Drum Level Instrumentation

and
The ASME Boiler Code Requirements

2011

Presented by: Jim Kolbus

 Topics

• ASME Code Section 1 Requirements for Drum Level

Instrumentation
• Water Columns and Water Gage Isolation Valves
• Prohibition of Structural Webs in Water Gage Glasses
• End to End Reflex Type Water Gages
• Magnetic Level Gages
• Code Design Requirements for Isolation Valves
• New Level Switch requirements for HRSG applications
• Low Water Cutouts
• Common Code Violations
• Recommendations for Level Instrumentation Piping
 ASME Code General Terms
Direct Reading Gage
Indirect Reading Gage

Glass Gage Remote Level Indicator

 Direct Reading Gages

Bi-Color
Prismatic to 3000 PSI
(Reflex)
Tubular Glass to 350 PSI
Flat Glass
to 250 PSI
(Transparent)
to 2000 PSI
Remote (Indirect) Level Indicators

Conductivity Probe Type

Level Indication System

PLUS OTHER TECHNOLOGIES

- Differential Pressure Transmitters
- Guided Wave Radar
Magnetic Level Gage
(equipped w/ 4-20 transmitter)
 ASME Boiler Code
Water Gage Requirements:
Operating up to 400 PSIG
One Direct Reading Gage Required
(which must be kept continuous service)

Operating over 400 PSIG

Two Direct Reading Gages in service
OR
Two Remote (Indirect) Level Indicators
On Continuous Display for the
Operator and One Direct Reading Gage
(Which may be Isolated but kept in serviceable condition)
Code Requirements for Gage Glass Placement

Level “A” = Lowest Permissible Water Level, at which

there will be no danger of overheating the vessel
 Water Gage Glass Placement Explained

• 1. Lowest Permissible Water Level- At which level there will be no

danger of overheating (Level A).
• 2. Water Connection for Water Column- Must be 1” below low
visibility point of gage glass and at least 1” NPT. The line must be level
or slope downward from column to drum.
• 3. Steam Connection for Water Column-Same as 2 above. Except slope
down ward from drum to column.
• 4. Steam Connection may come out of top of vessel- Centerline of
steam connection would be at point marked “B”.
• 5.The lowest visible part of water gage glass-Must be at least 2” above
the lowest permissible water level (Level A).
• 6. The highest visible part of water gage glass-Must be at least 1”
below center of steam connection.
• 7. Gage cock connections- Must not be less than 1/2” pipe size and
located within gage visibility range “V”. (Gage cocks are no longer
required by ASME
 ASME Code References
Water Columns (PG - 60.2)
-1” min. connection size for water column to boiler (PG-60.3.4)
- 3/4” min. drain connection size (PG60.2.3)
Stainless Steel is prohibited for the construction of water columns (PG12.3)

Water Level Indicators (PG-60.1)

* Water Gage Glass Requirements ( PG-60.1.1)
* Gage Glass & Connections ( PG-60.3)
* 3/4” min. connection size for Remote (Indirect) level indicators (PG-60.3.4)
* Highest visible permissible water level (PG - 60.3.2)
* Lowest visible permissible water level ( PG.60.3.3)
* Stainless Steel for Gage Glass Body (PG-12)
* Magnetic Level Gage Chambers permitted up to 900 PSI (PG-12), as of 2007
* 1” Gage overlap requirement for Transparent Gages (PG-60.1), since 1996
* Transverse or Cross Web Structural Webs are prohibited from use in the construction
of Transparent type Water Gage Glasses, which may obstruct the view of the level
(PG60.1), as of 2009
Ball Checks in Water Gages Valves considered to be a user option, if specified, must meet the
Code requirements (Automatic Shut Off Valves – Appendix A-18)
 ASME Code References
Gage Cocks (Trycocks) are not required (PG-60.4), since 1991
Many Operators continue to rely on Gage Cocks

Magnetic Water Level Gage: permissible for applications up to 900 PSI

External switches are
not permitted for control
Purposes, such as
Low Water Cutouts
(PG.12 and PG.60)

Switches not permitted

 Code Limitations for Materials
Used for Pressure Parts

• Cast Iron to 250 PSI

• Ductile Iron to 350 PSI
• SB-61 Bronze to 450 PSI
• SA106 Carbon Steel Pipe or SA105
Forgings to 3000 PSI
 Water Columns
• Cast Iron Water Columns are permissible up
to 250 PSI
• Fabricated Steel Water Columns are used for
applications up to 3000 PSI
• Three types of Water Column Functions
– No Alarm for the sole purpose of
supporting one or two water gage glasses
– Float Alarm Type
– Electrode (conductivity Probe) Type for
Alarms and Cut Outs (Trips)
Water Columns and Tie Tubes
• Water Columns are not required on Power
Boilers by ASME Boiler Code, but when
specified, must be designed and
manufactured to comply with Code

• Water Columns are considered to be a

Standard Pressure Part or Standard Welded
Part as defined in Section 1: PG-11 of the
ASME Boiler Code. Therefore, a code stamp
for manufacturing is not required. The use
Code recognized materials and applicable
welding procedures are a must.
 Always Install Chain
Operators for
Operator and Plant
Safety

PG.60.1.7 requires an
accessible operating
mechanism from the
isolation valves to the
operating floor or
platform
Structural Webs are Prohibited
From Flat Glass Gages Designs

- These Webs may

mask the actual
location of the water
level
- The risk of Masking
the level is enhanced
on elevated gage
glass installations
End-to-End Reflex Gage Glasses
Are Permitted
- PG.60.1 Clarifies
the use of multi-
section gages
without overlap,
due to the light
refraction
principle
Globe Valves for Isolation and Drain

Globe type valves are

now permitted if the
lowest edge of the seat
Acrobat Document
is at least 25% of the
port diameter.

In-line flow prevents

sediment or condensate
traps, which can lead to
false level indication
 Magnetic Water Level Gages

Magnetic Level Gage For Process For

(equipped w/ 4-20 transmitter) Power
Boilers
Code Issues and Concerns for the Use of
Magnetic Level Gages on Boiler Drums
• Acceptable as an acceptable Indirect Reading for applications Gage
up to 900 PSI (Ref: PG12.2)

• The Indication Scale must follow ASME guidelines (Ref: PG-60.3.2 &
PG60.3.3)

• May not be used to support a water Gage glass, due to prohibition of

stainless steel construction for water columns. Ref: PG-12.3

• No accessories are permitted to be attached for control purposes

(No Trip Switches). This device must be used for indication only.
Ref: PG-60.1.1.4

NOTE: The use of a Magnetic Level Gage does not replace the Code
requirement for a Direct Reading Water Gage Glass on any Power
Boiler Drum designed to meet the ASME Section 1 Boiler Code
 Concerns for the Application of
Magnetic Water Gages on Boiler Drums
• The float design is based on the operating
conditions(customer specified), not the boiler
design conditions. Therefore, if the boiler is
operated at a pressure lower than the
planned operating pressure, the Magnetic
Gage reading will be higher than the actual
drum level.
• If the user has poor water quality, the
potential exists for iron particles to attach
onto the float. This will result in a heavier
float, with an inaccurate level reading.
 Low Water Cutouts

• Two devices are required (Ref: CSD-1:

Controls and Safety Devices – ASME)

• These devices are typically activated

by floats or conductivity probes

• The two devices must be in separate

chambers or one of them may be
inserted directly into the boiler
 Low Water Cutouts
• The minimum connection pipe size is 1”
and separately piped devices must have
a vertical drain of no less than ¾ NPS

• One control must be set to activate

ahead of the other one

• A Manual Reset function may be applied

to the lower of the 2 controls, with a
maximum delay of 3 minutes, after the
fuel has been cut off
 Low Water Cutouts

Time Delays:

• The cutout circuit may incorporate a

time delay not to exceed 90 seconds or
the manufacturer’s recommendation
(whichever is less)
 New Requirements for Level Switches
on HRSG’s
• The Code now requires Drain Pots to be installed in the Boiler Proper or
Boiler External Piping either upstream or downstream of the Desuperheater to
ensure malfunctions of the devices will not allow water to enter hot boiler
components. These drain pots shall include automatic detection of water and
automatic operation of the drain pot valves. Drain pots with single element
level control with delay to close are an acceptable method of detecting and
removing spray water. Consult Code Section PHRSG-4 for more details

Example Drain
Pot Installation
 Recommendations for Level
Instrument Piping
• All piping from the drum to the water
level instruments are to be insulated, for
the following reasons:
• 1. Provide safety for plant personnel
• 2. Increases level accuracy
• 3. Reduce excess condensate formation

• Any slope in the piping should be

downhill on the steam line & uphill on
the water line from the drum.
• Piping from Drum to Level Instruments
should be kept to a minimum < 6 Ft
 Common Code Violations and
Concerns
• Isolated Inoperable Water Gages
• Missing Water Gage Glasses
• Missing Illumination from Ported type
gages
• Inadequate display of remote Level
Indicators in the control room combined
with isolated gages
 Common Code Violations and
Concerns Continued

• Contaminated Water Gage Glasses

that prevent viewing the actual level
(meniscus line)
• Multiple Section Flat Glasses without
the Code required overlap
• Poor Maintenance Practices
 Annual Violation
Report

 The data Illustrates

Boiler Controls as
the primary source
of violations

Source: The National Board of Boiler and Pressure Vessel Inspectors

Drum Level Instrumentation

Note: Photos are helpful for discussion

Photo of Serious Installation Error

Code Violation and Operation Risk to Boiler

Photo of Corrected Installation
 Top Questions for Users
• Are you having any operational issues with
Water Gage Glasses on Boiler Drum
applications?
• What instruments are installed for the display
Drum Level Indication in the Control Room?
• Are the water level limit controls on your boiler
applications working properly and tested
regularly?
• Does the existing Drum Level Instrumentation
meet the Code for the Design and Operating
Pressures of your Boiler Drum?
 Summary Recommendations for Drum
Level Instrumentation Installations
for Users

• Specify or Install Code Compliant Designs

• Examine Piping and isolation Valves

• Consult with the Insurance Underwriter or Plant

Safety Department for plant requirements, which
may exceed Code Minimum

• Always follow the OEM maintenance instructions

for the most accurate and reliable information
 Summary
Your time and attention to this information is
appreciated, along with your contributions to
Operator and Plant Safety of Power Boilers

Questions