1. World Leaders in Combustion Management Solutions Water Level System www.autoflame.com Autoflame Training Water Level System

2. World Leaders in Combustion Management Solutions Water Level System www.autoflame.com 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

3. World Leaders in Combustion Management Solutions Water Level System www.autoflame.com Water Level Control System

4. World Leaders in Combustion Management Solutions Water Level System www.autoflame.com 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

5. World Leaders in Combustion Management Solutions Water Level System www.autoflame.com 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

6. World Leaders in Combustion Management Solutions Water Level System www.autoflame.com 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

7. World Leaders in Combustion Management Solutions Water Level System www.autoflame.com 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

8. World Leaders in Combustion Management Solutions Water Level System www.autoflame.com Capacitance Probe Philosophy Combustion Management Systems

9. World Leaders in Combustion Management Solutions Water Level System www.autoflame.com

10. World Leaders in Combustion Management Solutions Water Level System www.autoflame.com Capacitance Probe Operation

11. World Leaders in Combustion Management Solutions Water Level System www.autoflame.com Average Reading

12. World Leaders in Combustion Management Solutions Water Level System www.autoflame.com 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

13. World Leaders in Combustion Management Solutions Water Level System www.autoflame.com 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

14. World Leaders in Combustion Management Solutions Water Level System www.autoflame.com 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

15. World Leaders in Combustion Management Solutions Water Level System www.autoflame.com 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

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

17. World Leaders in Combustion Management Solutions Water Level System www.autoflame.com Normal Operating Condition Combustion Management Systems

18. World Leaders in Combustion Management Solutions Water Level System www.autoflame.com Demand Increases- Actual System Pressure Drops Combustion Management Systems

19. World Leaders in Combustion Management Solutions Water Level System www.autoflame.com Water Level Rises Due To Reduced Pressure Combustion Management Systems

20. World Leaders in Combustion Management Solutions Water Level System www.autoflame.com Required Water Level Shifts with the Load Change Combustion Management Systems

21. World Leaders in Combustion Management Solutions Water Level System www.autoflame.com Burner Firing Rate Increases Due To Reduced Pressure Combustion Management Systems

22. World Leaders in Combustion Management Solutions Water Level System www.autoflame.com Feed Water Valve Opens Due To System Demand Combustion Management Systems

23. World Leaders in Combustion Management Solutions Water Level System www.autoflame.com System Begins To Stabilize Combustion Management Systems

24. World Leaders in Combustion Management Solutions Water Level System www.autoflame.com Water Level Starts To Fall As System Reaches Operating Pressure Combustion Management Systems

25. World Leaders in Combustion Management Solutions Water Level System www.autoflame.com Sudden Demand Stops Combustion Management Systems

26. World Leaders in Combustion Management Solutions Water Level System www.autoflame.com Burner Firing Rate Decreases Combustion Management Systems

27. World Leaders in Combustion Management Solutions Water Level System www.autoflame.com Feed Water Valve Begins To Close Combustion Management Systems

28. World Leaders in Combustion Management Solutions Water Level System www.autoflame.com System Demand Returns To Normal Combustion Management Systems

29. World Leaders in Combustion Management Solutions Water Level System www.autoflame.com 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

30. World Leaders in Combustion Management Solutions Water Level System www.autoflame.com 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

31. World Leaders in Combustion Management Solutions Water Level System www.autoflame.com “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

32. World Leaders in Combustion Management Solutions Water Level System www.autoflame.com Feed Water Valve Position

33. World Leaders in Combustion Management Solutions Water Level System www.autoflame.com Modulating/Pump On/Off Feed Water Control

34. World Leaders in Combustion Management Solutions Water Level System www.autoflame.com Probe Commissioning

35. World Leaders in Combustion Management Solutions Water Level System www.autoflame.com 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

36. World Leaders in Combustion Management Solutions Water Level System www.autoflame.com 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

37. World Leaders in Combustion Management Solutions Water Level System www.autoflame.com 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

38. World Leaders in Combustion Management Solutions Water Level System www.autoflame.com First Out Annunciation

39. World Leaders in Combustion Management Solutions Water Level System www.autoflame.com

40. World Leaders in Combustion Management Solutions Water Level System www.autoflame.com Annunciation Display

41. World Leaders in Combustion Management Solutions Water Level System www.autoflame.com 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

42. World Leaders in Combustion Management Solutions Water Level System www.autoflame.com 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

43. World Leaders in Combustion Management Solutions Water Level System www.autoflame.com 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 180 0 F (feedwater temp) to 85 PSI at 327 0 F = 1040BTU = 19,124 lbs/hr 3% blowdown losses = 18,550 lbs/hr steam flow Totalised calculation integrated over time (5s) Steam Flow Calculation

44. World Leaders in Combustion Management Solutions Water Level System www.autoflame.com Fuel Flow & Steam Flow Metering Display

45. World Leaders in Combustion Management Solutions Water Level System www.autoflame.com Steam Flow Metering without a De-aerator Steam Flow Metering without a De-aerator Combustion Management Systems

46. World Leaders in Combustion Management Solutions Water Level System www.autoflame.com Combustion Management Systems Steam Flow Metering without a De-aerator Steam Flow Metering without a De-aerator

47. World Leaders in Combustion Management Solutions Water Level System www.autoflame.com Heat Flow Metering Combustion Management Systems

48. World Leaders in Combustion Management Solutions Water Level System www.autoflame.com Heat Flow Calculation Description Imperial Units Metric Units Firing Rate 75%75% Input 20.47 MBTU/hr 6 MW Return Temp 167 0 F 75 0 C Flow Temp 185 0 F 85 0 C Sp Heat Water 1.0 BTU/lb/ 0 F 4.18 KJ/KG/ 0 C Density Water 60.86 lb/cuft 972 kg/m 3 Combustion Eff 82%82% Combustion Management Systems

49. World Leaders in Combustion Management Solutions Water Level System www.autoflame.com 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 176 0 F is 60.68 lbs/cuft cuft/hr = 15,118 cuft/hr Volume flow =1884.5 US G.P.M Combustion Management Systems

50. World Leaders in Combustion Management Solutions Water Level System www.autoflame.com Flanged Pot Design

51. World Leaders in Combustion Management Solutions Water Level System www.autoflame.com ASME Approved Chambers

52. World Leaders in Combustion Management Solutions Water Level System www.autoflame.com Probes Mounted Directly into Boiler Shell

53. World Leaders in Combustion Management Solutions Water Level System www.autoflame.com Probes Mounted Directly into Boiler Shell

54. World Leaders in Combustion Management Solutions Water Level System www.autoflame.com External Probe Chamber

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

56. World Leaders in Combustion Management Solutions Water Level System www.autoflame.com 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

57. World Leaders in Combustion Management Solutions Water Level System www.autoflame.com 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

58. World Leaders in Combustion Management Solutions Water Level System www.autoflame.com 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

59. World Leaders in Combustion Management Solutions Water Level System www.autoflame.com

60. World Leaders in Combustion Management Solutions Water Level System www.autoflame.com 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

61. World Leaders in Combustion Management Solutions Water Level System www.autoflame.com European CE TUV APAVE American UL cUL

62. World Leaders in Combustion Management Solutions Water Level System www.autoflame.com Thank you for listening