GMS

BOILER HOUSE PRODUCTS

Page2 Introduction3 Condensate Pumpsets6 Blowdown Vessels8 Boiler Feed Tanks

GMS manufacture a wide range of steam related products including : Fabricated to Pd5500 CAT III with notified body approval.to suit most applications incorporating electronic air/steam driven pumps. with optional with vortex flow pattern system.

complete with valves and tundish.

Blowdown Vessels Condensate PumpingSets Hotwell Tanks deaerator. Steam SeparatorsChemical Dosing Pot Vent Head used on GMS blow down vessels, hotwell tanks and condensate pump sets. Vent Heads are designedto remove water from discharged steam, and are fitted with an internal baffle.

Introduction to Boiler House Products

Typical Layout of Boiler House Products

Page 2

ContentsPage10 Chemical Dosing Pots11 Vent Heads11 De-Aerator Heads

Boiler

Hotwell

ChemicalDosing Pot

VentHead

FlashVessel

FlashVessel

Non StorageCalorifier

StorageCalorifier

BlowdownVessel

CondensatePumpset

PHEPlantPac

Not supplied by GMS

Introduction

Design

Sizing

By using the CPS condensate recovery system, the normally wasted energy in a steam system is recycled by recoveringthe condensate and returning back to the boiler hotwell feed tank. Not only does it save energy in heating new water, italso reduces the cost of chemical dosing as the recovered condensate has already been treated.

The condensate receiver can be sized to suit any additional condensate recovery lines available, the condensate lineinlet 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 anauto-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 304LStainless 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 hasindicator lights for Power On, Pump Run/Trip, hand selector for Pump Action and Leed Pump Selector. Door interlockedisolator. The panel is supplied complete with volt free contacts for pump tripped and level alarms for connecting to a BMSif desired.

Draw a line vertically from your required flowrate and draw a line horizontally from the pump delivery head required. Thiswill 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.

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Condensate Pumpsets

Page 3

Pumpset Receiver Thermal Insulation OptionsType MAü Consists of 50mm mineral wool with stuccoaluminium cladding. this gives good thermal insulationand a quality finish.

For some installations there will be a high risk of damage to thefactory fitted insulation. In these instances it is preferable toinsulate on site.

Level Control Switch

Condensate Receiver Vessel

Electrical Control Panel

Pump Discharge Isolation Valve

Vessel Drain

Vessel Overflow

Pumps

Receiver Level Gauge

Check Valve

1

2

3

4

5

6

7

8

9

Page 4

Condensate Pumpsets

CONNECTIONS (Unit Details on Page 5)

1

2

3

4

5

6

7

8

9

10

Sight Glass

Control Panel

Pumped Outlets

Pump Isolation Valve (Butterfly)

Level Control Switch c/w protection tube

Condensate Return

Condensate Inlet

Pump

Overflow

Drain c/w isolation valve

DetailsFlanged connections to BS EN1092-1:2002 PN16screwed connections BS21

The dimensions shown are the maximum overallof the specified unit. Please contact our salesoffice with any enquires with different dimensionsto those shown.

m³/h

Head (m)

CP1

CP3

CP2

CP4

CP5

CP6

Page 5

Condensate Pumpsets

Unit CP1 CP2 CP3 CP4 CP5 CP6

Dim

en

sio

n

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

Co

nn

ec

tio

nS

ize

s 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 6

Blow Down Vessels

Introduction

Background Information

Selection

Regulations

Ancillaries Supplied As Extras

BV blow down vessels are designed andmanufactured fully in accordance with the latestversion of Pd5500, inspected during design andmanufacture by an independent insurance companyand supplied complete with a data dossier. They alsocomply fully with the European Pressure EquipmentDirective 97/23/EC (SI 1999/2001) and are CEmarked.

When a steam boiler evaporates water the dissolvedminerals in the remaining boiler water areconcentrated. To prevent the concentration becomingexcessive and causing damage to the boiler some ofthe water is “blown down” from the boiler periodicallyand replaced with fresh water. The blow down waterloses pressure rapidly, resulting in the evolution offlash steam. This mixture of steam and hot water is apotential hazard. It is not permissible to drain water topublic sewers above 43°C so the blow down watermust be safely contained and allowed to cool first. TheBV Blow Down Vessel is designed to do this.

Select the appropriate blow down vessel from theTables 1 and 2. Table 2 allows for a loss of boilerpressure equal to 8 metres pipe length in the blowdown line. If the loss is less than 8 metres thenmultiply the actual boiler pressure by 1.2 before usingTable 2. Calculate the loss in pipe lengths using Table1 and adding the length of straight pipe.

Boiler blow down installations must comply with thePressure Systems and Transportable Gas ContainersRegulations 1989 (”Pressure Systems Regulations”)(HMSO). Recommendations on design of boilerinstallations are given in BS806 and PM60 (availablefrom BSI and HMSO respectively). Following theserecommendations will satisfy most of the requirementsof the Pressure Systems Regulations.GMS blow down vessels comply with BS806 andPm60. Also, the HSE Guidance Note PM5 (availablefrom HMSO) states various requirements for thesystem design. Blow Down Vessels must have aminimum design pressure of 7 BarG or 25% of boilerpressure, whichever is the greater.GMS blow down vessels have a standard designpressure 7 BarG - higher on request.

Vent Head - Stainless Steel, Screwed or FlangedCooling System - Direct Acting Valve & SensorInlet Manifolds (Three off) - Supplied Complete withIsolation & Check Valves.

Table 1

Main Blow Down Line

Size1" 1¼" 1½" 2"

Pipe Fitting 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

Size1" 1¼" 1½" 2"

Boiler Pressure (BarG) 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

Page 7

Blow Down Vessels

Design Code:PD5500CE MarkedComplies With SI 1999/2001Pressure Equipment DirectiveComplies with HSE Guidance Note Pm60

Material: Carbon SteelDesign Pressure: 7 BarGDesign Temperature: 171°CHigher Pressure and Temperature Units onRequest

Outlet (T) has an internal dip-tube to allow blowdown to cool before disposal. If disposaltemperature exceeds 43°C, water cooling will beneeded.

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

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)

Page 8

Hotwell Boiler Feed Tanks

Hotwell Boiler Feed Tank Thermal Insulation OptionsType MAü Consists of 50mm mineral wool with stuccoaluminium cladding. this gives good thermal insulationand a quality finish.

For some installations there will be a high risk of damage to thefactory fitted insulation. In these instances it is preferable toinsulate on site.

Thermometer

Vent Head

Tank Contents Sight Gauge c/w protector

Electronic Cold Water Make Up Feed

Electrical Level Control System

De-Aerator Head Assembly

Re-Cirrculation System

External Ladder System

De-Aerator Head Inlet Manifolds

HW boiler hotwells are the source of high heat losses and on-going maintenance. The GMS carbon steel hotwellis 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 causecorrosion and also reduces the amount of chemical dosing required.

All wetted parts are manufactured from quality British Standard steel plate and the internal surface is coated witha Water Research Council approved epoxy lining system offering good protection against internal corrosion.

GMS can manufacture the hotwell from both AISI 304L or AISI 316L grades stainless steel. The tank is internallysupported 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 arepresent in the system).

The HW hotwell is manufactured to suit the individual customers needs. Therefore a detailed drawing is producedto enable the customer to mark up his connection requirements (this is most helpful when the unit is areplacement and ensures pipework alteration is kept to a minimum) A test certificate is issued on completionalong with a report on the soundness of the internal coating (carbon steel tanks).

MaterialsCarbon Steel:

Stainless Steel:

Design

‘RC’ Recirculation SystemMaterials

Galvanised Steel Pipework (Mild Steel Tanks)Stainless Steel Pipework (Stainless Steel Tanks)Pump Isolation Valves: Stainless SteelPump Strainer: BronzePump: Stainless Steel

SizesRc075: 3/4” NBRc125: 1” NBRc175: 1 1/4” NBRc400: 1 ½” NB

‘DS’ Direct Steam InjectionMaterials

Galvanised Steel Pipework (Mild Steel Tanks)Stainless Steel Pipework (Stainless Steel Tanks)Isolation Valves: Stainless SteelStrainer: BronzeValve: SG Iron

Please contact our sales department for sizingand further details of steam injection equipment.

Components Included as Standard

Additional Components

Support and platform assembly

Direct steam Injection Kit11

1

2

3

4

5

6

7

8

9

10

Page 9

Hotwell Boiler Feed Tanks

Dimension and Main Connection Details

Dimensions mm Standard Connections Max kg

(Dry)Unit L W H DH RC VH MH OF DS

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

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)

* - The direct steam injection size is dependant upon the type of installation where the tank is to be used. Pleasecontact GMS Thermal Products for further information or help with sizing the system.

Page 10

Chemical Dosing Pots

Correct Water Treatment

Two Standard Sizes:-CDP6CDP16

is essential for the corrosion protection of heating systems. GMS Thermal Products chemicaldosing pots offer a safe and convenient way to introduce water treatment chemicals to the system.

(6 Litres)(16 Litres)

Other sizes are available on request.

Standard Specification: Each dosing pot is supplied as standard complete with:-System isolation valves

Dosing ValveDrain ValveAir VentFunnelBlue gloss paint finish

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GeneralGuidelines for installation and use are given below. However, the equipment and water treatment in use in any individualsystem may dictate variations so please consult your water treatment supplier to ensure best results.

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.

Installation

Use Caution: The dosing pot contents may be hot. Take care - avoid scalding. On higher temperature systemsthe contents may be above atmospheric boiling point. Opening valves may cause a release of flash steam.

Material Options:Shell:

Valves:

Tundish:

Specification:

Choose a location near a main run or system header. Fasten the chemical dosing pot securely in place using thebrackets provided. Pipe the drain away to safe disposal point. Connect the system connections to the pipe or systemheader. To ensure that there will be a flow through the chemical dosing pot leave sufficient gap between the connectionpoints to give a difference in dynamic pressure between them (1 metre apart should be enough). This will admit the watertreatment gradually to the system water. Alternatively, connect between flow and return headers, which will admit thewater treatment more quickly.

Isolate the chemical dosing pot from the system by closing the two ½” system ball valves.

Carbon Steel (Gloss Finish)Stainless SteelDZR BrassStainless SteelCopperStainless Steel

Max. Pressure: 10 BarGTest Pressure: 15 BarGMax. Temperature: 150°C

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þ

þ

þ

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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 11

Vent Heads

De-Aerator Heads

GeneralThe GMS range of de-aerator units heads comprise of a stainless steel mixing head and a stainless steelimmersion tube.

The mixing head is designed to mix incoming flows of condensate from the system, flash steam, cold watermake-up feed and re-circulation feed. Each inlet connection has an internal sparge which sprays the flow invarious 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 variousinlets. GMS can supply the pump re-circulation system as part of the package-please refer to separateliterature for further information.

The unit is designed to be maintenance-free with a stainless steel body (wetted parts). Gaskets and allbolting are supplied with the unit.

De-Aerator Head Thermal Insulation OptionsType MAü Consists of 50mm mineral wool withdimpled aluminium cladding. this gives goodthermal insulation and a quality finish.

For some installations there will be a high risk of damage tothe factory fitted insulation. In these instances it ispreferable to insulate on site.

Dimension and Connection Data

Unit

Ref

Connection

SizeH

mm

L

mm

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

Drain

GeneralVent heads are used on GMS blow down vessels, hotwell tanks and condensate pump sets. They are designed toremove water from discharged steam. The vented steam hits the internal baffle plate before discharging to atmosphereand any residue water drains out of the head.

Options: VH50 Screwed NPTVH80+ Flanged BS1560 ANSI #150VH80+ Flanged BS1560 ANSI #300VH80+ Flanged BS10 Table A+

Installation

Use Caution: The drain needs to be piped to a safe location.

Material Options:

The vent head is fitted in the required position using the screwed or flangedconnection. Suitable sealent or gaskets should be used on the joint.

The drain should be checked annually to ensure no blockages in the pipework.

Stainless Steel AISI 304LGalvanised Mild Steel

Connection Flange Options:Standard: VH50 Screwed 2” BSP BS21

VH80+ Flanged BS EN1092-1:2002 PN16

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

Connections * Dim. H x No. Connections

Unit Dia 'D' R V H-x2 H-x3 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

De-Aerator Head Details Immersion Tube Details

GMS Thermal Products LtdRiverside Works

Egmont StreetMossley, OL5 9NE

Tel. 01457 835700 Fax. 01457 832700sales@gmsthermal.co.uk

Products by GMSStorage Calorifiers

Buffer VesselsNon Storage CalorifiersPlate Heat Exchangers

Versa RangePlantPac

Boiler EquipmentSpares & Repairs

GMSThermal Products Ltdw w w. g m s t h e r m a l . c o . u k