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The Steam and
Condensate Loop Book
The control of liquid levels, for example in a process tank, is an important function. An example would be a hot
water tank where water is removed, perhaps for washing down, and the level needs to be restored ready for
the next wash cycle.
Control of water level and alarms for steam boilers is specifically excluded from this Tutorial, and the reader is
referred to Block 3 (The Boiler House), which deals with the subject in depth.
Many different types of level control systems are used in industry, covering a wide range of processes. Some
processes will be concerned with media other than liquids, such as dry powders and chemical feedstock. The
range of media is so wide that no single instrument is suitable for all applications.
Many systems are available to serve this wide range of applications. The following list is not exhaustive but, in
most cases, the final control signal will be used to operate pumps or valves appropriate to the application:
Float operated types- a float rises and falls according to the change in liquid level and operates
switches at predetermined points in the range.
Solid probe types- these measure conductivity or capacitance and are discussed in more detail in the
following pages.
Steel rope capacitance types - a flexible steel rope is suspended in the liquid, and the change in
capacitance is measured relative to the change in water level.
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Ultrasonic types- a high frequency acoustic pulse is directed down from a transducer to the surface
of the medium being measured and, by knowing the temperature and speed of sound in air, the time it
takes for the pulse to rebound to the sensor is used to determine the level.
Microwave radar types- similar in principle to the ultrasonic type but using high frequency
electromagnetic energy instead of acoustic energy.
Hydrostatic types- a pressure transmitter is used to measure the pressure difference between the
confined hydrostatic pressure of the liquid head above the sensor and the outside atmospheric
pressure. Changes in pressure are converted into a 4-20 mA output signal relative to the head
difference.
Differential pressure types- similar to hydrostatic but used where the application being measured is
subjected to dynamic pressure in addition to static pressure. They are capable of measuring small
changes in pressure in relation to the output signal range. Typical applications might be to measure
the level of water in a boiler steam drum, or the level of condensate in a reboiler condensate pocket.
Magnetic types- a float or cone is able to rise and fall along a stainless steel probe held in the tank
fluid being measured. The float can interact magnetically with switches on the outside of the tank
which send back information to the controller.
Torsion types- a moving float spindle produces a change in torsion, measured by a torsion
transducer.
It is important that the level control system is correct for the application, and that expert advice is sought from
the manufacturer before selection.
It is not within the scope of this Tutorial to discuss the pros and cons and potential applications of all the
above control types, as the types of level control systems usually employed in the steam and condensate loop
and its associated applications are float and solid probe types. The operation of float types is fairly
self-explanatory, but conductivity and capacitance probes may require some explanation. Because of this, this
section will mainly focus on conductivity and capacitance probe-type level controls.
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The final control element may be a valve that is adjusted to a point between fully open and fully closed, as a
function of the level being monitored. Modulating level control cannot be achieved using a conductivity probe.
Capacitance probes are ideal for this purpose (see Figure 8.3.2).
In systems of this type, the pump can run continuously, and the valve will permit appropriate quantities of liquid
to pass. Alternatively, the final control element may be a variable speed drive on a pump. The speed of the
drive may be adjusted over a selected range.
Advantage
A simple but accurate and relatively inexpensive method of level control.
Applications:
The system can be used for liquids with conductivities of 1 S/cm or more, and is suitable for condensate
tanks, feedwater tanks and process vats or vessels. Where the conductivity falls below this level it is
recommended that capacitance based level controls are used.
Point to note:
If the tank is constructed from a non-conductive material, the electrical circuit may be achieved via another
probe tip.
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Fig. 8.3.3 General arrangement of a non-adjustable on/off level control system for a tank
Advantage:
Adjustable on/off level control allows the level settings to be altered without shutting down the process.
Disadvantage:
More expensive than non-adjustable on/off control.
Application:
Can be used for most liquids, including those with low conductivities.
Point to note:
Can be used in situations where the liquid surface is turbulent, and the in-built electronics can be adjusted to
prevent rapid on/off cycling of the pump (or valve).
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Fig 8.3.4 General arrangement of an adjustable on/off level control system for a tank
Advantages:
1. Because the probe and controller only provide a signal to which other devices respond, rather than
providing the power to operate a device, there is no limit on the size of the application.
2. Steady control of level within the tank.
Disadvantages:
1.
2.
3.
4.
5.
Point to note:
To protect the supply pump from overheating when pumping against a closed modulating valve, a
re-circulation or spill back line is provided to ensure a minimum flowrate through the pump (neither shown in
Figure 8.3.5).
Fig. 8.3.5 General arrangement of a modulating control system maintaining the level in a tank
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The selection and application of components used to control flowrate require careful thought.
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The purpose of this pressure control valve is to provide a stable (rather than reduced) pressure, but it will
inherently introduce a pressure drop to the supply pipe.
A separator placed before any steam flowmetering station to protect the flowmeter from wet steam will also
protect the pressure control valve from wiredrawing.
The controller
Even if the output signal from the DP transmitter or computer is of a type that the control valve actuator can
accept, a controller will still be required (as for any other type of control system) for the following reasons:
1. The output signal from certain flowmeters/computers has a long time repeat interval (approximately 3
seconds), which will give enough information for a chart recorder to operate successfully, but may not
offer enough response for a control valve. This means that if the controller or PLC to which the
transmitter signal is being supplied operates at higher speeds, then the process can become unstable.
2. PID functions are not available without a controller.
3. Selecting a set point would not be possible without a controller.
4. The signal needs calibrating to the valve travel - the effects of using either a greatly oversized or
undersized valve without calibration, can easily cause problems.
Summary
It is usually better to install the flowmetering device upstream of the flow control valve. The higher pressure
will minimise its size and allow it to be more cost effective. It is also likely that the flowmeter will be subjected
to a more constant steam pressure (and density) and will be less affected by turbulence from the downstream
flow control valve.
In some cases, the application may be required to control at a constant flowrate. This means that features,
such as high turndown ratios, are not important, and orifice plate flowmeters are appropriate.
If the flowrate is to be varied by large amounts, however, then 'turndown' becomes an issue that must be
considered.
The subject of Flowmetering is discussed in greater depth in Block 4.
What do I do now?
The printable version of this page has now been replaced by The Steam and Condensate Loop Book
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