Boiler Installation and Setup (Courtesy of Rentech Boiler Systems)
It is not within the scope of this document to provide installation instructions. These should follow the design specifications of the Architect, Engineer, or Contractor. Good engineering practices must prevail.
The equipment must be installed to conform to applicable local, state, and National Codes. Compliance with Codes will help ensure a safe and dependable installation as the Codes have been formulated to safeguard life and property. Failure to comply with established Codes and regulations may necessitate costly modification and reconstruction.
The proper authorities should been consulted before preparation for a permanent installation is started. Application should be made immediately for all permits required by law for construction and installation.
The following generalizations are intended for assistance and do not supplant any Codes or construction criteria.
Necessary lifting and jacking attachments are an integral part of the equipment. When the components are received at the plant, they must be inspected for signs of damage prior to accepting the shipment or releasing the shipper. All boxes and cartons should be opened carefully and checked against the packing slip. In case of damage or shortage, immediately notify the carrier and file a claim. The equipment must be inspected during each phase of installation so that if any damage has occurred, repairs can be processed without delay.
When the contractor begins installation, his experience and discretion prevail and it must be clear that he is totally responsible for the proper care of the unit as it is moved into position.
The layout of the system has been designed with sufficient access for maintenance and inspection of all components and piping. The equipment must be set in level positions. Client's foundations must be designed with adequate load bearing characteristics to handle the weight of the equipment, filled with water, and applicable snow, wind, and seismic loads. All applicable codes relating to minimum clearances to combustible materials must be observed.
If the boiler is designed for operation with negative flue gas pressure, then all steel mating flanges may be designed to be welded rather than be bolted. The following steps are suggestions as aids in assembly.
1. Bring components near enough to each other so that the flanges are in close alignment.
2. Holes in the corners of the flanges are provided to insert pins or bolts for aligning the flanges.
3. Adjust alignment if necessary and bring the flanges together so they are just touching.
4. Weld the perimeter of the flange-to-flange joint with a 3/16" (min.) to ΒΌ" fillet (seal) weld. Variations in camber, leg length, etc. are inconsequential. Erector must fill any and all gaps with weld metal. A good choice of standards is E7018.
5. This weld is not only a structural weld, but also a seal weld to prevent flue gas leakage; therefore, a sound weld is required. This weld does not require an ASME Code-Qualified welder, since this is not a code item.
6. Remove alignment devices and plug weld corner holes to preclude leaking and the joint is complete.
7. Should removal of any welded flange component be required, grinding, torch cutting, or air-arc gouging can remove the weld.
All piping and valves must be installed in accordance with good engineering practices. Suitable strength piping and valves are to be used. All drain and discharge piping must be piped to a safe point of discharge. The discharge end of the piping should not be near platforms or elevated walkways.
The discharge piping from the safety valves and the method of connecting the piping is especially important. Safety valves should be inspected externally to see that they are free to operate and that their vent and drain piping are open to atmosphere and free to expand without imposing strain upon the safety valve body. Make sure that any gags used during testing are removed. Verify that the discharge piping from the safety valves, vents, and drains are piped to a safe point of discharge.
Electrical wiring must conform to applicable electrical codes and proper wiring used. The necessary switches, feed boxes, circuit breakers, etc. must be installed and operable.
All auxiliary equipment should be installed in accordance with the recommendations of the respective manufacturers. Fan wheels, bearings, couplings, and shaft alignment, should be checked and aligned. If the bases of the auxiliary equipment are grouted, the alignment should be checked before grouting or doweling and rechecked afterwards. Lubrication of the equipment should be verified in accordance with the manufacturer recommendations.
Aisles, ladders, and stairs should be completed and accessible for the convenience and safety of the operation personnel. All obstructions such as scaffolding, refuse, tools, etc. must be removed from ducts and platforms. Insulation of piping and ductwork should be done in accordance with accepted practices or project specifications.
When installation of the unit is completed but before operation, the entire system should be inspected. The following is a minimum checklist to aid the operator in checking the entire system prior to start up.
External
_____ Check seal welding of casings.
_____ Check that the structural supports have been installed.
_____ Check the nozzle alignment for bent or damaged nozzles.
_____ Check refractory and insulation for damage.
Piping
_____ Check that all the valves are oriented in the proper flow direction.
_____ Check linkages on all regulating devices, valves and dampers.
_____ Check that all metering devices have been installed in accordance with recommendations.
_____ Check all piping for leakage during hydrostatic test.
_____ Check with Owner's water treatment consultant to assure that feedwater and chemical feed
piping arrangement is appropriate.
_____ Check that all flange bolting has been torqued to proper levels.
Vent and Drain Piping
_____ Check all drain and vent lines for obstructions.
_____ Check that all drain and vent lines terminate away from platforms and walkways.
Water Column
_____ Check all connecting piping joints for leakage.
_____ Check all safety and alarm system wiring.
_____ Check isolation valves (if any) to be sure they are locked open.
Safety Valves
_____ Check for blockage on the outlet.
_____ Check that all vent pipe supports have been installed in accordance with
recommendations.
_____ Verify all valves for manufacturer's settings (set pressures as shown on valve tag).
Others
_____ Check proper alignment on all ducting and expansion joints.
_____ Check all sliding pad installations to ensure proper movement.
_____ Check that all temporary shipping supports and temporary bolting has been removed.
(Normally these temporary items are painted with yellow or red paint.)
_____ Remove any structural timber from gas passages. Please note that some wood, tape, etc.
can remain in the gas passages, to be burned out during firing of the unit.
_____ Check that all temporary shipping gaskets, manways, and handholes, have been properly
removed. The temporary gaskets allow internal inspections of the equipment prior to
operation.
_____ Check that all normal service gaskets, for the manways, handholes, ducts, and pipe
flanges, have been installed and have been properly torqued.
When the inspection is completed and all problems have been corrected, then the system can be subjected to its final testing before pre-commissioning and start-up.