BOILER HOUSE PRODUCTS GMS

GMS BOILER HOUSE PRODUCTS

Contents Page 2 Introduction 3 Condensate Pumpsets 6 Blowdown Vessels 8 Boiler Feed Tanks Page 10 Chemical Dosing Pots 11 Vent Heads 11 De-Aerator Heads Introduction to Boiler House Products GMS manufacture a wide range of steam related products including : Blowdown Vessels Fabricated to Pd5500 CAT III with notified body approval. Condensate Pumping Sets to suit most applications incorporating electronic air/steam driven pumps. Hotwell Tanks with optional deaerator. Steam Separators with vortex flow pattern system. Chemical Dosing Pot complete with valves and tundish. Vent Head used on GMS blow down vessels, hotwell tanks and condensate pump sets. Vent Heads are designed to remove water from discharged steam, and are fitted with an internal baffle. Typical Layout of Boiler House Products Vent Head Flash Vessel Non Storage Calorifier Boiler Not supplied by GMS Hotwell Chemical Dosing Pot Flash Vessel Storage Calorifier Blowdown Vessel Condensate Pumpset PHE PlantPac Page 2

Condensate Pumpsets Introduction By using the CPS condensate recovery system, the normally wasted energy in a steam system is recycled by recovering the condensate and returning back to the boiler hotwell feed tank. Not only does it save energy in heating new water, it also reduces the cost of chemical dosing as the recovered condensate has already been treated. Design The condensate receiver can be sized to suit any additional condensate recovery lines available, the condensate line inlet is maintained fairly low to aid installation on gravity fed systems. The pumpset is available as a single pumpset or a twin pump unit. The pump(s) on the unit are sized at 100% of the duty, with a cascade operation (twin pump units) should the design duty be exceeded. The twin pump unit also incorporate an auto-change over function. The pumps used are multi-stage with a stainless steel body and can handle condensate up to 99 C. The receiver can be manufactured from the following materials: Stainless Steel AISI 304L Stainless Steel AISI 316L The pipework material is in an appropriate material and would be screwed or welded to suit site conditions. Dependant on the size of the pumpset, the unit can be supplied in either 240v 1ph or 400v 3ph. The control panel has indicator lights for Power On, Pump Run/Trip, hand selector for Pump Action and Leed Pump Selector. Door interlocked isolator. The panel is supplied complete with volt free contacts for pump tripped and level alarms for connecting to a BMS if desired. Sizing Draw a line vertically from your required flowrate and draw a line horizontally from the pump delivery head required. This will give the required model of unit for the given duties. Once the correct model selection has been made, the required material selection should be made from the lists above. With this information, we can offer a competitive price for your condensate pumpset. Pumpset Receiver Thermal Insulation Options Type MA Consists of 50mm mineral wool with stucco aluminium cladding. this gives good thermal insulation and a quality finish. For some installations there will be a high risk of damage to the factory fitted insulation. In these instances it is preferable to insulate on site. 1 Level Control Switch 2 3 4 5 6 7 8 9 Condensate Receiver Vessel Electrical Control Panel Pump Discharge Isolation Valve Vessel Drain Vessel Overflow Pumps Receiver Level Gauge Check Valve Page 3

Condensate Pumpsets Head (m) CP2 CP3 CP6 CP1 CP4 CP5 m³/h CONNECTIONS (Unit Details on Page 5) 1 Sight Glass 2 Control Panel 3 Pumped Outlets 4 Pump Isolation Valve (Butterfly) 5 Level Control Switch c/w protection tube 6 Condensate Return 7 Condensate Inlet 8 Pump 9 Overflow 10 Drain c/w isolation valve Details Flanged connections to BS EN1092-1:2002 PN16 screwed connections BS21 The dimensions shown are the maximum overall of the specified unit. Please contact our sales office with any enquires with different dimensions to those shown. Page 4

Condensate Pumpsets Dimension Unit CP1 CP2 CP3 CP4 CP5 CP6 A 155 155 155 215 215 215 B 295 295 295 355 355 355 C 525 525 525 655 655 655 D 765 765 765 1155 1155 1155 E 915 915 915 1175 1175 1175 F 1065 1065 1065 1680 1680 1680 G 1300 1300 1300 2000 2000 2000 H 1370 1370 1370 2070 2070 2070 J 430 430 430 600 600 600 K 120 120 120 120 120 120 L 520 520 520 720 720 720 M 950 950 980 1200 1300 1300 N 490 490 490 490 490 490 P 457 457 457 675 675 675 Q 500 500 500 500 500 500 R 800 800 800 1100 1100 1100 S 70 70 70 100 100 100 T 200 200 200 400 400 400 U 655 655 655 865 865 865 V 20 20 20 20 20 20 W 145 145 145 145 145 145 X 350 350 350 550 550 550 Y 620 620 620 820 820 820 Connection Sizes 1 1/2" BSP 1/2" BSP 1/2" BSP 1/2" BSP 1/2" BSP 1/2" BSP 3 50mm PN16 50mm PN16 50mm PN16 80mm PN16 80mm PN16 80mm PN16 5 1" BSP 1" BSP 1" BSP 1" BSP 1" BSP 1" BSP 6 2" BSP 2" BSP 2" BSP 80mm PN16 80mm PN16 80mm PN16 7 2" BSP 2" BSP 2" BSP 80mm PN16 80mm PN16 80mm PN16 9 2" BSP 2" BSP 2" BSP 2" BSP 2" BSP 2" BSP 10 1" BSP 1" BSP 1" BSP 1" BSP 1" BSP 1" BSP Page 5

Blow Down Vessels Introduction BV blow down vessels are designed and manufactured fully in accordance with the latest version of Pd5500, inspected during design and manufacture by an independent insurance company and supplied complete with a data dossier. They also comply fully with the European Pressure Equipment Directive 97/23/EC (SI 1999/2001) and are CE marked. Background Information When a steam boiler evaporates water the dissolved minerals in the remaining boiler water are concentrated. To prevent the concentration becoming excessive and causing damage to the boiler some of the water is blown down from the boiler periodically and replaced with fresh water. The blow down water loses pressure rapidly, resulting in the evolution of flash steam. This mixture of steam and hot water is a potential hazard. It is not permissible to drain water to public sewers above 43 C so the blow down water must be safely contained and allowed to cool first. The BV Blow Down Vessel is designed to do this. Selection Select the appropriate blow down vessel from the Tables 1 and 2. Table 2 allows for a loss of boiler pressure equal to 8 metres pipe length in the blow down line. If the loss is less than 8 metres then multiply the actual boiler pressure by 1.2 before using Table 2. Calculate the loss in pipe lengths using Table 1 and adding the length of straight pipe. Table 1 Main Blow Down Line Size Pipe Fitting 1" 1¼" 1½" 2" Equivalent Length of Pipe in Metres Blow Down Valve 0.3 0.35 0.4 0.5 Long Radius Bend 0.5 0.65 0.75 0.9 Globe Valve 9.5 12 14 18 Check Valve 3.5 1.3 5 6.3 Mainifold Inlet 1.1 1.5 1.7 2.2 Table 2 Main Blow Down Line Size Boiler Pressure (BarG) 1" 1¼" 1½" 2" Blow Down Vessel Type BV 5.5 1 1 1 2 7.5 1 1 2 3 8.5 1 2 2 4 10.5 1 2 3 4 12 2 2 3 5 17.5 2 3 4 5 20.5 3 4 5 6 24 3 4 5 6 27.5 4 5 5 7 Regulations Boiler blow down installations must comply with the Pressure Systems and Transportable Gas Containers Regulations 1989 ( Pressure Systems Regulations ) (HMSO). Recommendations on design of boiler installations are given in BS806 and PM60 (available from BSI and HMSO respectively). Following these recommendations will satisfy most of the requirements of the Pressure Systems Regulations. GMS blow down vessels comply with BS806 and Pm60. Also, the HSE Guidance Note PM5 (available from HMSO) states various requirements for the system design. Blow Down Vessels must have a minimum design pressure of 7 BarG or 25% of boiler pressure, whichever is the greater. GMS blow down vessels have a standard design pressure 7 BarG - higher on request. Ancillaries Supplied As Extras Vent Head - Stainless Steel, Screwed or Flanged Cooling System - Direct Acting Valve & Sensor Inlet Manifolds (Three off) - Supplied Complete with Isolation & Check Valves. Page 6

Blow Down Vessels Design Code: PD5500 CE Marked Complies With SI 1999/2001 Pressure Equipment Directive Complies with HSE Guidance Note Pm60 Material: Carbon Steel Design Pressure: 7 BarG Design Temperature: 171 C Higher Pressure and Temperature Units on Request Outlet (T) has an internal dip-tube to allow blow down to cool before disposal. If disposal temperature exceeds 43 C, water cooling will be needed. Connections E Inlets (Three as Standard) G Pressure Gauge (3/8" BSP) H Inspection Opening J Drain (2" BSP) S Cooling Water (1" BSP) T Outlet V Vent W Temperature Sensor (1" BSP) Vessel Type Dimensions Connections (mm, Flanged PN16) Weight (kg) A B C D E H T V Dry Flooded BV1 600 700 1300 500 50 200 80 100 126 381 BV2 700 800 1500 600 50 200 80 100 176 600 BV3 850 950 1700 700 50 200 100 150 234 888 BV4 1050 1150 2100 800 50 300 100 150 340 1340 BV5 1300 1400 2600 1000 50 300 150 200 673 2715 BV6 1000 1100 2000 1450 50 300 150 200 858 4161 BV7 1400 1500 2800 1600 50 500 150 250 1563 7193 Page 7

Hotwell Boiler Feed Tanks HW boiler hotwells are the source of high heat losses and on-going maintenance. The GMS carbon steel hotwell is a fully lined carbon steel tank virtually maintenance free. Heating the boiler feed water prior to it entering the boiler reduces oxygen levels in the water which can cause corrosion and also reduces the amount of chemical dosing required. Materials Carbon Steel: All wetted parts are manufactured from quality British Standard steel plate and the internal surface is coated with a Water Research Council approved epoxy lining system offering good protection against internal corrosion. Stainless Steel: GMS can manufacture the hotwell from both AISI 304L or AISI 316L grades stainless steel. The tank is internally supported using stainless steel angle and the whole structure is acid cleaned after manufacture. (Please note that stainless steel hotwells can be subjected to corrosion if high concentrates of Chlorides are present in the system). Design The HW hotwell is manufactured to suit the individual customers needs. Therefore a detailed drawing is produced to enable the customer to mark up his connection requirements (this is most helpful when the unit is a replacement and ensures pipework alteration is kept to a minimum) A test certificate is issued on completion along with a report on the soundness of the internal coating (carbon steel tanks). RC Recirculation System Materials Galvanised Steel Pipework (Mild Steel Tanks) Stainless Steel Pipework (Stainless Steel Tanks) Pump Isolation Valves: Stainless Steel Pump Strainer: Bronze Pump: Stainless Steel Sizes Rc075: 3/4 NB Rc125: 1 NB Rc175: 1 1/4 NB Rc400: 1 ½ NB DS Direct Steam Injection Materials Galvanised Steel Pipework (Mild Steel Tanks) Stainless Steel Pipework (Stainless Steel Tanks) Isolation Valves: Stainless Steel Strainer: Bronze Valve: SG Iron Please contact our sales department for sizing and further details of steam injection equipment. Hotwell Boiler Feed Tank Thermal Insulation Options Type MA Consists of 50mm mineral wool with stucco aluminium cladding. this gives good thermal insulation and a quality finish. For some installations there will be a high risk of damage to the factory fitted insulation. In these instances it is preferable to insulate on site. Components Included as Standard Thermometer 1 2 3 Vent Head Tank Contents Sight Gauge c/w protector Additional Components 4 Electronic Cold Water Make Up Feed 5 6 7 8 9 10 11 Electrical Level Control System De-Aerator Head Assembly Re-Cirrculation System External Ladder System De-Aerator Head Inlet Manifolds Support and platform assembly Direct steam Injection Kit Page 8

Hotwell Boiler Feed Tanks Connection and Ancillary Details Ref Description Ref Description DH De-Aerator Head 1 Level Control (Switch 1" BSP Connection) RC Re-Circulation System 2 Boiler Feed (Size and Quantity To Suit Installation) VH Vent Head 3 Tank Contents Sight Gauge (1/2" BSP) Supplied C/W Gauge MH Inspection Opening 4 Temperature Gauge (1/2" BSP) Supplied C/W Gauge OF Overflow 5 Steam Injection Valve Sensor Pocket (Size To Suit Injector Vlave) DS* Steam Injection 6 Chemical Dosing Connection (1/2" BSP) Dimension and Main Connection Details Dimensions mm Standard Connections Max kg Unit L W H DH RC VH MH OF DS (Dry) HW1000 1000 1000 1000 DH150 RC075 DN80 450 80 * 280 HW2000 2000 1000 1000 DH150 RC075 DN80 450 80 * 400 HW3000 2000 1000 1500 DH150 RC075 DN80 450 80 * 500 HW4000 2000 2000 1000 DH150 RC075 DN80 450 80 * 600 HW4500 2000 1250 1500 DH150 RC075 DN80 450 100 * 805 HW6000 2000 2000 1500 DH200 RC075 DN100 450 100 * 895 HW8000 2000 2000 2000 DH200 RC075 DN100 450 100 * 1065 HW12000 300 2000 2000 DH250 RC125 DN100 600 100 * 1395 HW16000 4000 2000 2000 DH250 RC125 DN100 600 100 * 2040 HW20000 4000 2500 2000 DH250 RC125 DN150 600 100 * 2370 HW24000 6000 2000 2000 DH300 RC175 DN150 600 150 * 2850 HW30000 6000 2500 2000 DH300 RC175 DN200 600 150 * 3230 HW36000 6000 3000 2000 DH350 RC400 DN200 600 150 * 3640 * - The direct steam injection size is dependant upon the type of installation where the tank is to be used. Please contact GMS Thermal Products for further information or help with sizing the system. Page 9

Chemical Dosing Pots Correct Water Treatment is essential for the corrosion protection of heating systems. GMS Thermal Products chemical dosing pots offer a safe and convenient way to introduce water treatment chemicals to the system. Two Standard Sizes:- CDP6 (6 Litres) CDP16 (16 Litres) Other sizes are available on request. Standard Specification: Each dosing pot is supplied as standard complete with:- System isolation valves Dosing Valve Drain Valve Air Vent Funnel Blue gloss paint finish General Guidelines for installation and use are given below. However, the equipment and water treatment in use in any individual system may dictate variations so please consult your water treatment supplier to ensure best results. Installation Choose a location near a main run or system header. Fasten the chemical dosing pot securely in place using the brackets provided. Pipe the drain away to safe disposal point. Connect the system connections to the pipe or system header. To ensure that there will be a flow through the chemical dosing pot leave sufficient gap between the connection points to give a difference in dynamic pressure between them (1 metre apart should be enough). This will admit the water treatment gradually to the system water. Alternatively, connect between flow and return headers, which will admit the water treatment more quickly. Use Caution: The dosing pot contents may be hot. Take care - avoid scalding. On higher temperature systems the contents may be above atmospheric boiling point. Opening valves may cause a release of flash steam. Isolate the chemical dosing pot from the system by closing the two ½ system ball valves. Slowly open the drain valve - caution - some water and flash steam may be emitted to the disposal point. Open the dosing valve, and the vent screw. The contents will now drain out. Close the drain valve. Fill the chemical dosing pot to the vent with the required amount of chemicals, diluted as necessary. Close the dosing valve and vent screw. Open the system valves to allow system water through the unit. Material Options: Shell: Carbon Steel (Gloss Finish) Stainless Steel Valves: DZR Brass Stainless Steel Tundish: Copper Stainless Steel Specification: Max. Pressure: 10 BarG Test Pressure: 15 BarG Max. Temperature: 150 C Connections Dimension Unit A B C D D1 D2 H1 H2 W Kg CDP6 ½" BSP ½" BSP ½" BSP 1/8" BSP 150 166 320 527 267 12 CDP16 ½" BSP ½" BSP ½" BSP 1/8" BSP 150 273 320 527 373 23 Page 10

Vent Heads General Vent heads are used on GMS blow down vessels, hotwell tanks and condensate pump sets. They are designed to remove water from discharged steam. The vented steam hits the internal baffle plate before discharging to atmosphere and any residue water drains out of the head. Installation The vent head is fitted in the required position using the screwed or flanged connection. Suitable sealent or gaskets should be used on the joint. The drain should be checked annually to ensure no blockages in the pipework. Use Caution: The drain needs to be piped to a safe location. Material Options: Stainless Steel AISI 304L Galvanised Mild Steel Connection Flange Options: Standard: VH50 Screwed 2 BSP BS21 VH80+ Flanged BS EN1092-1:2002 PN16 Options: De-Aerator Heads VH50 Screwed NPT VH80+ Flanged BS1560 ANSI #150 VH80+ Flanged BS1560 ANSI #300 VH80+ Flanged BS10 Table A+ Unit Ref Dimension and Connection Data Connection Size H mm L mm Drain Drain Size Weight kg VH50 2" BSP 210 150 ½" BSP 1.5 VH65 2½" BSP 230 175 ½" BSP 1.7 VH80 DN80 PN16 270 200 ½" BSP 2 VH100 DN100 PN16 300 225 ½" BSP 6 VH150 DN150 PN16 325 250 ½" BSP 12 VH200 DN200 PN16 375 350 ½" BSP 18 VH250 DN250 PN16 400 500 ½" BSP 25 VH300 DN300 PN16 450 600 ½" BSP 32 General The GMS range of de-aerator units heads comprise of a stainless steel mixing head and a stainless steel immersion tube. The mixing head is designed to mix incoming flows of condensate from the system, flash steam, cold water make-up feed and re-circulation feed. Each inlet connection has an internal sparge which sprays the flow in various directions within the head. These gases are then vented to atmosphere. The de-aerator head re-circulation connection has an internal spray nozzle to help mixing of the various inlets. GMS can supply the pump re-circulation system as part of the package-please refer to separate literature for further information. The unit is designed to be maintenance-free with a stainless steel body (wetted parts). Gaskets and all bolting are supplied with the unit. De-Aerator Head Thermal Insulation Options De-Aerator Head Details Type MA Consists of 50mm mineral wool with Connections * Dim. H x No. Connections dimpled aluminium cladding. this gives good Unit Dia 'D' R V H-x2 H-x3 thermal insulation and a quality finish. H-x4 H-x5 DH150 168 1" BSP ½" BSP 450 550 600 750 DH200 219 1" BSP ½" BSP 450 625 800 975 DH250 273 1¼" BSP ½" BSP 500 725 950 1175 DH300 323 1½" BSP ½" BSP 550 775 1000 1225 DH350 374 1½" BSP ½" BSP 550 775 1000 1225 * Dimensions may vary depending on size of connections For some installations there will be a high risk of damage to the factory fitted insulation. In these instances it is preferable to insulate on site. Immersion Tube Details Dim P (As Per Tank Depth) Unit Dia 'D' 1000 1250 1500 2000 IH150 168 900 1150 1400 1900 IH200 219 900 1150 1400 1900 IH250 273 900 1150 1400 1900 IH300 323 900 1150 1400 1900 IH350 374 900 1150 1400 1900 De-Aerator Head Details Immersion Tube Details Page 11

Products by GMS Storage Calorifiers Buffer Vessels Non Storage Calorifiers Plate Heat Exchangers Versa Range PlantPac Boiler Equipment Spares & Repairs GMS Thermal Products Ltd w w w. g m s t h e r m a l. c o. u k GMS Thermal Products Ltd Riverside Works Egmont Street Mossley, OL5 9NE Tel. 01457 835700 Fax. 01457 832700 sales@gmsthermal.co.uk