| Standard Operating Procedure | SOP No. |
| --- | --- |
| Start-Up Procedure & Verification for Boilers | 8.036 |
|  | Effective: 6/14/99 |
| DCR No.: 98215 | Supersedes: New |
| Revision No.: New | Revision Date: New |
|  | Page No.: 1 of 8 |

## 1

## Purpose

1.1 Provide a standard procedure for start-up and commissioning of HVAC
equipment.

1.2 Provide a standard procedure for coordinating selection, receiving, check
out, and acceptance of new equipment.

## 2

## Scope

2.1 This procedure applies to (but is not limited to) the following types of
equipment: Hot Water Steam and Steam for Humidification Boilers.

## 3

## Responsibility

3.1 Project Managers have overall responsibility for new equipment from
procurement to start-up. To assure optimum selection of equipment and
smooth commissioning, the Project Manager is responsible for
coordinating the following activities:

3.1.1 Review of customer and specific job specifications.

3.1.2 Review of equipment selected with Service prior to ordering.
Assure equipment is on approved list.

3.1.3 Review drawings, assure drawing schedules, and equipment
details are correct.

3.1.4 Coordinate delivery and commission schedule with all team
members including (but not limited to): Site Foremen, Balance and
Service (start-up), Customer, General Contractor, and Safety (as
needed).

3.1.4.1 In most cases, Start-up should be scheduled a month in
advance.

3.1.4.2 If exact date is known, Service should be notified with
estimated time frame.

3.1.4.3 Communicate specific requirements to all team players in
writing and verbally.

3.1.4.4 Provide appropriate job number to team members.

3.2 Therma Service/Start-up has responsibility for the following activities:

3.2.1 Therma will provide a qualified service mechanic to perform
equipment start-up.

3.2.2 The start-up technician will perform the start-up tasks as specified
in the commissioning Standard Operating Procedure for that
equipment.

3.2.3 Service will provide estimated time required to Project Manager
(PM) prior to start-up. Service will meet agreed upon schedules to
assure customer satisfaction.

3.2.4 The start-up technician will fully complete a start-up sheet for each
piece of equipment. A copy of this sheet will be provided to the
Project Manager with the turnover documents: A second copy will
be filed in service by customer name and address.

3.2.5 All time will be charged to the appropriate job number as specified
by the Project Manager. If requested, Time and Material sheets
shall be completed.

3.3 The Start-up/Commissioning Coordinator has responsibility for the
following activities:

3.3.1 Provide a communication path between the Project Manager and
the Field Foremen.

3.3.2 Schedule qualified personnel for start-up, balance, test, and room
certification as required.

3.3.3 Coordinate punch-list completion with Project Managers.

3.3.4 Coordinate start-up, service, balance, and test report
documentation.

## 4

## Procedures

4.1 General: Service Technician is responsible for filling out start-up sheet
FN 8.036.1 for Boiler. A start-up sheet will be completed for each piece of
equipment. Each sheet requires the following information:

4.1.1 Job identification: The job name, job number, and job address are
to be completed by the start-up/commissioning coordination.
These will be provided to the service technician.

4.1.2 Section 5 - Equipment Description.

4.1.3 Section 6 - Equipment Pre-Installation Inspection.

4.1.4 Section 7 - Equipment Installation Inspection.

4.1.5 Section 8 - Operational Inspection.

4.1.6 Signature - As each section and page is completed, the Service
Technician must print and sign his/her name and record the date.
This document should also be signed off by an owner
representative when required.

## 5

## Equipment Description

5.1 This section should be completed by the Service Technician. Any design
documentation specifying equipment should be recorded in this section.
This includes: Specification number, Submittal number, Process and
Instrumentation Diagram number, and Drawing number. Also, record
which area this equipment will be serving.

5.2 Fill in the “design” column, record the following information as specified
on the design documents.  Unit Tag number (per drawings) Manufacturer
(per equipment schedule and/or  approved submittals) Model number (per
equipment schedule and approved submittals)

## 6

## Equipment Pre-Installation Inspection

6.1 For each of the following items: Check Yes, No or N/A for not applicable.
If No is checked, describe the difference in the comment section and
notify the Project Manager immediately. Initial and date each item as it
is checked.

6.2 Nameplate data matches vendor specifications. When the equipment is
delivered, verify it matches specifications. Complete Section 5. In the
“actual on site” column, record the actual data as shown on the
equipment and verify that it matches design criteria.

6.3 All parts are received and verify the packing slip(s).

6.4 Inspect for visible signs of damage, leak, or defective parts. Note any
discrepancies and notify the Project Manager.

6.5 Verify electrical service for correct voltage, current and thermal overload
protection.

6.6 Operation and Maintenance (O&M) manual is available in the field.

6.7 Start up technicians reviewed factory start up procedures in the Operation
and Maintenance manual.

## 7

## Installation Inspection

7.1 For each of the following items: Check Yes, No or N/A for not applicable.
If No is checked, describe the difference in the comment section and
notify the Project Manager immediately. Lock Out/Tag Out procedure
should be observed before most of the following steps.

7.2 Unit is installed level in approved room and properly protected from
weather and drafts. Approved room generally includes fire rated walls and
ceilings, concrete floor, etc. If equipment is installed outdoors it should be
rated as such.

7.3 No negative pressure in the approved room. Approved room generally
includes gravity ventilation ducts to eliminate chance of negative
pressure. Negative pressure causes boiler to malfunction and flue gas to
be pulled into room.

7.4 Proper air openings are provided. Gravity vents, ducts and or door
louvers are required to have proper air openings.

7.5 Unit is installed level on a concrete floor or non-combustible base. Check
Operation and Maintenance literature: some equipment needs to be level
to 1/8” or better to allow proper drainage and or operation.

7.6 Tag number is attached to the unit. Tag should be attached to service
disconnect or near unit identification plate, if mounted in a ceiling system
tagging should reflect location above or below.

7.7 Service clearance is adequate for maintenance. Service clearance
includes access to the equipment through the ceiling systems, over duct
work etc. Filter access for removal and replacement are essential.

7.8 Proper earth ground is connected to green ground screw in panel. Check
Operation and Maintenance literature.

7.9 Relief valve type, setting, and capacity are correct. Check Operation and
Maintenance literature.

7.10 Gas lines are bled of air.

7.11 Draft hood or barometric damper is installed. Check Operation and
Maintenance literature.

7.12 Vent stack is proper height and size. Check Operation and Maintenance
literature and mechanical drawing details.

7.13 Unrestricted vent cap on top to protect from weather and down drafts.
Check Operation and Maintenance literature.

7.14 Gas inlet piping is properly installed. Check Operation and Maintenance
literature and mechanical drawing details.

7.15 Main and pilot gas valves are installed. Check Operation and Maintenance
literature and mechanical drawing design.

7.16 Hot water supply outlet is proper size. Check Operation and Maintenance
literature and mechanical drawing design.

7.17 Hot water return inlet is proper size. Check Operation and Maintenance
literature and mechanical drawing design.

7.18 Make up water supply has proper shut-off and back flow device. Boilers
or any other equipment with make-up water generally is fed by (an
individual or a industrial water loop) a back flow prevention device to
eliminate treated water getting back into potable water.

7.19 Drain valve is installed. In boiler and related piping for maintenance.

7.20 Temperature and pressure gauges are installed. Check Operation and
Maintenance literature and mechanical drawing design.

7.21 High limit and operating controls are installed. Check Operation and
Maintenance literature and mechanical drawing design.

7.22 Tube surfaces are inspected. Check Operation and Maintenance literature
and mechanical drawing design.

7.23 Make-up water pressure regulator are installed. Check Operation and
Maintenance literature and mechanical drawing design.

7.24 Expansion tank is installed. Check Operation and Maintenance literature
and mechanical drawing design.

## 8

## Operational Inspection

8.1 Use Operation and Maintenance literature and follow start up procedures
the form FN 8.036.1 is a general out line and is to provide a quality
assured start up when used in conjunction with the Operation and
Maintenance literature. If there are any discrepancies, notify the Project
Manager immediately.

8.2 Unit vibration is acceptable. Check Operation and Maintenance literature
for tolerances. Check for vibration at different fan speeds and volumes.
Check unit, check around unit and below roof under unit.

8.3 Heating components perform per manufacturer’s specification. Check
Operation and Maintenance literature: verify all safety controls, operating
controls, ignition controls, pilot flames, and vent fans (blowers).

8.4 Natural gas supply pressure is at manufacturer’s specification. Check
Operation and Maintenance literature: use mag gauge or natural gas
pressure gauge to verify. Typically these units require 7”-14” w.c. inlet
pressure.

8.5 Manifold pressure is at manufacturer’s specification. Check Operation
and Maintenance literature: use mag gauge or natural gas gauge to
verify. Typically these units run from ½” w.c. on low fire to 5” w.c. on high
fire.

8.6 Make sure thermostat is set. Operate (or have operated) temperature
controls to ensure all functions and set points.

8.7 Record start up operating parameters in the Supplementary form(s),
FN 8.028.2 and FN 8.028.3. Use as many of the Supplementary forms as
necessary to complete Boiler start-up form FN 8.036.1.

## Document Approval

Service Manager

S-18 Date

Service Supervisor

Quality Assurance Manager

5-28-99

Date