4035950/6 IM-P403-103

EMM Issue 6

BCV Blowdown Control Valves

DN15 to DN50 (½" to 2")
Installation and Maintenance Instructions

Electrically actuated Pneumatically actuated

BCV boiler blowdown valve BCV boiler blowdown valve

BCV Blowdown Control Valves DN15 to DN50 (½" to 2")

© Copyright 2024
IM-P403-103 EMM Issue 6 1
Printed in France
 BCV Blowdown Control Valves DN15 to DN50 (½" to 2")

2 IM-P403-103 EMM Issue 6

 Contents

1. Safety information 4

2. General product information and application 9

3. Technical data 11

4. Installation and dimensions 25

5. AEL3 Actuator with spring return 29

6. Flow setting 33

7. Rotating the electrical actuator 37

8. Wiring of the electrical actuator 38

9. Pneumatic actuator - Stroke adjustment 40

10. Maintenance 42

11. Spare parts 47

BCV Blowdown Control Valves DN15 to DN50 (½" to 2")

IM-P403-103 EMM Issue 6 3

 1. Safety information
Safe operation of these products can only be guaranteed if they are properly installed, commissioned,
used and maintained by qualified personnel (see Section 1.11 on this document) in compliance
with the operating instructions. General installation and safety instructions for pipeline and plant
construction, as well as the proper use of tools and safety equipment must also be complied with.

WARNING
1. Your attention is drawn to any National or Regional regulations concerning boiler blowdown.
In the UK, guidance is given in Blowdown Systems, Guidance for Industrial Steam Boilers
(Ref: BG03).
2. When the EL actuator is used it must be electrically isolated before any maintenance is carried
out.

1.1 Intended use

Referring to the Installation and Maintenance Instructions, name-plate and Technical Information
Sheet, check that the product is suitable for the intended use/application. The products listed
below comply with the requirements of the EU Pressure Equipment Directive/UK Pressure Equipment

(Safety) Regulations and carry the mark when so required.

Pressure equipment not bearing the mark is classified 'Sound Engineering Practice' in

accordance with Article 3, Paragraph 3 of the PED.

Note: By law, SEP products cannot be marked with the symbol.

BCV Blowdown Control Valves DN15 to DN50 (½" to 2")

4 IM-P403-103 EMM Issue 6

BCV blowdown control valves fall within the following PED categories:

Product Group 2 Gases Group 2 Liquids

DN15 - DN25 SEP SEP
PN40 DN32 SEP SEP
DN40 - DN50 1 SEP
DN15 - DN25 SEP SEP
PN63
DN32 SEP SEP
PN100
DN40 - DN50 1 SEP
DN15 - DN25 SEP SEP

BCV4 ASME 300 DN32 SEP SEP

DN40 - DN50 1 SEP
DN15 - DN25 SEP SEP
ASME 600 DN32 SEP SEP
DN40 - DN50 1 SEP
DN15 - DN25 SEP SEP
JIS 20K
DN32 SEP SEP
KS 20K
DN40 - DN50 1 SEP
DN15 - DN25 SEP SEP
PN40 DN32 SEP SEP
DN40 - DN50 1 SEP
DN15 - DN25 SEP SEP
PN63
DN32 SEP SEP
PN100
DN40 - DN50 1 SEP
DN15 - DN25 SEP SEP
DN32 SEP SEP
BCV6 ASME 300
DN40 1 SEP
DN50 1 SEP
DN15 - DN25 SEP SEP
ASME 600 DN32 SEP SEP
DN40 - DN50 1 SEP
DN15 - DN25 SEP SEP
JIS 20K
DN32 SEP SEP
KS 20K
DN40 - DN50 1 SEP

BCV Blowdown Control Valves DN15 to DN50 (½" to 2")

IM-P403-103 EMM Issue 6 5

 Product Group 2 Gases Group 2 Liquids
DN15 - DN25 SEP SEP
PN25 DN32 - DN40 SEP SEP
DN50 1 SEP

BCV7 ASME 125

DN15 - DN25 SEP SEP
DN40 - DN50 SEP SEP

ASME 250 DN15 - DN25 SEP SEP

KS 10 DN40 - DN50 1 SEP
DN15 - DN25 SEP SEP
ASME 600 DN32 SEP SEP
DN40 - DN50 1 SEP
BCV8 DN15 - DN25 SEP SEP
PN63 PN100 DN32 SEP SEP
DN40 - DN50 1 SEP

i) Check material suitability, pressure and temperature and their maximum and minimum values.
If the maximum operating limits of the product are lower than those of the system in which
it is being fitted, or if malfunction of the product could result in a dangerous overpressure
or overtemperature occurrence, ensure a safety device is included in the system to prevent
such over-limit situations.
ii) Determine the correct installation situation and direction of fluid flow.
iii) Spirax Sarco products are not intended to withstand external stresses that may be induced by
any system to which they are fitted. It is the responsibility of the installer to consider these
stresses and take adequate precautions to minimise them.
iv) Remove protection covers from all connections and protective film from all name-plates,
where appropriate, before installation on steam or other high temperature applications.
v) Prior to use, the user shall ensure the fluid compatibility with the equipment material.

1.2 Access
Ensure safe access and if necessary a safe working platform (suitably guarded) before attempting
to work on the product. Arrange suitable lifting gear if required.

1.3 Lighting
Ensure adequate lighting, particularly where detailed or intricate work is required.

1.4 Hazardous liquids or gases in the pipeline

Consider what is in the pipeline or what may have been in the pipeline at some previous time.
Consider: flammable materials, substances hazardous to health, extremes of temperature.

BCV Blowdown Control Valves DN15 to DN50 (½" to 2")

6 IM-P403-103 EMM Issue 6

1.5 Hazardous environment around the product
Consider: explosion risk areas, lack of oxygen (e.g. tanks, pits), dangerous gases, extremes of
temperature, hot surfaces, fire hazard (e.g. during welding), excessive noise, moving machinery.

1.6 The system

Consider the effect on the complete system of the work proposed. Will any proposed action (e.g.
closing isolation valves, electrical isolation) put any other part of the system or any personnel at
risk? Dangers might include isolation of vents or protective devices or the rendering ineffective
of controls or alarms. Ensure isolation valves are turned on and off in a gradual way to avoid
system shocks.

1.7 Pressure systems

Ensure that any pressure is isolated and safely vented to atmospheric pressure. Consider double
isolation (double block and bleed) and the locking or labelling of closed valves. Do not assume
that the system has depressurised even when the pressure gauge indicates zero.

1.8 Temperature
Allow time for temperature to normalise after isolation to avoid danger of burns.

1.9 Tools and consumables

Before starting work ensure that you have suitable tools and/or consumables available. Use only
genuine Spirax Sarco replacement parts.

1.10 Protective clothing

Consider whether you and/or others in the vicinity require any protective clothing to protect
against the hazards of, for example, chemicals, high/low temperature, radiation, noise, falling
objects, and dangers to eyes and face.

1.11 Permits to work

All work must be carried out or be supervised by a suitably competent person. Installation and
operating personnel should be trained in the correct use of the
product according to the Installation and Maintenance Instructions. Where a formal 'permit to work'
system is in force it must be complied with. Where there is no such system, it is recommended
that a responsible person should know what work is going on and, where necessary, arrange to
have an assistant whose primary responsibility is safety. Post 'warning notices' if necessary.

1.12 Handling
Manual handling of large and/or heavy products may present a risk of injury. Lifting, pushing,
pulling, carrying or supporting a load by bodily force can cause injury particularly to the back.
You are advised to assess the risks taking into account the task, the individual, the load and the
working environment and use the appropriate handling method depending on the circumstances
of the work being done.

BCV Blowdown Control Valves DN15 to DN50 (½" to 2")

IM-P403-103 EMM Issue 6 7

1.13 Residual hazards
In normal use the external surface of the product may be very hot. If used at the maximum permitted
operating conditions the surface temperature of some products may reach temperatures of 580 °C
(1076 °F). Many products are not self-draining. Take due care when dismantling or removing the
product from an installation (refer to 'Maintenance instructions').

1.14 Freezing
Provision must be made to protect products which are not self-draining against frost damage in
environments where they may be exposed to temperatures below freezing point.

1.15 Disposal
Unless otherwise stated in the Installation and Maintenance Instructions, this product is
recyclable and no ecological hazard is anticipated with its disposal providing due care is taken.

Please visit the Spirax Sarco product compliance web pages

https://www.spiraxsarco.com/product-compliance
for up to date information on any substances of concern that may be contained within this product.
Where no additional information is provided on the Spirax Sarco product compliance web page,
this product may be safely recycled and/or disposed providing due care is taken. Always check
your local recycling and disposal regulations.

1.16 Returning products

Customers and stockists are reminded that under EC Health, Safety and Environment Law,
when returning products to Spirax Sarco they must provide information on any hazards and the
precautions to be taken due to contamination residues or mechanical damage which may present
a health, safety or environmental risk. This information must be provided in writing including
Health and Safety data sheets relating to any substances identified as hazardous or potentially
hazardous.

1.17 conformity of actuators

Electrical actuator: This actuator is CE marked. It complies with LV Directive 2014/35/EU.
EN60730-1, EN60730-2-14.
This actuator complies with EMC Directive 2014/30/EU, EN61000-6-2,
EN6100-6- 4
Pneumatic actuator: See the Technical Information for the PN9000 series

BCV Blowdown Control Valves DN15 to DN50 (½" to 2")

8 IM-P403-103 EMM Issue 6

 2. General product information
and application
2.1 Description
Spirax Sarco's BCV blowdown control valves are manufactured using the market proven Spira-trol TM body.
These valves are designed for the blowdown of steam boilers or for other high pressure drop, low flow
applications, and are generally used with a blowdown controller as part of an automatic BCV control system.
The valve may also be used for other high pressure drop, low flowrate applications such as boiler feedpump
recirculation.

Two versions are available:

- Electrically actuated
- Pneumatically actuated

Standards
These products fully comply with the requirements
of the EU Pressure Equipment Directive/UK Electrically
Pressure Equipment (Safety) Regulations. actuated

Certification
These produc ts are available with mater ial
certification to EN 10204 3.1. Note: All certification/
inspection requirements must be stated at the time
of order placement.

Note:
For additional product information see Technical
Information sheet TI-P403-102.

2.2 Size and pipe connections

½", ¾", 1", 1¼", 1½" and 2"
Screwed BSP or NPT,
Socket weld and Butt weld.

DN15, DN20, DN25, DN32, DN40 and DN50 Flanged:

EN 1092 PN25, PN40, PN63 and PN100
ASME class 125, 150, 250, 300 and 600
JIS/KS 10K, 20K, 30K and 40K

Pneumatically
actuated

Fig. 1 BCV blowdown control valves

BCV Blowdown Control Valves DN15 to DN50 (½" to 2")

IM-P403-103 EMM Issue 6 9

2.3 Available models:
Connections
Material
Screwed Socket weld Flanged Butt weld
Carbon steel BCV41 BCV42 BCV43 BCV44
Stainless steel BCV61 BCV62 BCV63 BCV64
SG iron BCV71 BCV73
Alloy steel BCV82 BCV83 BCV84

BCV blowdown control valves are compatible with the following actuators:
Version Actuator
AEL3 series
Electric
AEL3 comes with a Ø34 mounting flange. The J-Series body used for the higher
pressure BCV has a Ø50 connection diameter
Pneumatic PN9_ _ _ series

BCV Blowdown Control Valves DN15 to DN50 (½" to 2")

10 IM-P403-103 EMM Issue 6

 3. Technical data

Media Water

3.1 Actuator technical data

Actuator AEL3 Series
Supply voltage Standard 24 Vac/dc, Optional card 230 Vac and 100 Vac
Supply frequency 50 to 60 Hz
12W (24 Vac/dc)
Power consumption
28W (230 Vac, 110 Vac)
Actuator speed 0.5 mm/s (2 s/mm)- 0.25 mm/s (4 s/mm) - 0.16 mm/s (6 s/mm)
Actuators thrust maximum 2 kN

Size Actuator Maximum shut-off value

DN15 to DN25 ½" to 1" AEL3 series/PN9123E-B
103.4 bar g @100 °C
DN32 to DN50 1¼" to 2" AEL3 series/PN9223E-B

Maximum 24 volt version (Connect to class 2 circuit only) -10 °C to +55 °C (-4 °F to 131 °F)
ambient
temperature 110/230 volt versions -10 °C to +50 °C (-4 °F to 122 °F)

BCV Blowdown Control Valves DN15 to DN50 (½" to 2")

IM-P403-103 EMM Issue 6 11

3.2 Pressure/temperature limits
BCV41 Screwed
see Section 3.3
BCV43 Flanged EN 1092

BCV41 Screwed

BCV42 Socket weld

see Section 3.4
BCV43 Flanged ASME

BCV44 Butt weld

BCV43 Flanged JIS/KS see Section 3.5

BCV61 Screwed
see Section 3.6
BCV63 Flanged EN 1092

BCV61 Screwed

BCV62 Socket weld

see Section 3.7
BCV63 Flanged ASME

BCV64 Butt weld

BCV63 Flanged JIS/KS see Section 3.8

BCV71 Screwed
see Section 3.9
BCV73 Flanged EN 1092

BCV71 Screwed
see Section 3.10
BCV73 Flanged ASME

BCV73 Flanged JIS/KS see Section 3.11

BCV83 Flanged EN 1092 see Section 3.12

BCV82 Socket weld

BCV83 Flanged ASME Butt weld see Section 3.13

BCV84
BCV83 Flanged JIS/KS see Section 3.14

BCV Blowdown Control Valves DN15 to DN50 (½" to 2")

12 IM-P403-103 EMM Issue 6

3.3 BCV4_ Pressure/temperature limits
BCV41 
B C D
Screwed BSP


Temperature °C
A
BCV43 
Flanged EN 1092 Steam
 saturation
curve
 A A
 C D

     
Pressure bar g

The product must not be used in this region.

A-A Flanged EN 1092 PN40 and Screwed BSP
B-C Flanged EN 1092 PN63
B-D Flanged EN 1092 PN100

PN40, PN63 or PN100

Body design conditions
JIS/KS 20K, 30K or 40K
PN40 40 bar g @ 50 °C
PMA Maximum allowable pressure PN63 63 bar g @ 50 °C
PN100 100 bar g @ 50 °C
PN40 300 °C @ 27.6 bar g
TMA Maximum allowable temperature PN63 400 °C @ 37.5 bar g
PN100 400 °C @ 59.5 bar g
PN40 -10 °C
Minimum allowable temperature PN63 -29 °C
PN100 -29 °C
PN40 31.1 bar g @ 237 °C
Maximum operating pressure
PMO PN63 47.0 bar g @ 261 °C
for saturated steam service
PN100 70.8 bar g @ 287 °C
PN40 300 °C @ 27.6 bar g
TMO Maximum operating temperature PN63 400 °C @ 37.5 bar g
PN100 400 °C @ 59.5 bar g
PN40 -10 °C
Minimum operating temperature PN63 -29 °C
PN100 -29 °C
Designed for a maximum cold hydraulic test pressure of: 1.5 x PMA of the relative end connection of choice

BCV Blowdown Control Valves DN15 to DN50 (½" to 2")

IM-P403-103 EMM Issue 6 13

3.4 BCV4_ Pressure/temperature limits
Pressure psi g
BCV41        
Screwed NPT  E G H 


Temperature °F
Temperature °C
BCV42 
Socket weld 
 Steam

BCV43 saturation 
Flanged ASME  
curve

 F G H 
BCV44
 
Butt weld      
Pressure bar g
The product must not be used in this region.
E-F Flanged ASME class 150
E-G Flanged ASME class 300, Screwed NPT and Socket weld class 3000 (B 16.11)
E-H Flanged ASME class 600, Socket weld class 6000 (B 16.11) and Butt weld

PN40, PN63 or PN100 ASME class 150, class 300

Body design conditions
JIS/KS 20K, 30K or 40K or ASME class 600

ASME 150 40 bar g @ 50 °C 284 psi g @ 100 °F

Maximum allowable
PMA ASME 300 63 bar g @ 50 °C 741 psi g @ 100 °F
pressure
ASME 600 100 bar g @ 50 °C 1 480 psi g @ 100 °F
ASME 150 300 °C @ 27.6 bar g 797 °F @ 80 psi g
Maximum allowable
TMA ASME 300 400 °C @ 37.5 bar g 797 °F @ 418 psi g
temperature
ASME 600 400 °C @ 59.5 bar g 797 °F @ 834 psi g
ASME 150 -10 °C -20 °F
Minimum allowable temperature ASME 300 -29 °C -20 °F
ASME 600 -29 °C -20 °F

Maximum operating ASME 150 31.1 bar g @ 237 °C 201 psi g @ 386 °F
pressure for
PMO ASME 300 47.0 bar g @ 261 °C 605 psi g @ 489 °F
saturated steam
service ASME 600 70.8 bar g @ 287 °C 1 160 psi g @ 563 °F
ASME 150 300 °C @ 27.6 bar g 797 °F @ 80 psi g
Maximum operating
TMO ASME 300 400 °C @ 37.5 bar g 797 °F @ 418 psi g
temperature
ASME 600 400 °C @ 59.5 bar g 797 °F @ 834 psi g
ASME 150 -10 °C -20 °F
Minimum operating temperature ASME 300 -29 °C -20 °F
ASME 600 -29 °C -20 °F
Designed for a maximum cold hydraulic test pressure of: 1.5 x PMA of the relative end connection of choice

BCV Blowdown Control Valves DN15 to DN50 (½" to 2")

14 IM-P403-103 EMM Issue 6

3.5 BCV4_ Pressure/temperature limits

BCV43

 K L M
Flanged JIS/KS

Temperature °C
 J

Steam
 saturation
curve
 J J
 L M

       
Pressure bar g
The product must not be used in this region.
J-J Flanged JIS/KS 20K
K-L Flanged JIS/KS 30K
K-M Flanged JIS/KS 40K

PN40, PN63 or PN100

Body design conditions
JIS/KS 20K, 30K or 40K
JIS/KS 20K 34 bar g @ 120 °C
PMA Maximum allowable pressure JIS/KS 30K 51 bar g @ 120 °C
JIS/KS 40K 68 bar g @ 120 °C
JIS/KS 20K 300 °C @ 20 bar g
Maximum allowable
TMA JIS/KS 30K 425 °C @ 30 bar g
temperature
JIS/KS 40K 425 °C @ 40 bar g
JIS/KS 20K -10 °C
Minimum allowable temperature JIS/KS 30K -29 °C
JIS/KS 40K -29 °C
JIS/KS 20K 30.6 bar g @ 236 °C
Maximum operating
PMO pressure for saturated JIS/KS 30K 44.6 bar g @ 258 °C
steam service
JIS/KS 40K 58.5 bar g @ 276 °C
JIS/KS 20K 300 °C @ 20 bar g
Maximum operating
TMO JIS/KS 30K 425 °C @ 30 bar g
temperature
JIS/KS 40K 425 °C @ 40 bar g
JIS/KS 20K -10 °C
Minimum operating temperature JIS/KS 30K -29 °C
JIS/KS 40K -29 °C
Designed for a maximum cold hydraulic test pressure of: 1.5 x PMA of the relative end connection of choice

BCV Blowdown Control Valves DN15 to DN50 (½" to 2")

IM-P403-103 EMM Issue 6 15

3.6 BCV6_ Pressure/temperature limits

BCV61 
B C
Screwed BSP 

Temperature °C

A
BCV63 
Flanged EN 1092

Steam

saturation
 A curve A
 C D

     
Pressure bar g

The product must not be used in this region.

A-A Flanged EN 1092 PN40 and Screwed BSP
B-C Flanged EN 1092 PN63
B-D Flanged EN 1092 PN100

PN40, PN63 or PN100

Body design conditions
JIS/KS 20K, 30K or 40K
PN40 40 bar g @ 100 °C
PMA Maximum allowable pressure PN63 63 bar g @ 100 °C
PN100 100 bar g @ 100 °C
PN40 400 °C @ 27.4 bar g
Maximum allowable
TMA PN63 580 °C @ 39.5 bar g
temperature
PN100 580 °C @ 62.7 bar g
PN40 -10 °C
Minimum allowable temperature PN63 -29 °C
PN100 -29 °C
PN40 32.2 bar g @ 240 °C
Maximum operating
PMO pressure for saturated PN63 49.2 bar g @ 264 °C
steam service
PN100 75.1 bar g @ 291 °C
PN40 400 °C @ 27.4 bar g
Maximum operating
TMO PN63 580 °C @ 39.5 bar g
temperature
PN100 580 °C @ 62.7 bar g
PN40 -10 °C
Minimum operating temperature PN63 -29 °C
PN100 -29 °C
Designed for a maximum cold hydraulic test pressure of: 1.5 x PMA of the relative end connection of choice

BCV Blowdown Control Valves DN15 to DN50 (½" to 2")

16 IM-P403-103 EMM Issue 6

3.7 BCV6_ Pressure/temperature limits
Pressure psi g
E       
BCV61  
Screwed NPT
F G H 

Temperature °F
Temperature °C
BCV62 
Socket weld  
BCV63  Steam 
Flanged ASME  saturation 
curve
BCV64  F G H 
Butt weld  
     
Pressure bar g
The product must not be used in this region.
E-F Flanged ASME class 150
E-G Flanged ASME class 300, Screwed NPT and Socket weld class 3000 (B 16.11)
E-H Flanged ASME class 600, Socket weld and Butt weld class 6000 (B 16.11)

PN40, PN63 or PN100 ASME class 150, class

Body design conditions
JIS/KS 20K, 30K or 40K 300 or ASME class 600

ASME 150 19.0 bar g @ 38 °C 275 psi g @ 100 °F

Maximum allowable
PMA ASME 300 49.6 bar g @ 38 °C 719 psi g @ 100 °F
pressure
ASME 600 99.3 bar g @ 38 °C 1 440 psi g @ 100 °F
ASME 150 538 °C @ 1.4 bar g 1 000 °F @ 20 psi g
Maximum allowable
TMA ASME 300 538 °C @ 25.2 bar g 1 000 °F @ 365 psi g
temperature
ASME 600 538 °C @ 50.0 bar g 1 000 °F @ 725 psi g
ASME 150 -29 °C -20 °F
Minimum allowable temperature ASME 300 -29 °C -20 °F
ASME 600 -29 °C -20 °F

Maximum operating ASME 150 13.8 bar g @ 197 °C 200 psi g @ 386 °F
pressure for
PMO ASME 300 33.8 bar g @ 242 °C 490 psi g @ 467 °F
saturated steam
service ASME 600 64.6 bar g @ 281 °C 937 psi g @ 538 °F
ASME 150 538 °C @ 1.4 bar g 1 000 °F @ 20 psi g
Maximum operating
TMO ASME 300 538 °C @ 25.2 bar g 1 000 °F @ 365 psi g
temperature
ASME 600 538 °C @ 50.0 bar g 1 000 °F @ 725 psi g
ASME 150 -29 °C -20 °F
Minimum operating temperature ASME 300 -29 °C -20 °F
ASME 600 -29 °C -20 °F
Designed for a maximum cold hydraulic test pressure of: 1.5 x PMA of the relative end connection of choice

BCV Blowdown Control Valves DN15 to DN50 (½" to 2")

IM-P403-103 EMM Issue 6 17

3.8 BCV6_ Pressure/temperature limits
K L M
BCV63 
Flanged JIS/KS  J

Temperature °C


Steam
 saturation
curve
 J J
 L M

       
Pressure bar g

The product must not be used in this region.

J-J Flanged JIS/KS 20K
K-L Flanged JIS/KS 30K
K-M Flanged JIS/KS 40K

PN40, PN63 or PN100

Body design conditions
JIS/KS 20K, 30K or 40K
JIS/KS 20K 34 bar g @ 120 °C
PMA Maximum allowable pressure JIS/KS 30K 51 bar g @ 120 °C
JIS/KS 40K 68 bar g @ 120 °C
JIS/KS 20K 425 °C @ 20 bar g
Maximum allowable
TMA JIS/KS 30K 490 °C @ 30 bar g
temperature
JIS/KS 40K 490 °C @ 40 bar g
JIS/KS 20K -10 °C
Minimum allowable temperature JIS/KS 30K -29 °C
JIS/KS 40K -29 °C
JIS/KS 20K 30.6 bar g @ 236 °C
Maximum operating
PMO pressure for saturated JIS/KS 30K 44.6 bar g @ 258 °C
steam service
JIS/KS 40K 58.5 bar g @ 276 °C
JIS/KS 20K 425 °C @ 20 bar g
Maximum operating
TMO JIS/KS 30K 490 °C @ 30 bar g
temperature
JIS/KS 40K 490 °C @ 40 bar g
JIS/KS 20K -10 °C
Minimum operating temperature JIS/KS 30K -29 °C
JIS/KS 40K -29 °C
Designed for a maximum cold hydraulic test pressure of: 1.5 x PMA of the relative end connection of choice

BCV Blowdown Control Valves DN15 to DN50 (½" to 2")

18 IM-P403-103 EMM Issue 6

3.9 BCV7_ Pressure/temperature limits

BCV71 
A B
Screwed BSP

Temperature °C

BCV73
Flanged EN 1092 Steam saturation curve


 B

     
Pressure bar g

The product must not be used in this region.

A-B Flanged EN 1092 PN25 and Screwed BSP

PN25
Body design conditions
JIS/KS 10K
PMA Maximum allowable pressure PN25 25.0 bar g @ 120 °C
TMA Maximum allowable temperature PN25 300 °C @ 20 bar g
Minimum allowable temperature PN25 -10 °C
Maximum operating pressure for
PMO PN25 22.5 bar g @ 220 °C
saturated steam service
TMO Maximum operating temperature PN25 300 °C @ 20.0 bar g
Minimum operating temperature PN25 -10 °C
Designed for a maximum cold hydraulic test pressure of: 1.5 x PMA of the relative end connection of choice

BCV Blowdown Control Valves DN15 to DN50 (½" to 2")

IM-P403-103 EMM Issue 6 19

3.10 BCV7_ Pressure/temperature limits
Pressure psi g
   E  
BCV71  C D
Screwed NPT  

Temperature °F
Temperature °C  
BCV73 Steam
Flanged ASME  saturation 
curve
 
 D E 
 
      
Pressure bar g

The product must not be used in this region.

C-D Flanged ASME class 125
C-E Flanged ASME class 250 and Screwed NPT

PN25 ASME class 125 or

Body design conditions
JIS/KS 10K ASME class 250

ASME 125 11.5 bar g @ 140 °C 166 psi g @ 284 °F

PMA Maximum allowable pressure
ASME 250 26.7 bar g @ 140 °C 387 psi g @ 284 °F

Maximum allowable ASME 125 232 °C @ 8.6 bar g 449 °F @ 125 psi g
TMA
temperature ASME 250 232 °C @ 17.2 bar g 449 °F @ 249 psi g
ASME 125 -29 °C -20 °F
Minimum allowable temperature
ASME 250 -29 °C -20 °F
Maximum operating ASME 125 10.0 bar g @ 184 °C 145 psi g @ 363 °F
PMO pressure for saturated
steam service ASME 250 18.0 bar g @ 209 °C 261 psi g @ 408 °F

Maximum operating ASME 125 232 °C @ 8.6 bar g 449 °F @ 125 psi g
TMO
temperature ASME 250 232 °C @ 17.2 bar g 449 °F @ 249 psi g
ASME 125 -29 °C -20 °F
Minimum operating temperature
ASME 250 -29 °C -20 °F
Designed for a maximum cold hydraulic test pressure of: 1.5 x PMA of the relative end connection of choice

BCV Blowdown Control Valves DN15 to DN50 (½" to 2")

20 IM-P403-103 EMM Issue 6

3.11 BCV7_ Pressure/temperature limits

BCV73  F G
Flanged JIS/KS

Temperature °C

Steam saturation curve


 G

       
Pressure bar g

The product must not be used in this region.

F-G Flanged JIS/KS 10K

PN25
Body design conditions
JIS/KS 10K
PMA Maximum allowable pressure JIS/KS 10K 13.7 bar g @ 120 °C
TMA Maximum allowable temperature JIS/KS 10K 300 °C @ 9.8 bar g
Minimum allowable temperature JIS/KS 10K -10 °C
Maximum operating pressure for
PMO JIS/KS 10K 12.3 bar g @ 191 °C
saturated steam service
TMO Maximum operating temperature JIS/KS 10K 300 °C @ 9.8 bar g
Minimum operating temperature JIS/KS 10K -10 °C
Designed for a maximum cold hydraulic test pressure of: 1.5 x PMA of the relative end connection of choice

BCV Blowdown Control Valves DN15 to DN50 (½" to 2")

IM-P403-103 EMM Issue 6 21

3.12 BCV8_ Pressure/temperature limits

BCV83 
A B C
Flanged EN 1092 

Temperature °C


Steam saturation curve

 B C

     
Pressure bar g

The product must not be used in this region.

A-B Flanged EN 1092 PN63
A-C Flanged EN 1092 PN100

PN63 or PN100
Body design conditions
JIS/KS 30K or 40K
PN63 63 bar g @ 300 °C
PMA Maximum allowable pressure
PN100 100 bar g @ 300 °C
PN63 490 °C @ 42.8 bar g
TMA Maximum allowable temperature
PN100 490 °C @ 68.0 bar g
PN63 -29 °C
Minimum allowable temperature
PN100 -29 °C

Maximum operating pressure for PN63 63.0 bar g @ 280 °C

PMO
saturated steam service PN100 99.0 bar g @ 310 °C
PN63 490 °C @ 42.8 bar g
TMO Maximum operating temperature
PN100 490 °C @ 68.0 bar g
PN63 -29 °C
Minimum operating temperature
PN100 -29 °C
Designed for a maximum cold hydraulic test pressure of: 1.5 x PMA of the relative end connection of choice

BCV Blowdown Control Valves DN15 to DN50 (½" to 2")

22 IM-P403-103 EMM Issue 6

3.13 BCV8_ Pressure/temperature limits
Pressure psi g
       
BCV82  D 
E
Socket weld 

Temperature °F
Temperature °C 
BCV83 

Flanged ASME
 
BCV84 Steam saturation curve
Butt weld  
 E 
 
      
Pressure bar g

The product must not be used in this region.

D-E Flanged ASME class 600, socket weld and butt weld

PN63 or PN100
Body design conditions ASME class 600
JIS/KS 30K or 40K
PMA Maximum allowable pressure JIS/KS 10K 103.4 bar g @ 50 °C 1 500 psi g @ 122 °F
TMA Maximum allowable temperature JIS/KS 10K 538 °C @ 29.8 bar g 1 000 °F @ 432 psi g
Minimum allowable temperature JIS/KS 10K -29 °C -20 °F
Maximum operating pressure
PMO JIS/KS 10K 85.7 bar g @ 300 °C 1 243 psi g @ 572 °F
for saturated steam service
Maximum operating
TMO JIS/KS 10K 538 °C @ 29.8 bar g 1 000 °F @ 432 psi g
temperature
Minimum operating temperature JIS/KS 10K -29 °C -20 °F
Designed for a maximum cold hydraulic test pressure of: 1.5 x PMA of the relative end connection of choice

BCV Blowdown Control Valves DN15 to DN50 (½" to 2")

IM-P403-103 EMM Issue 6 23

3.14 BCV8_ Pressure/temperature limits

G H
BCV83 
F
Flanged JIS/KS 

Temperature °C


Steam saturation curve

 F H

       
Pressure bar g

The product must not be used in this region.

F-F Flanged JIS/KS 30K
G-H Flanged JIS/KS 40K

PN63 or PN100
Body design conditions
JIS/KS 30K or 40K
JIS/KS 30K 51 bar g @ 120 °C
PMA Maximum allowable pressure
JIS/KS 40K 68 bar g @ 120 °C
JIS/KS 30K 490 °C @ 30.0 bar g
TMA Maximum allowable temperature
JIS/KS 40K 510 °C @ 40.0 bar g
JIS/KS 30K -29 °C
Minimum allowable temperature
JIS/KS 40K -29 °C

Maximum operating pressure for JIS/KS 30K 44.6 bar g @ 257 °C

PMO
saturated steam service JIS/KS 40K 58.6 bar g @ 274 °C
JIS/KS 30K 490 °C @ 30.0 bar g
TMO Maximum operating temperature
JIS/KS 40K 510 °C @ 40.0 bar g
JIS/KS 30K -29 °C
Minimum operating temperature
JIS/KS 40K -29 °C
Designed for a maximum cold hydraulic test pressure of: 1.5 x PMA of the relative end connection of choice

BCV Blowdown Control Valves DN15 to DN50 (½" to 2")

24 IM-P403-103 EMM Issue 6

 4. Installation and dimensions
Note: Before actioning any installation observe the 'Safety information' in Section 1.
For unit sizes see Figures 5 and 6.

The actuator should be protected from excessive heat.

Actuator sealing is to IP54. Additional protection is recommended for outdoor installation.
The valve may be installed in horizontal or vertical lines with flow in the direction of the arrow.
Do not install with the actuator below the valve. For boiler blowdown applications the ideal take-off point for
the blowdown is from a boiler side connection (see Figures 2 and 3), to reduce the possibility of scale entering
the blowdown valve. If the bottom connection has to be used, make a 'T' connection upstream of the main
bottom blowdown valve as shown in Figure 4.
We recommend that where possible the 'T' is taken off the top of the blowdown line to reduce any problems
of scale.
The ¼" BSP plug may be removed and the connection used for boiler water sampling. A sample cooler is
recommended.
Fit a stop valve between the boiler and the BCV blowdown control valve. A check valve is recommended
downstream of the BCV. For single boiler installations the blowdown may discharge into the main blowdown
line downstream of the main blowdown valve. In the UK, regulations for multi-boiler installations require the
automatic blowdown lines to be separate from the main blowdown lines. For further information see Blowdown
Systems, Guidance for Industrial Steam Boilers (Ref: BG03).

Note: When installing with an S11 chamber, use M12 bolts for PN16, PN25, PN40 and
ASME 300 flanged connections.

Probe elbow CP32 twin tip conductivity probe used to

Boiler measure the BCV of the boiler water,
for the purpose of monitoring and
controlling blowdown.

Stop valve

Electrically
actuated BCV
blowdown control
valve shown.

Alternatively
Check valve use the
pneumatically
actuated BCV
version.

To sample cooler
Blowdown to heat recovery system
or blowdown vessel
Fig. 2 Installation on a probe elbow

BCV Blowdown Control Valves DN15 to DN50 (½" to 2")

IM-P403-103 EMM Issue 6 25

 Electrically actuated BCV blowdown control
valve shown.

Alternatively use the pneumatically actuated

BCV version.

Stop valve

Boiler

Blowdown to heat recovery

system or blowdown vessel

Sensor in Check
S11 chamber valve

To sample cooler
Fig. 3 Installation on a boiler side connection

Electrically actuated BCV blowdown

control valve shown.

Alternatively use the pneumatically

actuated BCV version.

Boiler
Stop valve Stop valve
Blowdown
to heat
recovery
system or
blowdown
vessel

Check valve
Strainer
Sensor in S11 chamber
300 mm (12")

Main blowdown to
Pipeline distance between boiler and blowdown vessel
sensor to be as short as possible Main
blowdown
valve
Fig. 4 Installation on a boiler with no suitable side connection

BCV Blowdown Control Valves DN15 to DN50 (½" to 2")

26 IM-P403-103 EMM Issue 6

Electric actuation - Dimensions/weights (approximate) in mm and kg
A B C D Weight
ASME ASME ASME ASME ASME ASME ASME ASME ASME
125 300 600 125 600 125 600 125 600
Size
ASME ASME ASME
300 300 300
PN40 PN100 PN40 PN100 PN40 PN100 PN40 PN100
DN15 - 190.5 203 130 210 392 422 230 42.5 49.5 12 16
DN20 - 190.5 206 150 230 392 422 230 57.0 49.5 12.8 18
DN25 184 197 210 160 230 392 422 230 54.5 56.5 13 19
DN32 - - 251 180 260 421 449 230 65.5 71.5 19.5 25
DN40 222 235 251 200 260 421 449 230 76.5 71.5 20 28
DN50 254 267 286 230 300 416 449 230 84.5 85.5 23 33

Electric
actuation

Fig. 5 A

BCV Blowdown Control Valves DN15 to DN50 (½" to 2")

IM-P403-103 EMM Issue 6 27

Pneumatic actuation - Dimensions/weights (approx.) in mm and kg
B1 C1 Weight

Size ASME 125 ASME 600 ASME 125 ASME 600

ASME 300 ASME 300
PN40 PN100 PN40 PN100

DN15 378 408 170 12 16

DN20 378 408 170 12.8 18
DN25 378 408 170 13 19
DN32 432 460 300 30.5 36
DN40 432 460 300 31 39
DN50 427 460 300 34 44

C1

Pneumatic
actuation

B1

Fig. 6

BCV Blowdown Control Valves DN15 to DN50 (½" to 2")

28 IM-P403-103 EMM Issue 6

 5. AEL Actuator with spring return

Y02158

Fig. 7
AEL3 actuator
Y10161

100%
100 %
D fDoirppera

1 o ion
ire ece tio
o o

1
t
ct tiroant n 2

io rao c
e
n
io ioo

er cpti Dir
n fn

n tfi
at eon
op firoe
2

oD

0 0%
%
00 V
V Output signal
Output signalyy 10 10
VV
B07650
B07650 Fig. 8

BCV Blowdown Control Valves DN15 to DN50 (½" to 2")

IM-P403-103 EMM Issue 6 29

 Running time Pushing Force Stroke Weight
Type
Motor s/mm Spring s N mm kg

5.7
AEL3 Series 2/4/6 15...30 2000 0...40
4.2 (without spring)

24 V ± 20%, 50...60 Hz
Voltage supply
with 110 V ± 15%
accessories
230 V ± 15%

Power consumption 12 W 28 VA

Stroke 20 mm

Duty cycle spring return > 40.000

Response time for 3-point 200 ms

Maximum temperature of medium 130 °C

Permitted ambient temperature -10...55(60) °C

Permitted ambient humidity < 95% rh without condensation

Degree of protection IP54 (EN 60529)

Protection class III (IEC 60730)

Switching Maximum 250 V

Switches
c apac it y Minimum current 250 mA at 12 V

Operation
After a new start, or after a start following activation of the reset (terminal 21), up to 45 seconds of waiting
time will pass before the drive is available again.

The run time of the drive can be set according to the specific requirements, using switches S1 and S2.

The external hand crank allows you to adjust the position manually. When the hand crank is folded out, the
motor is switched off. After the hand crank is folded back, the spring function is active again and the setpoint
position is adopted again (without initialisation). If the hand crank is unfolded, the drive stays in this position.

Initialisation and feedback signal

The drive initialises itself automatically, the drive moves to the lower limit stop on the valve, thus enabling
automatic connection with the valve spindle. Then it moves to the upper limit stop, and the value is recorded
and saved with the help of a path measurement system. To trigger an initialisation, fold the hand crank out
and back in again twice within 4 seconds. Both the LEDs will then flash red.

Spring return
If the voltage supply fails or is switched off, or if a monitoring contact (terminal 21) responds, the brushless
dc motor releases the gear and the drive is moved into the respective end position (de-pending on the
design version) by the pre-tensioned spring. As this happens, the control function of the drive is disabled for
45 seconds (both LEDs flash green) so that the end position can be reached in every case. The reset speed
is controlled with the help of the motor so that there are no pressure surges in the line. The brushless dc
motor has three functions: as a magnet to hold the position, as a brake (by acting as a generator) and as a
motor for the control function. After a spring return function, the drive does not re-initialise itself.

BCV Blowdown Control Valves DN15 to DN50 (½" to 2")

30 IM-P403-103 EMM Issue 6

LED display
The display consists of two dual-colour LEDs (red/green):

No LED lit No power supply (terminal 21)

LEDs flashing red: Initialisation procedure
Both LEDs lit green: Waiting time after switching on or after spring return
LEDs are flashing red and green: Drive is in manual mode
LED lit red: Upper limit stop or 'CLOSED' position reached
Upper LED flashing green: Drive running, moving towards 'CLOSED' position
LED lit green: Drive stationary, last direction of running 'CLOSED'
LED lit red: Lower limit stop or 'OPEN' position reached
Lower LED flashing green: Drive running, moving towards 'OPEN' position
LED lit green: Drive stationary, last direction of running 'OPEN'

Additional technical information

The yellow housing, comprising the front section, rear section and connection cover, only serves the
purpose of a cover. The crank for manual adjustment is located on the front. The dc motor, the control
electronics, the supporting components and the maintenance-free gear are accommodated in the housing.

Note on ambient temperatures: If the medium temperature in the valve is up to 110 °C, the ambient
temperature may reach 60 °C. For medium temperatures above 110 °C, the ambient temperature must not
exceed 55 °C.

BCV Blowdown Control Valves DN15 to DN50 (½" to 2")

IM-P403-103 EMM Issue 6 31

High Temperature Extension:
The extension kit is to be used on applications above
130 °C to up to 240 °C. There are two kit options of
up to 180 °C and another for up to 240 °C

1. Unscrew the actuator mounting plate screws

for pillars.
2. Screw the extension pillars into actuator pillars
and tighten to 12 Nm.
3. Screw the actuator mounting plate screws into
pillars and tighten to 25 Nm.
4. Mount the coupling extension into the actuator
coupling until it snaps closed.

High temperature
extension kit
for up to 180 °C

High temperature
extension kit
for up to 240 °C

Warnings:

- If the temperature of the medium in the valve is high, the drive columns and the shaft may also reach
high temperatures.

- Drives with safety functions must be regularly checked to see that they are in working order (trial run).

- If a failure of the final control element could cause damage, additional protective precautions must be
taken.

- It is forbidden to dismantle the springs in the device due to the high risk of injuries.

BCV Blowdown Control Valves DN15 to DN50 (½" to 2")

32 IM-P403-103 EMM Issue 6

 6. Flow settings
Table 1 Blowdown valve capacities

Valve size DN15 DN20 DN25 DN32 DN40 DN50

Kv value 0.5 0.5 0.5 1.6 1.6 1.6

For conversion:
C v (UK) = Kv x 0.963
C v (US) = Kv x 1.156

Kv chart
Pressure psi g
         



 








Water flow UK gallons/h


 

Water flow m 3/ h

 


 
 
 
 








 
                   
Pressure bar g

BCV Blowdown Control Valves DN15 to DN50 (½" to 2")

IM-P403-103 EMM Issue 6 33

Capacities

ke
ro
st
m
m
0

Water flow UK gallons/h

-2
")
-2 ke
Water flow m 3/ h

" ro
1¼ st
( m
m
50 15
N -
-D 2 ")
32 "- e
D
N ( 1¼ ok
5 0 str
DN mm
- - 10
32 2")
DN "- ro ke
( 1¼ m st
5 0 - 20 m
- DN "-1
" )
e
DN
32 5 (1½ st rok
DN2 5 mm
D N1
5 -
" - 1 ") - 1
5 (1½ o ke
- DN2 m m s tr
D N 15 ½" - 1" ) - 10
DN25 (1
D N 15 -

% opening

BCV Blowdown Control Valves DN15 to DN50 (½" to 2")

34 IM-P403-103 EMM Issue 6

Flow for stroke 20 mm
Differential Hot water Differential Hot water Valve
Kv
pressure (bar) flow (m3/h) pressure (bar) flow (m3/h) size
0 0.0 0 0.0
0.5 0.4 50 3.5
1 0.5 60 3.9
DN15
0.5 10 1.6 70 4.2 to
DN25
20 2.2 80 4.5
30 2.7 90 4.7
40 3.2 100 5.0
0 0.0 0 0.0
0.5 1.1 50 11.3
1 1.6 60 12.4
DN32
1.6 10 5.1 70 13.4 to
DN50
20 7.2 80 14.3
30 8.8 90 15.2
40 10.1 100 16.0

Flow for stroke 15 mm

Differential Hot water Differential Hot water Valve
Kv
pressure (bar) flow (m 3 /h) pressure (bar) flow (m 3 /h) size
0 0.0 0 0.0
0.5 0.3 50 2.7
1 0.4 60 2.9
DN15
0.375 10 1.2 70 3.1 to
DN25
20 1.7 80 3.4
30 2.1 90 3.6
40 2.4 100 3.8
0 0.0 0 0.0
0.5 0.8 50 8.5
1 1.2 60 9.3
DN32
1.200 10 3.8 70 10.0 to
DN50
20 5.4 80 10.7
30 6.6 90 11.4
40 7.6 100 12.0

BCV Blowdown Control Valves DN15 to DN50 (½" to 2")

IM-P403-103 EMM Issue 6 35

Flow for stroke 10 mm

Differential Hot water Differential Hot water Valve

Kv
pressure (bar) flow (m 3 /h) pressure (bar) flow (m 3 /h) size
0 0.0 0 0.0
0.5 0.2 50 1.8
1 0.3 60 1.9
DN15
0.25 10 0.8 70 2.1 to
DN25
20 1.1 80 2.2
30 1.4 90 2.4
40 1.6 100 2.5
0 0.0 0 0.0
0.5 0.6 50 5.7
1 0.8 60 6.2
DN32
0.80 10 2.5 70 6.7 to
DN50
20 3.6 80 7.2
30 4.4 90 7.6
40 5.1 100 8.0

BCV Blowdown Control Valves DN15 to DN50 (½" to 2")

36 IM-P403-103 EMM Issue 6

 7. Rotating the electrical actuator

Handwheel

The actuator may be rotated on the valve body

so that the terminal cover points are in the most
convenient direction.
Fig. 9

BCV Blowdown Control Valves DN15 to DN50 (½" to 2")

IM-P403-103 EMM Issue 6 37

 8. Wiring
All wiring materials and methods shall comply with relevant EN and IEC standards where applicable. For
installations in the US and Canada, the controller and valve must be wired in accordance to the Local and
National Electrical code (NEC) or the Canadian Electrical Code (CEC).
Check the actuator label to ensure the operating voltage is correct for the mains supply.

Suitable ac voltages are:

230 V version (additional card) 195 V - 265 V

110 V version (additional card) 96 V - 127 V

24 V version 19.3 V - 28 V

Frequency 50 - 60 Hz

Maximum power consumption 12W/28VA

Fig. 10

Additional card

Fig. 11

BCV Blowdown Control Valves DN15 to DN50 (½" to 2")

38 IM-P403-103 EMM Issue 6

 1 2a 2b L
230 V
N

µC

21 N 2a 2b

M
S1 S2 S3 S4 Module 230 V
On

Off AVF234S
S1; S2 = Drivetime
S3; S4 = Characteristic 2a Valve opening
2b Valve closing

Fig. 12

Limit switches configuration

Fig. 13

The limit switches box is already installed in the actuator cover.

Xs1 = Adjust to positioning the valve opening
Xs2 = Adjust to positioning the valve closing
Note: The Xs2 is set-up during the coupling with the valve consequently it
cannot be altered.





Fig. 14 



Turn the potentiometers Xs1 to adjust the stroke to   
the optimum for your application.   
1. Set the potentiometer
2. Measure the stroke of the valve
3. Adjust the set-up of the potentiometer

BCV Blowdown Control Valves DN15 to DN50 (½" to 2")

IM-P403-103 EMM Issue 6 39

 9. Pneumatic actuator stroke adjustment
The valve is supplied with a low flowrate setting of 10 mm (3/8") stroke.
To increase the stroke to 15mm (5/8") or 20 mm (¾"):

- Isolate the valve from the boiler pressure

and energise the solenoid valve so that the
air supply can be manually controlled by the
regulator. 26, 27
- Apply just enough air pressure to open the valve 13, 14
fully (see Figure 15).

Fig. 15

- Remove the clamp nuts and screws (26 and

27), and the clamp front and rear (13 and 14).
25

- Activate the air supply and allow the actuator to 10

retract fully (see Figure 15).

11

Fig. 16

- Loosen the actuator lock-nut (25), and screw the

connector (10) fully into the spindle.
- Loosen the nut locking the valve stem to the
adaptor (11).
- Position the adaptor so that only 8 mm of the
valve stem thread is engaged (see Figures 17
and 18).

Fig. 17
Correct - 8 mm thread engagement

Caution
The valve stem must not protrude beyond the
surface of the adaptor, otherwise the clamp will not
fit corectly and may be damaged (see Figure 18).

Fig. 18
Incorrect - thread protruding above the adaptor

BCV Blowdown Control Valves DN15 to DN50 (½" to 2")

40 IM-P403-103 EMM Issue 6

- Pull the valve stem upwards to fully close the
valve.
- Measuring from the top of the stuffing box,
mark the new stroke required on the valve
stem - 15 mm or 20 mm (Figure 19).

Fig. 19

- Push the valve stem down so that the mark lines

up with the stuffing box (Figure 20).

Fig. 20

- Remove the air supply to allow the actuator to

descend fully.
- Unscrew the actuator connector until it just
contacts the valve stem adaptor without opening
the valve (Figure 21).
- Tighten adaptor and actuator lock-nuts.
- Refit the clamp, and its nuts and screws.

Fig. 21

Please note:
It may be necessary to make final adjustments to the actuator connector and the valve adaptor to
ensure the clamp anti-rotation lugs engage with the yoke, and that the pointer is still on the scale.

BCV Blowdown Control Valves DN15 to DN50 (½" to 2")

IM-P403-103 EMM Issue 6 41

 10. Maintenance
Note: Before actioning any maintenance, observe the 'Safety information' in Section 1.

Warning for all stainless steel valves

The 316 type stainless steel used in the construction of these products particularly for screwed or close
fitting parts, is very susceptible to galling or cold welding. This is an inherent characterisitic of this type of
material and great care should therefore be taken when dismantling or reassembling.
If the application permits, it is recommended that a light smear of a PTFE based grease is applied to any
mating parts before reassembly.

10.1 General
Valve parts are subject to normal wear and must be inspected and replaced as necessary. Inspection and
maintenance frequency depends on the severity of the service conditions. This section provides instructions
on replacement packing, stem, plug and seat and bellows. All maintenance operations can be performed
with the valve body in the line.

Annually
The valve should be inspected for wear and tear replacing any worn or damaged parts such as valve plug
and stem, valve seat and gland seals, refer to Section 10 'Spare parts'.
Note 1: High temperature graphite packed seals are subject to wear during normal
operation. We therefore recommend the graphite packing be replaced during this routine inspection to prevent
premature failure of the packing during normal operation.
Note 2: It is recommended that all soft seals and gaskets be replaced whenever the valve is disassembled.

New torque values with lubrication:

The following new torque values should be used with lubricated nuts/bolts:

Table 2
Recommended tightening torques - Control valve sizes DN15 to DN50

SPIRA-TROL
Torque (N m)
valve size
1 3
DN15 - DN25 50

DN32 - DN50 70

4 2

Fig. 22
Bonnet tightening sequence

BCV Blowdown Control Valves DN15 to DN50 (½" to 2")

42 IM-P403-103 EMM Issue 6

10.2 Removal of valve bonnet
Note: This procedure is necessary before carrying out any of the maintenance procedures detailed below:

- Ensure that the valve is depressurised and clear of media and isolate it both upstream and downstream.
- Caution: care should be taken when disassembling the valve in case of residual pressure being trapped
between the isolation points.
- Remove the actuator from the valve. Refer to the Installation and Maintenance
Instructions covering Spirax Sarco actuators.
- Unscrew the stuffing box nuts (18).
- Undo and remove the bonnet nuts (27).
- Remove the bonnet (2) and plug and stem assembly (8)
- Remove and discard the body gasket.

10.3 Replacement of graphite gland packing

- Remove the lock-nut (3), stuffing box nuts, gland flange and gland follower (18), ensuring that the groove
is clean and undamaged, replace with new item.
- Remove the gland follower (9) and retain, withdraw the graphite packing (14) and discard. Remove the
spacer and lower bearing (16). Clean and examine these components and the upper bearing replacing
any that show signs of damage or deterioration.
- Clean the gland cavity and reassemble the gland components in the order shown in Figure 23. Note
that the lower bearing must be fitted with the radiused edge downwards. When fitting the graphite seals,
the scarf joints in each seal must be offset from the one below by 90°.
- Fit the packing follower and stuffing box ring into position. Lubricate the stuffing box nuts. Install and
tighten the packing flange nuts finger tight. and hold the packing without compressing them.
- Final adjustment of the gland must be carried out after refitting the bonnet as detailed in Section 10.5.

Scarf joint
Fig. 23

BCV Blowdown Control Valves DN15 to DN50 (½" to 2")

IM-P403-103 EMM Issue 6 43

10.4 Removal and refitting of the
valve plug /stem assembly and seat

- Lift out the seat retaining cage (5) followed by the

seat (6).
- Remove the seat back gasket (7) and discard.
- Clean all components, including the seat recess in
the valve body.
- Examine the seat and plug/stem assembly for
damage or deterioration and renew as necessary.
- Note: Score marks or scaly deposits on the valve
stem will lead to early failure of the gland seals and
damage to seat and plug sealing faces will result in
leakage rates higher than those specified for the
valve.
- Fit a new seat gasket (7) in the body seat recess
followed by the seat (6).
- Refit the cage (5) ensuring that the flow windows
are lower most and that it sits squarely on the seat
without impinging on the valve body.

Fig. 24

BCV Blowdown Control Valves DN15 to DN50 (½" to 2")

44 IM-P403-103 EMM Issue 6

10.5 Refitting the bonnet
Caution: The following must be carefully followed to enable the correct reassembly of the control valve, and
the subsequent test that is required to ensure that the plug moves freely inside the valve seat:

- Fit new bonnet gasket.

- Ensure the plug stem is fully extended without the upper stem threads making contact with stem seals
on the top of the bonnet.
- Replace the bonnet and stem assembly to the valve body, locating the plug centrally into the seat.
- Holding the Plug in position, push the bonnet down on to the valve body.
- Proceed to tighten the bonnet into position by following Step 1 through to 7:

1 2

Fit bonnet nuts. Finger tighten opposing bonnet

nuts or bolts evenly in pairs.

3 4

Raise the stem to the highest Firmly and briskly push the stem
position. fully down.

Repeat Steps 1 to 4 finger tightening bonnet nuts or bolts individually

until tight.

BCV Blowdown Control Valves DN15 to DN50 (½" to 2")

IM-P403-103 EMM Issue 6 45

 5 6 7

Using a torque wrench lightly After each tightening sequence Firmly and briskly push the stem
and evenly tighten each bolt lift the stem fully. fully down.
or nut by 45°, following the
sequence illustrated in Figure
22.

- Repeat Steps 5, 6 and 7 until the bonnet nuts or bolts have an even tension

- Continue Steps 5, 6 and 7 but use a torque wrench set at 10% of maximum required torque setting.

- Again, repeat Steps 5, 6 and 7, incrementally increasing the torque value to 20%, 40%, 60%, 80% and
finally 100% of the required torque value (as specified in Table 2).

- Pull the plug off its seat, rotate by 120° and slowly push it back down into the seat checking for any signs
of resistance as the plug comes into contact with the seat.

- Repeat the above Step, three more times.

- If any resistance is felt, this can indicate the plug

3
and seat is misaligned and the process will need
repeating.

- Tighten the the stuffing box nuts (18) until: 18

i) PTFE gland assembly: A gap of 10 mm between
the underside of the gland flange and the bonnet is
achieved.
ii) Graphite gland assembly: A gap of 12 mm between
the underside of the gland flange and the bonnet is
achieved.

- Refit the lock-nut (3).

- Reinstall the actuator.

- Bring the valve back into service.

- Check for leakage at the gland.

Note: Recheck the graphite seals and retighten the gland

if necessary after a few hundred cycles as the seals fully
bed in.

Fig. 25

BCV Blowdown Control Valves DN15 to DN50 (½" to 2")

46 IM-P403-103 EMM Issue 6

 11. Spare parts

C1

Fig. 26
B

Spare parts
The spare parts available are detailed below. No other parts
are supplied as spares.

Please note that the spare parts available for the BCV
blowdown control valve are the same for both the electrically
and pneumatically actuated versions.
D2
Available spares
Actuator clamping nut (only for high pressure version) A

Gasket set B, G

Stem seal kits Graphite packing C1

E Plug stem and seat kit Linear trim D2, E
(No gaskets supplied)
G
How to order spares
Always order spares by using the description given in the
column headed 'Available spares', and state the size and
type of valve and specify clearly the full product description
as found on the label of the valve body, as this will ensure
that the correct spare parts are supplied.

Example: 1 off Actuator clamping nut for a Spirax Sarco

DN15 BCV43HWSUSS blowdown control valve.

BCV Blowdown Control Valves DN15 to DN50 (½" to 2")

IM-P403-103 EMM Issue 6 47

 BCV Blowdown Control Valves DN15 to DN50 (½" to 2")

48 IM-P403-103 EMM Issue 6