iaWilii

AALBORG DP VJA TER L EVEL T RANSMITTER U N IT O fv1821 ()# 16 1

INDUSTRIES

dp water level transmitter unit

1 General

The dp water leve l transmitter unit controls and supervises the water level in the
boiler. The complete unit is installed in a vertica l position and connected to the
boiler sockets, provided for this purpose, by means of shut-off va lves (see Figure I) .
The dp water level transmitter unit includes reference leg, variable leg, transmitter
connection valves mounted on a manifold, and a differential pressure transmitter.
The differential pressure transmitter converts the detected water leve l into an
analogue signal (4-20 rnA) which is transmitted to the control system . The signal
can also be used for remote level indication in the engine control room .

Illustration of the dp water level transmitter unit

Filing plug

'I

IXalnvalve

Boiler
Fling plug
-,..

Figure 1 dpunit.cdr

The differential pressure transmitter is installed with the process connections upward
to prevent trapping of air. The pipes are mounted with continuous fall (at least 5°)
from the boiler connections to the transmitter also to prevent trapping of air.
The reference impulse leg (upper connection point) is connected to the high pressure
connection (+), and the variable impulse leg (lower connection point) to the low
pressure connection (-) .

Note: The dp water level transmitter unit or any part of it must not be
insulated to ensure the correct function.

Language UK Page 1110

 ilUUlii
AALBORG DP WATER LEVEL TRANSMITTER UNIT OM 8210# 161
INDUSTRIES

2 Commissioning

2.1 Initial commissioning

Before the boiler is pressuri sed and started for the first time some init ial
comm iss ioning procedures can be performed with regard to the valves of the dp
water leve l transmitter unit. The shut-off va lves, transmitter con nection va lves, and
eq ualising valve should be o perated in the fo llowing sequence durin g the initial
commissioning:
Step A: Initial setting; a ll valves of the dp water leve l transmitter unit closed (see
Figure I).

Step B: Open the equalis in g va lve located on the va lve manifold .

Step C: Unscrew the fillin g plugs for the reference leg and variable leg. Fill th e legs
with feed water.

Step D: Open the transmitter connection valve and venting facilit y on the reference
leg s ide of the transmitter.

Step E: C lose the venting faci lity on the reference leg s id e of th e transmitter when
no more ai r escape s.

Step F: Open the venting facility on the variable leg side of the tra nsmitter.

Step G: C lose the transm itter connection valve on the reference leg side of the
transmitter when no more air escapes.

Step H : Open the transmitter connection valve on the variab le leg side of the
transmitter.

Step I: C lose the venting facility on the variable leg side of the transmitter when no
more air escapes.

Step J : Close the transmitter connection va lve on the variab le leg side of the
transmitter.

Step K : Close the equalising va lve.

Step L: Refill the legs w ith feed water and screw on the fi lling plugs for the
reference leg and variable leg.

Step M: Open both transmitter connection valves fully.

2.2 Commissioning of the differential pressure transmitter

The differential pressure transmitter can be commissioned either through "blind

calibration" or "live cal ibration". In the followin g sections both methods are
described.

/'
Language UK Page2ltO
 ;,lim,;
AALBORG DP WATE R LE VEL TRANSM ITTER UNIT OM82 10# 161
INDUSTRIES

2.2. 1 Blind calibration

Blind calibration of the differentia l pressure transmitter can be performed if no
pressure source is available. This means when the boi ler can not be operated at
normal working pressure and the water level cannot be increased/decreased . The
"start of scale" and "fu ll scale" differential pressures are calibrated on the basis of
calculated values. The start of sca le value should be ca librated to obtain a 4 mA
output signal from the transmitter when the water leve l is at the lower connection
poi nt and the full scale value to obtain a 20 mA output signal when the water level is
at the upper connect ion point. To ensure an accurate ca librat ion it is necessary to
take the den sity difference between the water in the reference leg and in the bo iler
into consideration when calculating the differentia l pressure values.
4 mA outll ut signal from the differential press ure trans mitter:
When the water level in the boiler is at the lower connection point the pressure
difference over the transmitter is equal to the height between the connection
points (column of water) corrected with the density of the water in the reference
leg. The value must be specified and entered in engineering unit, e.g. in mm
H20.
20 rnA output signal from the differ ential pressure trans mitter:
When the water leve l in the boiler is at the upper connection point the pressure
difference over the transmitter is equal to the height between the connection
points corrected with the density difference between the water in the reference
leg and in the boi ler. The value must be specified and entered in eng ineering
unit, e.g. in mOl H2 0 .
Figure 2 indicates the calculation procedures of the differential pressures. As
standard it is assumed that the temperature in the reference leg (condensate receiver)
is 40°C. Table I shows the ca lcu lated values for some standard heights between the
connection points. If the actual boiler plant does not fit any o f the standard
calculations the specified calculated values can be entered in the table for calibration
record purpose.
If the boiler plant is intended to operate at different set points (high/low pressure
mode) the differential pressure transmitter must be calibrated so that the minimum
indicated "Too low water level" on the control system not is lower than the actual
"Too low water level " mark . Because of the density difference in the boiler water at
different working pressures/temperatures the indicated water levels wil l not be
identical. This means that the differential pressures for start of scale and full scale
should be calculated using the parameters from operation in high pressure mode.
When the differential pressures corresponding to the "start of sca le" and "full scale"
have been calculated carry out the following work steps (please also see the specific
instruction for the differential pressure transmitter) :
Step A: Unscrew the screws that hold the protective cover of the differential
pressure transm itter for access to the push buttons.

Step B: Use the "M" key to select modes on the differential pressure transm itter.
When a mode is selected. the keys t and J, are used to change the mode
value.

Language UK Page 311 0

 illiii"i
AALBORG OP \. iMTER LEVEL TRA NSr.lITTER UNIT U rv18210 # 1(,1
INDUSTRIIES

Step C: Set the values in mode 4 (electrical damping), 9 (output in error situation),
10 (push buttons function s), II (characteristic), 13 (value displayed), and 14
(engineering units). In mode 14 select e.g. "mm H20" as engineering units.

Step D: Select mode 5 using the "M" key.

Step E: Use the t or.j. key to set the start of scale in the se lected eng ineering unit. If
mm H20 is selected as engineering units, then set the start of scale to the
calculated value in mm H 20 (differential pressure at 4 rn A).

Step F: Press both the t and .j. keys simultaneously fo r about 2 seconds, and the
start of sca le is set to zero (in the selected engineering unit).

Step G: Se lect mode 6 using the "M" key.

Step H: Use the t or .j. key to set the full scale in the selected engineering unit. If
mm H20 is selected as engineering units, then set the full scale to the
calculated value in mm H20 (differential pressure at 20 rnA) .

Step I: Press both the t and .j. keys simultaneously for about 2 seconds, and the full
scale is set to the upper limit (in the selected engineering unit).

Step J: Mount the protective cover of the differential press ure transmitter aga in.

Calibration of differential pressure transmitter

Height between Working pressure T ransmitter outpu t, Differenti al press ure
Co nnection point
co nnection ImmJ Iba rR - kg/em' l Im A] ca libration fmm H OJ
Calculations for standard heighls, working pressures, and ambienl temperature (40 'C')
Lower connection 4 521
7.0
Upper connection 20 50
525
Lower connection 4 521
16.0
Upper connection 20 70
Lower connection 4 695
7.0
Upper connection 20 67
700
Lower connection 4 695
16.0
Upper connection 20 93
Lower connection 4 794
7.0
Upper connecti on 20 76
800
Lower connection 4 794
16.0
Upper connection 20 106
Calculalion records or other heiJ!hls. workinR pressures, and/or ambitnllemf)j ratures
Lower connection 4
Upper connection 20
Lower connection 4
Upper connection 20
Lower connection 4
Upper connection 20
Lower connection 4
Upper connection 20
Lower connection 4
Upper connection 20
Lower connection 4
Upper connection 20

Table t

Language UK Page 4110

 i'liUlii
AALBORG DP \'JATER LEVEL TRANSr\lITTER UNIT 0rv182 I O# 1b 1
INDUSTRIES

Calculation of the differential pressures

1, =~texisting

,
Differential pressure
between connections: Height between
525 x 0.9922 =
connections. e .g.:
S25mm
521 mm H,O (It 4 mAl

V\8ter level

t, =170·C at 7 barg,
204· C at 16 barg

t, = 40"C . density : 992.2 kglm' I, = not existing

Differential pressure _+c-_---t7l~rI::=-=,:_V\8==I.=r.:::le=vel

between connections
(817 borg) :
525 )( (0.9922 ·0.8970) =
Height between
50.0 mm HJO (at 20 mAl connections. e.g.:
525 mm
Differential pressure
between connections
(at 16 barg):
525 x (0.9922 . 0.8596) '"
69 .6 mm HID (at 20 mAl
~ =",rc at 7 borg .
density 897 0 k\pm'

204"C at 16 berg.
J
density 859.6 kglm

Figure 2 dpunit_cali1.cdr

2.2.2 Live calibration

Live calibration of the differential pressure transmitter can be performed when a
pressure source is available. This means when the boiler can be operated at normal
work ing pressure and the water level can be increased/decreased. The "start of scale"
and "full scale" output signals of the differential pressure transmitter are set during
actual operating conditions. It is therefore not necessary to take the density
difference between the water in the reference leg and in the boiler into consideration.
However, if the boi ler plant is intended to operate at different set points (highflow
pressure mode) the differential pressure transmitter must be calibrated so that the

Language UK Page 5110

 i,UUi'i
AALBORG DP IIJATER LEVEL TRANSMITTER UNIT OM8210#IG 1
IND U STRIES

minimum indicated "Too low wa ter level" o n the control system no t is lower than
the actual "Too low water leve l" mark. Because o f the dens ity di fference in the
bo iler water at different working pressures/temperatures the indicated water leve ls
will not be identical. This means that the di fferential pressure transmitter should be
ca librated when the boiler plant operates in high pressure mode .
When the boiler operates at nonna l working pressure carry out the following work
steps (please also see the specific instruct ion for the differential pressure
transmitter):
St ep A : Unscrew the screws that ho ld the protective cover of the d iffere ntial
pressure transm itter fo r access to the push buttons.

Step B: Use the "M " key to se lect modes on the differe ntial pressure tra nsmitter.
When a mode is se lected, the keys t and J. are used to change the mode
value.

Step C: Set the values in mode 4 (e lectrical damping), 9 (output in error situation),
10 (pushbuttons functions), I I (characteristic), 13 (value displayed), and 14
(eng ineering units) . In mode 14 select "rnA" as e ng ineeri ng units.

Ste p D: Ensure that the boiler cannot be filled with feed water by closing the feed
water valves or stopping the feed water pumps.

Ste p E : Slow ly decrease the water level in the boi ler until the lower connection
point is reac hed (socket centre line of the variab le leg) . The water level can
be decreased by means of the blow down va lves.

Step F : The upper and lower connection points will nonnally be beyond the v isual
indication area of the water level gauges. It is therefore impossible to see
when the water leve l is at these points. However, the rising/falling rate of
the water level can be controlled, by throttling the feed water valves/blow
down valves. By c locking the rate it can be ca lculated when the water leve l
has reached the connection po ints.

Step G: Select mode 2 using the "M " key.

Step H: Set the output c urrent corresponding to the start of scale using the t and J.
keys. Or set the output current to 4 rnA by press ing the t and J. keys
simu ltaneously for about 2 seconds.

Step I: Slowly increase the water level in the boiler until the upper connection po int
is reached (socket centre line of the reference leg). The water level can be
increased by means of the feed water pumps.

Step J : When the water leve l is increased operate the burner so that the boiler
pressure is kept at nonnal working pressure.

Step K : Select mode 3 using the "M " key .

Step L: Set the output current corresponding to the full scale using the t and J.
keys . Or set the o utput current to 20 rnA by pressing the t and J. keys
s imultaneously for about 2 seconds.

Language UK Page 6/ 10
 iilitilii
AALBORG OP '."lA TER L EVE L TRA N SMITT ER UN IT Cl M8210# 16 1
INOUSTRIES

Step M: Mount the protective cover of the differential pressure transmitter again .

2.3 Final commissioning

During final commissioning a function test of the dp water leve l transmitter unit
must be performed before the boi ler plant is put into normal operation . The purpose
of the function test is to check that the output signals from the differential pressure
transmitter are correct. Furthermore, it should be checked that the connected
alarms/shut downs and control functions are operational. The boiler should be
operated at normal work ing pressure during the test to provide for correct
indications. When the boiler is at normal water level and the burner is in operation,
carry out the following work steps:
Step A: Slowly increase the water level in the boiler by forcing operation of the feed
water pump until the water level has risen to the "High water level" level.
The control system shou ld indicate an alarm , (if provided).

Note: Note that shut downs, alarms, and cut out functions can be delayed via
timers in the control system.

Step B: Increase the water leve l somewhat until the "Too high water level" mark is
reached. The burner should stop, and a shut down shou ld be ind icated on
the control system, (if provided).

Step C: Increase the water level somewhat until the upper connection point is
reached (socket centre line of the reference leg). Check that the output
signal from the differential pressure transmitter is at 20 rnA or the ful l scale
value in the selected engineering units .

Step D: The upper and lower connection points will normally be beyond the visual
indication area of the water level gauges. It is therefore impossible to see
when the water level is at these points . However, the rising/falling rate of
the water level can be controlled, by throttling the feed water valves/blow
down valves. By clocking the rate it can be calculated when the water level
has reached the connection points.

Step E: Ensure that the boiler cannot be filled with feed water by closing the feed
water valves or stopping the feed water pumps.

Step F: Decrease the water level in the boiler by means of the blow down valves
until the water level has fallen to the " Low water level " level. The control
system should indicate an alarm.

Step G: Decrease the water level somewhat until the "Too low water leve l" mark is
reached . The burner should stop, and a shut down should be indicated on
the control system .

Step H : Decrease the water level somewhat until the lower connection point is
reached (socket centre line of the variable leg). Check that the output signal

Language UK Page 7110

 illiWai
AALBORG DP WATER LEVEL TRANS [c1ITTER UNI T 0 [1/18210#161
INDUSTRIES

from the differential pressure transmitter is at 4 rnA or the start of sca le

value in the selected engineering units.

Step I: After completion of the function test open the feed water valves or start the
feed water pumps.

3 Operation and maintenance

Attention: Both shut-off valves between the boiler and impulse legs must
always be fully open and the reference leg must be totally filled with
water during normal operation of the boiler.

To ensure a safe and reliable operation of the boiler plant check the dp water level
transmitter unit whenever an opportunity occurs by comparing the water leve l
indicated by the control system with the leve l indicated in the water level gauges.
A great difference in the water leve ls may indicate blocked connections to the
differential pressure transmitter. Therefore it is recomm ended to blow-through the
im pulse legs and connection pipes frequently. The blow-through procedures can be
performed, e.g. in connection with stopping the boi ler plant, in order to get rid of
dissolved particles that cou ld settle during the stop periods. In case of prolonged
standstill the dp water level transmitter unit should be checked for the correct
fu nction before the boiler plant is restarted.

3.1.1 Blow-through procedure of the impulse legs

The blow-through procedure should be performed as describe below when the boiler
plant is in operation and in steady load condition. The procedure should be carried
out at least once each month. When the blow-through procedure is carried out, it is
very important that the water level in the boiler is carefully and continuously
supervised by the ship engineering personnel. The feed water control valve must be
operated manually, if necessary .
Step A: Isolate the differential pressure transmitter by closing the two transmitter
connection valves in the manifold . The equalising valve must remain closed
during the blow-through procedure and normal operation.

Step B: Slowly open the drain valves of the impulse legs, and allow the legs to
blow-through for a few seconds.

Step C: Close the shut-off valve for the reference leg.

Step D: Close the drain valves again when the reference leg is completely
depressurised.

Step E: Unscrew the filling plug of the reference leg and fill the leg with feed water.

Step F: Screw on the filling plug and slowly open the shut-off valve for the
reference leg.

Step G: Open the two transmitter connection valves in the manifold.

Language UK Page 8/ 10
 i~iiilii
AALBORG DP \,!A I lCR LEVEL 1 RAN::>I,lITTER UNIT 0 1'118210# III 1
IN D USTRIES

Step H: After perfonning the blow-through check that the dp water level transmitter
unit and feed water control valve are fully operational.
In case of contaminated boiler water, e.g. sludge, mud, etc. , the blow-through
procedure of the impulse legs must be done more often.

3.1.2 Blow-through procedure of the connection pipes

The blow-through procedure shou ld be performed as describe below when the boiler
plant is stopped, but still pressurised. The procedure should be carried out at least
once each year.
Step A: Open the venting facilities located on the valve manifold for the impulse
legs. The transm itter connection valves must remain open and the
equalising valve closed during the blow-through procedure.

Step B: Close the venting facilities on the valve manifold when only clean water
escapes.

Step C: Close the shut-off valve for the reference leg.

Step D: Slowly open the drain va lve of the reference leg.

Step E: Close the drain valve again when the reference leg is completely
depressurised .

Step F: Unscrew the filling plug of the reference leg and fill the leg with feed water.

Step G: Screw on the filling plug and slowly open the shut-off valve for the
reference leg.
In case of contaminated boiler water, e.g. sludge, mud, etc. , the blow-through
procedure of the connection pipes must be done more often .

3.1.3 Function test of the dp water level transmitter unit

During nonnal operation of the boiler plant a function test of dp water level
transmitter unit should be carried out at least once each month . The purpose of the
function test is to check that the connected alarms/shut downs and control functions
are operational. The boiler should be operated at normal working pressure during the
test to provide for correct indications. When the boiler is at normal water level and
the burner is in operation, carry out the following work steps:
Step A: Slowly increase the water leve l in the boiler by forcing operation of the feed
water pump until the water level has risen to the "High water level" leve l.
The control system should indicate an alarm, (if provided).

Note: Note tbat shut downs, alarms, and cut out functions can be delayed via
timen in the control system.

Step B: Increase the water level somewhat until the "Too high water level" mark is
reached. The burner should stop, and a shut down should be indicated on
the control system , (if provided) .

Language UK Page 9110

 illUilii
AALBORG DP WA TER LEVEL TRANSM ITT ER UNIT OM8210#161
IN DU ST R IES

Step C : Ensure that the boi ler cannot be fi lled with feed water by clos ing the feed
water valves or stopping the feed water pumps.

Step D: Decrease the water level in the boi ler by means of the blow down valves
until the water level has fa llen to the "Low water level" level. The control
system should indicate an alarm.

Step E: Decrease the water level somewhat until the "Too low water level" mark is
reached. The burner should stop, and a shut down should be indicated on
the control system.

Step F: After completion of the function test open the feed water valves or start the
feed water pumps.

Language UK Page 10/ 10