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 Lifting lugs for safe
will cause foaming, and scaling of the boiler tubes. A build-up of solids at the bottom positioning of vessel
of the boiler could also have serious consequences. Most modern boilers are fitted on site.
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 Internal stainless steel
recommended way of cooling this water. wear plate.

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 Level control chamber
vessel. 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 Discharge from automatic
blowdown vessels should be constructed to PD 5500 and should be regularly TDS control system.
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.

User benefits
l Three inlets as standard with dedicated bottom blowdown connection. Line drain valves for
emptying a boiler that
l Fully complies with the requirements of the has been shut down.
European Pressure Equipment Directive 97 / 23 / EC.

l Full compliance with PM60 and PD 5500.

l Documentation in compliance with PD 5500, Modules B and F.

l Complete systems normally readily available from stock.

l Quick and easy to install and maintain.

l Safer and cheaper than a blowdown pit.

l Spirax Sarco's guarantee of worldwide knowledge, service and technical support.

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The BDV60 blowdown vessel has Dry vented
been designed with three inlets as flash
standard. steam

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 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.

The blowdown vessel is

Drain valve for removing designed and constructed
sludge from the to PD 5500 complete with
blowdown vessel. full documentation.

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 Sizing and selection
The selection of a blowdown vessel depends on the flowrate and
the proportion of flash steam released.
Table 1 - Equivalent straight lengths
Blowdown line 25 mm 32 mm 40 mm 50 mm
The following factors affect the selection:- size (1") (1") (1") (2")
n The boiler pressure. Pipe fitting or valve Equivalent length in metres
n The number of boilers.
Long radius bend 0.5 0.7 0.8 0.9
n The duration of blowdown.
n The blowdown line size. Manifold inlet 1.1 1.5 1.7 2.2
n The length of the blowdown line between the boiler and Globe valve 9.6 12.2 13.9 17.8
the blowdown vessel. Check valve 3.6 4.3 5.0 6.3
n The blowdown regime. Blowdown valve 0.3 0.4 0.4 0.5
For example, the sizing below assumes the blowdown line has an
'equivalent straight length' of at least 7 m.
Table 2 - Blowdown vessel selection
When estimating 'equivalent straight length' the lengths shown in
Table 1 should be added to the length of straight pipe to allow for Blowdown line 25 mm 32 mm 40 mm 50 mm
size (1") (1") (1") (2")
valves and fittings.
Boiler pressure Blowdown vessel
From Table 1 it will be seen that in most practical applications bar g psi g BDV60/_
it would be unusual for the equivalent straight length to be less
5.5 80 3 3 3 4
than 7 m.
7.6 110 3 3 4 5
If the length is less than 7 m multiply the actual boiler pressure by
8.3 120 3 4 4 6
1.15 before using the sizing table, Table 2.
10.3 150 3 4 5 6
The blowdown regime:
12.1 175 4 4 5 8
n Typical normal bottom blowdown of, perhaps, 5 seconds duration.
n Weekly low level alarm testing where practice is in accordance 17.2 250 4 5 6 8
with PM5 - steam down from normal level to first low water level 20.7 300 5 6 8 10
and blow down from first to second low water level. 24.1 350 5 6 8 10
n Blowdown discharges from sequencing valves on external 27.6 400 6 8 8 12
chambers, gauge glasses etc.
n Automatic TDS control discharges. Note: For intermediate pressures go to the next higher pressure.
The selection table (Table 2) only applies if the blowdown
duration is no longer than 20 seconds in total, starting with Graph 1 - Blowdown flowrates
a cold vessel (water at a temperature of 15C to 20C).
This graph will give the flowrate of blowdown in litres per second.
If this time is exceeded, carryover of water with the flash steam may When this value has been read, multiply it by the duration of
occur through the vent. The water may also be too hot to discharge blowdown (seconds), and the answer will be the maximum
safely and legally into a public drainage system. volume discharged.
Always incorporate a cooling water system for multi-boiler Blowdown line size 50 mm
20
applications or in instances where the frequency or duration of
blowdown is considerably in excess of PM60 or PM5 requirements. 40 mm
If there is any doubt about correct vessel selection, please
contact Spirax Sarco outlining the specific conditions and
blowdown regime. 10
9 32 mm
Blowdown flowrate (I /s)

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How to select the blowdown vessel: 7
Step 1 With the aid of Table 1, determine the equivalent straight 6
length of the blowdown line. 25 mm
5
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 4
boiler pressure by 1.15.
3 20 mm
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, 2
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 1
4 5 6 7 8 9 10 20 30 40
1st low level to 2nd low level alarm. If this volume is
unknown, it can be calculated with the aid of Graph 1, Boiler pressure (bar g)
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 Table 3 - Vent head selection
be selected in order to satisfy this requirement. Note: The vent head required depends on the vessel selected
Step 4 With the aid of Table 3, the correct vent head can now be For a BDV60 /3 select a VH4 vent head
selected to suit the vessel. For a BDV60 /4 select a VH4 vent head
For a BDV60 /5 select a VH6 vent head
The selection is now complete.
For a BDV60 /6 select a VH6 vent head
Selection example: For a BDV60 /8 select a VH8 vent head
For a 10 bar g boiler with 40 mm blowdown line at least 7 m long For a BDV60 /10 select a VH8 vent head
select, from Table 2, a BDV60/5.
From Table 3 select a VH6 vent head. For a BDV60 /12 select a VH10 vent head

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 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 (approximate) in mm, kg and L

Blowdown vessel type BDV60 /3 BDV60 /4 BDV60 /5 BDV60 /6 BDV60 /8 BDV60 /10 BDV60 /12
A Flanged PN16* 100 100 150 150 200 200 250
B Flanged PN16* 80 80 100 100 150 150 150
Height 100 100 100 100 100 100 320
C Oval
Width 150 150 150 150 150 150 420
D 460 610 765 915 1 205 1 500 1 800
Sizes,
pipe E 400 400 400 400 400 400 400
connections F 500 540 580 630 705 770 840
and G 310 350 390 440 525 590 660
dimensions
H 1 830 1 910 1 995 2 095 2 240 2 370 2 515
J 1 080 1 125 1 165 1 215 1 290 1 355 1 430
K 330 405 485 560 705 850 1 000
X 1080 1120 1163 1568 1612 1676 1427
Y - - - 864 962 1026 -
Number of legs 3 3 3 3 3 3 4
Empty 185 220 275 392 480 892 1 275
Weights
Full (e.g. for hydraulic test) 370 570 825 1 267 2 090 3 567 4 925
Capacities - standing water 92 175 275 437 805 1 337 1 825

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

J Safety information, installation and maintenance

For full details see the Installation and Maintenance Instructions
supplied with the product.
Y
* Note: There is a second inspection opening on the BDV60 / 6,
BDV60/8 and BDV60/10 which is fitted 180 to the top opening.
E 2" BSP drain 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
Inlet 3 concentrated blowdown water /sludge. Before reusing, the vessel
DN25 PN16 must be refilled with fresh water.
(Level control chamber and gauge Blowdown vessels should be thoroughly examined by a 'competent
Inlet 2 glass blowdown or TDS blowdown) person' every 14 months or at every major boiler inspection.
DN25 PN16 Spare parts:
(TDS control system New gaskets for the inspection openings are available as spares
or level control from Spirax Sarco.
chamber /gauge
glass blowdown)
How to order
Example: 1 off Spirax Sarco BDV60/5 blowdown vessel and a VH6
Inlet 1 vent head to suit a 10 bar g boiler having a 40 mm blowdown line.
DN50 PN16
(Main bottom
blowdown)
" BSP cooling water inlet

1" BSP temperature sensor

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 The BDV60 system

VH vent head W
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 H
Vent head type VH4 VH6 VH8 VH10
Inlet size 100 150 200 250
Drain size 1" BSP 1" BSP 1" BSP 1" BSP
H 320 390 430 495
W 240 340 425 525 Inlet connection with
Drain plated carbon steel lap
For full details see separate literature. connection joint flange to suit PN16

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 155
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

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. B
Dimensions (approximate) in mm
Valve size DN15 DN20 DN25 DN32 DN40 DN50
A 130 150 160 180 200 230
B 191 191 209 206 282 276
A

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Pressure gauge
A Useful to ensure that the
vessel is not pressurised
during blowdown. Improves
C safety since any pressure
would give early indication
B of pipework blockage.
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 40C). This equipment is particularly
useful when several boilers have to be blown down
in succession into the blowdown vessel.

The pressure gauge set consists of:- The interval between blowdowns needs to be
several minutes in order for the cooling system to
A 4" dial pressure gauge 0 - 1.6 bar (0 - 23 psi)
perform its function effectively.
B 2" BSP 'U' syphon Steel
A B C D A
C 2" BSP gauge cock Brass

E F

The system consists of:-

Nickel plated
A " BSP non-venting ball valve
brass
B " BSP LCV1 check valve Bronze
C " BSP SBRA control valve Bronze
D " BSP Fig 12 Y-type strainer Brass
E Sensor pocket Brass
128 range
F Temperature controller
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.

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 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 - Spirax Sarco blowdown vessel type BDV60/5 designed, constructed and tested to PD 5500
1 - Stainless steel vent head type VH6
For main blowdown from bottom of boiler:
1 - Inlet manifold: type MF2 (DN50), branch sizes DN40 PN16
2 - Check valves type DCV2, DN40
2 - Stop valves type G3, DN40 PN16/40
2 - Line drain valve type G3, DN40 PN16/40
For auto TDS control discharges:
1 - Inlet manifold: type MF2 (DN25), branch sizes DN25 PN16
2 - Check valves type DCV2, DN25
2 - Stop valves type G3, DN25 PN16/40
For level controls blowdown:
1 - Inlet manifold: type MF2 (DN25), branch sizes DN15 PN16
2 - Check valves type DCV2, DN15
2 - Stop valves type G3, DN15 PN16/40
Other fittings recommended in PM60:
1 - Blowdown vessel drain valve, 2" BSP
1 - Blowdown vessel pressure gauge set
1 - Cooling water system

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

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SB-P405-01 AB Issue 7