The Essential Steps of a Commercial Boiler Installation

What constitutes a successful boiler installation is all in the planning. A commercial boiler installation planned well is half completed. Below are what we consider the absolute essential steps to every boiler installation.

The first step to planning a commercial boiler installation is always determining the output required of the boiler or boilers. Often when we are replacing like for like we can simply match or slightly increase on the output of the existing boilers. Otherwise we need to prepare a heat loss for all the areas of the building the boiler will be heating and include for any hot water cylinders or plate heat exchangers. Alternatively it could be determined by adding up the output of all the emitter’s that it supplies and adding an allowance for losses in the pipework runs.

The second step is to look at the natural gas supply. Is the meter adequately sized to provide enough gas for the output of the new boilers? Also, is the size of the gas pipework large enough to provide the correct gas pressure the boilers will need taking into consideration the length of the run?

The third step is to look at the feasibility of the installation. What are the options for the flue route? Is there a drain nearby for the condensate waste? How much space do we have? What’s the access like for getting the new boilers in? Can we easily connect onto the existing heating pipework? Do we need a plate heat exchanger to separate the new boilers from the system? What existing controls are we connecting onto or does the system need new controls? Do we need a pressurisation unit and expansion vessel? Does the plantroom require new lighting?

Once the above questions have answers we can put a plan in place and come up with a brief programme of works. Changeovers may need to be planned in if down time is not a possibility. We also produce a risk assessment with a method statement to ensure that the team carrying out the works know the plan and are aware of the risks involved and can mitigate those risks. With a plan in place we can order the new boilers and all the materials required to complete the installation. Materials for larger installations may need to be ordered in stages or stored at our warehouse if there is a lack of storage space on site.

Its them time to implement the plan. We begin by isolating the equipment starting with the gas and removing the existing plant safely. once the area has been cleared and swept we can bring in the new kit.

First we get the new commercial boiler into position. we can then start piping this in and connecting on to the existing system. Once this is done its time to install the flue. This may require scaffold which will need to go up first. Then there are the electrical works and connecting on to the controls system.

Finally we have all the making good. This can include insulating the pipework, painting the plantroom floor, making good around any new holes such as for pipework or the flue.

Then the boiler needs to be commissioned into service. This includes analysing the flue gases to ensure that they are at a safe level. It may require adjustments to the gas valve to achieve this. We also check over the whole insulation to ensure its to the manufacturers instructions and that it is running satisfactorily.

Then all there is left to do is to fill in the paper work for the gas safety certificate and the warranty and your new boilers are all good to go.