Purpose of generating this method of statement is to define the procedure step by step to implement the correct practices for installation and testing of Steam Boilers through the guidelines contained herein so as to ensure that the job execution complies with the requirements and serves the intended function to satisfactory level.
This Method Statement refers to various work procedures contained within project control documents, which explains and covers the installation of Steam Boilers.
Below method statement also covers the pre-testing and starting up of hot water boilers, to ensure the correct measures are taken to allow a safe and successful start up of the oil fired boilers prior to distributing hot water throughout the hot water system.
Steam Boilers and accessories shall be in line with the approved material submittals and specifications.
Responsible Team:
- Plumbing Engineer
- Commissioning Manager
- Mechanical Supervisor
- Q.A /Q.C Manager
- Safety Manager
Below is list of necessary tools and equipment:
- Fork lift or Crane with capacity & arrangement ( strap ) in line with manufacturer’s recommendations.
- Portable hand tools,
- Spirit Level / Level Threads .
- Drill Machine / Hammering Machine
Testing Equipment:
Following instruments are required for testing and commissioning of the Boilers
Digital Multimeter: Fluke (With valid calibration certificate)
Digital thermometer: Fluke (With valid calibration certificate)
Material Handling and Storage
On receipt of the Steam Boilers and accessories at site, shall be off-loaded carefully at site using necessary manpower and required equipment to ensure that no damage is caused to the materials.
Necessary precautions shall be taken for unloading, shifting & storage.
All Packages for the Steam Boilers reaching to site shall be identified as per package list.
The Steam Boilers shall be preferably shifted directly to its location for installation. In case the Foundation is not ready the Steam Boilers will be stored in site stores as per manufacturer instruction.
Steam Boilers will be checked to ensure that it complies with the approved material submittals in terms of make, model, type, capacity etc.
Any discrepancies, damage etc., found will be notified and reported for further action.
Site Engineer (Plumbing) has to ensure that Steam Boilers used at site are free from any damage or deformity of any kind. Material found not suitable for site use will be removed immediately from site and the same will be replaced by correct item.
All packages shall be stored under dust protected area, till the Steam Boilers is shifted for installation.
Steam Boiler Installation Procedure
Ensure all civil works are completed for the area of installation, and clearance is obtained from respective authorities to proceed further.
Prior to start the installation, refer to the approved shop drawings related to the area of installation and ensure that required materials are available at site as per approved material submittals.
Ensure the materials are stored properly and there is no mark of damage or deformity of any kind before issuing the material from site store.
Approved Steam Boilers accessories shall be used for installation purpose.
Steam Boilers shall be installed on the foundation ensuring adequate space is available for valves, piping and for future maintenance.
Ensure that the concrete foundation is horizontal & smooth finishes from top. Painting to be done if required as per civil specifications and details.
Shift Steam Boilers from store to area of installation as per manufacturer’s instructions.
Steam Boilers should not be lift by the connections. Strap should be used when lifting, place strap according to the manufacturer’s instructions.
After putting down on the foundation the Steam Boilers should be leveled and aligned.
Foundation must be adequate to ensure that the unit will not settle down and cause pipe strain or distortion of the shell.
Steam Boilers accessories shall be installed as shown on the approved shop drawings and manufacturer installation instructions.
When connecting the pipe system to the Steam Boilers make sure that no stress or strain is imposed by the pipe system, on the Steam Boilers.
Tightening of the bolts should be evenly distributed over flanges, each bolt being gradually tightened in succession.
Install air vent and safety valves as per manufacturer’s recommendations.
Check all the gaskets are effective when unit is operating, if leaks are evident remove gasket or tighten bolts as necessary.
Provide drain connection as per shop drawing.
Do not operate equipment at pressure or temperatures or other conditions in excess of those specified on the name plate or vessel marking.
Installed Steam Boilers shall be offered for inspection and approval from client/consultant.
Pre Testing Requirements
Ensure that the boiler has been installed in accordance with the manufacturers requirements and the specifications and installation is approved by client/consultant.
Make sure that the hot water piping system has been hydrostatically tested and thoroughly flushed out, subsequently drained and inspected and refilled with treated water ready for boil-out.
Ensure the required and proper chemicals are available for boil-out.
Check and ensure that the boiler room has proper ventilation to permit adequate combustion air flow to the burner with all boiler room doors closed.
Ensure all fuel burning equipment is fully operational and fuel line piping is complete.
Check and ensure fuel lines are clear and free from dirt and obstructions.
Ensure the fuel oil line has been primed and purged.
Check strainers are fitted at fuel control valves.
Check that fuel supply system regulators are ensuring constant supply condition.
Ensure circulating pumps and their regulating devices are connected and operable.
Check the fuel grade and quantity in the fuel oil tank.
Check all electrical connections are in place and secure. Check electrical connections in control panel and ensure that all wires and connections are correct and tight.
Ensure all limit / safety devices mounted externally to the equipment are installed, wired and in operable condition.
Check earthing / grounding connections.
Check the correct voltage is available to the boiler.
Ensure the breaching is connected to the stack.
Method For Firing The Boiler
Only competent personnel will be in the vicinity of the testing area while carrying out the boiler testing.
Inspect all plumbing connections and safety components to ensure the safe operation of the Boiler.
The procedures to be followed will be in accordance with the recommendations of the manufacturer as indicated in the Operations and maintenance manual provided with the units.
Fill Boiler with water at the fill operating pressure and inspect leakage from connections, drain valve, safety relief valve and element flanges.
Attend to any work necessary to ensure the proper installation of the system.
Discharge water from sanitary fittings until air in the system has completely escaped.
Initiate firing sequence and light the boiler.
Carry out instrument checks in accordance with manufacturers recommendations.
Arrange distribution of hot water through network.
Boiler Operation Sequence
Energize panel.
Depress red button on manual reset high limit switches.
Observe the operation of the electrical components during the first heating cycle, take necessary precautions as the electrical circuits are energized.
Check operation of thermostat.
Adjust manually and check the operation.
Allow the Boiler to come up to temperature and ensure that the thermostat operates automatically at the required temperature.
Close the front panel.
Temperature regulation
- The Boiler temperature is controlled by thermostat whose contacts are open on a rise in water temperature.
- Adjust the setpoint to 131 0F (55 0) and allow the Boiler to operate until the thermostat operates, ensuring that the temperature of the water is at 55 0C
Repeat the procedure as necessary to achieve the required temperature.
Adjust thermostat to maximum and allow high temperature cut off switch to operate.
Pay particular attention to build up of pressure in the vessel.
Record temperature cutout in the Data sheet.
Prepare report of recommendations for correcting unsatisfactory performances, if any.
All test data to be recorded in forms which are enclosed for reference.
Contractor/manufacturer shall train the Owner’s maintenance personnel for operation and maintenance.
Relevant Records
- Risk Assessment
- Inspection and test plan
- Quality control procedure
- Installation Check sheets
- Test Sheets
- Performance Records
- Log Books
- Training Records