STEAMPAK Series
DrumPAK
Boiler Drum Level Control Packages
FEATURES
• Helps prevent unplanned boiler
shutdowns due to drum level and
feedwater pressure
• Increases safety for personnel and
equipment
• Pre-configured single-, two- or three-
element control strategies
• Optional level instrumentation
• Application-specific installation &
operations documentation
SYSTEM DESCRIPTION
DrumPAK is a series of pre-engineered control
packages designed to provide significant improve-
ments in maintaining drum water level, stabilizing the
effects of feedwater pressure changes, and respond-
ing to plant load changes.
Single-element control Two-element control requires
the addition of a steam flow measurement device.
Three-element control also requires feedwater
measurement. DrumPAK functions with either linear
or non-linear flow devices without modification to the
control programming or hardware.
DrumPAK-1
The DrumPAK controller receives the Drum Level
signal from the drum level transmitter, compares it to
a pre-determined setpoint, and adjusts the output to
the feedwater flow valve. A single-element system,
while simple and low-cost, does not protect against
“shrink” and “swell”, and cannot anticipate large or
sudden changes in plant steam demand. Therefore
DrumPAK-1 is typically used on small boilers with
slow load changes.
DrumPAK-2
DrumPAK-2 adds Steam Flow measurement for
“shrink” and “swell” compensation and better re-
sponse to load changes. The controller calculates
the feedwater flow requirement based on level, and
uses the Steam Flow signal from a flow transmitter or
vortex meter as a feedforward signal to anticipate the
effect of steam demand changes on level.
STEAM
FE
101
FT
101
BOILER DRUM
IP FEEDWATER
FE
101
FT
101
The output is fed to an X,Y lookup table that is
programmed with predetermined valve positions for
given steam flows (entered from the front panel during
commissioning) before being sent to the Feedwater
Flow Control Valve in the field.
DrumPAK-3
A three-element system adds measurement and
control of feedwater, which allows the system to
compensate for variations in feedwater pressure and
valve linearity. The output of the Drum Level control
algorithm, adjusted with the Steam Flow
feedforward input, becomes the Remote Setpoint
for the Feedwater Flow algorithm. The DrumPAK
controller rcompares the Feedwater Flow signal
from the flow transmitter ato this setpoint and
sends the output to an X,Y lookup table pro-
grammed with predetermined valve positions for
given steam flows (entered from the front panel
during commissioning). The resulting signal is
sent to the Feedwater Flow Control Valve in the
field. Large boilers or those with large or rapid
load changes benefit most from a 3-element control
system.
Installing DrumPAK can significantly reduce or
eliminate boiler shutdowns due to drum level or
feedwater pressure. DrumPAK not only helps
prevent loss of valuable production time and
materials, but increases the safety of your boiler.
A DrumPAK system more than pays for itself when
it prevents just one shutdown per year.
Specification Sheet
S-STEAMPAK-DrumPAK
STEAMPAK Series
DrumPAK Boiler Drum Level Control
EQUIPMENT DESCRIPTION
Each DrumPAK includes:
• DrumPAK controller, pre-configured, with the I/O
required for one-, two- or three-element drum
level control
• Drum level transmitter with 3-valve manifold
(optional)
• All necessary documentation for the installation,
startup and operation of the system.
The DrumPAK controller is a multiloop controller with
flexible, isolated I/O. It has a high-visibility display
with clear, informative screens for ease of operation.
The basic controller includes the CPU, power supply,
vacuum fluorescent display, and terminal block. The
controller memory is non-volatile RAM which contains
the configured database and all current process
parameters. The terminal block provides direct
connection of field wiring at the rear of the controller.
The power supply is 85-250Vac or 24Vcd, and the
front panel has a NEMA 4 rating. The controller also
provides failsafe and power fail-recovery settings for
all configured parameters and output points.
DrumPAK is part of the SteamPAK series of pre-engi-
neered boiler control packages. Each controller comes
network enabled, to connect to other packages in the
SteamPAK series. This peer-to-peer network provides
secure communications between SteamPAK controllers
to ensure your boiler stays up and running regardless of
traffic or failures on the plant information network.
DrumPAK OPTIONS
Modbus Communications - An RS-485 communications
module is added to the controller to provide a second
network connection for Modbus RTU over RS-485, for
connecting the TrimPAK controller to a host PC or
operator graphic panel.
Field Instrumentation - When purchased as part of the
DrumPAK system, the controller and level transmitter are
pre-ranged and pre-calibrated. No further adjustments
are required. The transmitter provides local and infinite
adjustment of zero and span and has an accuracy of
±0.075%. Two non-volatile EEPROMs, one in the
primary electronics and one in the secondary electronics,
back up the transmitter configuration. When replacing
the electronics, the new assembly instantly recognizes
the original configuration. The three-valve manifold
includes a single mounting flange that allows the
transmitter to bolt directly to the manifold to simplify
installation.
2
S-STEAMPAK-DrumPAK
Standard Application Engineering - This can include
setting up the TrimPAK controller database to
communicate with other SteamPAK cotnrollers, adding
Flue Gas Recirculation Control, configuration and display
of additional alarm and/or data acquisition points, or
integration with SteamVIEW software. (Note: FGR
control is not available if the Boiler Efficiency Calculation
option is selected).
Backup Memory Module - provides redundant, remov-
able non-volatile RAM which backs up the controller
database. In addition, if left on the controller during
operation, it is updated every 50ms with current process
data such as output values, controller mode, tuning
parameters etc. This allows immediate re-start of the
system after a power outage or equipment failure, with
the latest values.
Additional Data Acquisition / Alarm Points - depending
on the options selected, up to 4 additional inputs or
outputs may be specified for data acquisiton or alarming.
This option typically requires Custom Application
Engineering.
Custom Application Engineering - if the standard
TrimPAK configuration doesn’t meet your application
needs, MicroMod will work with you to develop a cost-
effective solution to improve your boiler’s efficiency and
optimize your fuel consumption.
The MicroMod SteamPAK SERIES
DrumPAK is just one of MicroMod’s pre-engineered
packages for industrial and institutional boiler controls.
The SteamPAK family includes:
PlantPAK and PlantPAK-LL - plant master controller, with
optional lead/lag
BoilerPAK - single-point jackshaft position control
TrimPAK - Parallel position combustion control
system with O2 trim. Ideal for upgrading jackshaft
control systems to obtain maximum boiler efficiency.
MeterPAK - Fully metered combustion control system
with O2 trim
BurnerPAK - Burner Management Systems
Combustion control packages are also available for High
Temperature Hot Water systems.
STEAMPAK Series
DrumPAK Boiler Drum Level Control S-STEAMPAK-DrumPAK

ORDERING INFORMATION

DrumPAK is a licensed package. The following end-user information must be supplied with each package ordered:
End-user Company Name
Complete Address
Contact Name
Telephone Number
Fax Number

DrumPAK __ __ __ __
01 - 07 08 09 10 11

DrumPAK DrumPAK
Drum Level Controller
Control Type
Single Element 1
Two Element 2
Three Element 3
Communication Option
1
None 0
Modbus - for communication to host PC 1
Operator Language
English E
Spanish S
Optional Field Instruments2
None 0
Drum Level Transmitter with 3-valve manifold 1

1
All TrimPAK controllers include peer-to-peer communications as standard, for connection to other SteamPAK products
2
If Level Transmitter is ordered, TrimPAK controller and transmitter are pre-ranged and pre-calibrated. Steam Flow
element & transmitter must be provided separately for 2- and 3-element control.

Available Options (please specify on order):

Standard Application Engineering (may include one or more of the following):
Configuration for communication with other SteamPAK controllers (e.g. PlantPAK)
Configuration / display of additional data acquisition points
Two-element furnace pressure control (requires furnace pressure transmitter signal)
Integration with SteamVIEW software

Backup Memory Module (blank)

Additional data acquisition points:

Analog (hardware only) - per point
Digital (hardware only) - per point

Custom Application Engineering

3
STEAMPAK Series
DrumPAK Boiler Drum Level Control S-STEAMPAK-DrumPAK

The Company’s policy is one of continuous product improvement

and the right is reserved to modify the information contained
herein without notice.
Printed in USA (August 2005)
© MicroMod Automation, Inc. 2004

75 Town Centre Drive

Rochester, NY 14623 USA
www.micromodautomation.com Tel: (585) 321-9200
Fax: (585) 321-9291
4 Email: boilers@micmod.com