4050150/7

IM-P405-31
AB Issue 7

BDV60
Blowdown Vessel
Installation and Maintenance Instructions

1. Safety information

2. Product - specific
safety information

3. Product information

4. Installation

5. Commissioning

6. Operation

7. Maintenance

8. Spare parts

IM-P405-31
Printed in the AB
UK Issue 7 1
© Copyright 2011
2 IM-P405-31 AB Issue 7
 1. Safety information
Spirax Sarco products are designed, manufactured and tested to exacting standards
to meet modern system requirements.

Safe operation of the unit can only be guaranteed if it is properly installed,

commissioned and maintained by a qualified person (see Section 1.10 on page 4)
in compliance with the operating instructions. General installation and safety
instructions for pipeline and plant construction, as well as the proper use of tools
and safety equipment must also be complied with.

The product is designed and constructed to withstand the forces encountered during
normal use. Use of the product for any other purpose, or failure to install the product
in accordance with these Installation and Maintenance Instructions, could cause
damage to the product, will invalidate the marking, and may cause injury or fatality
to personnel.

1.1 Intended use

Referring to these Installation and Maintenance Instructions, name-plate and Technical
Information Sheet, check that the product is suitable for the intended use /application.
The products listed below comply with the requirements of the European Pressure
Equipment Directive 97/ 23/ EC and carry the mark. The products fall within the
following Pressure Equipment Directive categories:
Group 2
Product
gases
BDV60 /3 3
BDV60 /4 3
BDV60 /5 3
BDV60 /6 3
BDV60 /8 4
BDV60 /10 4

i) The products have been specifically designed for use with steam which is in Group 2
of the above mentioned Pressure Equipment Directive. The product's use on other
fluids may be possible but, if this is contemplated, Spirax Sarco should be contacted to
confirm the suitability of the product for the application being considered.
ii) Check material suitability, pressure and temperature and their maximum and
minimum values. If the maximum operating limits of the product are lower than
those of the system in which it is being fitted, or if malfunction of the product
could result in a dangerous overpressure or overtemperature occurrence, ensure
a safety device is included in the system to prevent such over-limit situations.
iii) Determine the correct installation situation and direction of fluid flow.
iv) Spirax Sarco products are not intended to withstand external stresses that may be
induced by any system to which they are fitted. It is the responsibility of the installer
to consider these stresses and take adequate precautions to minimise them.
v) Remove protective covers from all connections and protective film from all name-
plates, where appropriate, before installation on steam or other high temperature
applications.

IM-P405-31 AB Issue 7 3
1.2 Access
Ensure safe access and if necessary a safe working platform (suitably guarded)
before attempting to work on the product. Arrange suitable lifting gear if required.

1.3 Lighting
Ensure adequate lighting, particularly where detailed or intricate work is required.

1.4 Hazardous liquids or gases in the pipeline

Consider what is in the pipeline or what may have been in the pipeline at some
previous time. Consider; flammable materials, substances hazardous to health,
extremes of temperature.

1.5 Hazardous environment around the product

Consider; explosion risk areas, lack of oxygen (e.g. tanks, pits), dangerous gases,
extremes of temperature, hot surfaces, fire hazard (e.g. during welding), excessive noise,
moving machinery.

1.6 The system

Consider the effect on the complete system of the work proposed. Will any proposed
action (e.g. closing isolation valves, electrical isolation) put any other part of the
system or any personnel at risk?
Dangers might include isolation of vents or protective devices or the rendering
ineffective of controls or alarms. Ensure isolation valves are turned on and off in a
gradual way to avoid system shocks.
Ensure that any pressure is isolated and safely vented to atmospheric pressure.
Consider double isolation (double block and bleed) and the locking or labelling of
closed valves. Do not assume that the system has depressurised even when the
pressure gauge indicates zero.

1.7 Temperature
Allow time for temperature to normalise after isolation to avoid danger of burns.

1.8 Tools and consumables

Before starting work ensure that you have suitable tools and / or consumables
available. Use only genuine Spirax Sarco replacement parts.

1.9 Protective clothing

Consider whether any protective clothing is required by yourself and /or others in
the vicinity to protect against the hazards of, for example, chemicals, high / low
temperature, noise, falling objects, and dangers to eyes and face.

1.10 Permits to work

All work must be carried out or be supervised by a suitably competent person.
Installation and operating personnel should be trained in the correct use of the
product according to these instructions.
Where a formal 'permit to work' system is in force it must be complied with. Where
there is no such system, it is recommended that a responsible person should know
what work is going on and, where necessary, arrange to have an assistant whose
primary responsibility is safety.
Post 'warning notices' if necessary.

1.11 Handling
Manual handling of Spirax-Sarco products may present a risk of injury. Lifting,
pushing, pulling, carrying or supporting a load by bodily force can cause injury
particularly to the back. You are advised to assess the risks taking into account the
task, the individual, the load and the working environment and use the appropriate
handling method depending on the circumstances of the work being done.

4 IM-P405-31 AB Issue 7
1.12 Residual hazards
In normal use the external surface of the product may be very hot. If used at the
maximum permitted operating conditions the surface temperature of blowdown vessels
may reach a temperature approaching 171°C (340°F).
Many products are not self-draining. Take due care when dismantling or removing
the product from an installation (refer to 'Maintenance Instructions').

1.13 Freezing
Provision must be made to protect products which are not self-draining against frost
damage if they are inoperative in environments where they may be exposed
to temperatures below freezing point during shutdown. The vessel should be
thoroughly defrosted prior to use. Trace heating should be considered under servere
environmental conditions, in order to prevent the operating temperature of the vessel
dropping below -10°C (14°F) during service.

1.14 Disposal
This product is recyclable and no ecological hazard is anticipated with its disposal
providing due care is taken.

1.15 Returning products

Customers and stockists are reminded that under UK and EC Health, Safety and
Environment Law, when returning products to Spirax Sarco they must provide
information on any hazards and the precautions to be taken due to contamination
residues or mechanical damage which may present a health, safety or environmental
risk. This information must be provided in writing including Health and Safety Data
Sheets relating to any substances identified as hazardous.

2. Product - specific safety information

The following information is specific to this product and should be read in conjunction
with the General Safety Information - Section 1.

Warning
If this product is not used in the manner specified by this IMI, then the
protection provided may be impaired.

2.1 Overpressure protection

The outlet flash steam connection should not be restricted in any way that would cause
a rise in the vessel pressure above ambient conditions.
Therefore no pressure safety device need be fitted to this vessel.

2.2 Guard rail

The vessel may need a guard rail and / or mesh screen to prevent injury caused by
accidental contact with the hot vessel or pipework.

2.3 Associated equipment

Please ensure that you make reference to the technical / installation information
for equipment coupled to this vessel to avoid any possible operational difficulties
with associated equipment.

IM-P405-31 AB Issue 7 5
 3. Product information
3.1 General information
Spirax Sarco products are designed, manufactured and tested to exacting standards to meet
modern system requirements. Where applicable, they satisfy current safety and design codes
and users can expect long service life when products are selected, installed and maintained
in accordance with Spirax Sarco recommendations.
BDV60 blowdown vessels are designed and constructed to comply with the European Pressure
Equipment Directive 97 /23 /EC.
These vessels are particularly suited to accept manual /automatically controlled bottom
blowdown, manually controlled bleed valves for continuous blowdown, automatically controlled
valves and control systems for TDS, vessels and ancillaries and heat recovery equipment.
This Installation and Maintenance Instruction document provides comprehensive information
on operation, installation and maintenance and should be read prior to commencing work on
the product.

3.2 Technical data

Materials of construction Carbon steel
Paint finish Temperature resistant silver paint

3.2 Pressure / temperature limits

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 (5 psi g).
Body design conditions PN16
Maximum design pressure 7 bar g @ 171°C (101 psi g @ 340°F)
Maximum design temperature 171°C @ 7 bar g (340°F @ 101 psi g)
Minimum design temperature -10°C (14°F)
Maximum operating pressure re. PM60 0.35 bar g (5 psi g)
Maximum operating temperature re. PM60 109°C (228°F)
Minimum operating temperature 0°C (32°F)
Designed for a maximum cold hydraulic test pressure of 10 bar g (145 psi g)
Note: This test is in accordance with the European Pressure Equipment Directive 97/ 23 / EC


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Fig. 1 Typical name-plate details

6 IM-P405-31 AB Issue 7
 Vent head with internal
separator removes moisture
from the steam.

Lifting lugs for safe

positioning of vessel on site.
Inlet number 3 for level
control chamber or TDS
blowdown.

Inlet number 2
for discharges Pressure gauge and
from automatic 'U' syphon for
TDS control monitoring operation.
system
or level control Outlet to drain
chamber / maintains internal
gauge glass standing water level
to cool incoming
blowdown). blowdown.
* Oval
DCV2 inspection
Check valve control opening
M21S2 Cooling water system
Ball valve for applications
where blowdown is
very frequent.
Line drain valves for
emptying a shutdown
boiler.

* Note: The BDV60/6,

BDV60 / 8 and
BDV60 / 10 have two
inspection openings,
one towards the top
Inlet and a lower one at
number 1 180°.
for main blowdown
from the bottom of the boiler. Vessel drain valve
for clearing sludge
from the blowdown vessel.

Note: Inlet 1 is dedicated to the main blowdown from the bottom of the boiler. Inlets 2 and 3
are interchangable, between level control chamber /gauge glass blowdown and TDS blowdown.

Fig. 2 Typical features of a blowdown vessel

IM-P405-31 AB Issue 7 7
 4. Installation
Before actioning any installation observe the 'Safety information' in Sections 1 and 2.

Ensure that any permanent plugs supplied with the vessel are fitted securely, both at ambient
and operating temperatures.
The vessel must be mounted with the flash steam outlet uppermost, as shown in Figure 2.
Each vessel incorporates a 3 /8" BSP screwed boss for a pressure gauge, U-syphon and cock.
Please refer to Table 1 for the numbers of legs and bolt holes.
The outlet flash steam connection should not be restricted in any way that would cause a
rise in the vessel pressure above ambient conditions.
Therefore no pressure safety device need be fitted to this vessel.

Table 1 Fixing bolts

Vessel feet have a pre-drilled hole for fixing bolts (diameters are as stated):-
Blowdown vessel No. of Legs PCD of bolt holes
BDV60 /3 3 Ø14 mm ( ") on a 406.0 mm PCD
BDV60 /4 3 Ø19 mm (¾") on a 536.0 mm PCD
BDV60 /5 3 Ø19 mm (¾") on a 679.0 mm PCD
BDV60 /6 3 Ø19 mm (¾") on a 833.0 mm PCD
BDV60 /8 3 Ø19 mm (¾") on a 1 126.0 mm PCD
BDV60 /10 4 Ø19 mm (¾") on a 1 376.0 mm PCD

4.1 Positioning:
- Use the lifting lugs to position the vessel.
- Ensure there is access to the inspection opening.
- Remove all plastic plugs and blanks from the vessel connections.
- Plug or blank off connections which are not to be used. WARNING: Do not blank off the vent
or the outlet connections.
- Use a spirit level to check that the blowdown vessel is perfectly vertical. This is essential
for optimum performance. Use a non-compressible packing under the legs if necessary.

4.2 Mating of vessel pipework on site

We offer as much guidance and technical detail as possible for the vessel to help with
connection to system pipework /valves.
When making the final connections between the blowdown vessel and the system pipework
please use any technical documents that refer to individual porting dimensions as a guide only
and use the final position of the vessel to match up the individual ports to the system pipework
for level and mating accuracy.

4.3 Inlet layout

Install the inlet pipework at a lower level than the vessel. This ensures that the blowdown line
remains flooded, minimising the effect of waterhammer. Ensure the proper use of stop valves
and check valves, or the combination of both to avoid adverse interaction between different
supply lines to and from the vessel. (Refer to the HSE, PM60 for full details).
Note: Inlet 1 (as shown on Figure 2, page 7) should only be used for the main blowdown from
the bottom of the boiler. Inlets 2 and 3 are interchangable, between level control chamber /
gauge glass blowdown and TDS blowdown.

8 IM-P405-31 AB Issue 7
4.4 Vent layout
Install the vent pipe vertically if possible. If it has to run horizontally then it should have a slight
slope to drain back to the vessel. It should not join other vent lines.
WARNING: Do not fit a check valve or stop valve in the vent line.
It is useful to fit a spool piece between the vessel and vent pipework, which can be removed
to facilitate blanking-off for hydraulic testing.
We strongly recommend the use of a Spirax Sarco vent head to maximise the separation of
any entrained water thereby offering protection to nearby personnel and buildings.
Connect the vent head drain to waste, ideally with an air break, which could take the form
of a tundish. Do not connect it into the blowdown vessel.

4.5 Outlet
Connect the outlet to drain, which must be at a lower level than the vessel.
WARNING: Do not fit a stop valve or a check valve in the outlet pipework.
It is useful to fit a spool piece between the vessel and the outlet pipework, which can be removed
to facilitate blanking-off for hydraulic testing.

4.6 Cooling water system

All vessels are fitted with two connections for a cooling water system, one for a temperature
controller and one for cooling water. Install the temperature controller as described in the relevant
Installation and Maintenance Instructions supplied with the product.
Set the controller to operate at a temperature below 43°C (109.4°F) in the UK, as this is the
maximum temperature at which water may be discharged to drain.

4.7 Paint finish

The vessel is protected with one coat of silver paint which would be deemed suitable for
protection during transit or for vessels located within the boiler house.
For vessels stored or used in external locations more appropriate protection such as
additional paint finish or insulation will need to be considered - See Section 4.8.

4.8 Frost protection

If the vessel is located outdoors there should be some consideration for vessel temperature
protection, guarding against the water reservoir freezing.
Provide trace heating in extreme cases.

5. Commissioning
Before putting the unit into service, ensure that:
- Permanent plugs are tight; Tighten these when the vessel has reached normal operating
temperature.
Caution! The maximum operating temperature is 171oC @ 7 bar g (340 oF @ 101 psi g).
- All connections to adjoining pipework /plant are sound and secured so that no external
stresses are introduced into the unit.
- No extraneous objects / material is present within the vessel.
- The vessel is filled with a standing level of water.

IM-P405-31 AB Issue 7 9
 6. Operation
Operation of the blowdown vessel is inherently simple and no special operating instructions are
required. The vessel allows for the safe expansion of hot water from high to lower pressures
with the accompanying production of flash steam.
Before use and after draining / flushing the vessel, it must be replenished to its normal working
level (level with the outlet on the centreline of the vessel shell) by introducing fresh water until
it discharges at the outlet.
On a precautionary note, vessels are designed to operate at high temperatures and care should
be taken to avoid personal injury as vessels are normally unlagged to dissipate heat.
We recommend that the pressure gauge is checked during bottom blowdown.
If it indicates more than 0.35 bar g (5 psi g) then it may indicate that the vent or outlet is blocked,
a situation demanding immediate attention.
WARNING: The stop valve at the vessel /manifold must be in the fully open position before
operating / testing any bottom blowdown valve, auto TDS control system, level control
system, etc. that may drain into the vessel.
This is particularly important in the case of level control systems, as level controls may
appear to be working correctly but in reality will be untested, and may be faulty.
Operating conditions
Spirax Sarco blowdown vessels are designed to operate up to: 7 bar g @ 171°C (101 psi g @ 340°F)
They have a minimum operating temperature of: 0°C (32°F)

10 IM-P405-31 AB Issue 7
 7. Maintenance
WARNING:
Isolate the vessel by closing and securing stop valves on blowdown lines at the vessel
inlet, closing all boiler blowdown valves and opening any line valves (i.e. double block
and bleed principle).
Repairs to pressure vessels are not recommended as specialist design procedures
and welding operations are required, together with reinspection by a qualified
competent person.

6 month intervals
The vessel must be drained every 6 months to remove concentrated blowdown water /
sludge. Any accumulation of sludge within the vessel must be cleared by passing a hose
through the inspection/access hatch and flushing with the drain valve open.
Before reusing, after draining /flushing the vessel, it must be replenished to its normal working
level (level with the outlet on the centreline of the vessel shell) by introducing fresh water until
it discharges at the outlet.

14 month intervals
Blowdown vessels should be thoroughly examined by a 'competent person' every 14 months
or at every major boiler inspection. An examination would normally include a visual examination
of the internal surfaces of the vessel to ensure that there is no excessive corrosion, erosion,
or scaling, and a check for scaling or other obstruction in the vessel vent, outlet or outlet anti-
syphon hole.
It is the task of the ‘competent person’ to determine which checks to carry out, and the necessary
action to be taken.
Fit a new gasket to the inspection opening every time the cover is removed (see Section 8,
Spare parts).

The Table below gives detail of inspection port openings for each model:
Vessel designation Inspection port opening
BDV60/3, BDV60/4, BDV60/5 Handhole size 150 x 100 mm oval
BDV60/6, BDV60/8, BDV60/10 2 x hole size 150 x 100 mm oval

Note:
Vessels should be included in a written scheme of examination compiled by a suitably qualified
competent person who is responsible for determining the frequency of examination.

IM-P405-31 AB Issue 7 11
 8. Spare parts
Gaskets are the only available spares for blowdown vessels:

Available spares - Inspection opening gaskets

Vessel type
BDV60 /3 1 off Torus gasket
BDV60 /4 Outside dimensions 180 x 130 mm Spirax Sarco Part no. 4050181
BDV60 /5
BDV60 /6 2 off Torus gasket
BDV60 /8 Outside dimensions 180 x 130 mm Spirax Sarco Part no. 4050181
BDV60 /10

How to order spares

Example: 1 off Inspection opening gasket for a BDV60 / 3 - Spirax Sarco Part no. 4050181.

12 IM-P405-31 AB Issue 7