is inherent because the level measuring instrument is at a lower tem-
perature than the boiler.
Various mechanical and electronic solutions are available to minimize the level indication error. The purpose of
this evaluation was to determine the actual level error under various laboratory conditions for three types of water
level gages and for an electronic level gage column. Lab measurements were compared with both design theory
and field observations. All this information was then used together to improve product design, application and
installation procedures that would minimize boiler level indication error.

INTRODUCTION determine the actual level error of sev- instead of one of the two required
eral instruments under various con- gage glasses (Figure 1c). When both
Boiler steam drum water level is one of trolled laboratory conditions. These remote level indicators are in reliable
the most important power plant para- measurements would then be com- operation, the remaining gage glass
meters to measure and control. If the pared with both design theory and may be shut off, but shall be main-
level is too low, boiler tubes will be field observations to develop installa- tained in serviceable condition. (Code
damaged by overheating. If the level is tion requirements and an understand- Case 2109)
too high, the superheater tubes and ing of specific application limitations.
the turbine may be damaged by mois- REMOTE LEVEL
ture or water treatment chemical car- LEVEL INDICATION
ryover. As boiler operating pressures
INDICATORS
and boiler drum wall thickness have
REQUIREMENTS
Several devices have been developed
increased, many boilers have become The requirements for boiler level indi- over the years to take advantage of
smaller. This reduced boiler drum vol- cation are clearly stated in the ASME the option offered by the Boiler Code
ume demands even more accurate Boiler and Pressure Vessel Code, for two independent remote level indi-
level control. Section I, Paragraph 60.1.1. A combi- cators instead of one of the two
A variety of instruments are available nation of gage glasses and remote required gage glasses. These devices
and approved by the ASME for power level indicators are required as follows: include:
boiler level indication. However, simply Each boiler (except forced flow 1. Differential Pressure Indicator.
specifying one or more of these instru- steam generators with no fixed steam These are available in both the
ments will not guarantee that the boil- and waterline, and high temperature mechanical and electronic type
er level will be indicated accurately. water boilers of the forced circulation (Figure 2). Both measure the differ-
The user must thoroughly understand type that have no steam and waterline) ential pressure between a refer-
the operating principles of each instru- shall have at least one water gage ence water level and the boiler
ment, instrument installation require- glass. (Figure 1a). level.
ments and the boiler operating Boilers operated at pressures over
scheme. 400 psi (except electric boilers of the 2. Electronic Water Level Gage
A difference in the water density electrode type) shall have two water (Figure 3). This device measures
between the level instrument and the gage glasses (Figure 1b). water level through conductivity
boiler is the major source of level error. Boilers with safety valves set at or probes installed in a water column
The purpose of this evaluation was to above 400 psi may operate two inde- connected to the boiler.
pendent remote level indicators

© 1996 Yarway Corporation


DENSITY LEVEL ERROR
ASME BOILER AND PRESSURE VESSEL Water level gages and all types of
CODE REQUIREMENTS remote level indicators are affected by
density level error. This level measure-
ment error occurs because the water
measured by the device is colder than
the boiler water, creating a density dif-
ference. This system can be explained
and modeled by a U Tube Manometer
(Figure 4).
The manometer contains fluid with
three different densities. On one side is
saturated water with boiler water den-
sity Dd. On the other side are two flu-
ids: water in the gage with an
unknown density Dg, and saturated
Steam with density Ds.
A pressure balance at point “A” in this
system produces the following rela-
tionships:
Equation 1.
HdDd = HgDg + HsDs
Equation 2.
Hs = Hd - Hg
Equation 3.
Hd(Dd - Ds)
Hg =
Dg - Ds
Equation 4.
Hg(Dg - Ds)
Hd =
Dd - Ds
The use of these formulas to deter-
mine the actual drum water level, Hd,
can be explained with the following
example.
Example:
Boiler operating pressure 3000 psia.
Average gage temperature is 20°F
below saturated steam temperature.
Hg, water level in the gage is 20 inch-
es above the water connection.
Using the steam tables:
Ds = 11.90 lbm/ft3
Dd = 31.94 lbm/ft3 (Assume the
average water temperature
in the drum is 10°F below
saturation)
Dg = 33.89 lbm/ft3
(33.89 - 11.90)
Hd = 20 inches
31.94 - 11.90
Hd = 22.0 inches, or a 10% error.
Figure 1 The factors that determine the magni-
tude of the level error are the operating

2
REMOTE LEVEL INDICATOR—DIFFERENTIAL PRESSURE

Mechanical Electronic

Figure 2

ELECTRONIC WATER LEVEL GAGE

Figure 3

3
LEVEL GAGE AND “U” TUBE EQUIVALENT

HdDd = HgDg + HsDs


Figure 4

GAGE OPERATING PRESSURE AND SUBCOOLING EFFECT ON LEVEL ERROR

Figure 5

4
pressure, the gage subcooling, and
the boiler drum level above the gage LEVEL GAGE WATER FLOW DYNAMICS
return connection. Figure 5 shows the
effect of operating pressure and gage
subcooling on gage error. As pressure
increases, the density of saturated liq-
uid and saturated steam converge
(Figure 5a). As gage subcooling
increases, the level error increases
(Figure 5b). As the drum level Hd
increases, the level error increases
proportionally. Hd can be minimized by
returning the water pipe from the gage
horizontlly to the drum, and by design-
ing the drum water connection to be a
minimum distance below the lowest
gage view port. GAGE WATER TEMPERATURE PROFILE
However, a significant question
remains unanswered. What is the
average gage temperature and corre-
sponding density Dg?

LEVEL GAGE DYNAMICS


Standard level gages and electronic
level gages connected to the boiler are
not in a static condition. If they were,
the water temperature in the gage
would be near ambient. Referring to
Figure 6, steam condenses in the sup-
ply piping and upper gage to the gage
waterline. This saturated water raises
the gage water level slightly above the
equilibrium point. The excess water
flows back into the boiler drum. The
circulation flow depends upon the Figure 6
condensing steam rate and the vol-
ume in the gage and water return pip-
ing.
The condensing steam enters the
gage at the saturation temperature. the glass to rise and will often obliter- ture compensated reference col-
The condensate continues to cool ate the meniscus. Indication will return umn. The purpose of this equip-
until it re-enters the boiler. A profile of to normal when thermal equilibrium is ment is to heat the water in the ref-
this temperature gradient is shown in re-established. Systems utilizing a ref- erence leg to a value that is halfway
Figure 6. erence column will indicate high as between saturation and ambient.
Many level gages are connected to water in the reference leg flashes to This corrects the indication if the
the boiler with a “tie bar” or “water col- steam. Indication will return to normal level is at the mid scale position,
umn” because the visibility of the gage very slowly as steam condenses to regardless of pressure. An addi-
may be adversely affected by exces- refill the reference leg. The reference tional pressure sensing device is
sive water flowing over the glass. The leg can also be manually filled to added to correct the pointer for
tie bar short circuits the excess water establish proper indication more water levels that are above or
from the steam supply piping. The quickly. below the mid scale value.
only flow through the gage is from 2. Differential Pressure Indicator, elec-
steam condensing in the gage itself GAGE CORRECTION tronic type (Figure 2). The most
and the gage piping. OPTIONS sophisticated of the devices mea-
Gages and remote level indication sures the differential pressure of
devices will indicate incorrectly if boiler Every level measurement device must
the reference and variable legs with
pressure decreases suddenly. The be corrected in some manner to com-
both at ambient temperature. The
temperature of the water in the gage pensate for density level error. A num-
ambient temperature and the boil-
or reference column is normally within ber of techniques have evolved over
er operating pressure are also
a hundred degrees of the saturation the years to address each indivicual
measured. An analog or digital pro-
temperature. If the boiler pressure device.
gram then corrects the apparent
should decrease rapidly, the water in 1. Differential Pressure Indicator, differential for boiler water density
the gage will flash to steam. The mechanical type (Figure 2).The to indicate the boiler level.
steam bubbles will cause the level in device is installed with a tempera-

5
WATER LEVEL GAGE TEST SETUP

Figure 7

Less sophisticated devices are cal- DENSITY LEVEL ERROR Figure 8 shows the level error and
ibrated to read correctly at only temperature gradient for a typical
one pressure, usually the normal
TEST PROGRAM AND gage as a function of operating pres-
operating pressure. They will indi- TEST RESULTS sure. As expected, the level error
cate improperly when operated at A test apparatus was constructed in increases with operating pressure.
pressures above or below the cali- the Yarway Test Lab, shown in Figure However, the temperature difference
bration pressure. 7, to measure the level error and gage between saturation and the water out-
3. Water Level Gages, direct reading temperature of various gages under a let remained relatively constant. This is
and electronic type. As discussed variety of conditions. Probes of the because the steam condensing rate
earlier, the primary difficulty in cal- same type used in the electronic gage increases significantly as pressure
culating the level error for devices were installed with 1/2" spacing in a increases. Performance graphs were
of this type is to determine the reference level column. The water in developed for each gage and configu-
average gage water temperature the reference column was maintained ration evaluated. Performance
and corresponding water density. within 10°F of saturation temperature. changes related to installation are
When this is calculated or mea- The level was maintained at a known summarized in Table I.
sured, then the gage glass is phys- point by throttling control valve V1. The Figure 8 shows the effect of connect-
ically installed in a lower position to gage under test was connected to the ing a standard level gage to an elec-
compensate for this error. Steam reference column with typical piping tronic level gage in two different man-
heated level gages are available and valves. ners. In the first case the gage lower
that significantly reduce the density Tests on various devices were per- connection is attached 4" above the
error. But these may be especially formed with a variety of connecting water return connection. In the sec-
susceptible to boiler pressure tran- pipe sizes, pipe lengths, operating ond case it is attached at the same
sients. The electronic gage can be pressures and insulation conditions. height as the water return connection.
corrected by locating each probe Since most of this information is pro- Connection in the second manner
individually to correct for the error prietary in nature, only general charac- causes minimal change to the normal
at that level. teristics will be discussed. temperature profile of the electronic
water gage.

6
TYPICAL GAGE LEVEL ERROR AND AVERAGE TEMPERATURE

GAGE CONNECTION EFFECT ON ELECTRONIC LEVEL GAGE PERFORMANCE

Figure 8

TABLE I
Configuration Gage Temperature Level Error

Gage Insulated Increases Decreases

* Steam supply pipe diameter larger Increases Decreases

* Steam supply pipe length longer Increases Decreases

Gage water level lower Increases Decreases

* Only applies to the electronic gage column since all standard gages were tested with a “tie bar” installed.

7
CONCLUSIONS Testing confirms that the gage tem- REFERENCES
perature is affected by a large number
The water level gage glass has been of conditions: steam supply and return Williams, James
used for many years to indicate boiler pipe size, length and configuration; “Methods of Obtaining Accurate
water level and it is required by the insulation, ambient conditions and Boiler Water Level Indication,”
ASME Boiler and Pressure Vessel water level. Maintaining the gage ASME Power Division Winter Annual
Code. A number of supplementary water temperature very close to the Meeting, New York, NY, December,
indicators are available that provide saturation temperature will have an 1960
convenient remote indication and level adverse effect on indication if the pres- Spencer, J. D.
control. All of these devices are sub- sure drops suddenly. However, if the “Design Considerations for an
ject to indication error because the gage temperature is significantly less Electronic Water Gage,” Fossil
water measured is external to the than the boiler water temperature, the Power Systems Technical Publica-
drum and is not at the same density level error will be significant at high tion 1988.
as the boiler drum water. pressure.
A number of techniques have been The best compromise is to deter- “Boiler Drum Level Indication in High
developed for each indicating device mine the average gage temperature Pressure Boilers,” Yarway Technical
to address this problem. The elec- and the gage level error that will exist Publication, November, 1992
tronic dp indicator can be adjusted by under certain boiler operating condi-
an analog or digital program. The Spencer, J. D.
tions. Then, the gage installation posi- “Density Error Considerations for
mechanical dp indicator uses a tem- tion can be corrected accordingly. For
perature compensated reference Steam Drum Water Gage Systems,”
the electronic level gage, probes can Nova Scotia Power Corp., Nova
chamber with a pressure compensa- be located individually to indicate
tion device. The standard level gage Scotia, Canada, June 1991.
properly. For the visual level gage,
and the electronic level gage can be repositioning the unit can compensate “Boiler Drum Pressure Correction,”
corrected by measuring or calculating for the density error. It is vital that the Rosemount application data sheet
the average gage water temperature gage installation follow the manufac- 3084, August 1990.
and installing the gage in the proper turer’s specifications. Only then will the
location. level device indicate accurately and
perform as designed and tested.

Y A R W A Y C O R P O R A T I O N
A SUBSIDIARY OF KEYSTONE INTERNATIONAL, INC.
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180 6M 396 Printed in U.S.A.

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