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Plant area: BOILER

PROCEDURE FOR COMMISSIONING OF DRUM WATER LEVEL INDICATOR

SL. NO LIST OF CONTENTS

1.0 PLANT DETAILS

2.0 OBJECTIVE

3.0 PROPOSAL

4.0 SERVICES REQUIRED

5.0 SAFETY PERECAUTIONS

6.0 EMERGENCY PROCEDURE

7.0 STATE OF THE PLANT

8.0 METHOD

9.0 COMPLETION CRITERIA

10.0 APPENDICES

A. TECHNICAL SPECIFICATIONS
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PROCEDURE FOR COMMISSIONING OF DRUM WATER LEVEL INDICATOR

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1.0 PLANT DETAILS

1.1 Vision – 20 System consists of a pressure vessel, with electrodes

mounted on it, Ascertor cabinet, local and remote display units.
An array of electrodes mounted on the pressure vessel measures
the resistance of water and steam. The electrode outputs are
processed in a compact electronics cabinet viz., Ascertor.
Water/Steam levels are indicated by a high bright LED based
local display mounted on the Ascertor cabinet. Information is
transmitted to the control room for driving the UCB mounted
remote display unit and optional display unit at fireman’s door.
Hence, the system consists of the following items.

1.2 Necessary mechanical hardware including a pressure vessel of

appropriate size with isolation and drain valves

1.3 Sufficient number of rugged flange type electrodes (typically 12

Nos.)

1.4 Ascertor cabinet mounted at drum floor with integral local display

1.5 PTFE cable between electrodes and the Ascertor cabinet

(Standard) 15 Metre length

1.6 Remote display unit for UCB

1.7 Remote display unit for fireman’s floor (optional)

1.8 Necessary cable from the Ascertor cabinet to remote display unit
at UCB and at fireman’s floor.

1.9 2 Nos. of pressure vessels fitted with electrodes. 2 Nos. of

VISION – 20 Ascertor cabinets and 2 sets of remote level
indicators are supplied, to cover both sides of the drum

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PROCEDURE FOR COMMISSIONING OF DRUM WATER LEVEL INDICATOR

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1.10 Employing the principle of measuring the different conductivities

of water and steam, VISION – 20 offers a degree of accuracy
unmatched by conventional level indicators.

1.11 The Ascertor continuously monitors the system. The electrodes

are exicted by the AC source and the output signals are precision
rectified and compared with necessary threshold values. If the
signal is less than the lower threshold value, the output indicates
the presence of water. On the other hand, if the signal is higher,
than the upper threshold value, the output indicates the presence
of steam

1.12 VISION – 20 incorporates several safety features. Notable among

these are:

1.13 • Separate electrical processing for each electrode to ensure

only single level loss on any component failure

1.14 • Firmware based validation circuitry to confirm the information

conveyed by the Ascertor is always true. Invalid sensing by
any electrodes (i.e. water above steam or steam below water)
is indicated by a fault lamp on the display. Only the valid
signals initiate the trip relays for high or low trip.

1.15 • Dual power supplies (one supplying odd channels and the
other even channels). Even if one power supply fails, the
other power supply automatically feeds the entire system,
thus ensuring availability of power supply all the time.

1.16 4 to 20 mA current output expounds the applicability of VISION –

20 both on indication and data acquisition for trending and
diagnostics.

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PROCEDURE FOR COMMISSIONING OF DRUM WATER LEVEL INDICATOR

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2.0 OBJECTIVE

2.1 The objective of this procedure is to commission the VISION – 20

Drum Level Indicator and make it available for Unit Operation.

PROPOSAL
3.0
It is proposed to commission this Drum Level Indicator and
3.1 compare its performance with respect to i) Direct water level
gauge and ii) Other remote water level Indicator of Drum

SERVICES REQUIRED
4.0
Communication and lighting facility at Drum Level and at Control
4.1 room.

Availability of boiler with drum filled and preferably, boiler in

4.2 steaming condition

Availability of a good working crew to attend to any electrode

4.3 leakages during commissioning

Availability of LT supply (AC & DC) (Refer Technical

4.4 Specification).

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PROCEDURE FOR COMMISSIONING OF DRUM WATER LEVEL INDICATOR

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5.0 SAFETY PRECAUTIONS

5.1 While charging the level indicator, extreme precaution taken to

slowly charge the vessel and gradually warm up.

5.2 Control Panels erected at Drum Level are ensured for safety from
hot water / steam etc.

5.3 Control Cabling done between Pressure Vessel and Control

Panel at drum level are safely routed avoiding hot zones.

5.4 Extreme precaution taken while attending any leaking electrode.

Required isolation are made before attending any leakage.

6.0 EMERGENCY PRECAUTION

6.1 The test team should be aware of the lay-out of the

VISION – 20 Drum Level Indicator, in order to react for any
emergency.

6.2 If there is any sudden electrode failure leading to heavy leakage

of water/steam, then extreme care to be taken to isolate the level
indicator by closing the isolating valves.

6.3 The test team should be aware of steps to be taken to meet any
emergency due to damage to any item / injury to personnel

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PROCEDURE FOR COMMISSIONING OF DRUM WATER LEVEL INDICATOR

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7.00 STATE OF THE PLANT

7.1 Pressure vessel erected as per recommended drawing to the

correct limbs in the drum (Both RHS & LHS)

7.2 Electrode erection completed

7.3 Control Cabinet (Ascertor Unit) and the connected cabling

completed from drum level to control room

7.4 PTFE Cabling from electrodes to Ascertor Panel completed

7.5 Remote indicator in control room erected and ready for

commissioning

7.6 Operating floor indicator erected (This is optional)

7.7 Input power supply is made available

a. 1110 V AC, 220 V AC/DC
b. 24 V DC
(Single or Dual feeder)

7.8 Electrical checks completed and system ready for commissioning

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Sheet 7 of 10

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PROCEDURE FOR COMMISSIONING OF DRUM WATER LEVEL INDICATOR

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8.0 METHOD

8.1 When the unit is under steaming condition, charge the pressure
vessel very slowly by opening the isolating valve in the water limb
first and then steam limb. Warm up the vessel sufficiently.

8.2 Observe for any leakage and attend

8.3 Slowly close the drain valve (kept open for warm up) and
pressurise the vessel to the unit working pressure

8.4 Observe for any leakage and attend

8.5 Charge the electrical system and switch on the circuits for
operation

8.6 Observe the level indicated by the level indicator and compare it
with direct level indicators / other drum level indicator

(Generally, this type of drum level indicators are more accurate

as it performs on conductivity and does not require any density
correction)

8.7 Both VISION – 20 Drum Level Indicators are commissioned as

above and released for operation of the Unit.

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PROCEDURE FOR COMMISSIONING OF DRUM WATER LEVEL INDICATOR

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9.0 COMPLETION CRITERIA

9.1 With completion of activities as proposed in Section 3.0,

Commissioning of Drum Level Indicator is concluded.

10.0 APPENDICES

a. Technical Specification

01) Basic Equipment

Electrodes - Typically 12

PTFE Cables from - 15m standard length

Electrodes to ascertor

Ascertor Unit - IP55 enclosure, wall mountable with rain

canopy.

Remote Indicator - Hi-bright LED type indicator with green

colour for water, red colour for steam
and yellow for fault.

Local Indicator - Same as above, mounted on Ascertor

Unit.

Operator Floor Indicator - Optional.

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PROCEDURE FOR COMMISSIONING OF DRUM WATER LEVEL INDICATOR

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02) Pressure Vessel

Capable of withstanding upto - 207 bar

Steam / Water tapping distance - 635 mm for 12 probes

(other sizes on request)

Probe sight range - 550 mm (for 12 probes)

Steam/ water connections - 25 mm bore butt weld.

Made up of forged carbon steel, thick wall design.

No. of probes variable based on boiler drum size. (Standard is 12

probes)

03) Electrodes

Type of construction - Rugged Flange type with SS body,

fitanium tip and ceramic insulator.

Manufacturer - /EPD, Bangalore.

04) Electrical Specifications

Freely selectable alarm/trip - 25 to 275 mm (in steps of 50 mm

for high and low).

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Sheet 10 of 10

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PROCEDURE FOR COMMISSIONING OF DRUM WATER LEVEL INDICATOR

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Change over - 0.25A @ 220V AC.

Contact rating - 0.5A @ 125V AC.
- 1.00A @ 60V AC
- 2.00A @ 30V DC.
Current output - smooth 4 to 20 mA
Corresponding to water level.

Self checking

Firmware based validation

100% resolution even with one power supply fail condition.

Input power supply - 110V AC, 220V AC/DC 24V DC

(Single or Dual feeder). Any
combination can be ordered.

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PROCEDURE FOR COMMISSIONING OF
DRUM WATER LEVEL INDICATOR