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notifies the control room or other Maintenance Safer & Easier

remote locations that a probe column


The system’s intelligence can • Operator ex
blowdown (cleaning) is necessary. areas is min
BOILER
BOILER INSPECTION
INSPECTION GUIDELINES
GUIDELINES FOR
distinguish “dirty”
FOR probes from
If
DRUM the blue light
LEVEL on the indicator is
INSTRUMENTATION “nuisance”
DRUM INSPECTION
BOILER LEVEL INSTRUMENTATION GUIDELINES FOR
probes that need to be replaced.
illuminated, a blowdown is needed. • Longer prob
DRUM LEVEL INSTRUMENTATION
Per
Per Section
Section II of
of the
the ASME
ASME Code
Code Also, the Eye-Hye SmartLevel blowdowns
necessary, r
Per Section I of the ASME Code
system eliminates the need for
• Pinpoints th
frequent blowdowns. Now, blow-
or periphera
downs can be performed when simplify rep
the blue indicator is illuminated
(the probes need cleaning) or for
scheduled cleaning of the
connecting piping.

Includes
Includes the
the 2013
2013 Code
Code Changes
Changesandand
and Updates
Updates
Includes
with the 2013 Code
Recommendations Changes
from Updates
Section 7
with
withRecommendations
Recommendations from
from Section
Section 7 7
1 Effective January 1, 2014
Effective January 1, 2014
Effective January 1, 2014
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Figure 1
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GAGE VISIBILITY

GOOD PRACTICE IS TO LOCATE ALL ALARMS AND CUTOUTS WITHIN


WATER GAGE GLASS VISIBILITY

ASME SECTION I WATER GAGE REQUIREMENTS

UNDER 400 PSIG 400 PSIG and ABOVE


At Least 1 Direct Reading Gage Glass 2 Direct Reading Gage Glasses
Must be “In-Service” at all times OR
1 Direct Reading Gage Glass and
2 Indirect (Remote) Level Indicators
Note: When the gage glass is not continuously visible to the operator, two Remote (Indirect) Reading Gages are used to meet
Section I requirements, the Direct Reading Gage Glass may be valved-off (only when operating above 400 PSI), but must be
maintained in serviceable condition. The two Remote Level Indicators must operate independently and be continuously displayed.
WATER COLUMNS • Valves must have an unrestricted ¼” drain
• 1” NPS minimum vessel connections opening
• ¾” NPS minimum drain connection
GAGE GLASS
• The steam connection may come out of the top
of the vessel (See Connection # 4 on Figure 1) • Upper visibility to be no higher than lower
edge of the steam connection to the drum (#6)
• The line for the steam connection from the
vessel to the water column should be level or • Lower visibility to be no lower than the upper
slope downward from the drum to the water edge of the water connection to the drum (#5)
column (#3) • The lowest visible part of the gage glass (#1)
• The line for the water connection from the must be at least 2” above the lowest
vessel to the water column should be level or permissible water level (Level A)
upward from the vessel to the water column (#2)
• Transparent or tubular glass gage glasses
• Water columns are defined as “Standard that rely on observing the steam-water
Pressure Parts” or Standard Welded Parts” in
Subsection PG-11. Therefore, a Manufacturers interface and have multiple sections, must
Data report or Code Stamp is not required. have a minimum of 1” overlap of the visible
• Water columns are not permitted to be portions.
constructed from austenitic stainless steel • Internal lateral structural supports (webs) in
a transparent gage glass that obstruct the
WATER GAGE VALVES viewing of the level are prohibited.
• ½” NPS (Min.) connection to the water column • Ported type water gage glasses must be
• The Shutoff valves between the drum and the fitted with proper illumination to provide visual
discrimination between water and steam.
water column must be OS&Y, of through-flow
design and orientation.
• Install chain operators for operating from the Gage Cocks (Try Cocks)
floor or platform for safe means of operation • Not required (Since 1991)
• Must show position as open or closed, and • If used, must be minimum ½” NPS to the
have lock open capabilities water column.
REMOTE LEVEL INDICATOR MAGNETIC WATER LEVEL GAGE
• ¾” NPS minimum vessel connections • Considered an Indirect level indicator because
• When used as a water column, the vessel the actual water line can not be viewed
connections must be 1” NPS minimum. • Does not replace the Code required direct
• ½” NPS minimum drain connection reading gage glass
• When used as a water column, the drain • Limited use to 900 PSI
connection must be ¾” NPS minimum. • Switches or accessories for control purposes are
• When the two remote level indicators are prohibited
used at 400 PSIG and above, the remaining • Can not be used as a water column for the
gage glass may be shut off, but must be attachment of water gage glasses or other Code
maintained in the serviceable condition. required instruments.
• The display of the two indirect indicators • Indication scale must comply to PG-60
must be continuously visible in the operators requirements regarding gage glass placement
control area. limitations for the viewing range
• Conductivity Probe Level Indication Systems • ¾” NPS minimum vessel connections
meet Section I requirements for Indirect • Can be fitted with a 4-20 mA transmitter for
(Remote) Level Indicators. See Figure 2. remote indication.
• Material of construction may include certain types
of stainless steel (refer to PG-12.3)
• ½” NPS minimum drain connections

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Figure 2
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WATER COLUMN ISOLATION SHUTOFF VALVES HRSG DESUPERHEATER DRAIN POTS
• Y-pattern globe valves are permissible, as long
• Drain pots that are installed to detect and
as the lowest edge of the seat is at least 25% of
remove unvaporized water shall include
the inside diameter below the centerline of the
automatic detection of water and automatic
valve. See Figure 3 below.
operation of the drain pot valves. See Figure 4
below.

Figure 3
Figure 4

Note: Any isolation valves between the drum and a


water column must be locked open on applications
operating above 250 PSI

MAXIMUMPRESSURE
MAXIMUM PRESSURE LIMITS
LIMITS FOR
FOR THREADED
THREADED CONNECTIONS
CONNECTIONS : ¾”: ¾” toNPS
to 3” 3” NPS (DN)
(DN) & PSI
& PSI (MPa)
(MPa)
3” (80) = 400 PSI (3)
3” (80) = 400 PSI (3) 1-1/2” (40) = 900 PSI (6)
1-1/2” (40) = 900 PSI (6) ¾” (20) & smaller = 1500 PSI (10)
¾” (20) & smaller = 1500 PSI (10)
2-1/2” (65) = 500 PSI (3.5)
2-1/2” (65) = 500 PSI (3.5) 1-1/4” (32) = 1000 PSI (7)
1-1/4” (32) = 1000 PSI (7)
2”(50)
2” (50)= = 600
600 PSI
PSI (4)(4) 1” (25) = 1200
1” (25) PSI(8)
= 1200 PSI(8)

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COMMON NON-COMPLIANT DRUM LEVEL EQUIPMENT
ARRANGEMENTS

 Magnetic Gages being used as direct reading gages. Magnetic Gages are permitted as a local
indirect gage or as a remote level indicator when used with a 4-20mA transmitter to a control area
indicator. A Magnetic Level Gage can not replace the Code required direct reading gage glass.
 When the over 400 PSI Code option arrangement is used (two independent indicators for one of
the gage glasses), the two indirect indicators must be continuously visible in the operators control
area and the gage valves may be isolated. Viewing the boiler level on a plant operation control
system computer screen does not qualify as a continuously visible indicator unless it is always on
the screen. If keystrokes or mouse clicks are required to view the indirect indicator, it does not
meet the Code requirements, as an indirect indicator.
 When the over 400 PSI Code Option Arrangement is used, the existing gage glasses must be able
to be brought into service without further action other than opening the isolation valves, closing the
drain valve, and powering on illuminators. Gage glasses that can not be turned on without repairs
do not meet ASME Code requirements.
 Bi-color ported type water gages must be fitted with proper illumination to provide visual
discrimination between water and steam. If not, the gage glass is not in Code compliance.
 Not having two independent indirect reading gages when the gage glass image is not directly
visible in the operators control area or transmitted to the operators control area, by means of a
camera, fiber optic system, or mirrors.

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Proper Care Recommendations from Section 7
• • Check
Checkwaterwaterlevel in 2 or more instruments prior to start up and verify and resolve a deviation if observed
level in two or more instruments prior to start up and verify when a deviation is
• Compare level indication accuracies regularly during operation
observed
• Conduct blow downs of water columns & gage glasses regularly and observe promptness of restored level
• • Check
CheckWaterWater Gage
Gage Glasses
Glasses to confirm
to confirm there there
is noisdeviation
no dirt or contamination
that that could
could be mistaken be mistaken
as water level
as water
• The Water level
Gage Glass should be maintained perfectly at all times, even if two remote indicators are in use
• • Water
WaterGage Glasses
Gages shouldshould be properly
be properly illuminated
illuminated for for easy
easy observation
observation
• Protect Water Gage Glasses from drafts, rain, or snow
• • ItItisisimportant
importanttoto keep
keep thethe water
water gagegage
glassglass
cleanclean
and and
easyeasy to read.
to read. However,
However, excessive
excessive blow
blow down may
down may cause premature wear
cause premature wear of the gage internals of the gage internals
• • Verification
Verificationofofhigh
high and
and lowlow water
water alarms
alarms is critical
is critical toprevention
to the the prevention of carryover
of water carryover or damage
damageto to
drum
druminternals
internals
• Verify there are no leaks around the level instrumentation, piping, related isolation valves, or water
• Verify there are no leaks around the level instrumentation, piping, related isolation valves, or
column. Leaks may affect the accuracy of the indicated level and eliminating any leaks prevents a hazard
water column. Leaks may affect the accuracy of the indicated level and eliminating any leaks will
• Check external instrumentation piping for any missing insulation
helpoftodamage
• Risk preventtoaequipment
hazard by steam cutting may also be prevented with routine inspections of the
• valves,
Checkand external instrumentation
external piping
piping, in addition for anyinspection
to regular missing insulation
of the water level
• • Use
Risk of damage to equipment by steam cutting may also procedures
Temporary Gage Glass for Boil Out (Chemical cleaning) be prevented with routine inspections of
• The function of all level instrumentation should be inspected and tested for the authorized boiler
the valves, and external piping, in addition to regular inspection of the water level.
inspector during external inspections
• • Two
Useindependent
Temporary Gage Glass
low water for Boil
cutoffs areOut (chemical cleaning)
recommended procedures.
on automatically fired boilers
• Automatic level trips should be set to trip the fuel supply,
before the water level reaches the low limit of the gage glass
• Procedures should be in place to prevent false trips, when testing water columns with automatic low
water trips
GOOD PRACTICE RECOMMENDATIONS
The following are not required by ASME Code, but are recommended for safe operation:

1. Chain Operators should always be installed to provide a safe means of operating gage glass
isolation valves under normal conditions and in the event of glass leakage.
2. A conductivity probe system combined with a 4-20 mA level transmitter, or, two conductivity
probe systems provide the best reliability due to the redundancy of probe systems. The use of
two or three differential pressure transmitters (redundant devices) is not recommended due to
the likelihood of simultaneous common mode failure, due to environmental variations
(especially freeze-up) or loss of device sensing leg primes.
3. Trip and alarm points are within the visible range of the gage glass for visual verification.
4. Freeze protection for outdoor applications should be provided to prevent damage to the level
instrumentation devices.
5. Transparent water gage glass illumination should be provided to give optimum viewing of the
drum level for the operator, especially in low lit areas and when a transparent gage glass is
elevated above the viewing platform.
6. Exposed piping to the gage glass or level instrument, especially the upper steam piping,
should be insulated to minimize risk and level density error due to excessive cooling and
condensate formation.
7. Note: Plant (owner) policies and procedures may exceed Code minimum requirements with the
number of level indicating instruments to be installed, which may prevent a violation if any single
instrument is out of service for maintenance.

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GOOD PRACTICE RECOMMENDATIONS for Inspection, Testing, and Servicing
GOOD PRACTICE RECOMMENDATIONS for Inspection, Testing, and Servicing
The following are not required by ASME Code, but are recommended for safe operation:
The following are not required by ASME Code, but are recommended for safe operation:

1. Water Gage Glasses, Water Columns, and Remote Level Indicators:


1. Water Gage Glasses, Water Columns, and Remote Level Indicators:
a. Visual Inspection and Blow Down should be conducted on routine basis to verify cleanliness
a. Visual
for Inspection
easy reading and
of the Blow
level Downdiscrimination”
“ready should be conductedbetween onsteam
routine basis
and to verify cleanliness
water.
for easy reading of the level “ready discrimination” between steam and water.
Also, to remove any sediment from collecting in the piping or valves.
Also, to remove any sediment from collecting in the piping or valves.
b. Visual inspection of all external instrumentation should be conducted on a monthly basis
b. Visual inspection
including of all external
piping, isolation instrumentation
valves, drain valves, andshould
lightingbe conducted on a monthly basis
accessories.
including piping, isolation valves, drain valves, and lighting accessories.
c. Annual Servicing of Water Gage glasses is recommended. Follow the OEM instructions.
c. Annual Servicing of Water Gage glasses is recommended. Follow the OEM instructions.
Semi-annual servicing is recommended for severe service applications with poor water quality
Semi-annual
or high-pressureservicing is recommended
applications > 1500 PSIG for(10
severe
MPa)service applications with poor water quality
or high-pressure applications > 1500 PSIG (10 MPa)
d. When freeze protection is not installed on level instruments, and the equipment is not in
d. Whenor
service freeze protection
is isolated, is not
it should beinstalled
drainedonand level
freeinstruments, and thetemperatures
of water if freezing equipment is are
not in
service orinisorder
expected isolated, it should
to prevent be drained and free of water if freezing temperatures are
damage.
expected in order to prevent damage.
2. Low Water Cutouts:
2. Low Water Cutouts:
a. Testing should to be conducted on a daily basis. Actual plant policies may dictate more or
a. Testing
less should
frequency. In to
anybecase,
conducted on a daily
the maximum basis.should
interval Actualnot
plant policies
exceed onemay dictate more or
week.
less frequency. In any case, the maximum interval should not exceed one week.
b. Annual servicing of low water cutouts is highly recommended. Disassemble the cutout
b. Annual
switch servicing
assembly, of low water
examine cutoutsprobes
conductivity is highly
or recommended. Disassemble
the float mechanism the cutoutor
for contamination
switchReplace
wear. assembly, anyexamine
suspectconductivity
components.probes
Followor the
the float
OEM mechanism for contamination or
instructions.
wear. Replace any suspect components. Follow the OEM instructions.
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BI-COLOR DIRECT READING GAGE
GLASS WITH ILLUMINATION (viewing
hood not shown)

LEVEL INDICATION
SYSTEM WITH LEVEL INDICATION
CONDUCTIVITY SYSTEM WITH
PROBES CONDUCTIVITY
PROBES

Typical Code Compliant


installation for pressures
CONTROL ROOM over 400 PSIG
INDICATOR CONTROL ROOM
INDICATOR

For questions, consult your local Boiler Inspector, Insurance Carrier, or a Reliance Applications Engineer.

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16633 Foltz Parkway • Strongsville,


16633OHFoltzUSA • Ph:
Parkway (440) 572-1500
• Strongsville, OH USA• •Fax:
Ph: (440) 238-8828• Fax:
(440) 572-1500 • www.clark-reliance.com • sales@clark-reliance.com
(440) 238-8828 • www.clark-reliance.com • sales@clark-reliance.com
CLA-009 01/14
y • Strongsville, OH 01/14
USA • Ph: (440) 572-1500 • Fax: (440) 238-8828 • www.clark-reliance.com • sales@clark-reliance.com
CLA-009

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