5.3102.19 Replacement of Steam Boiler

Topic: 
Hydronic Heating (Hot Water and Steam)
Subtopic: 
Equipment Installation
Desired Outcome: 
Proper installation and operation of new boiler
For supporting material, see Referenced Standards.
TitleSpecification(s)Objective(s)
5.3102.19a
Assessment

Confirmation of the scope of work will be made for the following:

  • Clearances
  • Proper drainage in boiler room
  • Flue/chimney conditions
  • Electrical capacity
  • Oil/gas availability
  • Piping connections

Verify scope of work

5.3102.19b
Boiler size calculation

For one-pipe steam system, radiation survey will be completed, and appropriate piping and pickup factor (e.g., insulation, water volume, return line configuration) will be incorporated

For two-pipe steam system:

  • Heat load calculations will be confirmed based on ACCA ACCA Air Conditioning Contractors of America, www.acca.org Manual J (for residential applications), Manual N, or ASHRAE ASHRAE American Society of Heating, Refrigerating and Air-Conditioning Engineers, www.ashrae.org equivalent (for commercial applications) and ASHRAE ASHRAE American Society of Heating, Refrigerating and Air-Conditioning Engineers, www.ashrae.org Std 183 (for high rise application)
  • Radiation survey will be completed, and appropriate piping and pickup factor (e.g., insulation, water volume, return line configuration) will be incorporated

Sizing will be confirmed for combined space heating and domestic hot water plant

Enable proper sizing of the heating appliance

5.3102.19c
Removal of condensate tank

The selection of the boiler will be influenced/dictated as to whether the condensate tank could be eliminated from the system

Selection will be based on:

  • Elevation of normal operating water level
  • Placement of the low water cutoffs
  • Elevation of lowest horizontal steam piping
  • Useable water volume of boiler

Lower cost while optimally designing system with fewer components

Ensure proper design considerations to eliminate the need for the condensate tank and associated steam traps

5.3102.19d
Mass selection

Systems will be selected with higher mass heat exchangers

A higher water volume boiler will be selected to ensure elimination of condensate return tanks (see also SWS 5.3102.19 Replacement of Steam Boiler)

Ensure longer life and improved durability of equipment

Ensure the ability/option to remove condensate return tanks

5.3102.19e
Multiple boilers/sequencing

Multiple boiler system controls will be equipped with lead-lag and sequencing capabilities

Systems will be set up to demonstrate/ensure optimal sequencing, and lead-lag will be accomplished

Ensure highest efficiency and performance of the systems

Ensure boilers do not short cycle

5.3102.19f
Fuel switching

Chimney will be assessed for proper sizing, lining, and draft

Ensure equipment and system components are compatible with new fuel

5.3102.19g
Hazardous material removal

Health concerns in the removal and replacement of equipment will be identified

Written notification of hazardous material will be provided to the property manager/occupant

Contact information for the regional EPA EPA U.S. Environmental Protection Agency, www.epa.gov asbestos coordinator will be provided

Asbestos abatement will be conducted by an EPA EPA U.S. Environmental Protection Agency, www.epa.gov -certified contractor before decommissioning and replacement

Property manager/occupant will be asked to contract with an EPA EPA U.S. Environmental Protection Agency, www.epa.gov -certified asbestos contractor to conduct asbestos removal

Remediate health hazards using EPA EPA U.S. Environmental Protection Agency, www.epa.gov -certified contractors

5.3102.19h
Decommissioning

Accepted industry procedures and practices will be followed to:

  • Remove old boiler and associated components
  • Seal any unused chimneys
  • Remove unused oil tank, piping, valves, and associated equipment

Ensure worker and occupant safety

Provide timely and efficient removal of old equipment

5.3102.19i
New equipment installation

New boiler and associated components will be installed to accepted industry procedures and practices; in instances where conflicts occur between the code and the manufacturer's installation instructions, the more restrictive provisions shall apply (IPC 101.3 and UPC 101.2; IPC 301.7 and IPC 101.4)

Concrete pads will be in accordance with the Uniform Mechanical Code and local building codes

All required operating and safety controls and boiler trim will be installed and set up in accordance with manufacturer and local code requirements

Near boiler piping will be installed in accordance with the manufacturer's recommendation

All existing and new uninsulated steam, domestic hot water, and condensate piping in the boiler room will be insulated to code minimum

Water meter will be installed on the makeup water/incoming line to the boiler so that it is capable of metering all water coming into the boiler, including both automatic feed or manual feed; this water meter should not be capable of being bypassed

Boiler will be installed so that it does not cause water hammer or overfilling

Isolation valves will be installed to allow for pressure testing of the boiler

Hydrostatic testing (for site-built boiler) will be performed to confirm there are no water leaks in the boiler

Ensure worker and occupant safety

Ensure optimal operation of the equipment

Ensure site-built boiler does not leak

5.3102.19j
Flushing of system

Isolation valve will be installed at the lowest point and immediately upstream of the Hartford loop

Flush valve will be located upstream of newly installed isolation valve

With the isolation valve to boiler closed and flush valve open, system will be run until drain water runs clear

Protect new and remaining equipment

Conform to performance efficiency

5.3102.19k
Startup/skimming of boiler

In accordance with manufacturer specifications, the new boiler will be flushed and skimmed before steam is released to the building for the first time

Proper startup will be done in accordance with manufacturer specifications

Steady state combustion efficiency and safety testing will be performed at multiple firing rates; a minimum of two tests, one at high fire and one at low fire, will be performed for low-high-low burner, and a minimum of three tests (low fire, medium fire, and high fire) will be performed for fully modulating burners

Remove impurities

Ensure longevity of equipment

Ensure occupant safety

Conform to performance efficiency

5.3102.19l
Education

Completed work will be reviewed with the building/property management team and operations staff

Building/property management team and operations staff will be educated on the safe and efficient operation and maintenance requirements of the installed item

Ensure building/property management team and operations staff is informed of the safe, efficient operation and maintenance requirements of the installed item