Level and Flow Control Applications Module 8.

SC-GCM-66 CM Issue 2 Copyright 2005 Spirax-Sarco Limited

Block 8 Control Applications

Module 8.3
Level and Flow
Control Applications

The Steam and Condensate Loop

8.3.1

Block 8 Control Applications

Level and Flow Control Applications Module 8.3

Level Control Applications

The control of liquid levels, for example in a process tank, is an important function. An example
would be a hot water tank where water is removed, perhaps for washing down, and the level
needs to be restored ready for the next wash cycle.
Control of water level and alarms for steam boilers is specifically excluded from this Module, and
the reader is referred to Block 3 (The Boiler House), which deals with the subject in depth.
Many different types of level control systems are used in industry, covering a wide range of
processes. Some processes will be concerned with media other than liquids, such as dry powders
and chemical feedstock. The range of media is so wide that no single instrument is suitable for all
applications.
Many systems are available to serve this wide range of applications. The following list is not
exhaustive but, in most cases, the final control signal will be used to operate pumps or valves
appropriate to the application:
o

Float operated types a float rises and falls according to the change in liquid level and operates
switches at predetermined points in the range.
Solid probe types these measure conductivity or capacitance and are discussed in more
detail in the following pages.
Steel rope capacitance types a flexible steel rope is suspended in the liquid, and the change
in capacitance is measured relative to the change in water level.
Ultrasonic types a high frequency acoustic pulse is directed down from a transducer to the
surface of the medium being measured and, by knowing the temperature and speed of sound
in air, the time it takes for the pulse to rebound to the sensor is used to determine the level.
Microwave radar types similar in principle to the ultrasonic type but using high frequency
electromagnetic energy instead of acoustic energy.
Hydrostatic types a pressure transmitter is used to measure the pressure difference between
the confined hydrostatic pressure of the liquid head above the sensor and the outside
atmospheric pressure. Changes in pressure are converted into a 4-20 mA output signal relative
to the head difference.
Differential pressure types similar to hydrostatic but used where the application being
measured is subjected to dynamic pressure in addition to static pressure. They are capable of
measuring small changes in pressure in relation to the output signal range. Typical applications
might be to measure the level of water in a boiler steam drum, or the level of condensate in
a reboiler condensate pocket.
Magnetic types a float or cone is able to rise and fall along a stainless steel probe held in the
tank fluid being measured. The float can interact magnetically with switches on the outside of
the tank which send back information to the controller.
Torsion types a moving float spindle produces a change in torsion, measured by a torsion
transducer.

It is important that the level control system is correct for the application, and that expert advice
is sought from the manufacturer before selection.
It is not within the scope of this Module to discuss the pros and cons and potential applications
of all the above control types, as the types of level control systems usually employed in the steam
and condensate loop and its associated applications are float and solid probe types. The operation
of float types is fairly self-explanatory, but conductivity and capacitance probes may require
some explanation. Because of this, this section will mainly focus on conductivity and capacitance
probe-type level controls.
8.3.2

The Steam and Condensate Loop

Level and Flow Control Applications Module 8.3

Block 8 Control Applications

Methods of achieving level control

There are three main methods of achieving level control:
o

Non-adjustable on /off level control.

Adjustable on /off level control.

Modulating level control.

Cable
entry

Non-adjustable on /off level control (Figure 8.3.1)

The final control element may be a pump which is switched

on /off or a valve which is opened /closed.

Insulation
sleeving

Two main types of on /off level control systems are usually

encountered; float operated types and types using
conductivity probes. Float type level controls either rely
upon the direct movement of a control valve, or upon
electrical switches being operated by a float moving on the
surface of the liquid. Conductivity probes (see Figure 8.3.1)
may have several probe tips; the control points being
located where the separate tips have been cut to
different lengths.

Probe tips

Fig. 8.3.1 A four tip level probe

Adjustable on /off level control (Figure 8.3.2)

Again, the final control element may be a pump which is

switched on /off or a valve which is opened /closed.

Amplifier
connection

One method used to adjust the control points is that of a

capacitance probe (see Figure 8.3.2). The probe will
monitor the level, with control points adjusted by the
controller. Capacitance probes are not cut to length to
achieve the required level and, of course, the whole probe
length must be sufficient for the complete control range.

Main
body

Modulating level control (Figure 8.3.2)

The final control element may be a valve that is adjusted to

a point between fully open and fully closed, as a function
of the level being monitored. Modulating level control
cannot be achieved using a conductivity probe. Capacitance
probes are ideal for this purpose (see Figure 8.3.2).

Insulated
probe

In systems of this type, the pump can run continuously,

and the valve will permit appropriate quantities of liquid
to pass. Alternatively, the final control element may be a
variable speed drive on a pump. The speed of the drive
may be adjusted over a selected range.

Fig. 8.3.2 A capacitance level probe

Alarms are often required to warn of either:

o

A high alarm where there is a danger of the tank overflowing and hot liquid being spilled,
with the attendant danger to personnel.
A low alarm where there is a danger of the tank water level becoming too low, with the
potential to damage a pump drawing from the tank, or running out of liquid for the process.

Installation of floats and probes in turbulent conditions

In some tanks and vessels, turbulent conditions may exist, which can result in erratic and
unrepresentative signals. If such conditions are likely to (or already) exist, it is recommended
that floats or probes be installed within protection tubes. These have a dampening effect on
the water level being sensed. The rest of this Module concerns itself with probes rather than
floats for level control applications.
The Steam and Condensate Loop

8.3.3

Level and Flow Control Applications Module 8.3

Block 8 Control Applications

Non-adjustable on /off level control

Description

Non-adjustable on /off level control uses a conductivity probe connected to an electronic controller.
The probe typically has three or four tips, each of which is cut to length during installation to
achieve the required switching or alarm level (see Figure 8.3.3).
o

When the tip of the probe is immersed in liquid it uses the relatively high conductivity of the
water to complete an electrical circuit via the tank metalwork and the controller.
When the water level drops below the tip, the circuit resistance increases considerably, indicating
to the controller that the tip is not immersed in the liquid.
In the case of a simple pumping in system with on /off level control:
- The valve is opened when the tank water level falls below the end of a tip.
- The valve is closed when the water level rises to contact another tip.
- Other tips may be used to activate low or high alarms.

Advantage:

A simple but accurate and relatively inexpensive method of level control.

Applications:

The system can be used for liquids with conductivities of 1 S / cm or more, and is suitable
for condensate tanks, feedwater tanks and process vats or vessels. Where the conductivity falls
below this level it is recommended that capacitance based level controls are used.

Point to note:

If the tank is constructed from a non-conductive material, the electrical circuit may be achieved
via another probe tip.
Conductivity probe controller
Rotary
pneumatic
valve

Solenoid
valve
Four element
conductivity
probe

Water
supply

Tank
Valve
Valve
closed
open
600 mm 750 mm

Water outflow

Low
alarm
850 mm

The 4th
conductivity
probe is used
as an earth

Fig. 8.3.3 General arrangement of a non-adjustable on /off level control system for a tank

8.3.4

The Steam and Condensate Loop

Level and Flow Control Applications Module 8.3

Block 8 Control Applications

Adjustable on /off level control

Description:

An adjustable on /off level control system consists of a controller and a capacitance probe (see
Figure 8.3.4), and provides:
o

Valve open /closed control plus one alarm point.

Alternatively two alarms - high and low.

The levels at which the valve operates can be adjusted through the controller functions.

Advantage:

Adjustable on /off level control allows the level settings to be altered without shutting down the
process.

Disadvantage:

More expensive than non-adjustable on /off control.

Application:

Can be used for most liquids, including those with low conductivities.

Point to note:

Can be used in situations where the liquid surface is turbulent, and the in-built electronics can be
adjusted to prevent rapid on /off cycling of the pump (or valve).
Controller
On-off
control
valve

Capacitance probe

Water
supply

Tank

Water outflow

Fig. 8.3.4 General arrangement of an adjustable on/off level control system for a tank

The Steam and Condensate Loop

8.3.5

Level and Flow Control Applications Module 8.3

Block 8 Control Applications

Modulating level control

Description

A modulating level control system consists of a capacitance probe and appropriate controller,
which provides a modulating output signal, typically 4-20 mA. Refer to Figure 8.3.5. This output
signal may be used to affect a variety of devices including:
o

Modulating a control valve.

Operating a variable speed pump drive.

Advantages:

1. Because the probe and controller only provide a signal to which other devices respond, rather
than providing the power to operate a device, there is no limit on the size of the application.
2. Steady control of level within the tank.

Disadvantages:
1.
2.
3.
4.
5.

More expensive than a conductivity probe system.

More complex than a conductivity probe system.
Supply system must be permanently charged.
Less suitable for stand-by operation.
Possibly greater electricity consumption.

Point to note:

To protect the supply pump from overheating when pumping against a closed modulating valve,
a re-circulation or spill back line is provided to ensure a minimum flowrate through the pump
(neither shown in Figure 8.3.5).
Controller
Modulating
control
valve
Air supply
Water
supply

Capacitance probe
Tank

Water outflow

Fig. 8.3.5 General arrangement of a modulating control system maintaining the level in a tank

8.3.6

The Steam and Condensate Loop

Level and Flow Control Applications Module 8.3

Block 8 Control Applications

Steam flow control applications

The control of steam flow is less common than pressure and temperature control, but it is used in
applications where the control of pressure or temperature is not possible or not appropriate to
achieving the process objectives. The following sections give more information on measuring
and controlling the flow of steam.

Flow control system

Typical applications:

1. Feed-forward systems on boiler plant, where the rate of steam flow from the boiler will
influence other control points, for example: feedwater make-up rate, and burner firing rate.
2. Rehydration processes, where a measured quantity of steam (water) is injected into a product,
which has been dried for transportation or storage. Examples of this can be found in the
tobacco, coffee and animal feedstuff industries.
3. Batch processes, where it is known from experience that a measured quantity of steam will
produce the desired result on the product.
The selection and application of components used to control flowrate require careful thought.
Pneumatic
control valve
Air supply
to valve
Flowmeter

Separator

Measured
steam flow

Steam
supply

Differential
pressure
transmitter

Condensate

Controller

AC Vac

Fig. 8.3.6 General arrangement of a flow control system

The flowmeter (pipeline transducer)

The flowmeter is a pipeline transducer, which converts flow into a measurable signal. The
most commonly used pipeline transducer is likely to relate flow to differential pressure. This
pressure signal is received by another transducer (typically a standard DP (differential pressure)
transmitter) converting differential pressure into an electrical signal. Some pipeline transducers
are capable of converting flowrate directly to an electrical signal without the need for a
DP transmitter.
Figure 8.3.6 shows a variable area flowmeter and standard DP transmitter relating differential
pressure measured across the flowmeter into a 4 - 20 mA electrical signal. The standard
DP transmitter is calibrated to operate at a certain upstream pressure; if this pressure changes,
the output signal will not represent the flow accurately. One way to overcome this problem
is to provide a pressure (or temperature) signal if the medium is saturated steam, or a pressure
and temperature signal if the fluid is superheated steam, as explained in the next Section.
Another way is to use a mass flow DP transmitter, which automatically compensates for
pressure changes.

The Steam and Condensate Loop

8.3.7

Level and Flow Control Applications Module 8.3

Block 8 Control Applications

The possible need for a computer

If steam is the fluid in the pipeline, then other temperature and / or pressure sensors may be
necessary to provide signals to compensate for variations in the supply pressure, as shown in
Figure 8.3.7.
Pneumatic
control valve
Air supply
to valve
Separator

Flowmeter

Steam
supply
Pressure
transmitter
Condensate

Measured
steam
flow

Differential
pressure
transmitter
Flow
computer
Flow
controller

AC Vac

Fig. 8.3.7 General arrangement of a flow control system

Multiple inputs will mean that an additional flow computer (or PLC) containing a set of electronic
steam tables must process the signals from each of these flow, pressure and temperature sensors
to allow accurate measurement of saturated or superheated steam.
If a flow computer is not readily available to compensate for changes in upstream pressure, it
may be possible to provide a constant pressure; perhaps by using an upstream control valve, to
give stable and accurate pressure control (not shown in Figure 8.3.7).
The purpose of this pressure control valve is to provide a stable (rather than reduced) pressure,
but it will inherently introduce a pressure drop to the supply pipe.
A separator placed before any steam flowmetering station to protect the flowmeter from wet
steam will also protect the pressure control valve from wiredrawing.

Using a mass flow DP transmitter

By using a mass flow DP transmitter instead of a standard DP transmitter, the need for a computer
to provide accurate measurement is not required, as shown in Figure 8.3.8.
This is because the mass flow transmitter carries its own set of steam tables and can compensate
for any changes in saturated steam supply pressure.
However, a computer can still be used, if other important flowmetering information is required,
such as, the times of maximum or minimum load, or is there is a need to integrate flow over a
certain time period.
A controller is still required if flowrate is to be controlled, whichever system is used.

8.3.8

The Steam and Condensate Loop

Level and Flow Control Applications Module 8.3

Block 8 Control Applications

Air supply
to valve

Pneumatic control valve

Steam
flow

Separator

Flowmeter

Mass flow
differential
pressure
transmitter

Condensate

Flow
controller

AC Vac

Fig. 8.3.8 General arrangement of a flow control system

The controller

Even if the output signal from the DP transmitter or computer is of a type that the control valve
actuator can accept, a controller will still be required (as for any other type of control system) for
the following reasons:
1. The output signal from certain flowmeters /computers has a long time repeat interval
(approximately 3 seconds), which will give enough information for a chart recorder to operate
successfully, but may not offer enough response for a control valve. This means that if the
controller or PLC to which the transmitter signal is being supplied operates at higher speeds,
then the process can become unstable.
2. PID functions are not available without a controller.
3. Selecting a set point would not be possible without a controller.
4. The signal needs calibrating to the valve travel - the effects of using either a greatly oversized
or undersized valve without calibration, can easily cause problems.

Summary
It is usually better to install the flowmetering device upstream of the flow control valve. The
higher pressure will minimise its size and allow it to be more cost effective. It is also likely that the
flowmeter will be subjected to a more constant steam pressure (and density) and will be less
affected by turbulence from the downstream flow control valve.
In some cases, the application may be required to control at a constant flowrate. This means that
features, such as high turndown ratios, are not important, and orifice plate flowmeters are
appropriate.
If the flowrate is to be varied by large amounts, however, then turndown becomes an issue that
must be considered.
The subject of Flowmetering is discussed in greater depth in Block 4.

The Steam and Condensate Loop

8.3.9

Level and Flow Control Applications Module 8.3

Block 8 Control Applications

Questions
1. Condensate has a conductivity of 0.1 s /cm. Name the best choice of solid probe
to give on /off level control for this application.
a| A single tip conductivity probe

b| Two single tip conductivity probes

c| A four tip conductivity probe

d| A capacitance probe

2. Name an advantage of modulating control over on /off control.

a| It tends to control at a steady level

b| It allows the level settings to be altered without removing the probe

c| It allows the alarm settings to be altered without removing the probe

d| All of the above

3. Why is a separator recommended before a flow control station?

a| It protects the pipeline transducer from the effects of a wet steam

b| It protects the pressure control valve from wiredrawing

c| It ensures that only dry steam is being measured

d| All of the above

4. Why is a flow computer recommended when controlling steam flow?

a| The system wont work without it

b| It compensates for changes in supply pressure to give accuracy

c| It contains a set of electronic steam tables

d| All of the above

5. What does a pipeline transducer actually do?

a| It always converts flow into a measurable signal

b| It always converts flow into an electrical signal

c| It always converts flow into a pressure signal

d| It converts differential pressure into a flow signal

6. What does a DP transmitter actually do?

a| It converts differential pressure into an electrical signal

b| It converts an electrical signal into differential pressure

c| It converts upstream pressure into an electrical signal

d| It converts differential pressure into a flow signal

Answers

1: d, 2: d, 3: d, 4: b, 5: a, 6: a

8.3.10

The Steam and Condensate Loop