Specification sheet

BP2468
May 09 Steam

Hydrastep & Hydratect

water/steam monitoring systems
Hydrastep electronic gauging system
Failure to detect low water levels in steam-raising
plant can have costly and potentially disastrous
consequences. Reliable water level detection is
vital to prevent damage to plant and personnel.
The Hydrastep electronic gauging system is the
ideal ‘fit and forget’ solution to overcome the
problems associated with unreliable, maintenance
intensive gauge glasses. Designed for totally
reliable operation. Hydrastep is both fail-safe and
fault tolerant.

Modern boilers are designed to provide clean dry

steam. Detection of incorrect water level in the
drum is essential: too high a level can give wet
steam, leading to turbine blade erosion and if the
level is too low, the boiler tubes can over heat, with
the danger of explosion. All national legislatures
Flexible require indication of water level in steam
• Modular system to match requirements generating plant, and drum level indication in the
• Choice of 8 to 32 electrode resolution control room is absolutely necessary. Conversely,
• Multiple remote displays however, false alarms leading to plant shutdown
• Up to 16 trips/alarms operable at selected and loss of revenue are also highly undesirable.
water levels Hydrastep offers exceptional levels of security. All
Exceptionally reliable measurements are interpreted as water, steam
• Electrodes continuously monitored for open or or contamination. Both short and open circuit
short circuit condition conditions are detected and indicated as faults. An
• Fault indication on all displays independent report by Factory Mutual Research
• Multi-segment LEDS provides built-in concluded that the probability of Hydrastep missing
redundancy a trip condition is less than 1 in 300 million and that
• All signal path wiring continuously monitored nuisance trips will be less than 1 in 10 million.
• Dual independent power supplies provide fail Hydrastep combines optimum safety indication
operational condition with virtually no risk of false alarms.
• No junction boxes required - fully tested
spliced cable as standard
Cost effective
• Zero maintenance – fit and forget
• No nuisance trips, no lost revenue
• No missed incidents
• Approved by insurance companies
Hydrastep 2468 electronic gauging system

The two interleaved vertical rows of electrodes are Operation

installed in a water column attached to the boiler Two wires are connected to each electrode, one
and usually aligned so that half the electrodes are for the signal drive and one for the signal return.
above the normal water level. The water column A low frequency square wave is used to drive the
is attached to the boiler via steam and water electrodes through drive resistors. Additional wires
connection, and should be isolated from the boiler are used for the ground connection.
by isolation valves.
Electrodes from each side of the column are
connected to the electronics unit by separate
cables. Two separate input boards, each powered
by its own power supply, measure the signal from
each electrode and feed alternate segments of the
display. This arrangement provides redundancy
against failure in any part of the system. Up to 16 When the electrode is in steam a high resistance
alarm relay outputs (dependant on the number of to ground (column wall) is presented, and therefore
relay boards installed) can be utilized to operate a large signal is returned. When the electrode is in
trips or control audible, visual or other alarm water a low resistance to ground is presented and
indication. Each relay can be set to operate at therefore a small signal is returned. If no signal or
any water level. For example, alarms could be set only a very small amplitude is returned then either
to give outputs on high-high, high , low and low- a short circuit to ground is present or a wire has
low levels, with trips on the high-high and low-low been broken or disconnected.
levels.

The electronics unit performs a resistance

measurement between the insulated tip of each
electrode and the wall of the water column. The
resistance measured in water is substantially less
than that measured in steam. The presence or
absence of water is sensed at each point and the
level of water is indicated. Fault conditions are
also shown on the display.

Remote display units are available for control room

indication or at other points in the plant.
All functions of the main display unit are repeated
on the remote displays, including fault indication.
Up to 6 remote displays can be used.

Hydrastep installation

Water column
& electrodes The Hydrastep system consists of a water column
Hydrastep electronics fitted with up to 32 electrodes, an electronic
mounted at drum level
measuring unit, local and remote displays and
connecting cables.

Each of these components is available with a

Control specification to provide reliable, cost effective
room display
protection in any application.

Alarm & trip

signals
4-20mA signal
Density Error Typical installation
All side arm level measuring systems experience For optimum performance and to minimize density
an effect called density error. Errors can be as error, Hydrastep water columns should be installed
much as 150mm (6in). Correct installation of the as shown here.
Hydrastep system reduces this error to less than For columns longer than 1m (3’3”), it may be
20mm (0.8in) – well below that obtainable with necessary to insulate the column itself.
most other side arm systems.
Density error occurs because temperature loss
causes water in the measurement system to be
cooler that the water in the drum or vessel. Since
cooler water has greater density a depression of
the water in the side arm occurs.
Density error is dependent on both water level
and operating conditions, so that simply offsetting
the water column cannot compensate for density
error. Correct installation of the Hydrastep system
(see diagram) reduces the density error to the
smallest possible by minimising the difference
in temperature between the water column and
the drum. Partially insulating the steam leg
encourages condensation which transfers latent
heat from the steam to the water in the water
column. Loss of heat from the water leg is
prevented by correct insulation. Such a scheme General
is not practical with other side arm systems ASME B31.1 design code
where condensate flow would create flooding or Custom manufacture
saturation and therefore incorrect level indication. Stainless steel covers
Hydrastep water level columns
Low pressure water level columns
The Hydrastep water level columns are designed Design pressure: 120 bar (1740 psi)
and manufactured to match the reliability of Design temperature: 343°C (650°F)
the rest of the Hydrastep system. They offer Threaded electrode fixing
plant operators the ideal answer for water level Helicoil protected threads
measurement on both HRSG drums and feedwater Metaflex gasket seal
heaters. 25mm (1") Sch.80 SA106 connections
All design calculations, manufacturing and test are
carried out to ASME ‘Boiler and Pressure Vessel High pressure water level columns
Code’ and B31.1 Power Piping Code. In addition, Design pressure: 210 bar (3045 psi)
columns can optionally be provided with full Design temperature: 370°C (698°F)
certification to customers requirements. Union-style electrode fixing
Metal to metal pressure seal
High pressure 25mm (1") Sch 160 SA106 connections
water Level
Columns
Supercritical pressure columns
Mobrey water columns and electrodes can
be specified for supercritical pressures and
temperatures. This means that level indication is
provided during subcritical operation and the need
for valving off when the boiler goes supercritical is
eliminated.
Design pressure: 300 bar (4350 psi)
Design temperature: 560°C (1040°F)
Union-style electrode fixing
Low pressure water Metal to metal pressure seal
level columns
25mm (1") XXS SA312-TP316 connections
Hydratect 2462 Steam / water detection system
The Hydratect 2462 system consists of electrodes,
an electronic unit and a manifold or water column.
Alternatively, inserts can be provided so that
the electrodes can be fitted directly into existing
pipework. Hydratect is a fault detection system
designed for maximum reliability. At installation,
each electrode is specified as being either normally
in steam or normally in water. Under normal
operating conditions. Hydratect’s alarm/trip relays
remain energized and no alarm is triggered. An
alarm/trip output is given if:
• The electrode detects a ‘not normal’ condition
• A fault occurs within the Hydratect system or
The Hydratect electronic water detection system associated wiring
is designed as an electronic alternative to • Power to the Hydratect system fails
conventional water level switches on steam raising ‘Water normal’ is used for low water level detection
plant. It can be used in a wide variety of situations ‘Steam normal’ is used for high water level
wherever the detection of water or steam is vital detection in steam drums, feedheaters and
for safe and efficient operation. Designed to use in turbine water induction prevention systems
the same water or steam detection system as (TWIPS) on steam lines.
Hydrastep, Hydratect provides much higher levels
of reliability than conventional devices, and can be
used in conjunction with Hydrastep level detection Hydratect and Hydrastep
for ultimate protection. Hydratect provides local For ultimate protection. Hydratect and Hydrastep
indication and configurable alarm / trip outputs. can be combined in a single column

Typical applications
• Steam normal
• Turbine water induction prevention
• Steam line drain control
• Boiler water high level protection
• Stator winding cooling circuits
• Water Normal
• Feedwater heater low level protection
• De-aerator level protection

Turbine Water Induction Protection

A Hydratect Level Switch installed on the drain
pot in the super-heated steam line will detect
Hydratect installation the level of condensed water in the pot. A single
electrode can be used, but for better protection a
The 2462 Hydratect is designed for: two electrode, dual power supply system ensures
• Fault tolerance trouble free, fault tolerant water detection. This can
• Fail-safe operation also be utilised for automatic operation of the drain
• Fully validated trips valve.
• Detection of electrode contamination
• Detection of open circuit electrode connections For site fabrication pre-threaded inserts are
• Detection of fault ground connections available for welding into standard pipework. The
insert is designed to maintain the integrity of the
The 2462: basic pipe.
• Makes routine testing unncessary Custom manifolds can be supplied for up to 4
• Conforms to all existing standards and legislation electrodes.
• Continuously verifies measurement integrity
• Is the most economical solution for all
installations
Specification

Hydrastep electronic gauging system 2468

Electrode channels: 8 to 32, in pairs

Water/steam threshold: 0.6µS/cm (normal) or 1.6µS/cm (alternate) depending on water purity.
Electrode cable length: 3m (10ft), 10m (33ft), 18m (60ft), 30m (98ft)
Fault detection: Electrode connection Open circuit
Short circuit to ground
Channel fault indication: Flashing display segment
General fault indication: Amber LED
Local display: Red/green bar graph, 32 LED segments
Display blanking from the bottom with less than 32 electrodes in use

Outputs:
Drive to remote displays, maximum 6 units
Opto-isolated fault output
Analogue output (proportional to water level):
Range: 0-20mA or 4-20mA, forward or reverse
Accuracy: ± 0.2mA
Drive capability 600Ω at nominal supply voltage
500Ω at minimum supply voltage

Optional output boards (for alarm indication)

No. of output boards: Up to 4 Delayed relay board 24680509B
Relay board 24680504C Specification as 24680504C
Relays: 4 Independent change-over Delay range 0 to 25s ±1s
Relays contact rating: ac dc Opto-coupled board 24680505A
Maximum voltage: 250V 125V Solid state relays: Four independent outputs
Maximum current: 8A 8A Rating: 30V dc 1A
Max. switching power: 1500VA type N safety Max. voltage drop: 1.1V @ 1A
240W <30V 5A at 12Vdc Max. leakage current: 1mA @ 30Vdc
65W <60V 100mA at 30Vdc
25W <125V 20mA at 125Vdc
General

Power supplies Operating temp: -20°C to +70°C

Power supply (ac) 94V to 130V or 187V to 256V (-4°F to 158°F)
48Hz to 65 Hz Relative humidity: up to 100%
60 VA maximum Enclosure: Stainless steel
Power supply (dc) 20V to 40V negative Wall mounting (four point)
ground or isolated IP65 / NEMA4X
425mm high x 325mm wide
x 185mm deep
(16.73" x 12.8" x 7.28")
Weight 12 kg (26.4Ib)

Approvals

LVD: EN 61010-1
ATEX: II3 G EEx nA IIC T4 (-20°C < ta < +70°C)
CSA: (Canada) Ex nA [nL] nL IIC T4
(USA) CI. 1 Zn. 2 AEx nA IIC with relay output connected only to energy limited circuits
EMC: EN 61326
PED: Safety accessory
Specification

Remote displays
Indication: Red/Green bar graph, 32 LED segments
Power supply: From 2468 unit (1 display only)
Local power
for additional displays: 20V to 54V dc, 240mA

2468 3B
Case style: Panel mounted
Dimensions: 144mm x 72 mm x 200mm deep (5.67" x 2.38" x 7.87")
Panel cutout: 137.5mm x 66mm (5.41" x 2.60")

2468 3C
Case style: Panel mounted
Dimensions: 192mm x 96mm x 209mm deep (7.56" x 3.78" x 8.23")
Panel cutout: 186mm x 92mm (7.32" x 3.62")

2468 3D
Case style: Rugged enclosure, IP65/NEMA 4X
Dimensions: 302mm x 186mm x 175mm deep (11.89" x 7.32" x 6.89")

Water columns
Parameter LP Rectangular HP Series 3 HP Super 3
section
Design pressure
120 bar: 1740 psi 210 bar: 3045 psi 300 bar: 4350 psi
Test pressure
180 bar: 2610 psi 315 bar: 4567 psi 450 bar: 6525 psi
Design temperature
343°C: 650°F 370°C: 698°F 560°C: 1040°F
Design code
ASME B31.1 ASME B31.1 ASME B31.1
Protective covers
18 SWG St. St. 18 SWG St. St 18 SWG St. St

(17 AWG St. St) (17 AWG St. St) (17 AWG St. St)
Gross weight* 12kg (26.5Ib) 17kg (37.5Ib) 17kg (37.5Ib)
Electrode types 459600602 or 2467 81Z or 2467 85A
459600802 2467 82A or
2467 84A

* Typical (610mm (24”) steam/water range, 12 port, with electrodes & covers.

High pressure water Level Columns Low pressure water level columns
Specification

2462 Hydratect steam / water detection system

Electrode channels Two

Water/steam threshold 0.6µS/cm (normal) or 1.6µS/cm (alternate) depending on water purity
Electrode cable length 3m (10ft), 10m (33ft), 18m (60ft), 30m (98ft)
Fault indication Electrode connection open circuit
Short circuit to ground
Indicators One Red LED for indication of steam
One Green LED for indication of water
One Amber LED for indication of fault
Status relay output
(one per channel)
Modes: Water normal: Energized in water
Steam normal: Energized in steam
Contacts Separate normally open and normally closed
Changeover relays are also available (2462E)
Relay contact rating ac dc Changeover: ac dc
Maximum voltage 250V 125V 250V 225V
Maximum current 8A 8A 8A 0.25A
Max. switching power 1500VA 240W(<30V)
(resistive load) 65W (<60V)
25W (<125V)
Opto-coupled:
Output rating “off” 30V dc max, leakage <1mA
Output rating “on” 1A dc, voltage <1.1V @ 1A
Fault relay output
(one per channel): Energized during normal operation (fail-safe)
Specification as status relay above
Power supply (ac) 94V to 130V or 187V to 256V
48Hz to 65Hz
2 x 10VA maximum
Power supply (dc) 20V to 60V
Operating temperature -20°C to +70°C (-4°F to 158°F)
Relative humidity: up to 100%
Enclosure: 190mm x 190mm x 90mm deep
(7.48" x 7.48" x 3.54")
Stainless steel grade 304
Wall mounting (two point)
Finish - natural
IP65 / NEMA4X

Manifolds
Available with 1 to 4 electrode ports.
Various materials depending on required pressure and temperature rating
Design sheets available on request
 Specification sheet
BP2468
Steam May 2009

Electrodes for Hydrastep and Hydratect Electrode Cables

At drum level, steam generating plant has ambient
A selection of electrode types are available for conditions which are hot and humid and in coal
pressures up to 300 bar (4350 psi) at 560°C and oil fired plants there are often sulphurous
(1040°F). Electrodes are available in two basic fumes present. This environment adversely affects
body styles. The low pressure type (up 120 bar) crimped copper cables, with the formation of
has a threaded style fitting: The high pressure type copper sulphate. In addition, the temperature at
(up to 300 bar) uses a union fitting. the screw connection to the electrode can exceed
the maximum operating temperature of PVC
Low pressure (up to 120 bar) insulation used on copper cables.
Choice of PTFE or ceramic insulator To overcome these problems, pure nickel
Threaded style fitting conductors with PTFE insulation can be used.
Metaflex gasket seal However, PTFE insulated cable is expensive and is
only required in the immediate vicinity of the drum.
The cables supplied with the Hydrastep system
have a 2m (6.6") tail of PTFE covered nickel cable
joined to the required length of PVC covered
copper. The junction between the two cables
High pressure (up to 300 bar) is by ‘High Performance Environment Resistant
Choice of insulators Sealed Crimp Splice’, to meet the requirements
Union style fitting of MIL-S-81824, providing a join of the highest
Metal to metal to seal possible integrity. (More information, with detailed
specification, is available on request).
In applications where a junction box is preferred,
this can be supplied with the appropriate cables.

Specification
Part No. Style Material Max pressure Max temp. ph range
Bar (psi) °C(°F)
459600802 Threaded L.P col PTFE 50 (725) 260 (500) 7 to 13.5
459600602 Threaded L.P col Zirconia 120 (1740) 370 (698) 7 to 11
2476 82A Union H.P col PTFE 50 (725) 260 (500) 7 to 13.5
2467 84A Union H.P col Ceramic PTFE coated 300 (4350) 260 (500) 7 to 13.5
2467 81Z Union H.P col Zirconia 210 (3045) 370 (698) 7 to 11
2467 85A Union Hydratect insert ZTA 300 (4350) 560 (1040) 7 to 11
2467 85Z Union Hydratect insert Zirconia 300 (4350) 370 (698) 7 to 11
2467 85P Union Hydratect insert PTFE 50 (725) 260 (500) 7 to 13.5

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Mobrey Measurement Rosemount Inc.
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