What types of contamination can the CCD system detect?

The CCD system detects contaminants that alter the conductivity of condensate, such as dissolved salts, acids, or process chemicals. It will not detect non-conductive contaminants like oils, fats, or sugars. For applications involving such contaminants, additional testing with a portable conductivity meter on known samples is recommended.

Can the system work with existing plant control systems?

Yes. The BC3200 and BC3210 controllers include a 0/4-20 mA analogue output that can be connected to PLCs, DCS, or SCADA systems for remote monitoring and data logging.

What is the minimum installation head required for the bypass arrangement?

A minimum head of 500 mm is required in the bypass line to prevent flash steam flow past the sensors and ensure accurate conductivity readings.

Can we use two 2-port valves instead of a single 3-port diverter valve?

Yes. An alternative configuration uses an isolating valve in the condensate return line (wired to close on high conductivity) and a dump valve in the drain line (wired to open simultaneously). Spirax Sarco offers electrically and pneumatically actuated valves for this purpose.

What accessories are available for the CCD system?

Spirax Sarco offers SCS20 sample cooler systems, MS1 portable conductivity meters, DCV2 check valves, DS1000 remote digital display units, and a range of actuated valves for complete system integration.

SPIRAX SARCO · CONDENSATE MANAGEMENT SYSTEMS

Spirax Sarco CCD Condensate Contamination Detection System

Name: Spirax Sarco CCD Condensate Contamination Detection System
Brand: Spirax Sarco

Spirax Sarco CCD system monitors condensate conductivity and diverts contaminated water to drain. Ideal for boiler protection in Indian factories.

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Spirax Sarco CCD System Layout and Components

Overview

The Spirax Sarco CCD (Condensate Contamination Detection) system is an automatic monitoring solution designed to protect boiler systems from contaminated condensate return. By continuously measuring the conductivity of condensate, the system detects contamination and diverts affected condensate to drain before it can enter the boiler feedtank.

Returning clean condensate to the boiler house is essential for energy efficiency, reduced water treatment costs, and lower make-up water consumption. However, even low levels of contamination can cause foaming, scaling, or corrosion in the boiler, leading to costly downtime and product quality issues. The CCD system provides continuous protection by automatically isolating contaminated condensate while allowing clean condensate to return normally.

The system uses a robust high-temperature conductivity sensor with integrated temperature compensation, ensuring accurate readings regardless of condensate temperature fluctuations. When conductivity exceeds the pre-set threshold, a 3-port diverter valve (or dual 2-port valve arrangement) redirects contaminated condensate to waste, resuming normal operation once conductivity returns to acceptable levels.

Key Features

Continuous real-time conductivity monitoring of condensate return lines
Automatic diversion of contaminated condensate to drain
Pt100 temperature compensation sensor for accurate readings across varying temperatures
Choice of wall-mounted (BC3200) or panel-mounted (BC3210) controllers
4-digit LED/LCD display with simple push-button commissioning and calibration
Dual relay outputs for diverter valve control and alarm activation
0/4-20 mA analogue output for integration with plant control systems
IP65 protection rating on controller for industrial environments

Specifications

Parameter	Value
Nominal Conductivity Range (Normal)	0–100 µS/cm (ppm)
Nominal Conductivity Range (Extended)	0–1,000 µS/cm or 0–10,000 µS/cm
Supply Voltage	230 V / 115 V
Supply Frequency	50–60 Hz
Maximum Ambient Temperature	55°C
Controller Protection Rating	IP65
Sensor Chamber Connection	1¼" BSP
Sample Connection	¼" BSP
Controller Models	BC3200 (wall-mounted), BC3210 (panel-mounted)
Sensors Included	CP10 conductivity sensor, TP20 temperature sensor

Applications

The Spirax Sarco CCD system is suitable for any industrial facility where condensate is returned to the boiler feedtank:

- Process industries: Chemical plants, pharmaceutical manufacturing, food and beverage processing - Textile mills: Dyeing and finishing operations with steam-heated equipment - Paper and pulp plants: Steam systems with multiple heat exchangers - Refineries and petrochemical plants: Critical boiler water quality requirements - General manufacturing: Any facility with indirect steam heating where product contamination of condensate is possible

The system is particularly valuable where condensate may become contaminated by process fluids through heat exchanger tube failures or leaking coils.

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