EN

Blowdown vessel

BDV

INSTALLATION, USE AND MAINTENANCE MANUAL

BDV_50_200_en_00 - 07/2019
INDEX

3 General information 8 Selection of the blowdown vessel size

3 Operating principle 8 Operations
3 Safety 9 Maintenance
3 Positioning 9 Protecting the environment
4 Connections 9 Decommissioning and disposal
5 Technical data 10 Risk analysis
6 Accessories 13 Nameplate
6 System diagram
7 Water characteristics Notes

SYMBOLS USED IN THE MANUAL

DANGER
a To indicate actions that, if not performed correctly, can result in injury of generic origin or may generate malfunction
or damage to the appliance; therefore require particular caution and adequate preparation.

IT IS FORBIDDEN
d To indicate operations that SHOULD NOT be performed.

IMPORTANT
m To indicate particularly useful information and important.

The illustrations and data presented are not binding. The company reserves the right to make without prior notice any changes it
deems appropriate for continuous improvement and constant updating.

2 
GENERAL INFORMATION
The blowdown vessel is designed to capture dissolved solids dispersed from the steam boiler and to facilitate cooling of the high
temperature water prior to discharging into the main drains without undue risk.

It is necessary to read the instructions carefully to ensure the safety of personnel and to use the equipment correctly.

The blowdown vessel complies with PED Directive 2014/68/UE.

OPERATING PRINCIPLE
The dispelled water from the bottom of the boiler comes into the vessel and falls to the bottom mixing with the inside cold water.
In this way the sludge is cooled and decanted. It is dispelled from the blowdown vessel as cleaner water at room temperature.
The boiler blowdown entering the vessel greatly decreases in pressure producing flash steam so that the upper big flange must
remain fully open to the atmosphere.

SAFETY
The blowdown vessel risks are:
–– Risk of high temperature of the surfaces of the vessel and the piping: prevent accidental contact with the vessel (the
temperature can reach 176°C) without suitable protective equipment (gloves). Since the interval of sludge discharge depends
on an automatic timer, it is hazardous to stay near the vessel even during stand-by so it is advisable to install a protective
barrier around the appliance.
–– Risk of mechanical vibrations due to force of the discharge of superheated contaminated water from the steam boiler: it is
necessary to bolt the legs to the floor.
–– Risk of noise due to force of the discharge: suitable protective equipment (headphones) should be worn.
–– Risk of overpressure: the vessel must operate completely open. It is necessary to maintain open the flash steam upper
connection so that the vessel can stay at pressure zero bar g both in discharge and in stand-by phase; the vessel must be
vented to atmospheric pressure. Safety valves must not be fitted.
–– Risk of overtemperature: if the drains are very large it may be that the water inside the vessel will lead to high temperature
and then treated water discharged can cause damage to the natural environment. Therefore in these cases it is advisable to
use a cooling unit that uses mains water controlled by a thermostat.
–– Risk of freezing: the vessel must be protect against very low temperature especially during stand-by because there isn’t any
thermal device.
–– Risk of incorrect plant operation: the vessel must be positioned and put into operation by competent technicians. Working
and maintenance of the blowdown vessel depends on operator experience.
–– Earthquake risk: the vessel is not sized for quake load.

POSITIONING
The blowdown vessel doesn’t need any foundation work, a flat floor only is required to fasten the legs to prevent movement due
to mechanical shock during the purge.

 3
CONNECTIONS
The blowdown vessel is connected the system as follows.

N1 Blowdown inlet: Dirty water connection (from the bottom N5 Cooling system: If the blowdown is considerable it’s
connection of the boiler) necessary to cool the purified water before it enters the
N2 Drain: Drain bottom connection for clearing sludge sewer. The cooling water solenoid valve is controlled by
N3 Vent: Flash steam vent connection; use a vertical tube the thermostat located inside the vessel
directly to atmosphere avoiding any valve or restriction in N6 Thermostat bulb well
order to be sure that there is no pressure inside N7 Boiler level indicators blowdown
N4 Overflow: The blowdown vessel is half full of water to cool N8 TDS blowdown
the incoming hot sludge N9 Pressure gauge
N9 Inspection

4 
TECHNICAL DATA

Technical data
BDV
DESCRIPTION u.m.
50 100 200
Rated pressure bar 12
Total capacity l 500 1000 2000
Design temperature °C 191,7
Minimum temperature °C -10
Total weight kg 250 350 650

Dimensions
BDV
DESCRIPTION u.m.
50 100 200
H mm 2174 2774 2934
H1 mm 1580 2130 2210
H2 mm 1540 2090 2170
H3 mm 1490 2040 2120
H4 mm 1165 1215 1295
H5 mm 740 790 870
H6 mm 400
H7 mm 1215 1515 1595
L4 mm 934 1082 1382
P4 mm 934 1082 1382
Øe fas. mm 650 800 1100

Attachments
BDV
DESCRIPTION u.m.
50 100 200
N1 DN/in 50
N2 DN/in 2
N3 DN/in 150
N4 DN/in 100
N5 DN/in 3/4
N6 DN/in 3/4 1
N7 DN/in 25
N8 DN/in 25
N9 DN/in 1/2
N10 DN/in 150

NOTE: Drawing, legend and data refer to standard models. For specific models refer to the supplied accessory manual.

 5
ACCESSORIES
TC2 immersion control thermostat - Encased thermostats
Immersion encased thermostat with liquid expansion, unipolar, with switch-over contacts,
complete with a watertight protection pocket.
The thermostat normally applied on delivery pipes is particularly suitable for the automatic
regulation of boilers, pumps and other applications.
It is also available in a capillary version.

SYSTEM DIAGRAM
IMPORTANT
m ICI CALDAIE S.p.A. is not liable for any harm to people, animals or property damage caused by errors in the choice of
components or in the construction of the plant.

IMPORTANT
m For reasons of technical expertise, the system components must be chosen and installed by the installer, that must
operate in accordance with good practice regulations and Laws in force.
The hydraulic circuit must be built by an authorised company or by qualified personnel, in compliance with the Technical Standards
and the Law in force.
The components shall be charged to the installer that, at the end of the works, must issue a declaration of conformity.

The figure is indicative

1 Steam boiler 5 Overflow 8 Coldwater mains

2 TDS control 6 Drain with boiler switched off 9 Cooling system
3 Bottom blowdown 7 Blowdown vessel drain 10 Vent
4 Level indicators 11 Flow indicator

6 
WATER CHARACTERISTICS
The values in the following table are taken from table 5.1 of EN 12953-10 (requirements for water delivery).
Even for the appliances not included in the mentioned standard, it is nevertheless necessary to adopt at least the indicated limits
and consult specialised companies to select the type of treatment to be carried out based on a comprehensive analysis of the
available water.
IMPORTANT
m Many faults and sometimes serious accidents are due to the use of water having non-conforming characteristics.

IMPORTANT
m Provide an adequate cooling water treatment in order to limit any damage due to corrosion.

5.1 Water supply - Threshold values (in input)

CHARACTERISTICS u.m. Water delivery
Appearance Clear, limpid, without foam or suspended solids
Direct conductivity at 25°C μS/cm See table values "Operating water - threshold values"
pH at 25°C (a) --- > 9,2 [b]
Total hardness (Ca+Mg) mmol/l < 0,01 [c]
Iron (Fe) mg/l < 0,3
Copper (Cu) mg/l < 0,05
Oxygen (O2 ) mg/l < 0,05 [d]
Oily substances mg/l <1
Concentration of organic substances - See note [e]

[a]
With copper alloys in the system, the pH value must be kept between 8.7 and 9.2.
[b]
With a softened water pH value > 7.0, the pH of the generator water should be provided according to table 5.2.
[c]
At operating pressure <1 bar, a maximum total hardness of 0.05 mmol/l must be acceptable.
[d]
Instead of respecting this value with intermittent operation or operation without deaerator, in case of agents forming the film
and/or excess of oxygen, the additive must be used.
[e]
Organic substances are generally a mixture of various different compounds. The composition of these mixtures and the
behaviour of their single components at the operating conditions of the steam generator are difficult to predict. Organic
substances can be decomposed to form carbonic acid or other acid decomposition products that increase acid conductivity and
cause corrosion and deposits. They can also lead to the formation of foam and/or production of steam with suspended water, that
must be kept as low as possible.

 7
SELECTION OF THE BLOWDOWN VESSEL SIZE
The choice depends on the amount of water that must be purged when testing the low level alarm device. The nominal volume
of BDV should be at least 4 times the amount of water contained between the normal working level and the low-level alarm..
According to the above, in general the combination with steam boiler is the following:
BDV
50 100 200
FX 50/100/150
- -
FX DUAL 100/200/300
BX 60-1000 BX 1200-1750 -
BNX 100-1700 BNX 2000-3000 -
SIXEN 350-1700 SIXEN 2000-5000 -
ECOVAPOR 350-1700 ECOVAPOR 2000-3000 -
- GX 1000-3000 GX 3500-12000

The frequency of boiler blowdowns, which depends on the hardness of the delivery water, determines the need to use the
cooling unit. Since by law discharges must be at ambient temperature, the cooling unit may not be installed only if the production
of sludge in the boiler is extremely low, i.e. when using a water treatment system with reverse osmosis (production of distilled
water) and/or when condensate from the system is completely recovered.

The blowdown vessel is not subjected to fatigue test as the exclusion requirements provided for by standard EN 12953:3 ed. 2016
chap. 5.1 are met.

The load cycle calculation is not required if the following requirements are met:
–– the number of start-ups from pressure zero to the set operating pressure (complete pressure cycle) is ≤1000
–– for materials with yield strength at ambient temperature ≤295 MPa, the number of partial pressure cycles with ∆P = 20% of PS
is ≤100,000 or, alternatively, with ∆P = 40% of PS is ≤10,000
–– for materials with yield strength at ambient temperature >295 MPa, the number of partial pressure cycles with ∆P = 10% of PS
is ≤100,000 or, alternatively, with ∆P = 20% of PS is ≤10,000
–– the welding of the set-in plates should have at least 10% UT.

OPERATIONS
FIRST START-UP
–– Make sure the vessel is secured to the ground
–– make sure all flanges are properly tightened
–– make sure the vessel is filled with water until it exits the overflow.

8 
MAINTENANCE
Periodic maintenance is an obligation required by the safety Legislation and duration of the appliance, and it must only be
entrusted to professionally qualified personnel.
IMPORTANT
m Before performing any maintenance or cleaning:
–– disconnect the electrical power supply by placing the main switch of the system, of the control panel and of the burner,
if any, at "OFF"
–– close the fuel supply
–– use all Personal Protective Equipment required by current Standards and Legislation
–– wait for the generator and the system to cool down.

Drain periodically the vessel (the interval depends on hardness of water and on how long the boiler works) in order to remove the
concentration of sludge opening the bottom connection and rinsing with main water. After cleaning operation it’s necessary to
refill the water to its normal level until it comes out from overflow. Since the sludge of a steam generator is very corrosive provide
an annual inspection inside the vessel to check the internal blowdown status.

During the maintenance operation, the following checks should also be carried out:
–– check the torque of the flange bolts and the state of the gaskets
–– periodically check the condition of the parts under pressure through non-destructive testing
–– check the wear of the drain valves, replace them if necessary.

PROTECTING THE ENVIRONMENT

Protection and respect for the environment is a fundamental principle for ICI CALDAIE S.p.A..
The quality of products, lower costs and protection of the environment are of equal importance for the
company. ICI CALDAIE S.p.A., also through ISO 14001 certification, strictly adheres to European laws and
standards for the protection and preservation of the environment.
In order to reduce its impact on the environment, the company uses the best technology and materials
in its production processes and always considers their economic impact.

DECOMMISSIONING AND DISPOSAL

Decommissioned appliances contain materials that can be recycled since they do not contain asbestos or non-reusable hazardous
materials.

 9
RISK ANALYSIS
CAUSE EVENT 1 EXCESSIVE PRESSURE Event Severity: B
The pressure must not exceed the maximum admissible value (PS, maximum admissible pressure)
EFFECT – CONSEQUENCE
Induced efforts exceed maximum admissible efforts
RISK – HAZARD
Vessel explosion (breakage of tube bundle and/or sleeves)
SOLUTION – PREVENTION
A pressure higher than the calibration of the safety valves cannot occur inside the vessel, therefore, the vessel is intrinsically protected to be matched with
boilers up to 12 bar.
The vessel is not sized according to a fatigue test as the conditions provided for in EN 12953:3 ed. 2016 cap.5.1 are verified
CAUSE EVENT 2 EXCESSIVE TEMPERATURE Event Severity: B
The temperature must not exceed the maximum admissible value (TS, maximum admissible temperature)
EFFECT – CONSEQUENCE
Induced efforts exceed maximum admissible efforts
RISK – HAZARD
Vessel explosion (breakage of tube bundle and/or sleeves)
SOLUTION – PREVENTION
A temperature higher than that of the design cannot occur inside the vessel as the vessel is communicating with the atmosphere, therefore, the water
temperature inside it cannot exceed 191.7°C.
EVENT CAUSE 3 EXTERNAL LOADS Event Severity: B
External loads acting on the vessel fittings represented by the weight and by the thermal expansions of the pipes
EFFECT – CONSEQUENCE
Breakage of fitting welds
RISK – HAZARD
Vessel explosion and/or breakage of the shut-off parts
SOLUTION – PREVENTION
Vessel fittings shall not be considered as pipe supporting points
Size the system so that it never exceeds the admissible loads provided in the drawing
It is good practice to allow for expansion joints and suitable supports for the pipes connecting the boiler to the system in order to avoid the transmissions of
loads to the vessel fittings
NOTE: these solutions are the user’s responsibility, see indications in the user manual
EVENT CAUSE 4 STRAY CURRENTS Event Severity: B
Corrosion phenomena due to stray currents
EFFECT – CONSEQUENCE
Corrosions of internal parts and consequent thinning of the parts
RISK – HAZARD
Risk of breakages and holes in the vessel body (statistic calculation no longer met)
SOLUTION – PREVENTION
Make sure that no stray currents are present on the vessel
Check the correct grounding of the vessel
Check the plant room electrical system
NOTE: these solutions are the user’s responsibility, see indications in the user manual
EVENT CAUSE 5 HOT PARTS Event Severity: C
Accidental contact with hot parts of the operating or briefly turned off vessel
EFFECT – CONSEQUENCE
Burning of hands or other body parts exposed to heat
RISK – HAZARD
Scalds
SOLUTION – PREVENTION
Avoid contact with vessel uninsulated parts during operation. Should adjustment or check activities be carried out during operation, the operators must wear
suitable protective equipment (gloves, shoes and thermal coverall)
The vessel should feature plates warning on the presence of hot parts
NOTE: see indications in the user manual
CAUSE EVENT 6 MINIMUM TEMPERATURE Event Severity: B
Pressurised vessel subjected to low temperature during transport and downtime
EFFECT – CONSEQUENCE
Risk of material fragility
RISK – HAZARD
Breakage due to fragility of the material with explosion risk during standard operation
SOLUTION – PREVENTION
Make sure that the temperature the vessel can be subjected to complies with the minimum permitted temperature set in the design and indicated on the
plate
NOTE: see indications in the user manual

10 
 CAUSE EVENT 7 EARTHQUAKE Event Severity: C
Earthquake
EFFECT – CONSEQUENCE
Damage caused to the vessel due to:
Direct stresses acting on the vessel
Structural failures of the heating plant room (fall of materials on the vessel and/or deformation of the support base of the accumulator).
Damage due to electrical and/or hydraulic connections of the heating plant room
RISK – HAZARD
Risk of failure of the pressure parts (explosion)
SOLUTION – PREVENTION
The appliance has not been dimensioned for installation in an earthquake zone.
NOTE: see indications in the user manual
CAUSE EVENT 8 ATMOSPHERIC CONDITIONS Event Severity: B
Keeping the vessel in unsuitable atmospheric conditions during transport and/or in heating plant room. These conditions refer to the minimum temperature
and to the effects produced by rain water
EFFECT – CONSEQUENCE
If the minimum temperature is lower than that indicated in the design and on the plate, fragile welds may break.
Rain water can damage and/or corrode the vessel structure from the outside
RISK – HAZARD
Vessel explosion
SOLUTION – PREVENTION
Protect the vessel against adverse climatic conditions.
NOTE: see indications in the user manual
CAUSE EVENT 9 INSTALLATION AND START-UP Event Severity: B
Wrong installation:
Hydraulic works
Thermal shocks and dilations
EFFECT – CONSEQUENCE
Hydraulic system: fluid leakage
Thermal shocks and dilations: breakages to the parts under pressure and welded joints
Improper installation
RISK – HAZARD
Hydraulic system: general scalds
Vessel explosion
SOLUTION – PREVENTION
The commissioning must be carried out in compliance with the current regulation in the country of vessel installation
Make sure that hydraulic connections are duly joined together
Check the correct operation of the accumulator
The vessel should be started avoiding thermal shocks.
NOTE: these solutions are the user’s responsibility, see indications in the user manual
CAUSE EVENT 10 FAILING TO CARRY OUT MAINTENANCE Event Severity: B
Maintenance not carried out by following what stated in the user manual
EFFECT – CONSEQUENCE
Damage caused to the vessel due to wrong maintenance
RISK – HAZARD
Accumulator explosion
SOLUTION – PREVENTION
Carry out a periodical preventive maintenance and any component repair or replacement operations according to the indications set forth in the Technical
Manual and consult ICI for the cases not provided for in the manual
NOTE: see indications in the user manual
CAUSE EVENT 11 POOR STORAGE Event Severity: B
The vessel has not been kept in optimal conditions during downtime
EFFECT – CONSEQUENCE
Damage caused to the vessel due to corrosions
Damage caused by harsh weather conditions
RISK – HAZARD
Accumulator explosion
SOLUTION – PREVENTION
The appliance must be stored according to the indications given in the Technical Manual (Wet storage and Dry storage)
The vessel must be protected against adverse climatic conditions (minimum temperature -10°C) and rain effects

 11
CAUSE EVENT 12 PRESSURISED BODY REPAIR Event Severity: B
The vessel has not been repaired correctly
EFFECT – CONSEQUENCE
Damage caused to the pressurised body
RISK – HAZARD
Accumulator explosion
SOLUTION – PREVENTION
To carry out repair operations, contact the manufacturer and/or the Body responsible for the check of operating steam generator (technical and bureaucratic
details), and use suitable means and materials
All repair operations must be carried out in compliance with the current regulation in the country of installation
NOTE: see indications in the user manual
CAUSE EVENT 13 DOWNGRADE AND CHANGE OF USE Event Severity: B
Compromised structural integrity
EFFECT – CONSEQUENCE
Compromised safety and functionality of the vessel during operation.
RISK – HAZARD
Accumulator explosion or malfunction
SOLUTION – PREVENTION
Vessel downgrade and change of use through preventive authorisation by the relevant bodies. These operations must be carried out in compliance with the
current regulation in the country of installation
The manufacturer shall not be held liable in the event of accidents caused by incorrect decommissioning.
NOTE: see indications in the user manual
EVENT CAUSE 14 HANDLING Event Severity: B
- Violent impact during lifting and transport due to lifting eyelet detachment or release, or breakage of the lifting means
EFFECT – CONSEQUENCE
Violent impact on the ground
Vessel breakage
RISK – HAZARD
Imminent crushing hazard for property or people standing underneath
Hazard due to possible breakages or faults caused to the vessel that pose risks during the operation of the accumulator
SOLUTION – PREVENTION
Calculation of the lifting eyelets
During handling, always stay at a distance of at least 5 metres from vessel projection to the ground
Visually check the integrity of the vessel in all its parts
Run the hydraulic test again
Handle the appliance in compliance with the indications set forth in the manual
CAUSE EVENT 15 FIRE Event Severity: B
Fire in the heating plant room
EFFECT – CONSEQUENCE
Damage to the vessel body
RISK – HAZARD
Explosion of the accumulator due to body damage
SOLUTION – PREVENTION
The plant room must be arranged in compliance with the fire protection regulations in force in the country of installation
Check that the body is intact and not damaged after the fire.
NOTE: these solutions are the user’s responsibility, see indications in the user manual
CAUSE EVENT 16 DECOMMISSIONING Event Severity: D
Compromised structural integrity
EFFECT – CONSEQUENCE
Compromised safety and functionality of the vessel during operation.
RISK – HAZARD
Vessel explosion or malfunction
SOLUTION – PREVENTION
Accumulator decommissioning through prior notification to the competent authorities.
CAUSE EVENT 17 CORROSION Event Severity: D
Corrosion phenomena due to oxidising agents.
EFFECT – CONSEQUENCE
Corrosions of internal parts and consequent thinning of the parts
RISK – HAZARD
Risk of breakages and holes in the vessel body (statistic calculation no longer met)
SOLUTION – PREVENTION
Periodically check the condition of the parts under pressure through non-destructive testing;
Provide an adequate cooling water treatment in order to limit any damage due to corrosion;
NOTE: see indications in the user manual

12 
NAMEPLATE
Each Blowdown vessel BDV can be identified by the technical plate bearing the technical-performance data such as:
–– serial number or identification marking
–– maximum and minimum operating pressure
–– maximum and minimum operating temperature
–– maximum capacity
–– weight
–– CE marking.

 13
1 Notes

14 Notes
Notes 15
ICI CALDAIE SpA
37059 Fraz. Campagnola di Zevio ( Verona) Italy
Via G. Pascoli 38 Phone: +39 0458738511 Fax:+39 0458731148
info@icicaldaie.com www.icicaldaie.com