TECHNICAL REFERENCE GUIDE APPLICATION GUIDE

Volume 1
Boiler house applications
 Boiler house applications Volume 1

Pressure control applications Volume 2

Temperature control applications Volume 3

Metering applications Volume 4

Trapping applications Volume 5

Condensate recovery applications Volume 6

Clean steam applications Volume 7

Trade applications Volume 8

The application drawings shown in this publication are intended as a guide only.
As different countries and local areas use different standards, certain items on some drawings
may require revision, e.g. Safety valves - all flanged safety valves are shown as SV5 type
with open bonnets. This may suit the preferences of many countries, however,
some areas may prefer to use safety valves with closed bonnets.
Please note the SV5 is also available in closed bonnet versions.
Selection of products subject to maximum pressure and temperature ratings.
Please contact your local Spirax Sarco engineer with details of specific applications.
In the interests of development and improvement of products, we reserve the right to change the specification.
Copyright 1998

2
 Volume 1 Boiler house applications

Boiler feedtank control 4

Boiler feedtank with steam injection temperature control (flanged) 5

Boiler feedtank with steam injection temperature control (screwed) 6

Modulating boiler feed control 7

Manual single boiler blowdown 8

Automatic single boiler blowdown 9

Multi-boiler blowdown vessel 10

BCS1 TDS control system 11

BCS2 TDS control system for steam generators 12

BCS3 TDS control system 13

BCS4 TDS control system 14

Condensate contamination detection system 15

Heat recovery from boiler blowdown 16

Boiler steam off-take with auto warm-up valve 17

Multi-boiler balanced header 18

Sample cooler system 19

Selection of products subject to maximum pressure and temperature ratings.

In the interests of development and improvement of products, we reserve the right to change the specification. Copyright 1998

3
 Boiler Feedtank Control

Drain back
to tank
5 9
8

6
From cold water 10
supply line or tank 15
2 3 4
Condensate
Steam supply return

1 Boiler feedtank
or Spirax Sarco
semi - deaerator
tank
11

13

12
14
Flash
steam

To boiler feedwater pumps

Table of parts
Part No. Description Spirax Sarco reference:
1 SELF-ACTING CONTROL Type 121 self-acting control
2, 12 STRAINER Fig 1, 3, 12, 12SG, 13, 14, 16, 16L, 33, 34 or 36 strainer
3 CONTROL VALVE SB, KA, KB or KC series valve
4 VACUUM BREAKER VB14 or VB21 vacuum breaker
5 ACTUATOR EL5500 series electric actuator
6 CONTROL VALVE KE43 or KE73 two port single seat control valve
7 VENT HEAD VH series vent head
8 AIR VENT AV13 or AV21 air vent
9 LEVEL CONTROLLER LC2200 proportional controller
10 CAPACITANCE LEVEL PROBE LP20 level probe with PA20 preamplifier
11 STEAM INJECTOR IN series steam injector
13 ISOLATING VALVE BSA1, BSA2 or BSA3 bellows sealed stop valve
14 RECIRCULATING SYSTEM Type RFS recirculating feedwater spray system
15 SEMI-DEAERATOR Type DH flash condensing deaerator head

Selection of products subject to maximum pressure and temperature ratings.

In the interests of development and improvement of products, we reserve the right to change the specification. Copyright 1998

4
 Boiler Feedtank with Steam Injection
Temperature Control (Flanged)

Vent and
drain to a
safe place
1 2 3 4 5 6 7 8 9

10 11 12 13 14 15
DP17T
16

Drain to
High safe place
pressure
steam supply Condensate
return
Cold water
make-up
supply

17 18 19 20 21 22
Boiler feedtank

To boiler feedpump

Table of parts
Part No. Description Bronze Cast iron SG iron Steel Stainless steel
1 SEPARATOR S3 1808 or S5 1808SS or S6
2, 8, 10, ISOLATING Bellows sealed type BSA1 BSA2 BSA3
15, 17, 22 VALVE Ball type M20 M20
3, 11, 18 STRAINER Fig 3 Fig 33 Fig 37SG Fig 34 Fig 36
4, 7 PRESSURE GAUGE 100 mm diameter pressure gauge with 'U' or ring syphon
PRESSURE REDUCING VALVE
5 DP17T
WITH TEMPERATURE CONTROL
6 SAFETY VALVE SV57 SV3 or SV54
9 VACUUM BREAKER VB14 VB 21
12, 19 SPIRATEC SENSOR CHAMBER ST143 ST163
13, 20 FLOAT TRAP FT14 FT44 FT46
14, 21 CHECK VALVE DCV2, 3 or 4
16 VENT HEAD VH

Selection of products subject to maximum pressure and temperature ratings.

In the interests of development and improvement of products, we reserve the right to change the specification. Copyright 1998

5
 Boiler Feedtank Steam Injection
Temperature Control (Screwed)

Vent and
drain to a
safe place

1 2 3 4 5 6 7 8 9

DP17T 10 11 12 13 14 15 16

High Drain to
pressure safe place
steam supply
Condensate
return
Cold water
make-up
supply

17 18 19 20 21 22
Boiler feedtank

To boiler feedpump

Table of parts
Part No. Description Bronze Cast iron SG iron Steel Stainless steel
1 SEPARATOR S2 S1 S5 S6
Globe type HV3 A3S
2, 8, 10, ISOLATING
Piston type RP31
15, 17, 22 VALVE
Ball type M10 M10
3, 11, 18 STRAINER Fig 1 or 12 Fig 13 Fig 12SG Fig 14 Fig 16 or 16L
4, 7 PRESSURE GAUGE 100 mm diameter pressure gauge with 'U' or ring syphon
PRESSURE REDUCING VALVE
5 DP17T
WITH TEMPERATURE CONTROL
6 SAFETY VALVE SV3 SV3
9 VACUUM BREAKER VB14 VB21
12, 19 SPIRATEC SENSOR CHAMBER ST171 ST141 ST161
13, 20 FLOAT TRAP FT14 FT16
14, 21 CHECK VALVE LCV1 LCV2
16 VENT HEAD VH

Selection of products subject to maximum pressure and temperature ratings.

In the interests of development and improvement of products, we reserve the right to change the specification. Copyright 1998

6
 Modulating
Boiler Feed Control

Spill back line

Boiler 5
feedtank
6
Steam to
plant
3

9 8 7 4

Table of parts
Part No. Description Spirax Sarco reference:
1 ISOLATING VALVE G3 gland sealed stop valve
2 ACTUATOR EL5500 series electric actuator
3 CONTROLLER LC2200 proportional level controller
4 CHECK VALVE DCV2B check valve
5 SIGNAL AMPLIFIER PA20 preamplifier
6 LEVEL PROBE LP20 capacitance probe
7 CONTROL VALVE KE43 valve
8 BALL VALVE M10 ball valve
9 STRAINER Fig 33 Cast iron strainer

Selection of products subject to maximum pressure and temperature ratings.

In the interests of development and improvement of products, we reserve the right to change the specification. Copyright 1998

7
 Manual
Single Boiler Blowdown

2 3 4 5

Blowdown
to drain

Manual
drain

Table of parts
Part No. Description Spirax Sarco reference:
1 BLOWDOWN VALVE KBV20 key operated boiler blowdown valve
2 STOP VALVE G3 gland sealed stop valve
3 BLOWDOWN VESSEL BDV60 blowdown vessel
4 VENT HEAD VH series vent head
5 PRESSURE GAUGE 100 mm diameter pressure gauge with 'U' syphon
6 DRAIN VALVE M10 ball valve

Selection of products subject to maximum pressure and temperature ratings.

In the interests of development and improvement of products, we reserve the right to change the specification. Copyright 1998

8
 Automatic
Single Boiler Blowdown

8 2 3 4 5 6

Blowdown
to drain

Manual
drain

Table of parts
Part No. Description Spirax Sarco reference:
1 BLOWDOWN VALVE ABV20 automatic boiler blowdown valve
2 TIMER BT1000 boiler blowdown timer
3 STOP VALVE G3 gland sealed stop valve
4 BLOWDOWN VESSEL BDV60 blowdown vessel
5 VENT HEAD VH series vent head
6 PRESSURE GAUGE 100 mm diameter pressure gauge with 'U' syphon
7 DRAIN VALVE M10 ball valve
8 AIR FILTER / REGULATOR Monnier IP2A with 0 - 7 bar pressure gauge

Selection of products subject to maximum pressure and temperature ratings.

In the interests of development and improvement of products, we reserve the right to change the specification. Copyright 1998

9
 Multi - Boiler Blowdown Vessel

Note: Other inlet connection

manifolds on blowdown vessel
not shown.

2
1 8 7 6 5

Blowdown
Cooling water to drain
supply
9

Bottom blowdown
from boilers

10

Manual
drain

Table of parts
Part No. Description Spirax Sarco reference:
1 STOP VALVE G3 gland sealed stop valve
2 FEED CHECK VALVE DCV2B check valve
3 VENT HEAD VH series vent head
4 PRESSURE GAUGE 100 mm diameter pressure gauge with 'U' syphon
5 BALL VALVE M10 ball valve
6 STRAINER Fig 1, 12, 12SG, 14, 16 or 16L strainer
7 CONTROL VALVE KX51 valve
8 CHECK VALVE LCV1 or LCV2 check valve
9 SELF-ACTING CONTROL Type 121 self-acting control
10 DRAIN VALVE M10 ball valve

Selection of products subject to maximum pressure and temperature ratings.

In the interests of development and improvement of products, we reserve the right to change the specification. Copyright 1998

10
 BCS1
TDS Control System

Note: The drawing shown is for

a single boiler installation only. A
multi-boiler installation requires
a separate line for each boiler
from the TDS system back to
the blowdown tank.

1 7 2 4 5 6

From boiler To blowdown vessel

Table of parts
Part No. Description
1, 6 ISOLATING VALVE
2 SENSOR CHAMBER
3 CONTROLLER
4 BLOWDOWN CONTROL VALVE
5 CHECK VALVE
7 STRAINER
8 BOTTOM BLOWDOWN VALVE
Spirax Sarco reference:
M10 ball valve
S10 sensor chamber with CP10 sensor and PT2 plug tail
BC3210 panel mounted, BC3200 wall mounted or BC1100 DIN rail mounted controller
BCV1 soleniod valve
LCV1 lift check valve
Fig 12 strainer
KBV20 blowdown valve

Selection of products subject to maximum pressure and temperature ratings.

In the interests of development and improvement of products, we reserve the right to change the specification. Copyright 1998

11
 BCS2
TDS Control System for Steam Generators

10
Separator

Boiler feedtank

Steam from Steam to plant

steam generator
2
1

8
7 5 9 6 4 3

To boiler
feedpump

Manual blowdown
to drain

Table of parts
Part No. Description Spirax Sarco reference:
1 CONTROLLER BC3100 DIN rail mounted, BC3200 wall mounted or BC3210 panel mounted controller
2 SENSOR CHAMBER S20 sensor chamber with TP20 temperature sensor and CP10 TDS sensor
3 TDS CONTROL VALVE BCV1, BCV20 or BCV30 blowdown control valve
4, 7, 8 ISOLATING VALVE M10 ball valve
5 STRAINER Fig 14, 16 or 16L strainer
6 FLOAT TRAP FT type float trap
9 SPIRATEC ST14, ST16 chamber
10 VACUUM BREAKER VB14, VB21 vacuum breaker

Selection of products subject to maximum pressure and temperature ratings.

In the interests of development and improvement of products, we reserve the right to change the specification. Copyright 1998

12
 BCS3
TDS Control System

Crown Steam Safety valve

valve to plant
Vent and drain
to safe place
To heat recovery
system or
blowdown vessel

Steam shell boiler Boiler

flue

1 2 3 4

8
5
6

Sample in

Sample out

Cooling
water
In

Out

Table of parts
Part No. Description Spirax Sarco reference:
1 CHECK VALVE DCV2 wafer check valve
BCV30 electrohydraulically actuated or
2 TDS CONTROL VALVE
BCV31 pneumatically actuated blowdown valve
3 STOP VALVE G3 gland sealed stop valve
BC3100 DIN rail mounted, BC3200 wall mounted, BC3210 panel mounted controller
4 CONTROLLER
or BC3100 DIN rail or chassis mounted controller
5 PROBE ELBOW Spirax Sarco probe elbow PE1, PE2, PE3, PE4 or PE5
6 PROBE CP30 conductivity probe
7 SAMPLE COOLER SCS20 sample cooler system (optional to BCS3 system)
8 REMOTE DISPLAY UNIT DS1000 digital display unit (optional)

Selection of products subject to maximum pressure and temperature ratings.

In the interests of development and improvement of products, we reserve the right to change the specification. Copyright 1998

13
 BCS4
TDS Contol System

Crown Steam to Safety valve

valve plant
Vent and drain
to safe place
To heat recovery
system or
blowdown vessel

Steam shell boiler

Boiler
1 2 3 4 flue

5
Sample in 7

Sample out
Burner
Cooling
water
In

Out

Table of parts
Part No. Description Srirax Sarco reference:
1 CHECK VALVE DCV2 wafer check valve
BCV30 electrohydraulically actuated or
2 TDS CONTROL VALVE
BCV31 pneumatically actuated blowdown valve
3 STOP VALVE G3 gland sealed stop valve
4 CONTROLLER BC3200 panel mounted or BC1100 DIN rail or chassis plate mounted
5 SENSOR CHAMER S11 sensor chamber and CP10 sensor
6 SAMPLE COOLER SCS20 sample cooler system (optional to BCS3 system)
7 REMOTE DISPLAY UNIT DS1000 digital display unit (optional)

Selection of products subject to maximum pressure and temperature ratings.

In the interests of development and improvement of products, we reserve the right to change the specification. Copyright 1998

14
 Condensate Contamination Detection System

2
1

Condensate Clean condensate

return main for return

5 6

9 Clean water
for flushing
and calibration
Contaminated
condensate
to drain
7
8

Manual
drain

Table of parts
Part No. Description Spirax Sarco reference:
1 CONTROLLER BC3200 wall mounted or BC3210 panel mounted controller
2 ACTUATOR EL5500 series electric actuator
3 CHECK VALVE DCV1, DCV2 or DCV3 wafer check valve
4 DIVERTING VALVE QL43 or QL73 three port valve
5, 6, 8, 9 ISOLATING VALVE M10 ball valve
7 SENSOR S20 sensor chamber with CP10 conductivity and TP20 temperature sensors

Selection of products subject to maximum pressure and temperature ratings.

In the interests of development and improvement of products, we reserve the right to change the specification. Copyright 1998

15
 Heat Recovery from Boiler Blowdown

Note: Line between cold water tank

and boiler feedtank not shown.
8 10 11

Cold water supply tank

2 From TDS 9
blowdown Boiler feedtank
valves

13 15 12

3
14
4
To boiler
5 16 feedpumps

Residual Manual
blowdown drain
to drain

Table of parts
Part No. Description Spirax Sarco reference:
1, 2, 6, 14, 16 ISOLATING VALVE M10 ball valve
3, 15 STRAINER Fig 14 'Y' type strainer
4 PUMP RP type recirculating pump
5 HEAT EXCHANGER HE type plate heat exchanger
7 THERMOSTAT HTS3 type thermostat
8 PRESSURE GAUGE 100 mm diameter pressure gauge with 'U' syphon
9 FLASH VESSEL FV type flash vessel
10 SAFETY VALVE SV3 safety valve
11 VACUUM BREAKER VB14 or VB21 vacuum breaker
12 STEAM DISTRIBUTOR SD type steam distributor
13 FLOAT TRAP FT type float trap

Selection of products subject to maximum pressure and temperature ratings.

In the interests of development and improvement of products, we reserve the right to change the specification. Copyright 1998

16
 Boiler Steam Off-Take
with Auto Warm -Up Valve

1 2 3 4 7

6
Boiler crown valve

Dry steam
to plant

Boiler

8 9 10 11 12 13

Condensate to
blowdown
vessel

Table of parts
Part No. Description Bronze Cast iron SG iron Steel Stainless steel
1 MAIN ISOLATING VALVE BSA3
2 SEPARATOR 1808 or S5 1808SS or S6
3, 9 STRAINER Fig 3 Fig 33 Fig 37 Fig 34 Fig 36
4 ACTUATOR EL5500 series electric actuator with EL5851 auxiliary switches
5 CONTROL VALVE KE73 KE43
6 PRESSURE GAUGE 100 mm diameter pressure gauge with 'U' or ring syphon
7 CONTROLLER EL pulsed output controller type S/E20
8, 13 BALL VALVE M20 M20
10 SPIRATEC SENSOR CHAMBER ST143 ST163
11 FLOAT TRAP FT14 FT44 FT46
12 CHECK VALVE DCV1 DCV2, 3 or 4

Selection of products subject to maximum pressure and temperature ratings.

In the interests of development and improvement of products, we reserve the right to change the specification. Copyright 1998

17
 Multi - Boiler Balanced Header

Steam to plant

3 5 7

1
Crown
4 6 valve 2 Condensate to
blowdown vessel
Condensate to
blowdown vessel

Table of parts
Part No. Description Bronze Cast iron SG iron Steel Stainless steel
1 BOILER ISOLATING VALVE BSA3
2, 4 CHECK VALVE DCV2, 3 or 4
3, 7 BALL VALVE M20 M20
TD24F
TD62 TD32F
5 THERMODYNAMIC TRAP
TD120 TD45
TD1464
6 SPIRATEC SENSOR CHAMBER ST143 ST163
BOILER HOUSE
8 BSA3
ISOLATING VALVE

Selection of products subject to maximum pressure and temperature ratings.

In the interests of development and improvement of products, we reserve the right to change the specification. Copyright 1998

18
 Sample Cooler System

Sample
in

Cooling
water
out

22

Cooling
water
in

Sample
out

Table of parts
Part No. Description Spirax Sarco reference:
1 SAMPLE COOLER SC20 sample cooler
2 COOLING WATER INLET VALVE " ball valve
3 SAMPLE INLET VALVE " needle valve
4, 5, 6, 7, 8 COMPRESSION FITTINGS Plated carbon steel / stainless steel compression fittings

Selection of products subject to maximum pressure and temperature ratings.

In the interests of development and improvement of products, we reserve the right to change the specification. Copyright 1998

19
 Notes

Selection of products subject to maximum pressure and temperature ratings.

In the interests of development and improvement of products, we reserve the right to change the specification. Copyright 1998

20
 Notes

Selection of products subject to maximum pressure and temperature ratings.

In the interests of development and improvement of products, we reserve the right to change the specification. Copyright 1998

21
 Notes

Selection of products subject to maximum pressure and temperature ratings.

In the interests of development and improvement of products, we reserve the right to change the specification. Copyright 1998

22
 Notes

Selection of products subject to maximum pressure and temperature ratings.

In the interests of development and improvement of products, we reserve the right to change the specification. Copyright 1998

23
 Some of the products shown in this guide may not be available in certain markets.
In the interests of development and improvement of the products, we reserve the right to
change the specification without notice.

Spirax-Sarco Limited, Charlton House,

Cheltenham, Gloucestershire, GL53 8ER UK
Tel: +44 1242 521361 Fax: +44 1242 573342
E mail:enq@spiraxuk.attmail.com
Internet:www.spirax-sarco.com
Copyright 1998 Spirax Sarco is a registered trademark of Spirax-Sarco Limited

TR-GCM-15 CM Issue 1