What is the Method Statement for Boiler Installation?
A method statement for boiler installation outlines the step-by-step procedure for safely and effectively installing a boiler system. It serves as a guide for the installation team to ensure that all tasks are carried out in a systematic and organized manner, following industry best practices and relevant safety regulations.
Table of Contents
The pre-testing and starting up of boilers are covered by this method statement.
Scope
To ensure that the proper steps are taken to allow a safe and successful start-up of the oil-fired boilers before distributing hot water throughout the hot water system.
Personnel
Commissioning Engineer
Mechanical Engineer
QA/QC Manager
Safety Officer
Pre-Installation Activity
Make that the boiler has been installed in accordance with the manufacturer’s requirements, the client’s or consultant’s specifications, and the installation.
Check that the system has been hydrostatically tested, completely washed out, then drained, examined, and replenished with treated water in preparation for boiling out.
Make sure the necessary and required chemicals are on hand for the boil-out.
Check and ensure that the boiler room has sufficient ventilation so that the burner can receive enough combustion air when all the doors are closed.
Verify that the fuel line pipe is finished and all the fuel-burning equipment is completely functional.
Ensure that the gasoline lines are clean and free of debris.
Inspect the fuel oil line to make sure it has been primed and purged.
At the fuel control valves, check strainers are installed.
Verify that the fuel supply system regulators are maintaining a steady supply.
Ensure that the controlling equipment for the circulating pumps is connected and working.
Verify the type and quantity of fuel in the fuel oil tank.
Make sure all electrical connections are made securely and in place.
Check to make that all limit devices located externally to the equipment are hooked, installed, and functional.
Verify the boiler is receiving the proper voltage.
Make sure the stack is connected to the breaching.
Firing the Boiler Methodology
Fire up the boiler and start the firing cycle.
In accordance with the recommendations of the manufacturer, perform instrument inspections.
Plan the networked distribution of hot water.
Environmental and safety requirements
According to the manufacturer’s specifications and any relevant legal requirements.
Records
Test Forms
Records of Performance
Logbook
Reference Materials
Method Statement For Steam Boiler Installation
Tools and Equipment
The following tools and equipment must be set up before the steam boiler installation.
Fork lift or Crane with capacity & arrangement ( strap ) in compliance with manufacturer’s specifications.
Portable hand tools
Power tools
Testing and commissioning tools
Level threads
Spirit levels
Drilling/hammering
Handling and Storage of Materials
To ensure that no damage is done to the materials, adequate precautions must be taken for unloading, transferring, and storage after receiving the steam boilers and accessories.
The only way to get a good deal on a steam boiler is to buy one.
In case the foundation is not ready, the steam boilers will be stored in site stores in accordance with the manufacturer’s instructions.
The only way to get a good deal on a steam boiler is to buy one.
The steam boilers will be examined to ensure that their manufacture, model, type, capacity, etc. conform to the authorized material submittals. Any discrepancies, damage, etc., identified will be reported for follow-up action and alerted.
The Plumbing Site Engineer must ensure that the steam boilers employed at the site are free of any damage or deformity of any kind. If material is deemed unfit for use on the site, it will be deleted right away and replaced with the proper item.
Until the steam boilers are moved for installation, all packages must be stored in a protected area from the elements.
Procedure for Steam Boiler Installation
Make sure that all necessary civil works for the installation area have been completed, and that the necessary permissions have been received from the appropriate authorities.
Ensure that the required materials are on site in accordance with approved material submittals before beginning the installation by consulting the approved shop drawings for the installation area.
Before releasing the materials from the site store, make sure they are stored correctly and have no signs of damage or deformity of any kind.
Accessories for approved steam boilers must be used during installation.
On the foundation, steam boilers must be installed with enough room for piping, valves, and future maintenance.
Make sure the concrete foundation is horizontal and has smooth finishes from top to bottom. Perform painting if required.
As directed by the manufacturer, move the steam boilers from the store to the installation area.
The connections should not be used to elevate steam boilers. When lifting, a strap should be utilized; it should be placed in accordance with the manufacturer’s recommendations.
The steam boilers should be leveled and positioned on the foundation after the foundation has been laid.
The only way to know if a product is safe is to test it out. Accessories for steam boilers must be installed according to the approved shop drawing.
Make sure the steam boilers won’t be put under any stress or strain when the piping system is connected to them.
The bolts should be gently tightened one after the other, equally distributed over the flanges. Installed safety valves and air vents in accordance with manufacturer guidelines.
When the unit is running, make sure all the gaskets are in place; if leaks are visible, remove the gasket or tighten the bolts as needed. Connect the drain in accordance with the shop drawing.
Never operate equipment above the pressure, temperature, or other parameters listed on the name plate or vassal marking. Installed steam boilers must be made available for client or consultant inspection.
Health and Safety Considerations
Personal Protective Equipment (PPE):
Enforce the mandatory use of appropriate PPE for all workers involved in the installation.
Required PPE: such as safety helmets, safety glasses, protective gloves, safety boots, high-visibility clothing, and respiratory protection.
Risk Assessment:
Conduct a comprehensive risk assessment specific to the boiler installation project.
Identify and highlight any potential risks associated with the installation process, such as electrical hazards, working at heights, manual handling, exposure to harmful substances, or confined spaces.
Consider external factors that may affect safety, such as adverse weather conditions or nearby hazards.
Outline the control measures in place to mitigate these risks, including engineering controls, administrative controls, and personal protective equipment.
Safe Work Practices:
Specify safe work practices that need to be followed during the installation, such as proper lifting techniques, safe use of tools and equipment, and secure storage of materials.
Provide guidelines for working at heights, including the use of fall protection equipment and proper scaffolding procedures.
Highlight the importance of maintaining a clean and organized work area to prevent slips, trips, and falls.
Electrical Safety:
Highlight the specific electrical hazards associated with the installation and the precautions to be taken.
Stress the importance of working with a qualified electrician and following electrical codes and regulations.
Specify the procedures for isolating and locking out electrical systems before commencing work.
Hazardous Substances:
Identify any potentially hazardous substances that may be encountered during the installation.
Provide procedures for safe handling, storage, and disposal of these substances.
Emphasize the need for appropriate ventilation and personal protective equipment when working with hazardous substances.
Emergency Procedures:
Outline the procedures to be followed in the event of an emergency, such as fires, gas leaks, or injuries.
Provide information on the location of emergency exits, first aid kits, fire extinguishers, and other emergency equipment.
Specify the responsibilities of workers and highlight the importance of reporting incidents or near misses.
Training and Competence:
Ensure that all workers involved in the installation receive appropriate training and are competent to perform their tasks safely.
Document and maintain records of training and certifications for relevant personnel.