Steam boiler water

level controls
and alarms
an overview
 Steam boiler water leve
This brochure gives an introduction to modern methods User benefits
of steam boiler water level controls and alarms, and
outlines some of the systems available from Spirax Sarco. • Accurate safe control
Significant developments in recent years have led to • Choice of systems for all applications
improved safety and reliability of boiler level controls,
and Spirax Sarco is at the forefront of this technology. • Approved by many authorities around the world
Electronic level controls are now standard, and have
largely replaced older high maintenance float based • All systems suitable for pressures up to 32 bar g
devices.
More detailed technical information is given in separate • On/ off or modulating control to suit application
literature.Your local Spirax Sarco Engineer will be pleased
• Single, two, or three element control
to advise on the most suitable system for your application.

Why do I need boiler water controls and alarms?

Controls
To achieve a steam output matched to the varying
requirements of the average steam plant, good control
of boiler water level is necessary. With the small steam
spaces now common in modern boilers, a quick and
accurate response to variations in water level is
essential.
Alarms (limiters)
In order to operate safely, all steam boilers need a
method of warning of excessively low or high water
levels. In many countries, regulations require two
independent low water level alarms, or limiters.
Independent high alarms are also required in many
cases. With the move towards unmanned boiler
houses, there is an increasing need for high integrity
self-monitoring alarms. These systems can operate
with extended test intervals in many cases.

What methods are used to control the water level?

Boiler water level is controlled either by switching the boiler feedpump on and off at water levels determined by
a probe and controller (on /off control), or by progressively opening or closing a feedwater valve as the steam
demand causes the water level to change in the boiler (modulating control).

On /off control Modulating control

On/off control systems are most suitable for
installations where a certain amount of variation
in boiler pressure and steam flowrate can be
tolerated. Examples might be smaller boilers with
stable load conditions.
Modulating control gives a steady pressure and
steam flowrate in steam boilers. The feedwater
flowrate is varied, for example through a modulating
valve, in response to changes in water level. With
modulating control, the boiler feedpump is running
all the time, and a spill-back line used to return
unused feedwater to the feedtank.

On /off control Steam flowrate Modulating control Steam flowrate

Water level
up and down
Water level
more steady
Feedwater
valve
Fuel Fuel
Feedwater on / off Firing rate Feedwater flowrate
varies matches
steam demand Steady
firing rate
Feedpump Feedpump
5 PM Spillback line 5 PM
M 17 M 17
4P 4P
16 16
15 M
15 M

3P
3P

M
M

2P
2P

14
14
1 PM

1 PM

Steam flowrate Steam flowrate

13

13

from a boiler with from a boiler with

on / off level controls modulating level controls
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el controls and alarms
The majority of boiler level controls and level alarms operate on the principle of conductivity or capacitance, and
Spirax Sarco is the world leader in using these principles for safe accurate control of water levels in boilers.

Conductivity or Capacitance?
Conductivity Capacitance
A conductivity probe (LP10-4) and controller can be A capacitance probe (LP20 with PA20 preamplifier)
used in a boiler or a tank for on/off pump control can be used in a boiler or a tank for modulating or
and /or alarm duties. adjustable on /off control. The probe consists of a
conductive core completely sheathed in an insulating
It has one electrode for each function, which is cut to
material. For this reason, capacitance probes cannot
the required length on installation. Each probe
be cut to size, so are available in several different
electrode acts as a simple switch, indicating a low
lengths. As the water level rises or falls, the
resistance to earth if in water, or a high resistance if
capacitance coupling effect changes.
out of water.
A high or a low level alarm switching point can also
For example, with a low alarm, the controller senses
be selected. Controllers are available for pneumatic
a change of resistance from low to high as the water
or electrically actuated valves or variable speed
level falls below the probe tip. This change in
pumps.
resistance causes the controller to disengage a relay
to operate an alarm bell, light, or both, and normally Used as an on /off adjustable level control, it avoids
will also cut the power to the burner. having to cut probe tips to length, and permits level
adjustments to be made at the controller without
Simple conductivity probes operate on this principle,
having to remove the probe from the boiler.
and have no self-checking facility.
High integrity self-monitoring level alarms (limiters)
(LP30 low alarm and LP31 high alarm probes)
operate on this same conductivity principle. The
probes are designed to detect numerous failure LP20 / PA20
modes and will, for example, sound an alarm if the capacitance probe -
Providing modulating level control
wiring is damaged. The controller has a cyclic self- plus one of the alarms in a boiler.
test facility which sounds an alarm if it fails to react Additional alarm(s) would
to a simulated fault. Boilers fitted with alarms of this be needed.
type in the boiler shell can operate with extended
test intervals in most countries, in many cases
allowing the boiler house to be de-manned.
Boiler shell
LP10-4 four-tip
conductivity probe-
On / off level control and
simple high and low alarms.
An additional low alarm would
be needed for a boiler. Protection tube Transmitter 100 %
(Protection tube not shown).
Adjustable high
High alarm or low level alarm
Valve closed
Adjustable
Adjustable set point
Pump off proportional
Water level band
Valve open
Pump on Comparator
tip
Low alarm level Transmitter 0 %

LP30 low alarm probe /limiter-

Conductivity probe with comparator tip
providing a high-integrity, self-monitoring
low level alarm in a boiler.

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 How do I chose the best system for my particular application?
Two system examples are shown below. Many other combinations may be used to comply with local /national
regulations and specific customer applications. Additional literature is available which gives detailed technical
information on each system and its components.
Example 1: Example 2:
On /off level control with Modulating level control with
simple low and high level alarms high integrity self-monitoring alarms
This system is suitable for a smaller boiler, or one Typically used for unmanned boilers where the steam
where there is not a great variation in steam load, load varies significantly. Extended alarm testing
and is a common arrangement for supervised boiler intervals are permitted in many cases.
houses where daily testing is carried out. The probes LP20 / PA20
may be mounted in side chambers, as shown, or in
the boiler shell. The probe tips are cut to length on LP30 LP30
installation to give the required switching levels.
Fig. 1 LP10 - 4 LP10 - 4 Fig. 2

Protection Boiler
tubes
High
alarm
Valve
High closed
alarm Valve
Pump off
Pump on open
1st low 2nd low
alarm alarm
1st Low
2nd Low

Two LP10-4 probes used for level control and alarms in a boiler. Boiler shell mounted LP20 / PA20 used for modulating level
Probes can also be mounted directly in the boiler shell in control and high alarm. Two LP30 probes are used for first
protection tubes. (Unused probe tips not shown). and second low alarms.

On/off level control with high integrity self-monitoring low level alarms (limiters)
In many countries, high integrity self-monitoring low level alarms mounted in the boiler shell allow testing
intervals to be extended. The boiler may then be operated without constant professional supervision.
Modulating level control with simple alarms
A capacitance probe is used for modulating level control and first low alarm, with second low and high alarms
provided by a conductivity probe. Modulating control is able to follow variations in steam load more closely
than on/off, minimising cycling of the steam output. This is a common arrangement for supervised boiler
houses where daily testing is carried out.
Two element control
The signal from a steam meter is used to adjust the signal from a level controller and move the set point. This
enables the system to cope with the large sudden variations in steam load typically found in laundries or breweries.
Three element control
Useful for heavily loaded multiple boiler systems and large water tube boilers on a feedwater ring main.
Similar to two element control, but also uses the input from a water flowmeter in the feedwater line.

Some of the products may not be available in certain markets.

Spirax-Sarco Limited, Charlton House,
Cheltenham, Gloucestershire, GL53 8ER UK.
Tel: +44 (0)1242 521361 Fax: +44 (0)1242 573342
E-mail: Enquiries@SpiraxSarco.com
Internet: www.SpiraxSarco.com
© Copyright 2004 Spirax Sarco is a registered trademark of Spirax-Sarco Limited

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SB-P402-101 AB Issue 4