Boiler Installation Checklist From The Boiler Experts

Installing a boiler is a complex process that requires attention to detail, compliance with safety standards, and adherence to manufacturer guidelines. Choosing the right company to assist you is key! The following boiler installation checklist, is informed by industry best practices and resources like the ABMA and the National Board of Pressure Vessel Inspectors. As always, follow manufactures recommendations when in doubt.

1. Pre-Installation PreparationBoiler Installation Action Shot

Site Evaluation

  • Verify the structural integrity of the boiler room floor and foundation. Many boilers weigh upwards of 100,000 lbs when in operation.
  • Ensure adequate space for installation, operation, and maintenance. Clearances must meet jurisdictional requirements or manufacturer specifications.
  • Confirm the room meets fire safety, ventilation, and thermal expansion requirements.

Permitting and Compliance

  • Obtain all necessary permits before beginning installation.
  • Review and adhere to local building codes, environmental regulations, and insurance requirements.

Boiler Selection

  • Select a boiler appropriate for the intended application (e.g., steam or hot water, capacity, and efficiency).
  • Verify the boiler’s specifications match your facility’s needs.

2. Combustion Air and Fuel

Combustion air vent for boiler room

Air Supply

  • Ensure the boiler room has adequate openings for combustion air per industry standards. Confirm openings are sized for peak demand and prevent negative pressure.
  • Install motorized dampers if required and verify no obstructions block ventilation pathways.

Gas Supply

  • Use proper materials (e.g., black iron pipe) and fittings for gas lines.
  • Test gas pressure to confirm it meets the boiler’s operating requirements.
  • Install manual shutoff valves and sediment traps.

Oil Supply

  • Verify proper sizing of oil supply lines and confirm compatibility with the burner.
  • Ensure oil lines are free of air and properly primed before startup.

3. Water and Steam Piping

Feedwater System

  • Ensure proper sizing and material selection for feedwater piping.
  • Install check valves and isolation valves where required.
  • Boilers with over 500 sq. ft. of water heating surface must have two independent feedwater methods unless specific exceptions apply. (ASME BPV Code Section I)

Blowdown SystemMan performing boiler blowdown

  • Install blowdown piping to facilitate regular boiler maintenance.
  • Ensure piping is routed to a disposal system that can handle high discharge temperatures.

Pressure Relief Valve

  • Mount the pressure relief valve vertically on the highest part of the boiler before any control valves.
  • Confirm safety valves comply with ASME BPV Code requirements:
    • Steam Boilers (Section IV): Set pressure not exceeding 15 psi, inlet size NPS ½–4½.
    • Hot Water Boilers (Section IV): Set pressure at or below MAWP, inlet size NPS ¾–4½.
    • Safety valve discharge capacity must exceed the boiler’s maximum steam output.

Condensate Return

4. Electrical and Control Systems

Power Supply

  • Verify the electrical service matches the voltage and amperage requirements of the boiler.
  • Confirm proper grounding to prevent electrical hazards.

Control Wiring

  • Install all wiring per NEC standards and manufacturer instructions.
  • Verify the proper operation of control systems, including safety interlocks and alarms.
  • For automatically fired boilers:
    • Install two pressure controls: one operating control and one high-limit control with manual reset (if jurisdiction requires).

5. Venting and Exhaust Systems

  • Design and install the venting system to handle the boiler’s flue gas volume and temperature.
  • Use corrosion-resistant materials for flue piping.
  • Verify proper draft conditions to ensure safe and efficient operation.
  • Install draft control devices, such as barometric dampers, if necessary.

6. Safety Systems

  • Test the operation of safety interlocks, including low-water cutoffs and flame safeguard systems.
  • Install high-limit pressure and temperature controls, ensuring proper calibration.
  • Ensure safety devices are accessible for testing and maintenance.
  • Ensure the emergency shutdown system is installed and tested.

7. System Start-Up and TestingFront of limpsfield burner

Hydrostatic Testing

  • Perform a hydrostatic pressure test to confirm the integrity of the boiler and piping systems (usually 1.5 times the maximum allowable working pressure (MAWP))

Combustion Analysis

Operational Testing

  • Test the boiler under full-load conditions to verify all systems operate as intended.
  • Document all test results and address deficiencies.

8. Post-Installation and Training

Documentation

  • Provide the owner with operation manuals, warranty details, and maintenance schedules.
  • Record and archive test results, installation diagrams, and as-built plans.

Training

  • Train operators on basic boiler operation, emergency shutdown procedures, and routine maintenance tasks.
  • Conduct a safety briefing on handling fuel systems and pressure components.

Boiler Installation Checklist Conclusion 

This checklist gives you industry best practices to ensure the safe, reliable, and efficient operation of your boiler system. Regular maintenance and monitoring after installation will further enhance system longevity and performance. For specific guidelines, consult Rasmussen Mechanical Services and your boiler manufacturer’s documentation.

Boiler maintenance checklist download