C

STEAM SYSTEM DESIGN

AND COMMISSIONING GUIDANCE

PRECOMMISSIONING CHECKLIST

The following activities should be completed prior to attempting to commission the

steam system.

1. Boiler installation
______ Ensure SRV and SRV tail pipes on each boiler vented to outside
boiler room.
______ Ensure sight glass assemblies and pressure gauges are installed on
each boiler.
______ Ensure combustion air ducting and hot exhaust venting are installed.
______ Ensure fuel train assemblies are installed on each boiler.
______ Ensure blowoff valves/piping is installed on each boiler to blow off
separator.
______ Ensure main power supply to boiler panel(s) is installed.
______ Ensure steam outlet valves and piping are installed to main steam
header.
______ Ensure boiler feed water line is piped to the boiler(s).
2. Feed water tank installation
______ Ensure tank sight glass and thermometer assemblies are installed.
______ Ensure level control system is installed.
______ Ensure preheat steam source/controls are installed.
______ Ensure condensate return piping to the tank is installed to tank.

Process Steam Systems: A Practical Guide for Operators, Maintainers, and Designers,
First Edition. Carey Merritt.
© 2016 John Wiley & Sons, Inc. Published 2016 by John Wiley & Sons, Inc.
294 STEAM SYSTEM DESIGN AND COMMISSIONING GUIDANCE

______ Ensure tank is vented to atmosphere (for DA, make sure you can see
vent plume).
______ Ensure feed water pumps and controls are installed and piped to the
boiler.
______ Ensure makeup water source is piped to the tank.
3. Blowoff separator installation
______ Ensure blowoff separator vent line is installed in a safe manner.
______ Ensure blowoff separator drain line is installed to a safe location.
______ Ensure blowoff drain water is cooled to less than 140°F, manually or
automatically.
4. Water treatment system installation
______ Ensure boiler blowdown scheme will keep the boiler TDS at or below
the warranty limits.
______ Ensure the boiler has ample corrosion, fouling, and scaling protection
via chemical or nonchemical means.
______ Ensure there is a boiler sample valve installed.
5. Steam delivery system installation
______ Ensure steam boiler outlets are piped to the main steam header.
______ Ensure all valves and sensors are installed in the steam piping.
______ Ensure there is a means to dump steam for boiler testing and over
pressure protection.
6. Condensate system installation
______ Ensure all steam using equipment is trapped.
______ Ensure the condensate return lines all cascade to a collection tank or
the condensate is discarded.
______ Ensure there are sample locations installed in the condensate lines.

STEAM SYSTEM COMMISSIONING DATA SHEETS

Date__________ Job No._______________ Owner/Client _________________

Commissioning Engineer_______________________

1. As‐found conditions: This is where the material condition, room ambient

conditions, installation discrepancies, workmanship, safety concerns, utility
service concerns, piping orientation concerns, missing equipment, and any
other system performance concerns are documented.
______________________________________________________________
______________________________________________________________
______________________________________________________________
STEAM SYSTEM COMMISSIONING DATA SHEETS 295

______________________________________________________________
______________________________________________________________
______________________________________________________________
______________________________________________________________
______________________________________________________________
_________________________________________________________

2. Commissioning the steam generator

a.  Verify proper fuel train/supply for rated load.
b.  Verify combustion creates blue (gas) yellow‐blue flame (oil) for high and
low fire outputs.
c.  Verify pre‐ and postpurge times are per manufacturer’s recommendations.
d.  Use test fire data or perform a performance test to verify rated output is
within 10% of nameplate stamping.
e.  Verify SRV settings are less than or equal to generator MAWP.
f.  Verify water level remains visible in the sight glass during operation.
g.  Verify low water cutoff, high pressure, combustion air, and fuel pressure
switches have been tested satisfactory.
h.  Verify the steam outlet will yield steam flows less than 5000 ft/min at rated
output.
i.  Verify blowdown scheme will keep the boiler solids level within warranty
limits.
j.  Verify each generator connected to a common steam header has high water
protection.
k.  Verify the operating pressure switch is set at least 10% below the high
pressure switch set point.
l.  Verify the steam generator will be able to build and maintain the desired
pressure during normal and peak load operation.
3. Commissioning the steam delivery system
a.  Verify the steam main is sized for steam velocities 6000–8000 ft/min.
b.  Verify the steam main has a trapped drip leg installed.
c.  Verify the steam main has a vacuum breaker/air vent installed.
d.  Verify PRV stations have been installed with all the recommended
equipment.
e.  Verify any installed sensors are located at least 10 pipe diameters from a tee,
elbow, or valve.
f.  Verify the steam mains are sloped in the direction of steam flow.
g.  Verify each piece of steam using equipment has an isolation valve.
4. Commissioning the feed water system
a.  Verify the tank has at least 10 min worth of water storage based on rated
boiler output.
296 STEAM SYSTEM DESIGN AND COMMISSIONING GUIDANCE

b.  Verify the feed water tank (for pressurized DA only) is being maintained at
3–5 psig and the stored water temperature corresponds to that pressure.
c.  Record the feed water tank temperature (for atmospheric tanks) and deter-
mine the residual oxygen concentration.
d.  Verify the residual oxygen is rendered harmless by water treatment chemical
additions.
e.  Verify the makeup water level control system keeps the feed water tank
level within the sight glass visible range.
f.  Verify the feed water pumps operate without cavitation and are able to keep
the boiler(s) full of water.
g.  Verify the feed water pump discharge pressure puts the pump operation in
the correct part of the pump curve.
h.  If the feed water tank is equipped with a steam injection system, verify the
steam injection is adjusted to keep the tank greater than 190 and less than 210°F.
i.  Verify the tank can be drained to a safe location.
5. Commissioning the condensate system
a.  Verify condensate traps of the right size and type are installed for each piece
of steam using equipment.
b.  Verify there are condensate drain valves installed that will allow cold con-
densate to be drained during startup periods.
c.  Verify the steam traps are functioning properly and not causing water log-
ging of the steam equipment.
d.  Verify the condensate receivers and pumps are functioning properly.
e.  Verify the surge tank (if installed) is logic tied to the feed water tank and
level control is being maintained in both.
f.  Verify adequate temperature sensors/gauges are installed to allow for steam
trap performance monitoring.
6. Commissioning the water treatment systems
a.  Verify the boiler blowdown scheme is keeping the boiler solids level within
warranty limits.
b.  Verify the boiler oxygen level is being maintained at less than .005 cc/l.
This can be done by showing a residual level of oxygen scavenging chemical
in the boiler.
c.  Verify the chemical feed pumps and tanks are installed and being operated
by competent operators.
d.  Verify the chemical feed pumps are delivering enough water treatment
chemicals to the steam system to protect the equipment.
e.  Verify each chemical storage tank is clearly labeled with the chemical
contained in the tank.
f.  Verify there is a safety shower/eyewash station in the vicinity of the
chemical treatment area.
STEAM SYSTEM DESIGN CHECKLIST 297

STEAM SYSTEM DESIGN CHECKLIST

Steam Load
1. Calculated load Btus / 34,500 Btu/bhp = __________ BHP
2. Pick up losses (30%), total steam requirement is BHP × 1.3 = __________
BHP

Boiler Design Specifications

1. Pressure vessel MAWP ___________psig Operating pressure___________
psig
2. Heating surface area ____________ft2/bhp (>3 ft2/bhp recommended)
3. Water content ____________gallons at normal full level
4. Steam exit velocity ___________ (<5000 ft/min at the operating pressure)
5. Boiler type _______________
6. Number of boilers _____________ (if >1, recommend a lead lag system)
7. Boiler external piping hydro test required? ____ Yes _____ No
8. SRV’s capacity/set points _______________ @ _______ pressure

Burner/ Input Requirements

1. Fuel type ___________(NG/LP/#2 Oil/ #6 oil/coal/wood chips, electrical,
others)
2. Fuel usage at rated output _______________ @ pressure ___________
3. Boiler turndown _________________
4. Combustion air requirement _____________ CFH
5. Fuel/air control ____________ (i.e., mechanical linkage, servomotors or
fixed)
6. Boiler vent pressure requirement __________ inches WC at rated output

Boiler Room Design Considerations

1. Electrical power required _____________ amps @ _________ voltage
2. Fresh air openings _______ ft2 (1″/4000 Btu input)____N/A, sealed combustion
3. Fuel line venting ___________ # lines @ ______ size
4. Water supply pressure and flow rate requirement __________ gpm @ ______
psig
5. Fuel line size required _____________
6. Boiler vent classification (i.e., I, II, III, IV)__________, size __________ in
7. Vent construction ______________________ Rise/run ___________
298 STEAM SYSTEM DESIGN AND COMMISSIONING GUIDANCE

8. Boiler blowdown rate

a.  Condensate return % ______________
b.  Boiler estimated blowdown rate _______________ gpm
c.  Cooling water requirement ____________gpm
9. Boiler room heat generation calculation
a.  Boiler radiant heat losses ___________Btu/h
b.  Uninsulated hot surface heat loss _______________ (@ 3 Btu/ft2‐ΔT)
10. Electrical disconnect/e‐stop installed ______Yes _____No

Feed Water Tank Design Considerations

1. Feed water tank working volume ___________gallons
2. Feed water tank full volume _______________gallons
3. Tank stand height _______________ft above level floor
4. Tank construction _________ (SS, CS) ___________gauge ______ × _____
size
5. DA type _______ (spray or tray) _______ .005 cc/l or .05 cc/l _______
Atmospheric
6. Tank operating level control type ____________________________
7. Tank low water cutoff control type ___________________________
8. Tank preheat system type ________________ sized for ____________lb/h
steam (kW)
9. Makeup water source __________________ maximum M/U rate
_____________gpm
10. Number of feed water pumps________________ type _________________
11. Pumps ________on/off __________ continuous run __________ VFD motors
12. NPSHA calculated ____________________________
13. Pump flow rate ___________gpm @ ___________psig with _________ft
NPSHR
14. Chemical quills installed ___________ (1 or 2) location _____________on
the tank
15. _________sight glass _________magnesium anode _______ tank insulation

Blowdown System Considerations

1. __________Blowoff separator included __________ Model __________
2. ASME rating _________ Construction CS/SS ______________
3. Cooling kit ____________ automatic TCV _____________ manual valve
4. _________sight glass installed on BO separator
5. Boiler bottom blowdown valves ___________type ______number
STEAM SYSTEM DESIGN CHECKLIST 299

6. ____________Surface blowdown system installed

7. Surface BD _________ automatic or ___________ manual
8. ______________conductivity based __________ timer based
9. Boiler EER calculation _________________________________________
10. Boiler COC calculation_______________________________________
11. Boiler total BD rate to meet COC ___________________________________

Steam Delivery System Considerations

1. Steam main size ________________ yields _____________ft/min steam flow
2. Multiple boiler high water protection method _________________________
3. __________PRV station __________ pressure to __________ pressure
4. ____________model PRV ____________size PRV
5. ____________ No. air vents installed ____________________________
6. ______________ Drip legs installed one every __________feet
7. Steam piping insulation spec _____________________________________
8. Type of control valves ______________________________

Condensate Collection System Considerations

1. Condensate line sizes_______________________________________
2. Steam trap type/sizes ______________________________________
3. ________pump traps ____________________ model, Air/steam pressure
___________________psig
4. ______________electric condensate collector ____________________pumps
5. Surge tank size _____×______ construction CS/SS ________ gauge
________ASME
6. ST pumps __________ Model___________ Capacity ___________gpm @
_____TDH
7. ST level control system__________________________________________
8. ST fresh make up rate estimate __________________gpm

Water Treatment Considerations

1. Corrosion protection scheme _____________________________________
2. Fouling protection scheme ________________________________________
3. Scaling protection scheme ________________________________________
4. No. of chemical feed systems___________ Tank sizes ____________
5. Pump rates _____________gph @ _________TDH, Model ______________
6. Makeup water rate _______________gpm ___________ °F temperature
300 STEAM SYSTEM DESIGN AND COMMISSIONING GUIDANCE

7. Makeup water treatment scheme __________________________________

8. RO size _________ gpm with __________ gpm permeate _________gpm
concentrate
9. Softener sizing ______________ Duplex or simplex____________ M/U water
______________gpg
10. Softener grain per day removal calculation ____________________________
_________________
11. Softener tank sizes _____________ Brine storage tank size _____________
12. Softener inlet water connection size _____________ inch