World Leaders in Combustion Management Solutions Water Level System Autoflame Training Water Level System

World Leaders in Combustion Management Solutions Water Level System Water Level Control First Out Annunciation Steam Flow Metering Heat Flow and Hot Water Flow Metering Bottom/Column Blowdown control Total Dissolved Solids (T.D.S.) Management/Surface Blowdown Shunt Switch Philosophy One Controller, Seven Functions

World Leaders in Combustion Management Solutions Water Level System Water Level Control System

World Leaders in Combustion Management Solutions Water Level System Traditional feedwater control in response to: Water Level Steam flow Feedwater flow Autoflame feedwater control in response to: Water level Firing rate Steam pressure The Autoflame 3-element level control has been granted a worldwide patent is the only system that can combine firing rate, steam pressure and water level within one controller for the purpose of improving feedwater control Three Element Feed Water Control

World Leaders in Combustion Management Solutions Water Level System Control of feedwater flow in response to: Water level Boiler pressure Firing rate of the burner PI to control flow into the boiler 2 port feedwater control valve Variable speed drive to the feed pump Wave signature and turbulence management software Safety, accuracy and integrity are guaranteed Method of Operation & Control Philosophy

World Leaders in Combustion Management Solutions Water Level System Safe and accurate control (+/- 2mm in still water) 20Hz=1mm 2 capacitance probes for measuring the water level including: high high level high level + high level pre-alarm required level 1 st low + 1 st low pre-alarm 2 nd low Capacitance Probe Operation & Integrity

World Leaders in Combustion Management Solutions Water Level System Capacitance readings constantly checked Self-check for electrical and mechanical integrity Comparison between probes Continual check with the commissioned data Checks to an internal reference capacitor Probe compensation Long term drift Changes in ambient temperature Capacitance Probe Operation & Integrity

World Leaders in Combustion Management Solutions Water Level System Capacitance Probe Philosophy Combustion Management Systems

World Leaders in Combustion Management Solutions Water Level System

World Leaders in Combustion Management Solutions Water Level System Capacitance Probe Operation

World Leaders in Combustion Management Solutions Water Level System Average Reading

World Leaders in Combustion Management Solutions Water Level System Ensures that either probe cannot read a still water condition when the burner is running Certifies that no static or stuck value can be accepted User adjustable to meet every application Default setting is 20Hz User definable: 0-100Hz Impossible on float type controls Movement Detection of Water

World Leaders in Combustion Management Solutions Water Level System Causes: Surface tension of bubble bursts releasing droplets Droplets coat the surface of the level probe which reads as an increase in the water level Wave reflection off the boiler Methods to avoid this: Probes externally fitted in float chamber/s Anti-surge pots in the boiler shell Bubble Wave Signature Explanation Spray

World Leaders in Combustion Management Solutions Water Level System When the boiler produces high quantities of steam it can produce swells and surging motions The user adjustable probe disparity can be adjusted to compensate for this situation Steam Flow Induced Surge

World Leaders in Combustion Management Solutions Water Level System Prevents intermittent shut downs due to 1 st low being switched during transitory conditions Autoflame system knows what the –Firing rate –Boiler pressure At any one time and thus identifies the above condition Only water level system in the world that has this function Swell Managent

World Leaders in Combustion Management Solutions Water Level System Leclerc Prison, Laval, Quebec, Canada Thermodesign, Aquatube Boilers 4 X Various BHP, High Pressure Steam, Thermodesign, Aquatube Boilers Combustion Management Systems

World Leaders in Combustion Management Solutions Water Level System Normal Operating Condition Combustion Management Systems

World Leaders in Combustion Management Solutions Water Level System Demand Increases- Actual System Pressure Drops Combustion Management Systems

World Leaders in Combustion Management Solutions Water Level System Water Level Rises Due To Reduced Pressure Combustion Management Systems

World Leaders in Combustion Management Solutions Water Level System Required Water Level Shifts with the Load Change Combustion Management Systems

World Leaders in Combustion Management Solutions Water Level System Burner Firing Rate Increases Due To Reduced Pressure Combustion Management Systems

World Leaders in Combustion Management Solutions Water Level System Feed Water Valve Opens Due To System Demand Combustion Management Systems

World Leaders in Combustion Management Solutions Water Level System System Begins To Stabilize Combustion Management Systems

World Leaders in Combustion Management Solutions Water Level System Water Level Starts To Fall As System Reaches Operating Pressure Combustion Management Systems

World Leaders in Combustion Management Solutions Water Level System Sudden Demand Stops Combustion Management Systems

World Leaders in Combustion Management Solutions Water Level System Burner Firing Rate Decreases Combustion Management Systems

World Leaders in Combustion Management Solutions Water Level System Feed Water Valve Begins To Close Combustion Management Systems

World Leaders in Combustion Management Solutions Water Level System System Demand Returns To Normal Combustion Management Systems

World Leaders in Combustion Management Solutions Water Level System Foaming on the surface of the boiler is brought about by a less than adequate blow down regime This should only occur in a badly managed boiler plant Poor TDS management/control Incorrect or insufficient water treatment Foaming will read as a step increase in the water level Foaming

World Leaders in Combustion Management Solutions Water Level System Wave signature is installation specific & driven by –Boiler size –Water treatment regime –Position of heat transfer surface relative to water level –Load pattern imposed on the boiler The Autoflame system takes into account all of these variables to produce perfect level control in complete safety Wave Signature Conclusion

World Leaders in Combustion Management Solutions Water Level System “2 nd Low” switches when either probe reads low for 10 seconds. Ultimate safety condition- no filtering software Switching point can be set at any point on the probe, no need to cut probe to length Must not cut probe! “2 nd Low” Switching Philosophy

World Leaders in Combustion Management Solutions Water Level System Feed Water Valve Position

World Leaders in Combustion Management Solutions Water Level System Modulating/Pump On/Off Feed Water Control

World Leaders in Combustion Management Solutions Water Level System Probe Commissioning

World Leaders in Combustion Management Solutions Water Level System Valve sizes: ½” to 2” Steel valve with stainless steel ball & stem Servo Torque: 37ftIbs (40Nm) / 72ftIbs (98Nm) NEMA 4 rated. Position feed back potentiometer Flange spec: ANSI 300Ib (PN16) Max pressure: 300psi (20bar) Max volume: 11,000gal/hr (42,000l/hr) Feed Water Valve

World Leaders in Combustion Management Solutions Water Level System 4 dedicated screens for recording of events relating to water level control & management of the boiler Each event tagged for: Time/Date of alarm Time/Date of reset of alarm Type of incident Each screen will give details of 4 events Information can be accessed through DTI Historical Record of Water Level Alarms

World Leaders in Combustion Management Solutions Water Level System 15 First Out Annunciations User definable descriptive labels Infra-red Upload/Download facility Selectable High/Low voltage alarm Accessible through D.T.I. First Out to be displayed or to lockout System lockout optioned by a manual reset or an auto reset of the alarm/fail condition Historical record of announced alarm (2005) First Out Annunciation

World Leaders in Combustion Management Solutions Water Level System First Out Annunciation

World Leaders in Combustion Management Solutions Water Level System

World Leaders in Combustion Management Solutions Water Level System Annunciation Display

World Leaders in Combustion Management Solutions Water Level System Auxiliary level controls can be incorporated into the Autoflame Water Level Control System DA tank level control Inputs to accommodate “high”, “1 st low” and “2 nd low” Accessed through “SETUPS” in the MK6 HIGH WATER FLOAT AUX LOW 1 st LOW 3 rd Party Water Level System Integration

World Leaders in Combustion Management Solutions Water Level System Feed water temperature monitored & displayed Steam temperature monitored & displayed Steam pressure monitored & displayed Instantaneous steam flow displayed Totalized steam flow displayed Fuel flow metering utilized for calculation All the above is logged and accessed through D.T.I. Steam Flow Metering

World Leaders in Combustion Management Solutions Water Level System Fuel gross heat input = 24,500,000 BTU/hr 1% standing losses = 245,000 BTU/hr 18% stack losses = 4,365,900 BTU/hr Net calorific value heat input = 19,889,100 BTU/hr Heat required to raise 1lb of water from F (feedwater temp) to 85 PSI at F = 1040BTU = 19,124 lbs/hr 3% blowdown losses = 18,550 lbs/hr steam flow Totalised calculation integrated over time (5s) Steam Flow Calculation

World Leaders in Combustion Management Solutions Water Level System Fuel Flow & Steam Flow Metering Display

World Leaders in Combustion Management Solutions Water Level System Steam Flow Metering without a De-aerator Steam Flow Metering without a De-aerator Combustion Management Systems

World Leaders in Combustion Management Solutions Water Level System Combustion Management Systems Steam Flow Metering without a De-aerator Steam Flow Metering without a De-aerator

World Leaders in Combustion Management Solutions Water Level System Heat Flow Metering Combustion Management Systems

World Leaders in Combustion Management Solutions Water Level System Heat Flow Calculation Description Imperial Units Metric Units Firing Rate 75%75% Input MBTU/hr 6 MW Return Temp F 75 0 C Flow Temp F 85 0 C Sp Heat Water 1.0 BTU/lb/ 0 F 4.18 KJ/KG/ 0 C Density Water lb/cuft 972 kg/m 3 Combustion Eff 82%82% Combustion Management Systems

World Leaders in Combustion Management Solutions Water Level System Heat Flow Calculation (cont) Efficiency = 100-(stack loss+(radiation loss*100)/75%) = 80.67% Useful heat into water = total heat * efficiency/100% = 16,515,440 BTU Volume flow = UHW/(Sp Ht Water * (flow temp-return temp)) = 917,397 lbs/hr Density of water at F is lbs/cuft cuft/hr = 15,118 cuft/hr Volume flow = US G.P.M Combustion Management Systems

World Leaders in Combustion Management Solutions Water Level System Flanged Pot Design

World Leaders in Combustion Management Solutions Water Level System ASME Approved Chambers

World Leaders in Combustion Management Solutions Water Level System Probes Mounted Directly into Boiler Shell

World Leaders in Combustion Management Solutions Water Level System Probes Mounted Directly into Boiler Shell

World Leaders in Combustion Management Solutions Water Level System External Probe Chamber

World Leaders in Combustion Management Solutions Water Level System Reduced maintenance Shields the probes Requires regular Blow Down Advantages of Using External Pots

World Leaders in Combustion Management Solutions Water Level System Up to 4 blowdowns can be accommodated in any 24 hour period Duration of each can be programmed from 0–60 secs Each blowdown can be repeated up to 10 times COMMS link to all systems ensures no more than one boiler can blowdown at any one time Bottom/Column Blowdown Management

World Leaders in Combustion Management Solutions Water Level System To optimise boiler efficiency and reliability, the Total Dissolved Solids must not exceed a designated level Water tube boilers <1500ppm Smoke tube boilers <2500ppm Probes Mounted Directly into Boiler Shell

World Leaders in Combustion Management Solutions Water Level System What Effects the T.D.S? The Total Dissolved Solids is directly proportional to the conductivity of the water (delta T=0) Temperature effects the conductivity by 2% per 0 C Steam temperature corrects the conductivity value Polarisation of the water sample Electrical energy from the probe builds up an offset above/below the earth/ground value (0 volt) Measured polarisation voltage used to correct conductivity Scale build up on the probe Sampling container creates turbulence to clean the probe Combustion Management Systems

World Leaders in Combustion Management Solutions Water Level System

World Leaders in Combustion Management Solutions Water Level System Water level test facility Enables column/boiler blowdown without water level alarms and the burner continues to fire When initiated the feedwater valve closes/pump off until 1 st low is reached, followed by 2 nd low Both alarm levels must be attained within user- definable times Once tested the feedwater valve opens/pump on to return to control point Test satisfied Shunt Switch Philosophy

World Leaders in Combustion Management Solutions Water Level System European CE TUV APAVE American UL cUL

World Leaders in Combustion Management Solutions Water Level System Thank you for listening