BHELVISION 20 M

BHELVISION 20 M
ELECTRONIC WATER LEVEL
INDICATOR

Installation & Maintenace Mannual

(Version II)

MAHA RASHTRA STATE ELECTRICITY BOARD

NEW PARLI THERMAL POWER PROJECT-EXTN.
1x250MW. UNIT- 1

DANGEROUS VOLTAGES ARE

PRESENT IN THIS EQ UIPMENT.
GREAT CARE SHOULD BE
EXCERCISED WHEN SERVICING
THE EQUIPMENT AND ANY
WARNING NOTICES OR
PROCEDURES CONTINUED IN THIS
MANUAL OR ON THE EQUIPMENT
SHOULD BE STRICTLY OBSERVED

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BHELVISION 20 M
ELECTRONIC WATER LEVEL INDICATOR

CONTENTS

Section 0 Do’s and Don’ts

Section 1 Introduction
Section 2 Installation
Section 3 Maintenance
Section 4 Troubleshooting
Section 5 Installation/part
drawings
Section 6 Specifications
Section 7 Checklists

Section 0 – Do’s & Don’ts

Do Switch off power supply Don’t Keep the cabinet door
before replacing any open.
module.
Do Ensure proper Don’t Use a blower for
connector seating and cleaning the panel.
screws fixed at top &
bottom of rack after
inserting any module.
Do Follow jumpering Don’t Attempt field
details before inserting servicing. Return
any module. faulty module to BHEL
(T) for servicing.
Do Return faulty module to - -
BHEL Trichy for
servicing

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Section 1 – Introduction

1.2 Main components

BHELVISION 20M system consists

of following major sub-systems:
1.0 General
?? Pressure Vessel & Accessories
?? Electrode Probe
The BHELVISION 20M Electronic ?? Ascertor Cabinet & Electronic
Drum Water Level Indicator is modules
Conductivity based water level sensing ?? Displays
system for reliable level monitoring
used in High pressure applications like The system arrangement showing the
steam boiler drums. above components are given below:
Traditional Visual Gauges & Differential
Pressure Manometer Gauges used for
Boiler Drum water level sensing suffer
from the inherent measuring errors due
to density difference. In addition, they
require constant attention &
maintenance.

BHELVISION 20 M operates on the

principle of discrimination between the
differing resistivities of Steam and
Water at high pressure and
temperature.

1.1 Salient Features

An automatic choice for critical

applications like boiler drum water level
sensing, BHELVISION 20 M is
Fig. 1.1.1 SYSTEM ARRANGEMENT
designed with features to cater

?? Easy Installation
?? Low & Easy Maintenance
?? High Accuracy
?? Reliability
?? Built-in Fail safe features
?? Built-in Fail operative features

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1.2.1 Pressure Vessel & 1.2.2Steam / Water tapping and

accessories Isolation valves
Each Water and Steam connections are
BODY VESSEL: provided with 2 Nos. of Isolation vales
to isolate the Body vessel. 2 Nos. Vent
The pressure vessel is made up of and Drain valves are also provided for
SA105 material of thickness 115 mm. each body vessel. The pressure and
The design, fabrication and inspection temperature rating of these valves are
of vessel will be as per IBR. The body same as that of drum design rating. The
vessel is designed for 207 Kg/Sq.cm valves are made of carbon steel
pressure and 368 Deg.C temperature. material SA105.
The hydraulic test pressure for vessel is
310.5 Ks/Sq.cm. The major items for
body vessel are Body, flat end cover,
stub, vent / drain nipple, lifting lug,
clamping plate and guard assembly.
The electrode pitch is 50mm apart.
Normal water level marking is provided
on the vessel.

ELECTRODE:

The electrode as shown in Fig 1.2.2

consists of several sub items. To meet
the specified service, the raw material
is sourced carefully. The electrode
body, electrode tip, body insulant & Fig.1.2.1 PRESSURE VESSEL
center stud are important items of an
electrode. The electrode body is
manufactured from martensitic stainless
steel to Firth Vickers specification
FV520 (B) /SA276 type 410 which has
good resistance to stress corrosion and
low coefficient of expansion. The center
stud is manufactured from IMI titanium
so that the coefficient of expansion
closely matches that of electrode body.
The brazing is carried out with special
brazing foil in closely controlled vacuum
furnace. The spiral wound SS316L
graphoil filled sealing gasket is used
with the electrode.

Fig.1.2.2 ELECTRODE

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b) Ascertor module (AS2018) 1 No

1.2.3 Ascertor Cabinet
configured for 4 ports
The ascertor cabinet Consist of c) Display driver module 2 Nos.
following modules and components (DD2018) configured for 16
mounting in a cabinet for 500MW ports
boilers, normally four ascertor cabinets d) Relay driver module 1 No.
(2 per side) are provided. In one side configured for the required
two ascertor cabinets, one for Lo alarm Lo trip setting
Validation vessel serving 8 ports and e) Micro controller module 1 No.
another for indication vessel serving 16 (MC2018) configured for 8
ports are provided. The OGA of ports
ascertor cabinet is shown in fig.1.2.3. f) Power supply module 2 Nos.
The cabinets are identical for both (PS2018) suitable for 24V
indication and validation vessel. A DC Input
typical component layout arrangement g) System mother board 1 No.
of indication system is shown in Fig. (MB2018)
1.2.4.Ascertor cabinet (Validation) h) Power supply mother 1 No.
houses the following modules and board
components: i) Required electrical components like
a) Ascertor module (AS2018) 1 No. MCBs, TBs etc are assembled and
configured for 6 ports duly wired.
b) Ascertor module (AS2018) 1 No.
configured for 2 ports
c) Display Driver Module 1 No.
(DD2018) configured for 8
ports
d) Relay driver module 1 No.
configured for the required
Lo alarm Lo trip setting
e) Micro controller module 1 No.
(MC2018) configured for 8
ports Fig. 1.2.3 OGA OF ASCERTOR
f) Power supply module 2 Nos. CABINET
(PS2018) suitable for 24V
DC Input
g) System mother board 1 No.
(MB2018)
h) Power supply mother 1 No.
board
i) Required electrical components like
MCBs, TBs etc are assembled and
duly wired.
Ascertor cabinet (Indication) houses
the following modules and components:
a) Ascertor module (AS2018) 2 Nos. Fig. 1.2.4 LAYOUT OF
configured for 6 ports COMPONENTS
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1.3 Ascertor Module AS 2018

?? Six channels per module
?? Multilevel comparators for
fault diagnostics
?? Relays for auto simulation

1.3.1 AS2018 Operation

The oscillator circuit generates &

feeds an AC square wave signal of
50 Hz (approx) frequency to the
electrodes. Signal output from
electrode varies depending on the Fig 1.3.1 ASCERTOR MODULE
resistivity of medium that surrounds
it (water or steam) in the pressure
vessel. This output is precision
rectified and compared with a preset-
reference to determine the medium.

Presence of water is ascertained if

the electrode resistance falls below
100 k? (approx.). Presence of steam
is ascertained only when electrode
resistance rises greater than 200
k? (approx.).

Between water and steam status, a

hysterisis band of 100 k? (approx)
accommodates the changes in
medium resistance due to process
variation in Pressure, Temperature,
Conductivity, pH, etc.

This adjustment is
factory set and not
recommended to change
at site
Fig 1.3.2 AS2018 – BLOCK
SCHEMATIC
The AS2018 is powered from the
motherboard with 12 V DC. All
Input/Output connections are
through motherboard.

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A watchdog circuit generates ‘AC

1.3.3 AS2018 Function blocks
excitation failure fault’ (Clock fault) in
case of oscillator failure.
AS2018 has six channels per
module and may be programmed to Auto simulation drivers (Miniature
select two to six channels by relays) are present which facilitate
appropriately setting the jumpers. the check of system healthiness for
Each AS2018 provides excitation steam / water status, when simulated
voltage through a biasing network for from Micro controller module -
six Electrodes. The intelligence from MC2018 by pressing the test button
these electrodes are further provided in the remote display unit at
processed to indicate water / steam. UCB.
Each individual channel consists of
the following:
?? Precision rectifier
?? Filter
?? Multi-level Comparator

Precision rectifier and filter process

the signal output from the electrode.
The rectified filtered signal is then
fed to the comparator

Each comparator has a Threshold

and Hysterisis. The comparator
monitors the signal level and
depending on the values of the
electrode resistance encountered, it
provides logical 0 or logical 1 output,
Fig 1.3.3 AS2018 – JUMPER
corresponding to steam or water
SETTINGS
status

All the water and steam information

from this module are communicated
through a common bus structure on
the motherboard printed circuit to all
other modules.

1.3.4 AS2018 Features

Another comparator detects any

Open / short fault condition of cable /
Electrodes. When a fault is detected,
‘Electrode fault’ signal is generated
Fig 1.3.4 AS2018 – JUMPER
for further processing
SETTINGS

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1.3.5 AS2018 – Jumper

configuration

The AS2018 module has two sets of

four jumpers for selecting output
signals and fault signals of individual
channel.

The normal configuration of these

berg-stick jumpers is shown in fig
1.3.3 for indication vessel (16 port)
and fig 1.3.4 for validation vessel (8
port) respectively.

Note that the jumper settings are slot

dependent. The appropriate jumper
configuration of AS2018 modules
must be ensured slot wise before
powering up the system.

These modules will have the

following markings to indicate the
setting of jumpers.

Sl. Description Marking

No.
1 AS2018(6 channel) A
2 AS2018(4 channel) B
3 AS2018(2 channel) C

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1.4 Display Driver Module DD 2018

?? Single module for two displays

?? No separate power source
required for displays
?? In-built protection circuit
?? User settable channel
selection

1.4.1 DD2018 Operation

Fig 1.4.1 DISPLAY DRIVER
MODULE
Ref. Fig. 1.4.2 DD2018 for block
schematics. This module serves as
buffer and current driver for driving
the display units. Each module can
cater to two display units.

The Display driver DD2018 is

powered from the motherboard with
12V DC. Power to the display units is
derived from this module. This
power supply is protected against
short circuit by a current fold back
circuitry.

All input/output connections are

through the motherboard. The
DD2018 drives display LEDs -
Red/Green/Yellow at LOCAL and
display units located at UCB based
on Water / Steam / Fault information
from the status bus.
One module caters to two display
units with a maximum of 18 ports.
The number of output drives
selected through jumpers can be 8, Fig 1.4.2 DD2018 – BLOCK
10,12,14, 16 and 18.
SCHEMATIC

Note: Jumper setting is to be

ensured before powering up.

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1.4.2 DD2018 Jumper Setting

The DD2018 module has ten

jumpers for selecting number of
display channels.

The normal configuration of these

berg-stick jumpers are shown in fig
1.4.4 for indication system (16 port)
and fig 1.4.3 for validation system (8
port)
Fig 1.4.4 DD2018 JUMPER
SETTINGS

Fig 1.4.3 DD2018 JUMPER

SETTINGS

These modules will have the

following markings to indicate the
setting of jumpers.

Sl. Description Marking

No.
1 DD2018(16 channel) A
2 DD2018(12 channel) B
3 DD2018(8 channel) C

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1.5 Relay Driver Module RD 2018

?? Drives trip & alarm contacts

?? Individual displays for trip &
alarms
?? 2 out of 3 voting for trip
generation
?? Fault annunciation displays

1.5.1 RD2018 Operation Fig.1.5.1 RELAY DRIVER MODULE

RD2018 receives the STEAM /

WATER signals from the Ascertor
through the status bus.

This module provides following

contact outputs
?? Water level very high
?? Water level very low
?? For initiating trips and alarms

The Relay driver RD2018 is powered

from motherboard with +12V DC. All
Input / Output connections are
through motherboard. It houses
seven relays.
1.5.2 RD2018 Features

RD2018 may be configured for the

required Hi/Lo alarm setting.
Contacts are also given for Fig 1.5.2 RD2018 – BLOCK
?? System fault SCHEMATIC
?? Electrode fault and LED indications are provided in the
?? Trip disable. fascia plate for
Trip relay is actuated if any two ?? High Trip
channels vote for trip. i.e. if Nth port ?? Low Trip
is connected to trip, then N+1 and N- ?? High Alarm
1 ports are also considered for ?? Low Alarm
voting. ?? System Fault
?? Electrode Fault
In case of System fault, steady
output is given to energies fault LED
In display units whereas the same
flashes in case of Electrode fault.

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System Fault consists of The key can be released / removed

only in the trip enabled mode. When
?? Any power supply failure a disable mode is selected then the
trip driver logic output is kept isolated
?? Absence of any module
and trip relays will be at ”No Trip“
?? Excitation ac failure condition.
?? Validation fault
1.5.3 RD2018 Trip & Alarm
Electrode Fault consists of Voting

?? Electrode, cable open circuit 2 out of 3 logic is used to initiate a

trip signal. If Nth (Maximum port
?? Electrode short circuit
number can be 16 -1 say 15) port is
NOTE: Since probe fault detection is opted for High Trip then (N-1), N &
also based on the measurement of (N+1) known as Steam ports have to
input resistance, this detection will be selected through jumpers.
be effective only after the water in
the drum crosses a specified Similarly if nth (Minimum port number
pressure / temperature, depending can be 1+1 say 2) port is opted for
on the actual site condition like Low Trip then (n-1), n & (n+1) known
conductivity of water etc., Hence as Water ports have to be selected
during initial boiler start up. Probe through jumpers.
fault LED of this module may light up
(and the fault LED in the display unit When the water in the pressure
may flash) which will not affect any vessel reaches the steam ports and
other function like steam / water any two steam ports vote for
detection, alarm / trip function etc., presence of water then a High Trip is
This fault indication will vanish generated with a time delay.
automatically after a specified
temperature / pressure at the drum is Similarly when the steam in the
reached. In view of this, fault pressure vessel reaches the water
indication may be ignored during ports and any two water ports vote
boiler start-up operation. Normally for presence of steam then a Low
probe fault detection facility is not Trip is generated with time delay
recommended. If needed this facility
may be by-passed by suitable Alarm initiation is similar to Trip,
jumper connection in ascertor except 2 out of 3 logic and without
(AS2018) modules. time delay. The port (range)
selectable for Low & High alarms is
A manual lockable switch is given on between 2 & 16, selected through
the fascia to Enable / Disable the trip jumpers.
(Low & High) functions as and when
required during maintenance, testing
etc.

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These modules will have the

following markings to indicate the
setting of jumpers.

Sl. Description Marking

No.
1 RD2018(16 channel) A
2 RD2018(12 channel) B
3 RD2018(8 channel) C

1.5.3 RD2018 Facia Indication

1.5.4 RD2018 – Alarm & Trip

Values

High Trip +225 mm from

NWL
Low Trip -225 mm from
NWL
High Alarm +125 mm from
NWL
Low alarm -125 mm from
NWL

1.5.5 RD2018 – Jumper setting

The Alarm and trip values are

set in the RD2018 module at the
manufacturers works. The settings
are permanently soldered jumper
configurations as per the contract
requirement and should not be
disturbed at Site under any
circumstances.

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1.6 Microcontroller Module MC 2018

?? State-of-art architecture
?? Input signal validation
?? In-built logic for fault detection
?? RS 232 interface to DDC MIS

1.6.1 MC2018 Operation

The Micro controller MC2018 is

powered from motherboard with Fig. 1.6.1 MICROCONTROLLER
+12V DC. All Input / Output MODULE
connections are through
motherboard. MC2018 may be
programmed for channels viz. 8 / 10
/ 12 / 14 / 16 / 18 with jumper
connection.
This module does validation checks
on the Electrode inputs. This
module gives 4 – 20 mA DC current
output corresponding to water level.
Water above steam and steam
below water are invalid conditions
which are detected by this module.
In such case the current output is
forced to 4 mA level. Once the fault
is cleared, the current output will
automatically go to the value
determined by the level of water.
RS 232 C outputs are also
generated, which gives information
on level of water, trip / alarm status
etc. This output can be used to
interface with DDCMIS. Auto
simulation signal is generated to
Fig 1.6.2 MC 2018 – BLOCK
drive the relay drivers housed in the
SCHEMATIC
AS2018 modules.
Watch dog timer circuit interrogates
the CPU at regular intervals and
flashes the ‘CPU OK’ LED in the
front facia. This LED will be off, if
CPU failure occurs.

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1.6.2 MC 2018 – Jumper setting

These modules will have the
following markings to indicate the
MC2018 may be configured setting of jumpers.
for channels viz. 8 / 10 / 12 / 14 / 16 /
18 with jumper connection. Sl. Description Marking
No.
The normal configuration of these 1 MC2018(16 channel) A
berg-stick jumpers are shown in fig 2 MC2018(12 channel) B
1.6.3 for indication vessel (16 port) 3 MC2018(8 channel) C
and fig 1.6.4 for validation vessel (8
port)

Jumper configuration of this module

must be ensured before powering up
the system.

Fig 1.6.3 MC 2018 –JUMPER

SETTINGS

Fig 1.6.4 MC 2018 – JUMPER

SETTINGS

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1.7 Power supply Module PS 2018

?? Input 230V AC +/- 10 % These power supplies are designed

with appropriate de-rating of the
?? 12 V DC regulated output components operating conditions so
?? Redundant failsafe configuration that the power supplies can still
??
function satisfactorily. None of the
Auto-changeover feature
component used in the module will
be proprietary in nature.
1.7.1 PS2018 Operation
Regulated +12 V DC output is fed to
system motherboard by these
This module generate 12 V modules for feeding power to various
DC regulated output. This regulated functional modules.
output feeds power to all the
modules. Two such modules are
used for redundancy, so that even if
one power supply fails, other power
supply takes over automatically &
instantaneously, through
Auctioneering Diodes provided in
power supply mother board. Input
AC power supply is connected to
terminals provided in the power
supply mother board. Regulated
+12V DC output is fed to the system
mother board for feeding power to
various functional modules. Fig.1.7.1 BLOCK SCHEMATIC OF
LINEAR POWER SUPPLY
These modular power supplies are
designed to mount in a standard 19
inch single euro rack in the form of a
plug-in power supply. The AC mains
input and DC outputs are provided
on H15 rack connector for easy
insertion of the power supply unit in
the rack.The power supplies are fully
enclosed with sufficient ventilation
cutouts so that cooling can take
place with natural convection
method. These power supplies are
designed using approved
components for highest reliability. Fig.1.7.2 FRONTVIEW OF 230V PS

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1.8 Display Unit

?? Coloured LED displays for

steam/water level status
?? Individual display units for
Local, operating floor &
remote indication
?? Test/Simulation facility for
system check
?? Compact & rugged display
unit

1.8.1 Display unit Operation

The Display unit is provided with a

parallel array of Red and Green
LEDs (18 pair of LEDs) and 1 Yellow Fig. 1.8.1 DISPLAY UNIT
LED arranged at the panel front.
The number of glowing LED pair is Immediately next, all simulated
equal to the number of electrodes. inputs are changed to steam so that
One such display unit is fixed on the green LEDs should switch off and
Ascertor Panel door itself for local now all red LEDs should glow for
viewing and one more display unit is one second. During this period of 2
supplied for mounting at UCB for seconds test simulation TEST LED
each end of the drum, for the glows.
Indication system. One No. Display During this test simulation period, trip
unit for operating floor indication is status corresponding to pre test
also provided. period is maintained. However,
The power supply and the drive for alarm status is not maintained.
this unit come from display driver By this arrangement, on line
module. simulation testing of BHELVISION-
20M system from UCB is made
1.8.1 Display unit Test possible. Normally, test simulation
Simulation button in Ascertor display is kept
disconnected. This facility is made
By momentarily pressing the ‘Test’ available only in UCB display.
push button is given in this unit, one These modules will have the
can quickly check the functioning of following markings to indicate the
the equipment, on line. setting of jumpers.
During this self-test period, all the Sl. Description Marking
channels are given a simulated input No.
corresponding to water for one 1 DU2018(16 channel) A
second and all green LEDs should 2 DU2018(12 channel) B
glow now. 3 DU2018(8 channel) C
4 DU2018(16 channel A-UCB
UCB display)

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Section 2 – Installation
Each vessel is delivered with four
isolation valves and two Drain / Vent
2.0 General
Valves. All 8 / 16 electrode ports
have blanking plugs fitted that should
The installation procedure comprises not be removed until later, when the
the following activities electrodes are fitted. The Pressure
?? Pressure vessel erection Vessel is delivered complete with 8 /
?? Ascertor cabinet installation 16 electrodes and 8 / 16 Metaflex
?? Display unit installation gaskets. These are fitted
?? Cabling & Termination immediately prior to electrical pre-
?? Electrode installation commissioning. It is essential that
electrodes are NOT fitted until acid
and steam purging has been
2.1 Pressure vessel completed. The Pressure Vessel is
provided with lifting eyes at its upper
end to support its weight from the
superstructure.

Fig.2.1.1 PRESSURE VESSEL INSTALLATION

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2.1.1 Pre-erection checklist 2.1.3 Vessel installation

Before drawing the Pressure Vessel The steam and water connections on
from store the following points must the Pressure Vessel have to be
be checked. aligned in the vertical plane with the
?? Ensure that access to work on steam and water connections
this part of the plant is clear. provided on the Boiler Drum ends
?? Ensure vessel Isolating and welded to those connections.
Valves have been fitted to the The Steam and Water connections
steam and Water connections on the drum have been set to
on the Drum and are ready to position the Pressure Vessel at the
have the Pressure Vessel correct level when they are welded in
welded to them. place. However, due to the length of
?? Check hardware required for the connecting pipe work, these
supporting the pressure could be offset and care must be
vessel are available. exercised to ensure that they are not
?? Ensure the location of allowed to take the unsupported
suspension points on the weight of the vessel. Bearing this in
superstructure has been firmly mind, installation should commence
supported as per site with the attachment of the vessel
requirement. supports to the superstructure. The
?? It should be noted that all Pressure Vessel may then be
joints in pipe work must be attached to the supports that will
welded, tested and inspected carry the weight of the vessel and
in accordance with the allow it to be accurately aligned with
standard welding procedure. the drum steam and water
connections before and during the
2.1.2 Vessel checklist welding operation. After welding to
Notify the unit operator of the intention the connecting pipe work and fitting
to commission the vessel, in drainpipe work is complete, a further
accordance with recognised check for level should be carried out
procedures. and adjustments made, if necessary.
?? Check that the electrode guard NOTE: The water connection to the
is in place. Pressure Vessel must be lagged.
?? Close drain & vent valves. The steam connection should NOT
?? Open water and steam isolating be lagged within the last 1.5m from
valves nearest to boiler drum. the Pressure Vessel. The body of
?? Crack opens the isolating steam the Pressure Vessel itself must NOT
valve nearest to the pressure be lagged.
vessel. Check with the unit When the installation of the Pressure
operator that the vessel slowly Vessel has been completed,
fills with condensate (about 10 precautions must be taken to protect
-15 minutes). it against damage during the
?? Crack opens the isolating water installation of adjacent plant
valve nearest to the pressure equipment / pipe work etc.
vessel. Check with unit operator
that the water level is falling to
approximately normal water level.
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2.2.1 Pre-installation 2.3 Display installation

checklist
Before drawing Ascertor Cabinet
from store, the following points The installation of the Display Unit in
should be checked: the Central Control Room will be
?? The exact position for carried out by other contractors,
along with other UCR equipment as
installation has been
determined. and when required. The display cut-
?? Access to work on that part of
out details are provided on OGA of
the plant is clear. display unit drawing.
?? Lifting tackle and adequate
suitable layout are available to The method of fitting is as follows:
?? Remove top and bottom
raise the unit to its position at
Drum Level. clamping plates by removing
holding screws.
?? Insert the display to the cut
2.2 Ascertor cabinet out hole in Control Room
installation Desk or Panel.
?? Re-fit the clamping plates,
The Ascertor Cabinet is to be sited at making certain that they hold
Drum Level. Ensure by examining the display rigidly to the
the internals that the correct unit is Control Desk or Panel.
drawn from store that it is ?? Connect cable to appropriate
undamaged and in a suitable connections.
condition for installation to start. The
unit is to be wired to the Pressure
Vessel and is to be positioned so
that the length of cabling connecting
it to its Pressure Vessel does not
exceed 15 meters (appx).
The Ascertor Cabinet is
provided with fixing holes in the rear
vertical face for bolting it to the wall
or suitable support structure.
Transport Ascertor Cabinet to
location. Bolt and position carefully
on prepared surface. Fix using bolts,
nuts and washers or equivalent
fastenings. When the unit has been
positioned and bolted in place,
adequate precautions must be taken
to ensure that it is protected against
accidental damage during the
installation of adjacent plant /
equipment and pipe work or the
completion of any local building
work.

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installation prior to pre-

2.4 Cabling commissioning tests being carried
out after the electrodes have been
fitted under his supervision.

The external connection Drawing 2.6 Electrode assembly

shows details of connections
between the Pressure Vessel and Electrode assembly should be
Ascertor Cabinet at the Boiler Drum carried out immediately prior to the
level. electrical pre-commissioning of the
This wiring is to be carried out using complete system.
P.T.F.E insulated, 10 pair 0.6 sq.mm This consists of removing specified
special cable supplied with the blanking plugs and Metaflex gaskets
system. and replacing them with the
These are terminated, at the electrodes and new Metaflex
electrode end with crimp-ring gaskets.
terminals and at the Ascertor Before starting on this work, the
Cabinet end with crimp pins. The following points must be checked:
conductors should be identified with ?? Ensure that access to work on
suitably marked ferrules at each end. this part of the plant is clear
and that the Pressure Vessel
The cables from each electrode of has been fitted and is ready to
the Pressure Vessel must be be worked on.
grouped together and laced with ?? Check that hydraulic testing,
heat resistant lacing thread, or tie acid cleaning and steam
wraps, to form a loom throughout purging have been carried
their length. out.
The loom must be securely cleated ?? The Vessel Isolating Valves
where it leaves the vessel and shall must be CLOSED and the
be supported by and cleated to the drain / vent valves OPENED.
perforated cable tray throughout its
length to the Ascertor Cabinet. NOTE: - A suitable M18/M19 socket
The cables from the vessels, where spanner is required for removal of
it enters the base of the Ascertor the blanking plugs and fitting of the
Cabinet, must pass through glands electrodes. This must be fitted with
provided. The wiring within the an extension to clear the electrical
Cabinet is run neatly and terminated terminal end at the top of the
as prescribed above (crimp pins). electrode being fitted.
2.5 Pre-commissioning The electrode positions on the
check vessel are protected by two hinged
When all the installation and guards, which must be opened to
cabling work called for in this gain access to the electrodes. Each
specification has been completed, electrode or blanking plug is held in
the commissioning engineer must be the wall of the vessel by a clamping
advised so that arrangements may plate, which is secured by four M19
be made for him to inspect the studs, nuts, and washers.
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2.6 Electrode assembly

(contd.,)

When the nuts are removed, the

clamping plate, blanking plug and
Metaflex gasket may be withdrawn.
The blanking plug and old Metaflex
gasket must be discarded and
replaced by the electrode and a new
Metaflex gasket.
The clamping plate and four washers
are then replaced and the nuts
assembled finger tight. Using the
socket spanner, tighten the nuts
progressively, a quarter turn each,
until there is NO gap visible
anywhere between the inside face of
the Clamping Plate and the
machined face of the Pressure
Vessel. Care must be exercised to
prevent damage to the electrode
when tightening the nuts, THE
MAXIMUM torque to be applied to
the nuts in order to close the gap
referred to be 110 Nm (80lb ft).
Normally 70Nm (50lb ft) is sufficient.
Refer to the instruction sheet issued
with each electrode. Care should be
taken when attaching the prepared
PTFE cable ends to avoid
mechanical damage to the electrode.

NOTE: For scope and size of cable,

refer “Scope And Cabling Diagram”

Fig.2.6.1 Electrode Assembly

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2.7 Commissioning checklist

SYSTEM CHECK / TEST / STATUS COMMENTS /

DETAILS OBSERVATION RECORD

COMPLETE Installation Visually Correct

SYSTEM

ELECTRONICS System Cabling and Termination

& CABLES

WATER Verification against Drum NWL.

COLUMN (e.g. Clear Plastic Tube filled with
coloured water)

POWER Ensure power supply fuses are

SUPPLY removed.
Check for correct voltage and fuse
ratings before installing fuses and
switching power on.

SYSTEM TESTS
DISPLAY’S
Connect Bhelvision electrode
simulator (at Ascertor Panel)
switch all Ports to STEAM.

WATER Starting at Port 1, switch each Port

INDICATION to water until ALL WATER is
shown; At each Port verify correct
indication of level at Local, UCB &
operating floor displays.

STEAM Starting from Port 16, switch each

INDICATION Port to steam until ALL STEAM is
shown. At each Port verify correct
indication of level at Local and
UCB displays.

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2.7 Commissioning checklist (contd.,)

SYSTEM
DETAILS CHECK / TEST / STATUS COMMENTS /
OBSERVATION RECORD
FAULT Switch Ports to ALL STEAM
ALARM
Starting from Port 2, switch each
Port to water to introduce a “WATER
ABOVE STEAM” condition to induce
the FAULT ALARM. Normalize each
Port to steam to clear alarm before
proceeding to next Port. At each
Port, check relay fault output
terminals for correct contact state.

LOW LEVEL Switch Ports to indicate 50% water

ALARM level (Typical NWL). Starting from
the top of the indicated water level,
switch each port to STEAM until the
LOW LEVEL ALARM relay acts. Note
Port & contact state in alarm
condition.

LOW LEVEL Continue to switch Ports to STEAM

TRIP until the LOW LEVEL TRIP relay acts.
Note Port & contact state in Trip
condition.
HIGH
LEVEL Switch Ports to indicate 50% water
ALARAM level. (Typical NWL). Continue to
switch ports to WATER until the
HIGH LEVEL ALARM relay acts. Note
Port & contacts state in Trip
condition.

HIGH Continue to switch Ports to WATER

LEVEL TRIP until the HIGH LEVEL TRIP relay
acts. Note Port & contact state in Trip
condition.

ANALOG Switch Ports to ALL STEAM

OUTPUTS Check output is 4mA.

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2.7 Commissioning checklist ( contd.,)

23 SYSTEM
DETAILS CHECK / TEST / STATUS COMMENTS /
OBSERVATION RECORD
Switch Ports 1 to 4 to indicate water.
(25 % water level)
Check output is 8mA.

ANALOG Switch Ports 1 to 8 to indicate water.

OUTPUTS (50 % water level)
Check output is 12mA.

Switch Ports 1 to 12 to indicate

water. (75 % water level)
Check output is 16mA.

Switch Ports to ALL WATER.

(100 % water level)
Check output is 20mA.

Switch Ports to ALL WATER.

Simulate Water above Steam
condition (Validation fault)
Check output is 4mA.

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Section 3 – Maintenance

3.0 General 3.3 Monthly check list

So for as the valves and pipe work to
the pressure vessels are concerned Pressure vessel
both regular maintenance and repair
work should follow existing site ?? Check the WATER pipe
practice. No regular maintenance on lagging is secure
the vessels, or electrodes is ?? Check Vessels & STEAM
required, except as detailed below. pipes are NOT lagged.
?? Blow or brush off gently any
large accumulations of
3.1 Required Tools pulverized fuel dust or fly ash
on the external insulators of
Tool Purpose the electrodes.
?? Check that electrode
Torque To tight clamping connections are tight and the
wrench plate leads are intact.
Simulator To simulate Steam/
water condition of Ascertor Cabinet
the port
Gasket To remove gasket ?? Check all cabling for secured
Remover connection.
Face Cutter To repair damaged ?? Check all modules are in its
electrode gears position.
?? Check operation of relays
?? Check local & operating floor
3.2 Daily Check list
displays

?? Visual Check for steam leaks

at the vessel 3.4 Annual overhaul
?? Visual check for damage to
electrodes To avoid mechanical damage to
?? Visual check for indication in the vessels, electrodes and
Display units at UCR, Firing electrode wiring due to other
floor & drum work, which may be required at
drum level, should be protected
by temporary shielding.

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The vessels should be drained, errors in water level indication (due

but need not be isolated from the to pressure vessel water columns
cold empty drum. being at a lower temperature than
boiler drum water temperature) are
After other works has been reduced to less than 25mm for the
completed and the temporary temperatures and pressures
protection removed, check that specified.
no visible damage has occurred
to electrodes and leads, and that This is achieved by stimulating
the electrode connections are condensate (by omitting lagging on
tight and free of dust. the vessel steam pipe flow in the
upper part of the vessel) the heat
The drains should be closed and thus released is conducted to the
the isolation valves left open water column in the lower part of the
immediately before the hydraulic vessel.
pressure test on the drum, so that
the vessels with their electrodes The flow of condensate itself also
can be included in this test. maintains the temperature of the
water column.
Any electrodes showing signs of
leakage should be replaced 3.4.2 Electrode & Seal
immediately after this test, the Leaks
vessels should again be drained
until required for service (this is to The distinction between seal and
prevent the accumulation of electrode leaks is often difficult to
sludge in the vessels). determine prior to removal of the
electrode, unless the leak is small.
3.4.1 Pressure parts
Steam wisps which appear to
emanate between the outside of the
electrode body and the bore of the
gland clamping plate are indicative of
With any water/steam detection
a seal leak, whereas steam
gauge, even a very small leak
appearing through the external
anywhere on the detection device or
ceramic insulator (which is only a
its connections will cause error, as
spacer and is not intended to be
also can a partial blockage. Except
pressure resistant) suggests that the
for an extremely severe leak either a
electrode itself is faulty.
leak or blockage, whether on the
steam or the water side of the device
Even if the electrode is in water, the
or its connections, will cause the
water temperature in an operating
detector to give incorrect readings.
detection device will cause the water
to flash off to steam as atmosphere
It should be noted that the (EWLI)
is reached.
BHELVISION pressure vessel
thermal design is such that density

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3.4.2 Electrode & Seal To assist in identification, a seal leak

Leaks (contd.,) may be caused either by:
?? Incorrect centering of the
DO NOT attempt to cure a seal leak sealing washer on the
by over tightening the gland electrode prior to its insertion
clamping plate nuts. in the vessel, so that it
catches on the edge of the
The base of the gland clamping plate land and is distorted by
seats on to a land in the vessel itself subsequent tightening of the
and the most probable fault lies in clamping plate nuts, even if in
damage to the Metaflex sealing the process it eventually
washer. enters the recess.
?? Failure on a previous
The correct degree of compression occasion to remove the old
on this washer is inherent in the washer or all the broken parts
depth of the recess below the land, thereof, from the recess
which accepts the washer with the before inserting the prevent
gland clamping plate seated on the washer and electrode.
?? Re using an old and already
land.
previously compressed
Tightening beyond this point will only washer instead of a new one.
?? Failing to ensure that the land
cause damage to the studs or the
nuts. and the recess were clean
and undistorted.
The correct procedure for repairing
either a seal or a failed electrode is Before reinserting an electrode,
to isolate and drain the vessel. check that an old washer or part of
has not been wedged in the recess
Remove the electrode lead and the and that the land is not obstructed.
knurled nut completely from the
electrode, remove the gland A small Electrode with a L shaped
clamping plate and remove the pointed end, could be used to
electrode complete with its sealing dislodge it by hooking the pointed
washer. end into the v - shaped groove in the
gasket, NOT between the gasket
Examination of these items may give and the seat. In addition, check that
a more positive identification of the the gland clamping plate and studs
cause of the leak. Unless it can are not distorted.
definitely established however, that
the electrode was not the cause, it is If a serious “blow” occurs, immediate
advisable to fit a new electrode at attention is required. Ensure that the
this stage. vessel is ISOLATED AS SOON AS
POSSIBLE (at least within a few
hours), otherwise electrode port seat
erosion may necessitate removal of
the vessel.

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Site machining of the pressure

3.6 Vessel Isolation
vessel is possible and satisfactory
results are usually obtained; After obtaining authority to isolate
however, it is more difficult to the vessel:
determine accurately the depth of
the cut. ?? Close off the steam and water
isolating valves nearest to
When a seat is cut, the pressure vessel.
corresponding amount of metal must ?? Close off the steam and water
be removed from the face of the isolating valves nearest to
clamping plate flange to ensure that boiler drum.
the gasket is correctly compressed. ?? Open drain & vent valves and
proceed with work required.
3.5 Safety Precautions
3.7 Electrode replacement

?? PROCEED ONLY WITH A

VALID ‘PERMIT TO WORK’ There is no need to switch off the
?? Ensure that tripping is BHELVISION system electronic
disabled and that operators equipment for this procedure. Carry
expect erroneous indications out the isolation and draining
or alarms. procedure as follows:
?? Ensure that you know the ?? Open the electrode cover
valve positions and other guard, taking care to avoid
procedures BEFORE working knocking the electrodes.
on the pressure vessel. ?? Remove only one electrode at
?? Wear industrial gloves to a time (avoids risk of incorrect
change electrodes. reconnection)
?? Replace convention chimney ?? Remove the four nuts,
electrode covers before washers and clamping plate,
pressurising vessel. extract the electrode and the
gasket carefully without
damage to seat face.
?? Inspect the vessel seat,
removing any remnants of old
gasket and taking care not to
damage the seat.

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?? Apply a high temperature,

copper / lead bearing grease Notify the unit operator of the
to the studs to reduce contact intention to commission the vessel,
friction between nuts, studs in accordance with recognised
and washer, so avoiding procedures.
excessive loading on the
studs and possible shearing. ?? Check that the electrode
?? Fit a new gasket to the electrode guard is in place.
and carefully insert into the ?? Close drain & vent valves.
electrode port. Ensure that the ?? Open water and steam
gasket is located correctly, isolating valves nearest to
replace the clamping plate, boiler drum.
washers and nuts, and tighten
?? Crack opens the isolating
the nuts evenly using a torque
wrench until the bottom face of steam valve nearest to the
the clamping plate meets the pressure vessel. Check with
corresponding face of the the unit operator that the
pressure vessel. 70Nm (50lb ft) vessel slowly fills with
is usually sufficient. Max. Limit condensate (about 10 -15
110Nm (80lb ft)Replace the minutes).
electrical lead(s) and guard. ?? Crack opens the isolating
Re-commission as stated water valve nearest to the
below. pressure vessel. Check with
unit operator that the water
3.7.1 Vessel commissioning level is falling to
approximately normal water
level.
The method given allows the vessel ?? Open water valves fully.
to fill slowly with condensate from
the steam leg through a crack
Opened steam valve and for
warming to continue at a controlled
rate as the water is forced back
through the crack opened water
valve by the few inches of differential
water pressure which exists when
the steam valves are opened.

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3.8 Accessories
The switches are numbered 1 to 18,
3.8.1 BHELVISION Electrode where 1 corresponds to the lowest
Simulator level electrodes and 18 to the
highest level electrode. A general
view of the Electrode Simulator is
shown in Fig. – 3.8.2

The Eighteen switch circuits can

The BHELVISION Electrode be considered as two groups, one
Simulator (BES) can be connected to group comprising the ODD channel
the EWLI BHELVISION – 20M circuits, and the other the EVEN
equipment to simulate the working of channel circuits. Each group has its
sixteen electrodes mounted in a own earth connection, which is
pressure vessel. Sixteen switches, common to all switches in that group.
one for each electrode, can be set The circuit diagram for the
individually to provide a simulated BHELVISION Electrode Simulator
WATER or STEAM condition at any (BES) is shown in Fig. 3.8.1
electrode level.

Fig.3.8.1 CIRCUIT DIAGRAM OF BHELVISION ELECTRODE STIMULATOR

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Each switch circuit consists of a 2- vessel shall be isolated from process

position switch (STEAM / WATER) by closing water and steam isolation
and two resistors (1Meg ohm and valves. Also empty the pressure
270K ohm) connected so that the vessel in full by opening the drain
resistance between the common valves.
earth and the numbered wire Now the BHELVISION system
connection for that switch will is ready for simulation.
simulate a WATER or STEAM
condition, depending upon the switch Toggling the switches between
setting. Water and Steam position will
Connection for the BES is by means simulate the condition of Water and
of a 3-metre long (approx). Cable Steam respectively, for individual
with 25-pin ‘D’ connector (male) electrodes numbered 1 to 16 from
termination. In the Ascertor cabinet bottom to top.
a set of connection from probe
excitation signal at TB2 terminals 1 By operating the 16 switches (1 to
to 14 have been provided and 16) the following shall be
terminated with 25 pin ‘D’ (female) simulated and tested.
connector.
The Table below shows the condition
applicable for a Standard 16 port
system (Vision range 550mm) With
Alarm / Trip levels. For this project
the following port shall be switched
for Alarm / Trip levels.
th
High 13 Port Water 225mm From
Trip to Steam NWL
d
Low 4 Port Water 225mm -do-
Trip to Steam
h
High 11 Port Water 125mm -do-
Alarm to Steam
th
Low 6 Port Water 125mm -do-
Alarm to Steam
Fig.3.8.2ELECTRODE SIMULATOR

3.8.2 OPERATION

The BES shall be electrically

linked by connecting the 25 pin ‘D’
connectors (Male and Female at
BES and Ascertor cabinet
respectively) together. Pressure

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BES SWITCH EWLI - PORT ALARM / TRIP / ANALOG

STATUS INDICATION FAULT STATUS O/P in mA
(Nominal)
1 to 16 - Steam 1 to 16 - Red Low Alarm - Yes 4.00
V.Low Trip - Yes
1 - Water 1 - Green Low Alarm - Yes 5.00
2 to 16 - Steam 2 to 16 - Red V.Low Trip - Yes
1 to 2 - Water 1 to 2 - Green Low Alarm - Yes 6.00
3 to 16 - Steam 3 to 16 - Red V.Low Trip - Yes
1 to 3 - Water 1 to 3 - Green Low Alarm - Yes 7.00
4 to 16 - Steam 4 to 16 - Red V.Low Trip - Yes
1 to 4 - Water 1 to 4 - Green Low Alarm - Yes 8.00
5 to 16 - Steam 5 to 16 - Red V.Low Trip - Yes
1 to 5 - Water 1 to 5 - Green Low Alarm - Yes 9.00
6 to 16 - Steam 6 to 16 - Red
1 to 6 - Water 1 to 6 - Green Low Alarm - Yes 10.00
7 to 16 - Steam 7 to 16 - Red
1 to 7 - Water 1 to 7 - Green Nil 11.00
8 to 16 - Steam 8 to 16 - Red
1 to 8 - Water 1 to 8 - Green Nil 12.00
9 to 16 - Steam 9 to 16 - Red
1 to 9 - Water 1 to 9 - Green Nil 13.00
10 to 16 - Steam 10 to 16 - Red
1 to 10 - Water 1 to 10 - Green Nil 14.00
11 to 16 - Steam 11 to 16 - Red
1 to 11 - Water 1 to 11 - Green High Alarm - Yes 15.00
12 to 16 - Steam 12 to 16 - Red
1 to 12 - Water 1 to 12 - Green High Alarm - Yes 16.00
13 to 16 - Steam 12 to 16 - Red
1 to 13 - Water 1 to 13 - Green High Alarm - Yes 17.00
14 to 16 - Steam 12 to 16 - Red V. High Trip - Yes
1 to 14 - Water 1 to 14 - Green High Alarm - Yes 18.00
15 to 16 - Steam 15 to 16 - Red V. High Trip - Yes
1 to 15 - Water 1 to 15 - Green High Alarm - Yes 19.00
12 to 16 - Steam 12 to 16 - Red V. High Trip - Yes
1 to 16 - Water 1 to 16 - Green High Alarm - Yes 20.00
V.High Trip - Yes
Water above Steam/ As per individual port Alarm - Enabled 4.00
Steam below Water condition Fault - Yes

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3.8.3 USING THE TORQUE

3.8.2 Torque wrench
SPANNER
?? Check that the ratchet
direction is correct. Torque Spanner is essential
?? Select the correct size of 1/4”, for the correct tightening of the high
3/8” or 1/2” socket and push it tensile bolts used in pressure
onto the square. vessel.
?? Tighten the nut until the tool
‘clicks’ and is felt to ‘give’ Both over and under-tightening can
slightly. STOP pulling cause the failure of highly stressed
immediately. bolt, so they must be correctly
The tool will automatically re-set tightened to be safe.
itself when hand pressure is
relaxed, ready for the next The even tightening produced by a
tightening cycle torque spanner used on clamping
plate head studs prevents electrode
damage or studs being broken.

3.8.4 OPERATING INSTRUCTIONS

Setting tools fitted with a

MetalAdjusting Knob.

a)Pull the adjusting knob out

of the body tube until it clicks
into position(about 6mm). It
may be necessary to turn the
knob silightly while pulling.

b)Rotate the adjusting knob

untile the cursor line lies
opposite the desired torque.
Fig.3.8.3 TORQUE WRENCH c)Push the metal knob back
to its ‘Free Wheel’ position to
avoid accidental setting
alteration.

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Fig. 3.8.4 OPERATING INSTRUCTION

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3.8.5 ACCIDENT PREVENTION 3.8.6 DO’S AND DON’TS

Do set the spanner at a lower
A torque wrench is a precision tool figure (3/4 of maximum) than
for the accurate tightening of nuts required; tighten all nuts and re-set
and bolts. to final figure and tighten again.
It should never be used as a lever to Do pull tool squarely from the
undo frozen nuts. center of the handle.
When tightening or loosening a nut it Do refer to the maker’s
is possible that something might handbook, or recognised repair
break or slip. Always stand firmly manual for correct torque setting.
with one foot well in front of the other Do see that bolt threads are
and pull the torque wrench towards clean and lightly oiled before torque
you. tightening.
Make sure that the socket is the Don’t adjust the tool either above
correct size to fit the nut and in good the maximum on the scale or below
condition. the minimum.
Use an extension driver between the Don’t snatch the tool when
wrench and the socket if there is any tightening, a smooth continuous
danger of scrapping your knuckles pull gives more accurate results.
due to a sudden release. Accidents Don’t put oil through the hole in
can occur using the simplest tools. the body tube, or adjust the screw
So , “BE SAFETY CONSCIOUS.” beneath it.

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Fig. 3.8.6 ACCESSORIES OF TORQUE WRENCH

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removed at each machining. If it is

3.8.7 Face cutter necessary to remove more metal
from a seat than this stated
The face cutter is used to repair maximum, guidance first be sought
damaged electrode port seats. from BHEL - TRICHY.
Damage may occur either due to a Using a depth gauge or depth
leaking electrode gasket or due to micrometer, measure the depth of
the sealing gasket being incorrectly the electrode port and compare it
removed. If the leak is allowed to with the dimension stated in Fig.
continue, the damage will become 3.8.8
too severe for effective repair. Repair NOTE: If the depth of the electrode
is possible by machining the seat to port exceeds the dimension stated in
produce a clean sealing face. Fig. 3.8.8 + 1.15mm, guidance
Positioning of the face cutter has must be sought from BHEL -
shown in fig. 3.8.11 TRICHY before proceeding with the
The following instructions enable the machining operation.
electrode port to be effectively Inspect the face cutting tool Fig.
repaired. 3.8.10 to ensure that the teeth of the
?? Remove electrode and gasket cutter are in good order. Attempting
as per the instruction briefed to machine an electrode seat using a
earlier. cutter with a damaged tooth may
?? Whenever the electrode is well result in worse damage to the
changed (or) taken out for electrode seat.
inspection, the gasket shall be At all times during this operation,
replaced with a new one. The great care must be taken that the
gasket can be removed with minimum amount of material is
the help of gasket remover allowed to fall through the electrode
shown in fig. 3.8.7. port into the body of Pressure
?? Carefully examine the Vessel.
damaged seat and assess MACHINING
whether the damage is too ?? Insert the cutter into the
severe to be remedied by electrode port with the shaft
site machining. This decision protruding outwards, ensuring
must be based on judgement, that it is seated properly.
but as a guide, the minimum ?? Fit the guide plate over the
amount of metal should be shaft of the cutter and locate it
removed from the seat to over the four studs in the body
enable a clean seating face to of the vessel.
be produced. The maximum ?? Fit the nuts and washers onto
that may be removed is the studs and tighten finger
1.15mm. tight.
NOTE:The stated maximum, ?? Attach a spanner or socket

1.15mm, is the total amount of metal wrench (11 mm) size to the
that can be removed from any one square section, drive end, of
seat during the lifetime of the vessel. the cutter.
This is not the amount than can be

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?? The depth of the electrode

3.8.7 Face cutter ( contd.,) port should now be measured
and the difference between
?? Turn the cutting tool gently in this and the measurement
a clockwise direction. As the shown in Fig. 3.8.8 must be
cutter turns, a degree of “feel” less than 1.15mm.
is required to ensure that the ?? The difference calculated as
cutter is making the correct above has now to be
depth of cut. machined off the face of the
?? If the four securing nuts are electrode clamp plate. The
not sufficiently tight, the clamp plate must have a
cutting face of the tool will raised face machined on it as
skim across the electrode shown in Fig. 3.8.9
seat and not remove any
metal. The nuts should then The vessel interior must be
be tightened gently until it is cleaned of any foreign
felt that the correct cut is material by using air or by
being made. If the four washing through with water
securing nuts are over tight, with the drain valves open
the cutting teeth of the tool will until the vessel body is clear
bite too deeply into the of metal debris.
electrode seat and the cutter
will “bind up”. In this
instance, the four securing 3.8.8 MARKING AND RE-
nuts should be slackened until ASSEMBLY
lit is felt that the correct cut is
being made.
?? At regular intervals, the nuts, NOTICE: Follow the instruction
washers, guide plate and
cutter should be removed and The electrode clamping plate and the
the electrode seat examined electrode port, which have just been
to check progress of the machined, must both be stamped
repair operation. with a unique identification mark.
?? If the seat is still scored, This is due to the fact that this
reassemble the tool and electrode clamp plate will only
continue the operation until, provide the required seal when used
when examining the seat in this electrode port.
unmarked, bright metal
shows. ?? Re-assemble the electrode
?? At this point, the operation is into the pressure vessel,
discontinued and the taking care to use a new
electrode port thoroughly Metaflex gasket.
cleaned out to remove ?? Re-commission the vessel.

any swarf. Ensure that the

swarf is removed outwardly
and not into the vessel.

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Fig. 3.8.7 GASKET REMOVER

TOOL

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 BHELVISION 20 M

Section 4 – Troubleshooting
4.2 Visual Inspection
4.0 General The visual inspection checks that will
aid in trouble shooting

Pressure vessel
?? Electrode damage
?? Protector Hood damage
Trouble shooting procedure is ?? Loose,Broken cables
intended to help the user to identify
the nature of problem from a set of Ascertor cabinet
defined elimination process. ?? Both PS2018 modules LED
‘ON’
Also this procedure helps to ?? Modules configuration as per
eliminate minor problems such as legend pasted on cabinet door
loose contacts, blown fuse, blown ?? RD2018 LED status
LED etc., In case of PCB defects, it
is not recommended to correct at
site. Faulty PCBs may be sent to
BHEL / Trichy for rectification.

Faults may be diagnosed from the 4.3 Function check

following flow charts and from the
block diagrams. Power supply must
1) Momentarily just press once
be switched off while replacing any
module. Dangerous supply voltages gently and leave the test push button
in display unit mounted in UCB.
are present in the relay driver
module ‘D’ Connector. Precautions 2) For approx. 1 sec. all display
must be observed while handling LEDs show water (green) and all
LEDs switch to steam (Red) and stay
RD2018.
If a module or power supply is for approx. 1 sec.
3) During this period, trip relays will
found to be defective, it is preferable
to replace it, with a new one and not maintain the status prior to test
to attempt local repair. function.
4) After approximate duration of 2
secs. test period, equipment goes to
4.1 Required Tools normal mode.
?? Card extender 5) This facility is given only in UCB
?? Digital Multimeter display unit.
?? Continuity Tester 6) This on line testing can be done
?? Screw driver whenever required to verify the
?? Electrode Simulator Keys healthiness of the equipment.
?? Ascertor cabinet key
?? Trip disable keys

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4.3.2 Water above Steam

4.3 Trouble shooting charts

Trouble shooting Flow Charts guide

the maintenance engineer to
eliminate cause of trouble in a
systematic manner

4.3.1 Faulty Display

4.3.3 Steam below Water

Do not attempt to work on

Faulty electronic modules at
site. Faulty PCBs may be
sent to BHEL / Trichy for
rectification.

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 BHELVISION 20 M

THE EWLI-BHELVISION VESSEL AND PROBE SYSTEM

PROVIDES A SELF FLUSHING FEATURE THAT
PREVENTS ACCUMULATION OF DEBRIS IN THE
VESSEL.

THIS ELIMINATES THE NEED FOR PERIODIC BLOWING

DOWN OF THE VESSEL.

DO NOT BLOW DOWN THE VESSEL IF A BLOCKAGE IS

SUSPECTED.

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Section 5 – Installation/ part drawings

5.0 General

OGA for Ascertor cabinet - Drg. No. 3-97-088-13054

OGA for Display unit - Drg. No. 3-97-088-13055

OGA for operating floor indication box - Drg. No. 3-97-088-14095

External connection diagram (Indication) - Drg. No. 3-97-088-13515

External connection diagram (Validation) - Drg. No. 3-97-088-13518

Internal wiring diagram (Indication) - Drg. No. 3-97-088-13514

Internal wiring diagram (Validation) - Drg. No. 3-97-088-13517

Layout of Ascertor cabinet (Indication) - Drg. No. 3-97-088-13513

Layout of Ascertor cabinet (Validation) - Drg. No. 3-97-088-13516

Basic Scope Diagram - Drg. No. 3-97-088-12319

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Section 6 – Specifications

6.1 Pressure Vessel &

accessories

Material Forged carbon steel, thick wall design

Operating pressure 207 Kg/Sq.cm
Operating temp 450 Deg.C
Steam / Water distance 835mm for 16 probes
Probe sight range 550mm
Steam / water connection 25mm bore, butt weld
Electrode pitch 50 mm
Material Thickness 115 mm

6.2 Displays

Enclosure Polycarbonate/Aluminium
Degree of Protection IP 55
LED HP make, highest bright, industrial grade, square type
Size 99 (W) x 244 (H) mm
Cutout 90 (W) x 234 (H) mm
Depth 79 mm
Special feature Display for fault status and remote test push button
for UCB display
Mounting Suitable clamps for mounting will be provided.

6.3 Power supply Module

PCB material & grade Glass epoxy FR4, 1.6mm thick

35 Micron copper thickness
Mother board Suitable to fix behind 19 inch rack
LED Indications Provided
Power connection Thro’D-Connector cable of 0.5 Sq.mm silver coated
copper Multistrand, PTFE insulated wire
Power supply Linear Power Supply Module
Input / Output 230V AC / 12V DC @ 3.0Amp
Load regulation Better than + 0.2 %
Line regulation + 0.1 %
Over voltage protection (13.8 V DC)
Short circuit protection 120 % rated curremt
Mounting Suitable for 19 inch rack
Indication Power on
Ambient (max) 55 Deg C

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6.4 Electrode
Type Flange type
Body material SS
Tip Titanium tip with ceramic insulator
Gasket Spiral wound metaflex gasket

6.5 Special cable

Application Interconnection between probe and ascertor cabinet

Specification 10 pair, 0.6 Sq.mm PTFE insulated, nickel plated
copper, pair shielded and collective shielded,
extruded.

6.6 Ascertor Cabinet

Size 600 (W) x 600 (H) x 350 (D) mm

Degree of Protection IP 55
Application Outdoor
Operating Temp. 50 Deg.C
Relative Humidity 95%
Power supply 24V DC
Outputs Alarm / Trip contacts & Analogue outputs
Cabinet accessories Door lock, rain canopy, earth stud & mounting plate
Mounting Wall mounted
Mounting accessories Will be supplied

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Section 7 – Checklists

7.1 INSTRUCTION BEFORE 7.3 MONTHLY CHECK LIST FOR

INSTALLATION ASCERTOR
1. Visual inspection to check 1. Check all cabling for secured
damages, if any. connection
2. Check the items received are 2. Check all modules are in its
as per shipping list position
3. Ensure availability of following 3. Check operation of relays
drawings/documents : 4. Check local & operating floor
a) Drum fittings displays
b) Ascertor GA & Display
GA 7.4 VESSEL ISOLATION
c) Layout arrangement CHECKLIST
d) Interconnection detail
e) Jumper details After obtaining authority to isolate the
f) Scope and cabling vessel:
diagram 1. Close off the steam and water
4. Check for correct supply of isolating valves nearest to
OPERATING pressure vessel.
FLOOR/Operating floor display 2. Close off the steam and water
5. Ensure the location of ascertor isolating valves nearest to boiler
cabinet as much close as drum.
possible to pressure vessel. 3. Open drain & vent valves and
7.2 CHECK LIST BEFORE proceed with work required.
COMMISSIONING
1. Entire installation shall be 7.5 VESSEL COMMISSIONING
checked thoroughly as per CHECKLIST
drawings.
2. Check complete interconnection 1. Notify the unit operator of the
as per drawing. intention to commission the
3. Check all terminals for secured vessel, in accordance with
connection. recognised procedures.
4. Check the modules position as 2. Check that the electrode guard
per rack layout arrangement. is in place.
5. Check the jumper settings as 3. Close drain & vent valves.
per requirement. 4. Open water and steam isolating
6. Check for correct display unit at valves nearest to boiler drum.
operating floor and UCB. 5. Crack opens the isolating steam
7. Check the input voltage. valve nearest to the pressure
8. Check IR by using 500 V vessel. Check with the unit
Megger. operator that the vessel slowly
fills with condensate (about 10
-15 minutes).

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6. Crack opens the isolating water

valve nearest to the pressure
vessel. Check with unit operator
that the water level is falling to
approximately normal water
level.
7. Open water valves fully
7.6 TORQUE WRENCH USAGE
CHECKLIST

1. Check that the ratchet direction is

correct.
2. Select the correct size of 1/4”, 3/8”
or 1/2” socket and push it onto the
square.
3. Tighten the nut until the tool ‘clicks’
and is felt to ‘give’ slightly. STOP
pulling immediately.

7.7 PLEASE ENSURE THE

FOLLOWING BEFORE/DURING
COMMISSIONING

1. The pressure vessel shall be

mounted and supported as per
DRUM FITTING drawing.
2. The pressure vessel guard
assembly should not touch the
electrode tip.
3. Check the cabling as per
interconnection drawings
4. Check the modules position as
per rack arrangement drawings.
Do not change the module
position.
5. Do not try to remove / replace
the modules when the power is
ON.
6. On line testing of equipment
feature is provided from UCB
mounted display unit only.
Check correct installation of
UCB display unit.

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