Blowdown vessels

Meeting the requirements of HSE PM60

BDV60 blowdown vessels

A complete range of equipment for the safe disposal of boiler blowdown
Boiler blowdown
Steam boilers must be blown down to remove contaminants, as too high a level will cause foaming, and scaling of the boiler tubes. A build-up of solids at the bottom of the boiler could also have serious consequences. Most modern boilers are fitted with TDS controls to remove dissolved solids, and a blowdown valve that is opened at regular intervals to remove precipitated solids. Because the bottom blowdown valve is opened once per day for just a few seconds, it is not economical to recover the heat, yet water cannot be discharged to drain unless it is cool. Nowadays, blowdown vessels have replaced blowdown pits as the recommended way of cooling this water. Blowdown from TDS controls should ideally be connected to a heat recovery system, but where this is not practical, TDS blowdown may also be piped to a blowdown vessel. Lifting lugs for safe positioning of vessel on site.

Internal stainless steel wear plate.

Level control chamber and gauge glass blowdown.

Regulations
The key UK regulations are those issued by the Health and Safety Executive and British Standards. The Health and Safety Executive Guidance Note PM60 states that blowdown vessels should normally be provided for all new installations instead of blowdown pits. The blowdown vessels should be constructed to PD 5500 and should be regularly inspected by a competent person such as an insurance inspector. The implications of PD 5500 construction include design approval, material certification, independent approval of the welders and welding processes. On completion, a data dossier is prepared and issued to the customer. Spirax Sarco blowdown vessels fully comply with all these requirements plus the requirements of the European Pressure Equipment Directive 97 / 23 / EC. Blowdown from the bottom of the boiler.

Discharge from automatic TDS control system.

User benefits
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Three inlets as standard with dedicated bottom blowdown connection. Fully complies with the requirements of the European Pressure Equipment Directive 97 / 23 / EC. Full compliance with PM60 and PD 5500. Documentation in compliance with PD 5500, Modules B and F. Complete systems normally readily available from stock. Quick and easy to install and maintain. Safer and cheaper than a blowdown pit. Spirax Sarco's guarantee of worldwide knowledge, service and technical support.

Line drain valves for emptying a boiler that has been shut down.

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The BDV60 blowdown vessel has been designed with three inlets as standard. One inlet is dedicated to bottom blowdown, whilst the other two inlets are interchangeable between TDS blowdown and level gauge glass blowdown. A typical two-boiler application is shown below. Separated water to drain

Dry vented flash steam

Inlet from blowdown vessel

Vent head with internal separator removes moisture from the steam.

Pressure gauge for monitoring operation.

Outlet to drain maintains internal standing water level to cool incoming blowdown.

Oval inspection opening with non-asbestos gasket.

Cooling water system for application where frequent blowdown is necessary.

Fully complies with the requirements of the European Pressure Equipment Directive 97 / 23 / EC.

Drain valve for removing sludge from the blowdown vessel.

The blowdown vessel is designed and constructed to PD 5500 complete with full documentation. 3

Sizing and selection

The selection of a blowdown vessel depends on the flowrate and the proportion of flash steam released. The following factors affect the selection:-

Table 1 - Equivalent straight lengths

Blowdown line 25 mm 32 mm 40 mm 50 mm size (1") (1") (1") (2") Pipe fitting or valve Equivalent length in metres Long radius bend 0.5 0.7 0.8 0.9 Manifold inlet 1.1 1.5 1.7 2.2 Globe valve 9.6 12.2 13.9 17.8 Check valve 3.6 4.3 5.0 6.3 Blowdown valve 0.3 0.4 0.4 0.5

n n n n n

The boiler pressure. The number of boilers. The duration of blowdown. The blowdown line size. The length of the blowdown line between the boiler and the blowdown vessel. n The blowdown regime. For example, the sizing below assumes the blowdown line has an 'equivalent straight length' of at least 7 m. When estimating 'equivalent straight length' the lengths shown in Table 1 should be added to the length of straight pipe to allow for valves and fittings. From Table 1 it will be seen that in most practical applications it would be unusual for the equivalent straight length to be less than 7 m. If the length is less than 7 m multiply the actual boiler pressure by 1.15 before using the sizing table, Table 2. The blowdown regime: n Typical normal bottom blowdown of, perhaps, 5 seconds duration. n Weekly low level alarm testing where practice is in accordance with PM5 - steam down from normal level to first low water level and blow down from first to second low water level. n Blowdown discharges from sequencing valves on external chambers, gauge glasses etc. n Automatic TDS control discharges. The selection table (Table 2) only applies if the blowdown duration is no longer than 20 seconds in total, starting with a cold vessel (water at a temperature of 15C to 20C). If this time is exceeded, carryover of water with the flash steam may occur through the vent. The water may also be too hot to discharge safely and legally into a public drainage system. Always incorporate a cooling water system for multi-boiler applications or in instances where the frequency or duration of blowdown is considerably in excess of PM60 or PM5 requirements. If there is any doubt about correct vessel selection, please contact Spirax Sarco outlining the specific conditions and blowdown regime.

Table 2 - Blowdown vessel selection

Blowdown line size Boiler pressure bar g psi g 5.5 80 7.6 110 8.3 120 10.3 150 12.1 175 17.2 250 20.7 300 24.1 350 27.6 400 25 mm (1") 32 mm 40 mm (1") (1") Blowdown vessel BDV60/_ 3 3 3 4 4 4 4 5 4 5 5 6 6 8 6 8 8 8 50 mm (2")

3 3 3 3 4 4 5 5 6

4 5 6 6 8 8 10 10 12

Note: For intermediate pressures go to the next higher pressure.

Graph 1 - Blowdown flowrates

This graph will give the flowrate of blowdown in litres per second. When this value has been read, multiply it by the duration of blowdown (seconds), and the answer will be the maximum volume discharged.
20 Blowdown line size 50 mm 40 mm

How to select the blowdown vessel:

Step 1 With the aid of Table 1, determine the equivalent straight length of the blowdown line. Step 2 Use Table 2 to initially establish the correct size of the vessel. Note: if the result of Step 1 is less than 7 m, multiply the boiler pressure by 1.15. If the vessel is only used in the conditions set out above, then continue to Step 4. Step 3 Using Table 4 , page 5, containing the vessel data, establish the volume of standing water in the selected blowdown vessel. This volume should be at least twice that of the maximum volume of blowdown. The maximum volume of blowdown is usually the volume discharged when blowing down from 1st low level to 2nd low level alarm. If this volume is unknown, it can be calculated with the aid of Graph 1, where details on its use are given. If it is determined that the volume of standing water is insufficient, then a larger blowdown vessel must be selected in order to satisfy this requirement. Step 4 With the aid of Table 3, the correct vent head can now be selected to suit the vessel.

Blowdown flowrate (I /s)

10 9 8 7 6 5 4 3

32 mm

25 mm

20 mm

7 8 9 10

20

30

40

Boiler pressure (bar g)

Table 3 - Vent head selection

Note: The vent head required depends on the vessel selected For a BDV60 /3 select a VH4 vent head For a BDV60 /4 select a VH4 vent head For a BDV60 /5 select a VH6 vent head For a BDV60 /6 select a VH6 vent head For a BDV60 /8 select a VH8 vent head For a BDV60 /10 select a VH8 vent head For a BDV60 /12 select a VH10 vent head

The selection is now complete.

Selection example:
For a 10 bar g boiler with 40 mm blowdown line at least 7 m long select, from Table 2, a BDV60/5. From Table 3 select a VH6 vent head.

BDV60 technical data

The BDV60 is constructed from carbon steel to meet all the requirements of PD 5500. The paint finish is silver.

Table 4 - Sizes, pipe connections, dimensions, weights and capacities

Blowdown vessel type A B C Sizes, E pipe connections F and G dimensions H J K X Y Number of legs Weights Empty D Flanged PN16* Flanged PN16* Oval Height Width BDV60 /3 100 80 100 150 460 400 500 310 1 830 1 080 330 1080 3 185 92 BDV60 /4 100 80 100 150 610 400 540 350 1 910 1 125 405 1120 3 220 570 175 BDV60 /5 150 100 100 150 765 400 580 390 1 995 1 165 485 1163 3 275 825 275 BDV60 /6 150 100 100 150 915 400 630 440 2 095 1 215 560 1568 864 3 392 1 267 437

(approximate) in mm, kg and L BDV60 /10 200 150 100 150 1 500 400 770 590 2 370 1 355 850 1676 1026 3 892 3 567 1 337 BDV60 /12 250 150 320 420 1 800 400 840 660 2 515 1 430 1 000 1427 4 1 275 4 925 1 825

BDV60 /8 200 150 100 150 1 205 400 705 525 2 240 1 290 705 1612 962 3 480 2 090 805

Full (e.g. for hydraulic test) 370 Capacities - standing water

* Note: Flanged BS 1560 ANSI Class 150 or ANSI Class 300 connections are available at extra cost. For further details contact Spirax Sarco.
K D A vent G F 2" BSP pressure gauge Name-plate H B outlet Please note: For the application of boiler blowdown and to comply with the HSE Guidance Note PM60 the vessel internal pressure should not exceed 0.35 bar g . Body design conditions PN16 PMA Max allowable pressure 7 bar g @ 171C TMA Maximum allowable temperature 171C @ 7 bar g Minimum allowable temperature 0C PMO Maximum operating pressure re. PM60 0.35 bar g TMO Maximum operating temperature re. PM60 109C Minimum operating temperature 0C Designed for a maximum cold hydraulic test pressure of 12 bar g PTMX Maximum test pressure 17 bar g K

Pressure /temperature limits

*
J

Safety information, installation and maintenance

For full details see the Installation and Maintenance Instructions supplied with the product. There is a second inspection opening on the BDV60 / 6, * Note: BDV60/8 and BDV60/10 which is fitted 180 to the top opening. Other sizes have a single central opening, similar to the one shown on page 3. Maintenance note: The vessel must be drained every six months to remove concentrated blowdown water /sludge. Before reusing, the vessel must be refilled with fresh water. Blowdown vessels should be thoroughly examined by a 'competent person' every 14 months or at every major boiler inspection. Spare parts: New gaskets for the inspection openings are available as spares from Spirax Sarco.

Y E 2" BSP drain

Inlet 2 DN25 PN16 (TDS control system or level control chamber /gauge glass blowdown) Inlet 1 DN50 PN16 (Main bottom blowdown)

Inlet 3 DN25 PN16 (Level control chamber and gauge glass blowdown or TDS blowdown)

How to order
Example: 1 off Spirax Sarco BDV60/5 blowdown vessel and a VH6 vent head to suit a 10 bar g boiler having a 40 mm blowdown line.

" BSP cooling water inlet 1" BSP temperature sensor

The BDV60 system

VH vent head
Stainless steel vent head which fits on top of the flash steam vent pipe. The vent head incorporates an internal separator to remove water spray from the steam and discharge it separately through the drain connection. Dimensions (approximate) in mm Vent head type Inlet size Drain size H W VH4 100 1" BSP 320 240 VH6 150 1" BSP 390 340 VH8 200 1" BSP 430 425 VH10 250 1" BSP 495 525 Drain connection Inlet connection with plated carbon steel lap joint flange to suit PN16
H W

For full details see separate literature.

MF manifold
For blowdown vessel inlets on multi-boiler installations. Available with manifold size DN50 flanged PN16 or DN25 flanged PN16 and with 2 (MF2) to 6 (MF6) branches sizes 15, 20, 25, 40 or 50 mm. Note: 40 and 50 mm are only available in DN50 size. Carbon steel welded construction with swept bends. Hydraulically tested to 24 bar g. Paint finish is grey.
90 275 150

155

DCV2 check valve

Disc check valve which fits between flanges. Stainless steel construction. For further details see separate literature.

G3 stop valve and line drain valve

Cast steel stop valve with stainless steel valve seat and disc. Flanged PN40 but suitable for use with PN16 flanges. Dimensions (approximate) in mm Valve size A B DN15 130 191 DN20 150 191 DN25 160 209 DN32 180 206 DN40 200 282 DN50 230 276
A B

Pressure gauge
A

Cooling water system

Designed to cool the standing water in the blowdown vessel prior to the next blowdown discharge into the vessel. The system is thermostatically controlled and injects cooling water into the blowdown vessel when standing water exceeds a set temperature (typically 40 C). This equipment is particularly useful when several boilers have to be blown down in succession into the blowdown vessel. The interval between blowdowns needs to be several minutes in order for the cooling system to perform its function effectively. A B C D A

C B

Useful to ensure that the vessel is not pressurised during blowdown. Improves safety since any pressure would give early indication of pipework blockage.

The pressure gauge set consists of:A 4" dial pressure gauge B 2" BSP 'U' syphon C 2" BSP gauge cock 0 - 1.6 bar (0 - 23 psi) Steel Brass

The system consists of:A " BSP non-venting ball valve B " BSP LCV1 check valve C " BSP SBRA control valve D " BSP Fig 12 Y-type strainer E Sensor pocket F Temperature controller Nickel plated brass Bronze Bronze Brass Brass 128 range 20C to 110C

For full details see separate literature. Caution: Where the cooling water is likely to give rise to scale formation, the advice of a water treatment specialist should be sought.

Vessel drain valve

2" BSP nickel plated brass non-venting ball valve on the bottom connection of the blowdown vessel. Regular opening ensures that the vessel is kept clear of sludge. 7

How to specify
A typical specification for the blowdown vessel shown on pages 2 and 3 for a two boiler installation complete with all the ancillaries recommended in PM60 might be as follows:Blowdown vessel 1 1 1 2 2 2 Spirax Sarco blowdown vessel type BDV60/5 designed, constructed and tested to PD 5500 Stainless steel vent head type VH6 Inlet manifold: type MF2 (DN50), branch sizes DN40 PN16 Check valves type DCV2, DN40 Stop valves type G3, DN40 PN16/40 Line drain valve type G3, DN40 PN16/40 Inlet manifold: type MF2 (DN25), branch sizes DN25 PN16 Check valves type DCV2, DN25 Stop valves type G3, DN25 PN16/40 Inlet manifold: type MF2 (DN25), branch sizes DN15 PN16 Check valves type DCV2, DN15 Stop valves type G3, DN15 PN16/40 Blowdown vessel drain valve, 2" BSP Blowdown vessel pressure gauge set Cooling water system

For main blowdown from bottom of boiler:

For auto TDS control discharges: 1 2 2 1 2 2 1 1 1 -

For level controls blowdown:

Other fittings recommended in PM60:

Some of the products may not be available in certain markets.

Spirax-Sarco Limited, Charlton House, Cheltenham, Gloucestershire, GL53 8ER UK. Tel: +44 (0)1242 521361 Fax: +44 (0)1242 573342 E-mail: Enquiries@SpiraxSarco.com Internet: www.SpiraxSarco.com
Copyright 2005 Spirax Sarco is a registered trademark of Spirax-Sarco Limited

SB-P405-01

AB Issue 7