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 DCV2

and CP10 sensor 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
SCS20 Cooling
compared with the set point in the controller. If it is water
sample cooler
lower than the set point the blowdown valve closes at system (optional) outlet
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. Cooling water inlet
The system is easy to calibrate and commission and
the set point can be quickly adjusted. Sample outlet Not to scale
2
 The BCS4 system is available The requirement for blowdown
with one of three types of controller: 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
The wall mounted BC3200
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 panel mounted BC3210 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.

Deciding on the
boiler water TDS
Conventional shell boilers are normally operated with
the TDS ranging from 2 000 ppm to 3 500 ppm. These
The DIN rail / chassis
TDS levels should ensure that reasonably clean and
plate mounted BC1100
dry steam is delivered to the plant, providing that:
n The boiler is operating near to its design pressure.
n The steam load conditions are not too severe.
n Other boiler water conditions are correctly controlled.

The boiler manufacturer usually recommends a ppm

or µS / cm figure.

User benefits
l Accurate TDS level control minimises blowdown.
l Reduces carryover of boiler water with steam.
l Automatic control decreases need for
supervision.
l For boiler pressures up to 32 bar g.
l For blowdown flowrates up to 11 000 kg / h
at 32 bar g.
l Simple retrofit installation.
The DS1000 is an optional remote
l Easy to clean sensor.
digital display unit
3
 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 230 V or 115 V (50 - 60 Hz) supply, selected by an
internal switch.
n Selectable ranges (ppm or µS / cm), to suit all types
of boilers.
n Four digit LED display of TDS (as well as system
status e.g. blowing down or probe cleaning in
operation).
n High TDS alarm relay output, which may be wired
to give remote indication.
n 4 - 20 / 0 - 20 mA output.
n Automatic probe cleaning circuit, (UK patent
No. 2276943), which allows the system to maintain
its accuracy even when some boiler scaling is
taking place.
n Remote display option using DS1000.
n Electronic filtering to give more representative TDS
measurement under high turbulence conditions.
n Selectable security feature to prevent unwanted or
inadvertant changes to settings. (Settings can still
be viewed, but not altered).
n 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 230 V or 115 V (50 - 60 Hz) supply, selectable.
n Switch selectable ranges in ppm or µS / cm.
n 4 - 20 / 0 - 20 mA output for optional local or remote
display using a DS1000, or can be connected to a
building management system.
n 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 BCV31
(DN20 version shown)

Manual override Air inlet from

solenoid valve

Electrohydraulic The BCV30 and BCV31 Pneumatic

actuator have an adjustable actuator
spring-to-close valve stroke to suit spring-to-close
on power failure flow conditions. on air/ power
The valve is supplied failure
set to 10 mm stroke.
The DN20 valve can
be set to 15 mm or Valve position
Valve position 20 mm stroke on site indicator
indicator if required.
The DN40 is fully
adjustable over its
complete range Adjustable
Adjustable gland packing
gland packing

Cast steel body

with stainless steel
internals

Sample take-off Sample take-off

connection 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.

n 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 µS / cm (B).

2. The feedwater TDS in parts per million or µS / 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 µS / m Blowdown rate = x S
B = Required boiler water TDS in ppm or µS /cm B-F
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 DN20 BCV30 DN40 BCV30
pressure 10 mm 15 mm 20 mm 5 mm 10 mm 15 mm 20 mm
bar g Stroke Stroke Stroke Stroke Stroke Stroke Stroke
5 380 530 730 450 2 900 3 450 3 550
7 460 710 1 150 475 3 300 4 100 4 500
10 570 950 1 500 500 3 700 4 750 5 450
15 700 1 150 1 650 550 4 550 6 450 7 150
20 780 1 250 1 700 800 5 750 8 100 8 650
32 940 1 400 1 800 1 300 8 400 10 300 11 050

Manual versus automatic blowdown

Manual blowdown Automatic TDS control
Poor control is causing wastage of boiler water through TDS controlled accurately, near to maximum level,
excessive blowdown. minimising blowdown, yet avoiding carryover and foaming
caused by high TDS level.
Boiler water TDS
Boiler water TDS

Maximum allowable TDS Maximum allowable TDS

Average TDS
Average TDS

Time Time
6
 Technical information (Dimensions approximate in mm)

s
BC3200 Controller
Functional range 193 103
10 - 99 (ppm or µS/cm)
100 - 999 (ppm or µS/cm)
1 000 - 9 990 (ppm or µS/cm)
Supply voltage 230 V, 115 V 161
Supply frequency 50 - 60 Hz
Maximum ambient temperature 55°C
Protection rating IP65

s
BC3210 Controller
Functional range 144 133
110 - 99 (ppm or µS/cm)
100 - 999 (ppm or µS/cm)
1 000 - 9 990 (ppm or µS/cm) 72
Supply voltage 230 V, 115 V
Supply frequency 50 - 60 Hz
Maximum ambient temperature 55°C
Protection rating IP65 (front panel only) Optional cover 34
s

BC1100 Controller
52 120
Functional range
40 - 400 (ppm or µS/cm)
120 - 1 200 (ppm or µS/cm)
400 - 4 000 (ppm or µS/cm)
1 200 - 12 000 (ppm or µS/cm)
Supply voltage 230 V, 115 V 112
Supply frequency 50 - 60 Hz
Maximum ambient temperature 55°C
Protection rating IP40
Optional display available (DS1000)
s

DS1000 Digital display unit

Loop powered 4 - 20 mA
Pre-calibrated for percentage indication
48
Can be scaled to suit controller range (in ppm or µS/cm)
Protection rating IP65 (front panel only)
Maximum ambient temperature 50°C 96 93
s

BCV30 Blowdown valve

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
390 (DN20) Supply voltage 230 V, 115 V, 24 V
480 (DN40) 378 (DN20)
Supply frequency 50 - 60 Hz 426 (DN40)
s

BCV31 Blowdown valve

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
¼" BSP Air pressure 2 to 6 bar g ¼" BSP
for sample 152 (DN20) Air consumption (20 mm travel) 0.33 litres 152 (DN20) for sample
take-off 200 (DN40) 200 (DN40) take-off
7
 Technical information (Dimensions approximate in mm)
CP10 sensor,

s
S11 sensor chamber, PT2 plug tail
CP10
35 PT2
Sensor chamber S11 in stainless steel
107
DN20 fits between BS 4504 PN16, 25 and 40 S11
BS 1560 Class 300 and BS 10 Table 'H' flanges
69
Associated equipment Ancillaries
DCV2 check valve Solenoid valve (BCV31 only).
Stainless steel wafer pattern DN20, PN40 MP2 filter regulator (BCV31 only).
SCS20 sample cooler system.
G3 stop valve Strainer for bottom blowdown take-off installations.
Carbon steel DN20, PN40 stainless steel seat and disc.
MS1 conductivity meter.

How to specify How to order

Wall mounted blowdown controller calibrated in Controller BC3200 or BC3210 or BC1100
µS / cm and ppm Digital display DS1000
or Blowdown valve BCV30 or BCV31
DIN rail / chassis mounted blowdown controller and (DN20 or DN40)
loop powered digital display. flanged BS 4504 PN40
Between flange mounting sensor chamber and sensor. Sensor chamber S11 with CP10 sensor and
PT2 plug tail
Blowdown valve, DN20 flanged BS 4504 PN40 with
electrohydraulic (pneumatic) actuator with stainless Stop valve G3, DN20, PN40
steel valve internals. Check valve DCV2, DN20, PN40

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: [email protected]
Internet: www.SpiraxSarco.com
© Copyright 2004 Spirax Sarco is a registered trademark of Spirax-Sarco Limited

SB-P403-04 AB Issue 5