BCS4 Blowdown control system

The BCS4 blowdown control system

BCV30 blowdown valve (electrohydraulically actuated) or BCV31 blowdown valve (pneumatically actuated)

Boiler Stop valve To heat recovery system or blowdown vessel

S11 sensor chamber and CP10 sensor

DCV2 check valve

How the BCS4 system works

The BCS4 blowdown system works by periodically opening the blowdown valve in order to purge the pipework and set up a flow of boiler water past the sensor. To avoid wasteful blowdown, especially whilst a boiler is on stand-by or low load, the system can be wired to purge every half hour of boiler firing. The controller measures the electrical conductivity of the boiler water which is closely related to the level of total dissolved solids (TDS). This measured value is compared with the set point in the controller. If it is lower than the set point the blowdown valve closes at the end of the purge time and remains closed. If the measured value is higher than the set point the controller continues to blow down until the measured value drops below the set point. The controllers give indication of the blowdown status, and have a manual purge facility. The system is easy to calibrate and commission and the set point can be quickly adjusted.

SCS20 sample cooler system (optional)

Cooling water outlet

Cooling water inlet Sample outlet Not to scale

The BCS4 system is available with one of three types of controller:

The requirement for blowdown

Boiler feedwater can contain a high level of dissolved solids, even if a feedwater treatment plant is installed. Water treatment can chemically modify the form of the dissolved solids, but will not usually remove them completely, and can even increase the total dissolved solids (TDS) level. As steam is evaporated, the TDS level increases in the boiler water. If the TDS is allowed to get too high then carryover of the boiler water with steam will occur. This can cause serious damage to the steam and condensate systems through waterhammer, corrosion, and deposits on heat transfer surfaces. Deposits in control valves and steam traps can build up rapidly, causing operating problems. Product contamination and reduced heat transfer rates may affect productivity. In order to limit the TDS to the level recommended by the boiler maker it is normal practice to periodically drain off, (or 'blow down') boiler water and allow it to be replaced by relatively low TDS feedwater. Excessive blowdown is of course very expensive in terms of lost energy and water treatment chemicals.

The wall mounted BC3200

The panel mounted BC3210

Deciding on the boiler water TDS

The DIN rail / chassis plate mounted BC1100 Conventional shell boilers are normally operated with the TDS ranging from 2 000 ppm to 3 500 ppm. These TDS levels should ensure that reasonably clean and dry steam is delivered to the plant, providing that:
n n n

The boiler is operating near to its design pressure. The steam load conditions are not too severe. Other boiler water conditions are correctly controlled.

The boiler manufacturer usually recommends a ppm or S / cm figure.

User benefits
l

Accurate TDS level control minimises blowdown. Reduces carryover of boiler water with steam. Automatic control decreases need for supervision. For boiler pressures up to 32 bar g. For blowdown flowrates up to 11 000 kg / h at 32 bar g. Simple retrofit installation. Easy to clean sensor. 3

The DS1000 is an optional remote digital display unit

The controllers
The BC3200 is a wall mounted controller with 4 digit LED display and two push buttons for simple commissioning, calibration and operation. Features include:n

n n

n n

230 V or 115 V (50 - 60 Hz) supply, selected by an internal switch. Selectable ranges (ppm or S / cm), to suit all types of boilers. Four digit LED display of TDS (as well as system status e.g. blowing down or probe cleaning in operation). High TDS alarm relay output, which may be wired to give remote indication. 4 - 20 / 0 - 20 mA output. Automatic probe cleaning circuit, (UK patent No. 2276943), which allows the system to maintain its accuracy even when some boiler scaling is taking place. Remote display option using DS1000. Electronic filtering to give more representative TDS measurement under high turbulence conditions. Selectable security feature to prevent unwanted or inadvertant changes to settings. (Settings can still be viewed, but not altered). An optional front cover lock is available.

The BC3210 has exactly the same features as the BC3200, but has an enclosure suitable for mounting in a boiler panel. An optional lockable cover is available.

The BC1100 is a DIN rail or chassis plate mounted controller with LED indication of blowdown status and potentiometer adjustment of set point and calibration. A purge button on the front panel manually opens the blowdown valve. Features include:n n n

230 V or 115 V (50 - 60 Hz) supply, selectable. Switch selectable ranges in ppm or S / cm. 4 - 20 / 0 - 20 mA output for optional local or remote display using a DS1000, or can be connected to a building management system. Switch selectable purge time.

The DS1000 digital display unit is an optional extra that can be used with the BC1100 controller as a local or remote TDS display. It can also be used as a remote display unit with the BC3200 or BC3210 controllers. 4

The blowdown valves

Two types of blowdown valve are available, the electrohydraulically actuated BCV30, and the pneumatically actuated BCV31, both in DN20 and DN40 sizes. The DN20 valve has a maximum flow capacity of 1 800 kg /h at a boiler pressure of 32 bar g. The DN40 has a maximum flow capacity of 11 000 kg/ h at a boiler pressure of 32 bar g. Both valves can be adjusted for different flow conditions.

BCV30
(DN20 version shown) Manual override Air inlet from solenoid valve

BCV31

Electrohydraulic actuator spring-to-close on power failure

Valve position indicator

The BCV30 and BCV31 have an adjustable valve stroke to suit flow conditions. The valve is supplied set to 10 mm stroke. The DN20 valve can be set to 15 mm or 20 mm stroke on site if required. The DN40 is fully adjustable over its complete range

Pneumatic actuator spring-to-close on air/ power failure

Valve position indicator

Adjustable gland packing

Adjustable gland packing

Cast steel body with stainless steel internals

Sample take-off connection

Sample take-off connection

The BCV30 and BCV31 are specifically designed for boiler TDS blowdown applications:n The valve plug and seat ensure the correct alignment and a tight shut-off. To avoid the problems of seat erosion, the valve plug is moved away from the seat before any flow occurs. n The flow velocities in the valve ensure sludge is not precipitated in the valve. 5

Controlling the blowdown

Spirax Sarco have developed the BCS4 boiler blowdown system that, by measuring the TDS level in the boiler water, will minimise the amount of blowdown required, reduce carryover of boiler water and provide automatic TDS control. The BCS4 system is suitable for shell and water tube boilers. The controllers can be linked to energy / building management systems.

Calculating the blowdown rate

Before it is possible to select a suitable boiler blowdown TDS control system it is necessary to estimate the amount of boiler water which has to be blown down. The following information is required:1. The required boiler water TDS in parts per million or S / cm (B). 2. The feedwater TDS in parts per million or S / cm (F). An average value may be obtained by looking at water treatment records or a sample of feedwater may be obtained and measured using the Spirax Sarco MS1. Note: The feedwater sample must be taken from the feedtank or feedwater line. Do not use a sample of the make-up feedwater. 3. The quantity of steam which the boiler generates, usually measured in kg / h (S). For selecting a blowdown system, the most important figure is usually the maximum quantity of steam that the boiler can generate at full-load. When the information in 1, 2 and 3 is available the required blowdown rate can be calculated as follows: where:F F = Feedwater TDS in ppm or S / m Blowdown rate = x S B-F B = Required boiler water TDS in ppm or S /cm S = Steam generation rate kg / h The blowdown rate is then given in kg / h.

Selection
Having established the required blowdown rate, check the Table below to ensure that the valve has sufficient capacity at the operating pressure. Note: Intermediate flowrate strokes can be set on the DN40 BCV30, but not the DN20. Blowdown valve capacity kg/ h Boiler pressure bar g 5 7 10 15 20 32 10 mm Stroke 380 460 570 700 780 940 DN20 BCV30 15 mm Stroke 530 710 950 1 150 1 250 1 400 20 mm Stroke 730 1 150 1 500 1 650 1 700 1 800 5 mm Stroke 450 475 500 550 800 1 300 DN40 BCV30 10 mm 15 mm Stroke Stroke 2 900 3 300 3 700 4 550 5 750 8 400 3 450 4 100 4 750 6 450 8 100 10 300 20 mm Stroke 3 550 4 500 5 450 7 150 8 650 11 050

Manual versus automatic blowdown

Manual blowdown
Poor control is causing wastage of boiler water through excessive blowdown.
Boiler water TDS

Automatic TDS control

TDS controlled accurately, near to maximum level, minimising blowdown, yet avoiding carryover and foaming caused by high TDS level. Maximum allowable TDS Average TDS

Maximum allowable TDS Average TDS Time

Boiler water TDS

Time

Technical information
s

(Dimensions approximate in mm) 193 103

BC3200 Controller
Functional range 10 - 99 (ppm or S/cm) 100 - 999 (ppm or S/cm) 1 000 - 9 990 (ppm or S/cm) Supply voltage 230 V, 115 V Supply frequency 50 - 60 Hz Maximum ambient temperature 55C Protection rating IP65

161

BC3210 Controller
Functional range 110 - 99 (ppm or S/cm) 100 - 999 (ppm or S/cm) 1 000 - 9 990 (ppm or S/cm) Supply voltage 230 V, 115 V Supply frequency 50 - 60 Hz Maximum ambient temperature 55C Protection rating IP65 (front panel only)

144

133

72

Optional cover
s

34 120

BC1100 Controller
Functional range 40 - 400 (ppm or S/cm) 120 - 1 200 (ppm or S/cm) 400 - 4 000 (ppm or S/cm) 1 200 - 12 000 (ppm or S/cm) Supply voltage 230 V, 115 V Supply frequency 50 - 60 Hz Maximum ambient temperature 55C Protection rating IP40 Optional display available (DS1000)

52

112

DS1000 Digital display unit

Loop powered 4 - 20 mA Pre-calibrated for percentage indication Can be scaled to suit controller range (in ppm or S/cm) Protection rating IP65 (front panel only) Maximum ambient temperature 50C
s

48

96

93

BCV30 Blowdown valve

390 (DN20) 480 (DN40)

Carbon steel valve DN20 and DN40, flanged BS 4504 PN40 Also available as BS 10 Table 'H' and BS 1560 Class 300 Maximum pressure 32 bar g Stainless steel internals Electrohydraulically actuated with manual override Supply voltage 230 V, 115 V, 24 V Supply frequency 50 - 60 Hz
s

378 (DN20) 426 (DN40)

BCV31 Blowdown valve

" BSP for sample take-off

152 (DN20) 200 (DN40)

Carbon steel valve DN20 and DN40, flanged BS 4504 PN40 Also available as BS 10 Table 'H' and BS 1560 Class 300 Maximum pressure 32 bar g Stainless steel internals Pneumatic actuator Air pressure 2 to 6 bar g Air consumption (20 mm travel) 0.33 litres

152 (DN20) 200 (DN40)

" BSP for sample take-off

Technical information
CP10 sensor, S11 sensor chamber, PT2 plug tail
Sensor chamber S11 in stainless steel
s

(Dimensions approximate in mm)

35 107

CP10 PT2

DN20 fits between BS 4504 PN16, 25 and 40 BS 1560 Class 300 and BS 10 Table 'H' flanges

S11 69

Associated equipment
DCV2 check valve Stainless steel wafer pattern DN20, PN40 G3 stop valve Carbon steel DN20, PN40 stainless steel seat and disc.

Ancillaries
Solenoid valve (BCV31 only). MP2 filter regulator (BCV31 only). SCS20 sample cooler system. Strainer for bottom blowdown take-off installations. MS1 conductivity meter.

How to specify
Wall mounted blowdown controller calibrated in S / cm and ppm or DIN rail / chassis mounted blowdown controller and loop powered digital display. Between flange mounting sensor chamber and sensor. Blowdown valve, DN20 flanged BS 4504 PN40 with electrohydraulic (pneumatic) actuator with stainless steel valve internals. Controller

How to order
BC3200 or BC3210 or BC1100 DS1000 BCV30 or BCV31 (DN20 or DN40) flanged BS 4504 PN40 S11 with CP10 sensor and PT2 plug tail G3, DN20, PN40 DCV2, DN20, PN40 Digital display Blowdown valve

Sensor chamber Stop valve Check valve

Some of the products shown 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 2004 Spirax Sarco is a registered trademark of Spirax-Sarco Limited

SB-P403-04

AB Issue 5