INSTALLATION AND MAINTENANCE MANUAL

Blowdown Vessels

This manual must be available to the operator at all times. BDV-IMM-2018-6

TABLE OF CONTENTS Fulton Ltd

I Warnings & Cautions Explained III

II Warnings & Cautions In Manual III

III Regulations IV

SECTION 1 - INTRODUCTION
1.1 General 1

1.2 Technical Data 1

1.3 Product Overview 1

SECTION 2 - INSTALLATION
2.1 General 5

2.2 Pre-Installation 5

2.2.1 Receiving Inspection 5

2.2.2 Siting 6

2.3 BDV Pipework Connections 6

2.3.1 Vent Connection 6

2.3.2 Discharge Connection 8

2.3.3 Blowdown Inlet Connections 8

2.3.4 Drain Connections 8

2.3.5 Blowdown After Cooler Connections 9

2.4 Piping Specifications 10

2.5 Insulation 10

SECTION 3 - MAINTENANCE
3.1 Visual Checks 11

3.2 Hydraulic Testing 11

3.3 Recommended Water Conditions 11

3.4 Blowdown Vessel Internal Inspection 12

3.5 Fitting New Gaskets To Inspection Holes 12

3.5.1 Important Information 12

3.5.2 Fitting Procedure 13

APPENDIX A - TI SHEETS
Blowdown Vessel Dimensions & Specification 16

Typical Blowdown Layout Vertical Fuel Fired 18

Blowdown After Cooling System 20

Page II BDV-IMM-2018-6
Fulton Ltd SAFETY PRECAUTIONS

I Warnings & Cautions Explained

For your safety!

The following WARNINGS, CAUTIONS and NOTES appear in various sections of this manual.

• WARNINGS must be observed to prevent serious It is the responsibility and duty of all personnel involved
injury or death to personnel. in the operation and maintenance of this equipment
to fully understand the WARNINGS, CAUTIONS and
• CAUTIONS must be observed to prevent damage NOTES by which hazards are to be eliminated or
or destruction of equipment or loss of operating reduced.
effectiveness.
Personnel must become familiar with all aspects
• Notes: must be observed for essential and of safety and equipment prior to operation or
effective operating procedures, conditions and as maintenance of the equipment.
a statement to be highlighted.

II Warnings & Cautions In Manual

SAFETY
The instructions provided for the operation and maintenance of the boiler MUST be observed. Failure to do so could result in
damage to the boiler and serious personal injury.

! WARNING ! WARNING
Blowdown vessels are a potential hazard, possibly fatal When opening any drains on the equipment or piping
if not properly maintained. system, steps should be taken to avoid scalding/
burning of personnel due to hot fluids. Whenever
Blowdown vessels reach high temperatures but MUST possible, the system should be cooled prior to opening
NOT be insulated. any drains.
Suitable guards should be installed where deemed
necessary to prevent injury.

Do not try to do repairs or any other maintenance work ! CAUTION

you do not understand. Obtain a service manual from
Fulton Ltd or call a Fulton service engineer. Obey all laws and local regulations which affect you
and your boiler.
LIFTING EQUIPMENT
Make sure that lifting equipment complies with all local It is vitally important that the instructions given in this
regulations and is suitable for the job. You can be manual are strictly adhered to. Failure to carry out the
injured if you use faulty lifting equipment. Make sure the routine maintenance checks could result in a drastic
lifting equipment is in good condition. reduction in the life expectancy of the blowdown vessel.

Non-approved modifications can cause injury and Blowdown pipework is subject to very rapid increases
damage. Contact your Fulton dealer before modifying in temperature and pressure resulting in high levels of
the boiler. mechanical and thermal stress.
It is therefore very important that blowdown pipework
is designed correctly using the correct materials, with
Only qualified persons should be allowed to
suitable brackets to allow for expansion.
operate and maintain the boiler and its equipment.

The blowdown vessel should never be used for boiler

Boilers should always be drained through an approved
blowdown when empty.
blowdown vessel.

Never attempt to operate equipment that has failed to

pass all the safety checks.

BDV-IMM-2018-6 Page III

SAFETY PRECAUTIONS Fulton Ltd

! CAUTION ! CAUTION
Blowdown pipework is positioned where operatives can HYDRAULIC TEST - RISK OF BRITTLE FRACTURE
easily come into contact with hot surfaces. Hydraulic testing requires specialist equipment and
Always insulate pipework where this possibility exists is normally only required by engineering surveyors /
and /or display suitable notices warning of the danger. inspectors. In order to ensure the material/ pressure
vessel does not suffer from brittle fracture, hydraulic
Failure to comply with recommended water conditions testing should not be carried out below 7 °C.
will invalidate the Guarantee on your Blowdown vessel.

III Regulations

Observe the following when working on this system:

• Work on electrical equipment must only be carried out by a qualified electrician.

• All legal instructions regarding the prevention of accidents,

• All legal instructions regarding environmental protection,

• The Code of Practice of relevant trade associations,

• All current safety regulations as defined by DIN, EN, DVGW, TRGI, TRF, VDE and all locally applicable
standards.

! CAUTION
In case of emergency
This blowdown vessel has been designed and constructed to meet all of the essential requirements of the applicable
European Directives and subject to proper maintenance should not give occasion to any hazardous conditions.

The Pressure System Safety Regulations 2000

Fulton blowdown vessels fall within the scope of the Pressure Systems Examination Scheme.
Regular inspections are therefore required by a competent person.
The scope of the examination and the actual intervals between examinations is at the discretion of the competent
person.
It is the responsibility of the user to provide a written scheme of examination for those parts of the system in which
a defect may give rise to danger.
Instructions in this manual are provided for the safe operation and maintenance of the blowdown vessels and do
not cover periodic statutory inspections.

For further information contact:

(a) SAFed
SAFETY ASSESSMENT FEDERATION Limited.
Nutmeg House,
60 Gainsford Street,
Butlers Wharf,
London, SE1 2NY.

(b) Health and Safety Executive local office.

(c) Your Competent Person.

Page IV BDV-IMM-2018-6
Fulton Ltd INTRODUCTION - 1

SECTION 1 - INTRODUCTION

1.1 General

Prior to shipment, the following inspections and tests are made to ensure the highest standards of
manufacturing for our customers:

• Material inspections
• Manufacturing process inspections
• Hydrostatic test inspection
• Operating test
• Crating inspection

This manual is provided as a guide to the correct operation and maintenance of your Fulton
equipment, and should be read in its entirety and be made permanently available to the staff
responsible for the operation of the boiler. It should not, however, be considered as a complete
code of practice, nor should it replace existing codes or standards which may be applicable.
Fulton reserves the right to change any part of this installation and maintenance manual.

Installation and maintenance of this equipment can be hazardous and requires trained, qualified
installers and service personnel. Trained personnel are responsible for the installation, operation,
and maintenance of this product, and for the safety assurance of installation, operation, and
maintenance processes. Do not install, operate, service or repair any component of this
equipment unless you are qualified and fully understand all requirements and procedures.

1.2 Technical Data

For a full specification refer to Appendix A - TI-119-Blowdown Vessels Dimensions &

Specification.

1.3 Product Overview

Fulton blowdown vessels are designed to BS EN 13445:2014, and have full compliance with
PM60 and the requirements of the European Pressure Equipment Directive 2014/68/EU. They
are intended to reduce the pressure of the blowdown discharge to atmospheric pressure, and to
reduce the discharge to drain to an acceptable temperature.

The energy released by the high temperature and pressure from the boiler blowdown valve(s)
is separated into flash steam, which is discharged to atmosphere, and hot water/effluent which
is discharged to drain. The standing water volume within the vessel is sized to accommodate a
normal blowdown, such as would be required to test the boiler water level controls between first
& second low water, or a 5% main blowdown rate, while limiting the discharge temperature to that
required by water authority by-laws.

CONTINUED ON NEXT PAGE

BDV-IMM-2018-6 Page 1
INTRODUCTION - 1 Fulton Ltd

The blowdown vessel is not intended to cool the discharge to a safe temperature when the boiler
is drained completely at full pressure, or when continuous or intermittent blowdown systems are
used. Under these circumstances an after cooler system should be used together with blowdown
procedures designed to prevent high temperature discharge to drain.

Fulton blowdown vessels are designed for a maximum working temperature of 150 °C and a
minimum working temperature of 5 °C. They are not intended for use in locations where the
ambient temperature is likely to be below 5 °C.

BDV2 BDV3/4 BDV5-7

Figure. 1 - Blowdown Vessel Range

Page 2 BDV-IMM-2018-6
Fulton Ltd INTRODUCTION - 1

A G

B H

C
K

D M

E N

Q
F R
S

Figure. 2 - Blowdwon Vessel ID Plate (typical)

Description Comments
A Serial number Unique number given to each Fulton blowdown vessel for identification
B Model Name of product
C Product Group Type of product
D Year of manufacture Year that the product was made (not year it was sold or commissioned)
E Notified Body A notified body is an entity that has been accredited by a Member State
to assess whether a product to be placed on the market meets certain
preordained standards
F CE marking European Conformity - mandatory conformity marking for certain products
sold/manufactured within the European Economic Area
G Date of test This is the date of the hydraulic testing
H Capacity Internal space of blowdown vessel
K Design pressure The pressure used in the design calculations
M Maximum allowable Maximum safe pressure the vessel has been designed to operate at
pressure
N Test pressure The pressure the vessel was tested to during hydraulic testing
P Design Temp Max The max temperature used in the design calculations
Q Design Temp Min The min temperature used in the design calculations
R Manufactured by Company that manufactured the product
S Design code British standard (BS) used to design and manufacture the product

BDV-IMM-2018-6 Page 3
 Fulton Ltd

Page 4 BDV-IMM-2018-6
Fulton Ltd INSTALLATION - 2

SECTION 2 - INSTALLATION

2.1 General

Only suitably qualified and competent persons should undertake the installation of steam,
condensate and blowdown equipment.

In the UK, the installation should be carried out to the requirements of HSE Guidance Note PM60
and BS EN 13480:2017 “Metallic industrial piping”.

2.2 Pre-Installation

Prior to delivery of the vessel, consideration should be given to the following:

(Planning regulations may call for more consents than those listed below, always check with your
Local Planning Authority).

A. Local Planning consents where appropriate.

B. Consideration given to access for delivery and positioning of the vessel.

C. Preparation of a suitable base, which must be able to support the total weight of the system
under operating conditions.

The locations of services to the site required for the system, under operating conditions.

D. Drainage system, check the suitability of the drainage system.

E. Local regulations for discharge into existing drains.

F. Safe access to the plant when installation is complete.

2.2.1 Receiving Inspection

The customer should examine the equipment for any damage. It is the responsibility of the installer
to ensure all parts supplied with the equipment are fitted in a correct and safe manner.

BDV-IMM-2018-6 Page 5
INSTALLATION - 2 Fulton Ltd

2.2.2 Siting

! WARNING
Failure to provide required and safe access to the equipment could impede commissioning and maintenance.
Service technicians are instructed not to commence commissioning if hazardous conditions exist.

The blowdown vessel should not be sited close to walk ways or any position where the general
public could gain access.

It should not be located where:-

• There is a risk of freezing.

• In areas where the noise and possible vibration caused by blowdown will have a detrimental
effect.

• Where the vent connection route to outside the building is too long or necessitates many
changes in direction.

Reference should be made to Appendix A - TI-119-BDV Dimensions & Specification to

ascertain the relevant dimensions and weights.

The flooring must be level, laid in a non-combustible material and be of sufficient strength to
support the vessel.

2.3 BDV Pipework Connections

For connection sizes, refer to Appendix A - TI-119-BDV Dimensions & Specification.

2.3.1 Vent Connection

The vent connection and discharge from the vessel are sized to comply with the requirements of
(UK) HSE Guidance Note PM60 and should not be reduced.

The vent should be run to a position outside the boiler house at high level away from areas where
pedestrians may have to walk directly below the discharge point.

A blowdown exhaust head should always be used to reduce the level of condensate that is
discharged with the flash steam.

The vent connection should not be joined to vents or discharge pipes from other equipment,
e.g. safety valve, or feedwater tank vent.

Page 6 BDV-IMM-2018-6
Fulton Ltd INSTALLATION - 2

Blowdown Exhaust Head

Condensate
Drain 20 mm (3/4 in.)

Condensate Drain
(piped to low level)
Exhaust vent pipe

Vent Connection

Pressure Gauge (not

supplied as standard)

Main Blowdown Inlet

Discharge Connection
Auxiliary Blowdown Inlet

Handhole
Cooling Water
Sensor Connection
Handhole
Cooling Water
Injector Connection

Drain

Drain Connection

Figure. 3 - Typical Blowdown Vessel Layout Arrangement

BDV-IMM-2018-6 Page 7
INSTALLATION - 2 Fulton Ltd

2.3.2 Discharge Connection

The discharge from the blowdown vessel should not normally exceed 43 °C when level control
testing between first and second low water, or for main blowdown rates not exceeding 5% of the
boiler water capacity. Where blowdown rates higher than this are anticipated a cooling system
should be used to prevent excess temperatures being discharged into the drain.

UK - Discharge temperature into public drains must not exceed 43 °C as stated in the Water
Industry Act 1991.

! CAUTION
Discharge temperatures reaching 100 °C could occur in a fault condition (i.e. loss of cooling water
supply) or as a result of human error.
Damage could occur where plastic drainage systems are used.
Procedures to prevent high temperature discharges when blowing down or draining a hot boiler should
be rigorously applied.

2.3.3 Blowdown Inlet Connections

Fulton blowdown vessels are provided with three blowdown inlet connections: 1 x Main boiler
blowdown and 2 x Auxiliary blowdowns. Inlet manifolds are available for multi-boiler application.

In the UK, the permitted arrangements for single and multi boiler blowdown pipework installations
are covered by HSE Guidance Note PM60.

Blowdown pipework should never be smaller than the bore of the blowdown valve supplied with
the boiler.

! CAUTION
Blowdown pipework is subject to very rapid increases in temperature and pressure resulting in high
levels of mechanical and thermal stress.
It is therefore very important that blowdown pipework is designed correctly using the correct materials,
with suitable brackets to allow for expansion.

Blowdown pipework is positioned where operatives can easily come into contact with hot surfaces.
Always insulate pipework where this possibility exists and /or display suitable notices warning of the
danger.

! WARNING
Blowdown vessels reach high temperatures but MUST NOT be insulated.
Suitable guards should be installed where deemed necessary to prevent injury.

2.3.4 Drain Connections

The blowdown vessel should be fitted with a drain valve (available on request) which can be
either locked and piped permanently to drain, or plugged. The drain connection is there to drain
the vessel for inspection and/or sludge removal. The vessel should be refilled with cold water
prior to use.
Page 8 BDV-IMM-2018-6
Fulton Ltd INSTALLATION - 2

! CAUTION
The blowdown vessel should never be used for boiler blowdown when empty.

Mains Gas In
Main Gas
Valve

Main
Steam
Valve
TDS SYSTEM
Blowdown
Exhaust Head

Mains Cooling Water

Water Out Level
Water
Mains Cooling Level Control
Water In Sight Column
(valves omitted
Gauges for clarity)
SAMPLE (valves omitted
COOLER for clarity)
Feedwater
Pump

Main Blowdown
and Boiler Drain
BLOWDOWN VERTICAL STEAM BOILER
VESSEL
CAUTION
Blowdown water
Mains Cooling
is required to Water In
be cooled
to 43◦C before
entering AFTER COOLING SYSTEM
public drains (UK).

Figure. 4 - Typical Boiler Blowdown Vessel and Ancillary Equipment Layout

2.3.5 Blowdown After Cooler Connections

The blowdown vessel has 2 connections to fit an after cooler system, one connection is for the
sensor and one is for the injector.

After-cooling systems are automatically controlled by a temperature sensor located in the

blowdown vessel, mains water is injected into the vessel when a pre-set temperature is reached
to cool down the contents.

For more information on the Blowdown Aftercooler, please refer to the Fulton technical information
sheets, included in this manual (Appendix A - TI-40 BlowdownAfterCoolingSystems).

BDV-IMM-2018-6 Page 9
 Fulton Ltd

2.4 Piping Specifications

For piping the basic considerations are: the design temperature, the pressure retained by the
pipe, the fluid in the pipe, the load resulting from thermal expansion or contraction, impact or
shock loads imparted (such as water hammer, external loads, wind loads and vibration from
equipment).

Adhere to the following:

1. The arrangement of the piping must take into consideration the location of other structures and
equipment adjacent to the piping. The potential for freezing interference and/or damage as a
result of expansion, contraction, vibration, or other movements must be factored.

2. Valves are used in piping systems to stop and start the flow of fluids, to regulate flow, to
prevent back flow, and to relieve excessive pressure build-up in the piping. Consideration
should be given to the appropriate location and orientation of valves necessary for safe
operation and isolation of the piping.

3. All piping and piping components used should be suitable for the design temperatures,
pressure and fluid used in the system.

4. During the installation, ensure that no dirt, water, or residue from welding is left in the system.

5. Expansion joints or properly designed and sited expansion loops should be provided to
accommodate thermal expansion. Thermal expansion should be calculated using the
maximum possible utilization fluid temperature. Steel pipe will expand approximately 1 mm per
meter over 100 °C rise.

6. Supports and anchors must be provided for all pipes, as necessary, to prevent undue stresses
from being placed on equipment, including pumps, valves, and the boiler. Supports and
anchors which will not interfere with thermal expansion should be chosen. The equipment
should never be used or considered as an anchor.
No additional loads should be applied to any factory connection.

7. Gaskets must be used to make all flanged connections. Gasket material must be suitable for
use with the pressure, temperature and fluid in the system. Ensure that all bolts are tightened
evenly and to the torque recommended values provided by the gasket manufacturer.

2.5 Insulation

Note: It is recommended that for inspection and maintenance, flanges, valves and fittings be left uninsulated but
suitably shielded for safety.

Adhere to the following:

1. Blowdown vessels should not be insulated.

2. Equipment should be insulated with material suitable for the application and temperatures
expected.

Page 10 BDV-IMM-2018-6
Fulton Ltd MAINTENANCE - 3

SECTION 3 - MAINTENANCE

Fulton blowdown vessels are open vented atmospheric vessels with no moving parts or controls.
The only maintenance required is visual checks and an annual statutory inspection.

3.1 Visual Checks

Visually check for leaks paying particular attention to the inspection opening gasket.

When replacing the inspection opening cover it is important that a new gasket is used.

3.2 Hydraulic Testing

! CAUTION
HYDRAULIC TEST - RISK OF BRITTLE FRACTURE

Hydraulic testing requires specialist equipment and is normally only required by engineering
surveyors/inspectors. The material that the vessel is manufactured from has not been impact
tested, as it is not a requirement of the construction standard. In order to ensure the material/
pressure vessel does not suffer from brittle fracture hydraulic testing should not be carried out
below 7 °C.

3.3 Recommended Water Conditions

For recommended water conditions, refer to manufacturers boiler manual or contact the boiler
manufacturer.

! CAUTION
Failure to comply with recommended water conditions will invalidate the Guarantee on your
Blowdown vessel.

BDV-IMM-2018-6 Page 11
MAINTENANCE - 3 Fulton Ltd

3.4 Blowdown Vessel Internal Inspection

! WARNING
Blowdown vessels reach high temperatures and should be drained and cooled before the removal
of hand holes.

The hand hole should be removed Hand Hole Cover Plate

after one month of operation and
the interior of the blowdown vessel Gasket
thoroughly examined. If scale or
sludge build-up is observed, it should Crab
be removed and the water treatment
supplier advised.

New gaskets must be fitted every

time a hand hole is removed (see
Section 3.5 - Fitting New Gaskets To
Inspection Holes).

Subsequent interior examinations

should be carried out on a regular
basis until satisfactory conditions are Figure. 5 - Hand Hole
observed.

3.5 Fitting New Gaskets To Inspection Holes

3.5.1 Important Information

! CAUTION
TOPOG-E gasket have a finite life after installation and must be renewed annually.
It is important that the instructions given in this section are adhered to.

The blowdown vessel is fitted with TOPOG-E gaskets in all of the inspection holes. These gaskets
work very well and millions have been safely used over the last 30 years, however, it is absolutely
essential to observe a few simple rules in order to get the best performance from your installation.

Elastomeric Vulcanizates, which form the basis of TOPOG-E gaskets, undergo degradation
from many sources including heat, oxygen, stress, and overdosing from certain types of water
treatment. This takes the form of material oxidation, hardening/embrittlement and cracking which
may result in gasket failure. Steps must be taken to minimise the effects of such attacks.

Water treatment and oxygen attack can be minimised by ensuring that the gasket is aligned
correctly so that only the extreme edges of the gasket are exposed. If a new gasket leaks after
fitting this is almost certainly due to incorrect seating or alignment. As such gaskets are very
flexible it is possible to cure the leak by excessive tightening, but such an action will seriously
reduce the life of the gasket and cause problems later.

Gentle warming of the vessel at first use after maintenance will also help to ensure that the rubber
‘cures to shape’. If the rubber post-cures, the elastic memory will be destroyed and any initial
over tightening will cause the gasket to become hardened and embrittled, leading to cracks and
eventual failure.

Page 12 BDV-IMM-2018-6
Fulton Ltd MAINTENANCE - 3

3.5.2 Fitting Procedure

Drain the vessel completely and examine all inspection holes. If any leakage is evident, proceed
as follows:

1. Disassemble the crab and cover plate and remove the inspection hole assembly.
Remove the old gasket and thoroughly clean the mating faces of the cover plate and vessel
ring.

2. Place the new Topog-E gasket on the cover plate, ensure the gasket is the correct size and is
seating flat against the plate. Do not use any grease, lubricant or adhesive. If the new gasket
is not seated properly before the plate is tightened, the gasket may be pinched causing a
failure when the pressure builds up.

3. Position the cover plate in the vessel ring, ensuring that the plate is correctly centred.
An off centre cover plate can concentrate forces on the gasket and cut it in two. The cover
plate may also drag on the vessel hole ring and fail to seal as the pressure rises.
Set the crab and hand tighten the securing nut(s) sufficiently to provide a snug fit.
Tighten the nuts a further quarter of a turn using a spanner. DO NOT OVER TIGHTEN.

Note: Ensure the gasket is aligned correctly so that only the extreme edges are exposed to water treatment or
oxygen attack. If the gasket is misaligned, over tightening to seal a leak will not prevent subsequent leakage at a
later date.

4. If the gasket leaks during pressure build-up, tighten the securing nut(s) sufficiently only to stop
the leakage.

Note: New gaskets fitted to inspection holes located along the bottom of the vessel are more difficult to install
without leaking. Small particles of scale or sand tend to run down on the mating surfaces after cleaning but prior
to assembling. This condition is likely to have occurred if excess tightening is required to stop a leak before
warming the vessel. In this event, the best course of action is to drain the vessel and repeat the gasket fitting
procedure. Failure to do so will severely reduce the life of the gasket.

COVER PLATE AND

GASKET IN PLACE
CORRECT DO NOT COVER PLATE
PLACEMENT OVER-COMPRESS NOT IN CENTRE
GASKET

Figure. 6 - Fitting a New Topog-E Gasket

BDV-IMM-2018-6 Page 13
 Fulton Ltd

Page 14 BDV-IMM-2018-6
Fulton Ltd APPENDIX - A

APPENDIX A - TI SHEETS

The Fulton blowdown vessels manual refers to TI sheets. These TI sheets can be found in this
Appendix.

Note: The TI sheets in this appendix can be updated/replaced without revising the manuals issue number. To
check you have the most up to date TI sheet, please check the downloads section on the Fulton website
(www.fulton.co.uk/support/downloads) or consult Fulton Ltd.

BDV-IMM-2018-6 Page 15
APPENDIX - A Fulton Ltd

Technical Information
Sheet No. 119 Issue 7

Blowdown Vessels
Dimensions & Specification

Fulton Blowdown vessels are manufactured to BS EN 13445:2014 and designed to reduce the pressure of the
blowdown discharge from the boiler to atmospheric pressure, and also reduce the blowdown discharge to drain to
acceptable temperatures for compliance to water bylaws.

Dimensions
G D
PRESSURE
30° GAUGE
COOLING
WATER SENSOR G1
(SOCKET 30°) COOLING
WATER INJECTOR* PRESSURE
45°
GAUGE
HAND HOLE
A
A
D
A
D B
L
M
B
F F
B M
F H1 H2 H1 H2
M J
H1 J C
H2 K C L C
K
L K N
J E E E
BDV2 BDV3/4 BDV5-7

MODEL: BDV 2 3/4 5/7

A Shell Diameter 273 457 610
B Vent Height 985 1480 2075
C Discharge Height 615 910 1215
D Discharge Depth to Centre of Vessel 250 350 400
E Drain Height 233 382 329
F Main Blowdown Height 800 1200 1580
Main Blowdown Depth to Centre of
G - 305 400
Vessel
G1 Distance Between Blowdown Inlets - 320 400
H1 1st Auxiliary Blowdown Height 700 1200 1580
H2 2nd Auxiliary Blowdown Height 600 1135 1455
J Handhole Height Size: 102 x 76 360 990 1280 (x 2)
K Cooling Water Sensor Height 510 550 1055
L Cooling Water Injector Height 435 650 / 1384 1957
M Pressure Gauge Height 820 1384 1957
N Temperature Gauge Height - - 955

Note: Dimensions mm
Note: Dimensions are approximate and only intended as a guide to aid installation.

* Cooling water injector: BDV3/4 has 2 optional positions for this connection

Page 1 of 2

Page 16 BDV-IMM-2018-6
Fulton Ltd APPENDIX - A

TI-119-BDV-DS-2018-7
Specification
MODEL: BDV UNIT 2 3/4 5/7
Complies to H & SE Guidance Note PM60 and BS EN 13445:2014.
General
Design Pressure barg 6.9 6.9 7.0
Weight
Shipping Weight kg 64 167 275
Standing Water Capacity L 15 69 210
Connection Sizes All threads BSPT unless otherwise specified
Vent DN 80 PN6 100 PN16 125 PN16
Discharge DN 80 PN6 80 PN16 80 PN16
Drain DN 50 40 50
Main Blowdown inlets DN 25 25 PN16 32 PN16
1st Auxiliary Blowdown inlet DN 15 25 PN16 32 PN16
2nd Auxiliary Blowdown inlet DN 15 15 15
Cooling Water Sensor DN 25 25 25
Cooling Water Injection DN 25 25 25
Pressure Gauge DN 15 15 15
Temperature Gauge DN - - 15

Page 2 of 2

Telephone: +44 (0) 117 972 3322

Fulton Ltd Fax: +44 (0) 117 972 3358
5 Fernhurst Road, Fishponds, Bristol. E-mail: [email protected]
BS5 7FG. England. Website: www.fulton.co.uk
Every effort is made to ensure accuracy at time of going to press. However as part of our policy of continual product improvement, we reserve the right to alter specifications without prior notice.

BDV-IMM-2018-6 Page 17
APPENDIX - A Fulton Ltd

Technical Information
Sheet No. 64 Issue 2

Typical Blowdown Layout

AUTO T.D.S UNIT

To sample cooler
Vertical Fuel Fired Boilers AUTO T.D.S UNIT
CHECK VALVE
FLOW To sample cooler
ONE DIRECTION ONLY
CHECK VALVE

Auto operated blowdown systems VALVE OPEN

FLOW
VALVE CLOSED ONLY
ONE DIRECTION

VALVE OPEN
Single Boiler Installation VALVE CLOSED

TO SAMPLE
COOLER AUTO
T.D.S. BLOWDOWN
UNIT VESSEL
TO SAMPLE WATER WATER LEVEL
AUTO BOTTLE GAUGES
COOLER
T.D.S. BLOWDOWN
UNIT VESSEL
WATER WATER LEVEL
BOTTLE GAUGES
BOILER

BOILER
SEE NOTE 2.

SEE NOTE 2.
Multiple Boiler Installation
TO SAMPLE
AUTO Manifolds At Blowdown Vessel
COOLER
T.D.S. Each Manifold One Branch Per Boiler
UNIT BLOWDOWN
TO SAMPLE TO SAMPLE WATER WATER LEVEL VESSEL
AUTO AUTO BOTTLE GAUGES BOILER
Manifolds At Blowdown Vessel
COOLER COOLER BLOWDOWNS
T.D.S. T.D.S. Each Manifold OneWATER
Branch LEVEL
Per Boiler
GAUGESBLOWDOWN
UNIT UNIT
WATER WATER LEVEL WATER WATER LEVEL & WATER BOTTLE VESSEL
TO SAMPLE MANIFOLD
BOILER
AUTO BOTTLE GAUGES BOTTLE GAUGES BRANCHES BLOWDOWNS
COOLER BLOWDOWNS
T.D.S. BOILER WATER LEVEL GAUGES
UNIT & WATER BOTTLE
WATER WATER LEVEL MANIFOLD
BOTTLE GAUGES BRANCHES BLOWDOWNS
BOILER BOILER

SEE NOTE 2.
BOILER

SEE NOTE 2.

(Blowdown valves shown, excludes valves for water level gauges, drains etc.)

Note 1: Position valves as close as practicable to their associated component, eg. Boiler blowdown valve close to
the boiler.

Note 2: Drain lines must only be taken off blowdown lines downstream of manual & auto boiler blowdown valves,
water bottle, water level gauges & auto TDS and upstream of blowdown vessel valves.

AUTO T.D.S UNIT

To sample cooler

CHECK VALVE
FLOW
ONE DIRECTION ONLY

VALVE OPEN

VALVE CLOSED

Page 1 of 2

BLOWDOWN
VESSEL

Page 18 BDV-IMM-2018-6
 Fulton Ltd AUTO T.D.S UNIT
APPENDIX - A
To sample cooler
AUTO T.D.S UNIT
CHECK VALVE
To sample cooler
FLOW
ONE DIRECTION
CHECK VALVE ONLY

Manually operated blowdown systems TI-64-Typical

FLOW OPEN Blowdown-2018-2
VALVE
ONE DIRECTION ONLY
VALVE CLOSED
VALVE OPEN

Single Boiler Installation VALVE CLOSED

BLOWDOWN
VESSEL
WATER WATER LEVEL
BOTTLE GAUGES
SAMPLE BLOWDOWN
COOLER VESSEL
WATER WATER LEVEL
BOTTLE GAUGES
SAMPLE
COOLER BOILER

BOILER
Cooling Drain
water supply SEE NOTE 2.

Cooling Drain
water supply SEE NOTE 2.
Multiple Boiler Installation
Manifolds At Blowdown Vessel
Each Manifold One Branch Per Boiler
BLOWDOWN
WATER WATER LEVEL VESSEL
SAMPLE BOTTLE GAUGES Manifolds At Blowdown Vessel
BOILER
BLOWDOWNS
Each Manifold One Branch Per Boiler BLOWDOWN
COOLER WATER LEVEL GAUGES
WATER WATER LEVEL & WATER BOTTLE VESSEL
WATER WATER LEVEL BOTTLE GAUGES BOILER
MANIFOLD
BOTTLE GAUGES SAMPLE BLOWDOWNS BLOWDOWNS
SAMPLE BRANCHES
COOLER BOILER WATER LEVEL GAUGES
COOLER & WATER BOTTLE
WATER WATER LEVEL MANIFOLD
BOTTLE GAUGES BLOWDOWNS
SAMPLE
BOILER
*
BRANCHES
COOLER BOILER

* *
BOILER SEE NOTE 2.
Cooling Drain
water supply
* SEE NOTE 2.
Cooling Drain
water supply

(Blowdown valves shown, excludes valves for water level gauges, drains etc.)

* Safety, only one boiler valve allowed to be open at a time. eg. all the valves to be operated by just one handle
which can only be removed when valve is closed or lockable valves to be provided.

Note 1: Position valves as close as practicable to their associated component, eg. Boiler blowdown valve close to
the boiler.

Note 2: Drain lines must only be taken off blowdown lines downstream of manual & auto boiler blowdown valves,
water bottle, water level gauges & auto TDS and upstream of blowdown vessel valves.

AUTO T.D.S UNIT

To sample cooler

CHECK VALVE
FLOW
ONE DIRECTION ONLY

VALVE OPEN

VALVE CLOSED

Page 2 of 2

BLOWDOWN
VESSEL
Telephone: +44 (0) 117 972 3322
Fulton Ltd Fax: +44 (0) 117 972 3358
5 Fernhurst Road, Fishponds, Bristol. E-mail: [email protected]
BS5 7FG. England. Website: www.fulton.co.uk
Every effort is made to ensure accuracy at time of going to press. However as part of our policy of continual product improvement, we reserve the right to alter specifications without prior notice.

SEE NOTE 2.

BDV-IMM-2018-6
Manifolds At Blowdown Vessel Page 19
Each Manifold One Branch Per Boiler BLOWDOWN
TER LEVEL VESSEL
AUGES BOILER
BLOWDOWNS
WATER LEVEL GAUGES
APPENDIX - A Fulton Ltd

Technical Information
Sheet No. 40 Issue 4

Blowdown After Cooling System

Blowdown vessels are designed in accordance with the Health & Safety Executive Guidance Note PM60 and
BS EN 13445, and are selected typically having sufficient standing water volume to cool the discharge from the
vessel to 43°C for a 2.5% boiler water content blowdown, assuming that the vessel contents were cold at the start
of the blowdown.

Where there are multiple boilers, high blowdown rates or where TDS blowdown systems are in use, the blowdown
vessel discharge may well reach 100°C.

Apart from the Water Supply Bye-laws obligation not to exceed 43°C there are the practical considerations such as
the possible damage that may be caused to plastic drains by high temperatures.

The solution for normal use is to fit a blowdown after cooling system which automatically adds cooling water to the
blowdown vessel to cool the contents to 43°C.

Note: After cooling systems are not intended to guarantee a maximum discharge temperature of 43°C under any
circumstances.

Should the main manual blowdown valve be left open unintentionally with the boiler at full pressure, it would
be extremely difficult if not impossible to provide the volume of cooling water required to maintain a discharge
temperature from the blowdown vessel of 43°C.

There are several methods of after cooling, two of which are used by Fulton.

1. A direct acting system which is offered by Fulton Ltd uses a 3/4 in. BSP two port normally closed direct
acting control valve in the cooling water pipework. This is operated via a capillary connected to a
temperature controller mounted in an immersion pocket in the side of the blowdown vessel. The cooling
water pipework must also include an isolating valve and strainer upstream of the control valve and a
non-return valve between the control valve and blowdown vessel connection (see Fig. 1).

Type 128 Temperature Control

Non-return Valve

SBRA Normally Closed Valve

Cooling Water
(see note a.)

Isolating Valve

Strainer

Fig. 1- Typical after cooling pipework arrangement.

Page 1 of 2

Page 20 BDV-IMM-2018-6
Fulton Ltd APPENDIX - A

TI-40-BDV-Aftercooling System-2017-4

1. (continued)
The advantages of this system are that it is extremely robust, there are no electrical connections and
maintenance is minimal.

The disadvantage is that the whole of the contents of the blowdown vessel have to be cooled before
the discharge temperature is reduced to the set temperature. This can cause a delay for a short time
resulting in temperatures above the set point being discharged.

2. A solenoid operated system which detects the discharge temperature from the blowdown vessel, and
then introduces cooling water direct into the discharge pipe.

The advantages of this system are that it is a lower cost option, is faster acting, can be retro fitted to
systems where there are no spare connections in the blowdown vessel, and only cools the discharge.

The disadvantages are that electrical wiring between the solenoid valve, sensing thermostat, and power
supply are required, and solenoid valves do occasionally require replacement.

Method 2 is occasionally used on small boiler installations where capital cost, and the relatively small amount of
blowdown are key considerations.

An adequate supply of cooling water is crucial for the systems to function correctly. Both systems require a
minimum water pressure of 3 bar.

Note:
a) Blowdown is classified as a contaminated substance. Water used to cool the blowdown discharge
must only be supplied from a system that incorporates a Type A air gap or a Water Authority approved
equivalent device.

b) The cooling water supply must be of sufficient capacity to cool the discharge in a very short time.
Blowdown rates vary dramatically depending upon the percentage condensate return, raw water TDS,
and water treatment chemicals added. For an estimate of the flow rate required contact Fulton Ltd.

c) When installing feedwater tank steam injection systems and blowdown after cooling systems care must
be taken to ensure that the correct two port control valves are fitted for each application.

i. The steam injection systems use a two port normally open valve: 1/2 in. type SB, 1 in., 1 1/2 in. and 2
in. type KB51.

ii. The after cooling system uses a 3/4 in. two port normally closed valve type SBRA. The temperature
controllers are the same for both applications.

d) In order to limit the possibility of high temperature blowdown discharge to the building drains it is essential
that blowdown procedures are clearly displayed and that all operatives are trained and understand the
consequences of their actions.

Page 2 of 2

Telephone: +44 (0) 117 972 3322

Fulton Ltd Fax: +44 (0) 117 972 3358
5 Fernhurst Road, Fishponds, Bristol. E-mail: [email protected]
BS5 7FG. England. Website: www.fulton.co.uk
Every effort is made to ensure accuracy at time of going to press. However as part of our policy of continual product improvement, we reserve the right to alter specifications without prior notice.

BDV-IMM-2018-6 Page 21
 Fulton Ltd

Page 22 BDV-IMM-2018-6
Fulton Ltd

Material & Workmanship Guarantee

1 Year
GUARANTEE

D
FU
LT
ON L

T
On the Fulton Blowdown Vessel
Fulton Ltd will repair or replace EXW factory any Fulton blowdown vessel which within one (1)
year of the date of delivery is found to be defective in workmanship, or material, provided this
equipment is operated and maintained by the buyer for the purpose for which it was designed and
in accordance with the manufacturer’s handbook. This guarantee does not cover damage or
failures that can be attributed to corrosion, scale or dirt accumulation or to low water conditions.
This guarantee is good only in the United Kingdom of Great Britain and Northern Ireland.
This guarantee does not include labour or delivery charges of any kind.

General Guarantee
The Fulton general guarantee is given in lieu of cause whatsoever. Defective goods or parts
and in exclusion of any warranty expressed or must be returned to us as soon as possible
implied, statutory or otherwise, as to the state, after discovery of the defect. Costs of carriage
condition, performance, quality or fitness of and of detaching and incorporating parts will
the goods. Save thereunder we shall be under be borne by you. In all cases at the termination
no obligation or liability of any kind to you in of such 12 months all liability on our part will
regard to the goods. In the case of new goods cease. No liability whatsoever is to be incurred
manufactured and supplied by us we will make by us in respect of gauge or sight glasses,
good any defect developing therein under proper packing glands or electric motors or any goods
use within 12 months of delivery, provided that or accessories not of our manufacture. But so
after investigation in our sole discretion we are far as we are able, we shall let you have the
satisfied that the defect arose from faulty design, benefit of any guarantee or warranty given to us
materials or workmanship and from no other in respect thereof.

BDV-IMM-2018-6 Page 23
 www.fulton.co.uk

BDV-IMM-2018-6

Fulton Ltd
5 Fernhurst Road
Fishponds
Bristol BS5 7FG
England

Telephone: +44 (0) 117 972 3322

Fax: +44 (0) 117 972 3358
Email: [email protected] BS EN ISO 9001:2015 Company Registration 855790 England