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Effective Boiler-Level Control
Apr 15, 2008 2:18 PM
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By most manufacturers standards, high-quality steam is 99.5-percent dry saturated steam. For a boiler to provide an appropriate amount of such steam safely, efficiently, and at the correct pressure, the amount of water inside of the boiler must be carefully controlled.
This article will discuss problems associated with high- and low-water-level conditions, the effects of steam pressure and load on water level, components of an effective water-level-control system, the importance of maintaining a mass/heat balance, boiler-level-control strategies, and types of level-measurement sensors.
Repercussions of Poor Control
High-water-level conditions. When a boiler operates with an excessive amount of water, carryover and priming are likely to occur.
As water rises above the horizontal center line of a boiler drum, the water-surface, or steam-release, area decreases. When water-surface area is not sufficient enough for steam to be released at a controlled velocity, carryover of water droplets through the steam header occurs. Other causes of carryover include poor control of boiler-water total dissolved solids (TDS) and contamination of boiler feedwater. Water that is carried over contains dissolved and suspended solids, which can contaminate controls, heat-transfer surfaces, steam traps, and steam itself.
Priming takes place when a large, rapidly applied load results in a sudden reduction in steam pressure, which, in turn, causes boiler water to be pulled into piping.
Low-water-level conditions. When a boiler operates with an insufficient amount of water, severe damage and, in extremely rare cases, explosions can occur. With low water, tubes are uncovered and no longer cooled by boiler water. The temperature of the metal increases rapidly, the metals strength is reduced, and collapse or rupture occurs.
Effects of Pressure and Load
Departing from a boilers design operating pressure raises the p
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