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dti
1)epartmenc of Trade and Industry
Boilers

CIBSE Commissioning Code B

 The rights of publication or translation are reserved.

No part of this publication may be reproduced, stored in a

. retrieval system or transmitted in any form or by any means
without the prior permission of the Institution.
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0 November 2002 The Chartered Institution of Building

Services Engineers London

Registered charity number 2781 04

ISBN 1 903287 29 4

This document is based on the best knowledge available at

the time of publication. However no responsibility of any
kind for any injury, death, loss, damage or delay however
caused resulting from the use of these recommendations can
be accepted by the Chartered Institution of Building Services
Engineers, the authors or others involved in its publication.
In adopting these recommendations for use each adopter by
doing so agrees to accept full responsibility for any personal
injury, death, loss, damage or delay arising out of or in
connection with their use by or on behalf of such adopter
irrespective of the cause or reason therefore and agrees to
defend, indemnify and hold harmless the Chartered
Institution of Building Services Engineers, the authors and
others involved in their publication from any and all liability
arising out of or in connection with such use as aforesaid
and irrespective of any negligence on the part of those
indemnified.

Typeset by CIBSE Publications Department

Printed in Great Britain by Page Bros. (Norwich) Ltd.,

Norwich, Norfolk, NR6 6SA

Note from the publisher

This publication is primarily intended to provide guidance to those responsible for the
design, installation, commissioning, operation and maintenance of building services. It is
not intended to be exhaustive or definitive and it will be necessary for users of the guidance
given to exercise their own professional judgement when deciding whether to abide by or
depart from it.
 Foreword
As Technical Director of the Carbon Trust, I am delighted to have been invited to write the
foreword to CIBSE Commissioning Code B. Commissioning of buildings and building
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services is vitally important to the safe and energy efficient operation of buildings but it is
not always carried out - or carried out systematically. The CIBSE Commissioning Codes
set out clearly and systematically the steps required to commission buildings and building
services in a proper and timely manner. This key step in the life of the building enables the
system to operate as it was designed to do, and, coupled with good maintenance practice,
helps provide building occupiers with a safe, good quality, comfortable internal environ-
ment delivered energy efficiently.

Boilers and their associated equipment and controls have evolved dramatically over the
25 years since the last edition of this Code, and it has therefore been comprehensively
rewritten to reflect modern technology and statutory changes. The chance has also been
taken to reflect the growing realisation that many key decisions relating to the construction
process are taken in the very early stages of a project. The Code therefore gives the strongest
encouragement to designers and clients to consider commissioning and to seek specialist
input at the earliest stages of a project.

CIBSE Commissioning Code B presents current standards of good commissioning practice

in the form of recommendations and guidance. The Code acknowledges that it may be
applied in a variety of contractual frameworks. Users will need to ensure that the use of the
Code is considered when contractual arrangements are being made, to ensure that the
recommendations of the Code are not in conflict with those of the contract.

The Carbon Trust fully supports the development of good practice guidance for building
professionals. Buildings in the UK account for around 45% of energy demand and therefore
are a key target for action to improve energy efficiency and reduce carbon emissions. The
objectives of the Carbon Trust are: to ensure that UK business and the public sector meet
ongoing targets for carbon dioxide emissions; to improve the competitiveness of UK
business through resource efficiency and to support the development of a UK industry
sector that capitalises on the innovation and commercial value of low carbon technologies.
The Carbon Trust therefore welcomes the publication of this new Code, seeking as it does
to enable UK boiler manufacturers and installers to supply and fit systems which are more
effective and which have a lower carbon footprint over the lifetime of the plant. Everyone
has to play their part to help the UK move to a low carbon economy: this CIBSE
Commissioning Code ensures that the necessary information is available to key profes-
sionals responsible for energy use in buildings.

David Vincent
Technical Director, The Carbon Trust

Authors

J Armstrong (consultant)
G T Machin (consultant)

Commissioning Code R Steering Group

Bryan Franklin Chairman
Peter Davey (Haden Young)
Peter Day
Mike Duggan (Federation of Environmental Trade Associations (FETA))
Andrew Ford (Fulcrum Consulting, for DTI)
Gordon Hudson (University of Northumbria)
Stephen Laws (Clyde Boilers)
Martin Lowe (Commissioning Specialists Association)
George Moss (C R Burgess Commissioning Ltd.)
Kevin Pennycook (BSRIA Ltd)
Dr Hywel Davies (CIBSE Research Manager)

CO-ordinating editor

Dr Hywel Davies
 Editor
Ken Butcher

CIBSE Publishing Manager

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Jacqueline Balian

Acknowledgements
This work was part funded by the Department Trade and Industry (DTI) under the
Partners in Innovation Scheme, and the CIBSE Research Fund. This document is
published with the Department’s consent, but the views expressed are not necessarily
accepted or endorsed by the DTI.
CIBSE acknowledges the use of passages from publications of the Institution of Gas
Engineers and Managers and the British Combustion Equipment Manufacturers
Association.
 Contents
BO Introduction
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BO.l Scope
B0.2 Terminology
B0.3 New technologies
B0.4 Purpose
B0.5 Summary of commissioning requirements
B0.6 The importance of commissioning
B0.7 Other guidance
B0.8 Definitions

B1 Safety issues 4
B 1.1 Legislation 4
B 1.2 Good practice 5

B2 Design for ease of commissioning

B2.1 Appropriate boilers and burners
B2.2 Access to boilers and burners
B2.3 Cleanliness in plant room
B2.4 Adequate boiler and burner specification details
B2.5 Means of isolation from fuel supply
B2.6 Means of isolation from water circuits
B2.7 Means of isolation from electricity supply
B2.8 Other requirements

B3 Specification issues
B3.1 General
B3.2 Building Regulations
B3.3 Boiler specification details required for commissioning
B3.4 Specifying requirements for commissioning

B4 Commissioning project management

B4.1 Commissioning manager
B4.2 Commissioning engineer
B4.3 Commissioning management team
B4.4 Responsibilities
B4.5 Commissioning management: general considerations
B4.6 Off-site pre-commissioning work

B5 Sequence of commissioning
B5.1 Manufacturers’ instructions
B5.2 Commissioning periods

B6 Planning and programming 10

B6.1 Planning 10
B6.2 Programming 10
 87 Pre-commissioning: verification and inspection 10
B7.1 Verification 10
B7.2 Inspection 13
B7.3 Boiler log book 14
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68 Activation, dry and live runs 14

B8.1 General 14
B8.2 Dryrun 14
B8.3 Live run 15
B8.4 Further checks 17

B9 Operation and calibration 17

B9.1 Establishment of operating levels 17
B9.2 Boiler over-heat test 18
B9.3 Boiler log book 18

610 Recording data, reporting and training 19

B 10.1 Recording 19
B10.2 Labelling 19
B10.3 Reporting 19
B10.4 Training 19
B10.5 Interlocks 19

B11 System handover 19

B11.1 Witnessing 19
B11.2 Operation 20

References 20

Bibliography 21

Additional sources of technical advice 22

Appendix BA1: Instrumentation and calculations 23

Appendix BA2: Guidance t o the design of boiler log books 26

Index 33
 1

Boilers
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- hot water and heating system water circulation

Introduction
- fire and safety equipment
BO.l Scope - flushing and cleaning
- treatment of the heating system water
T h i s Code deals with t h e work stages required to
- disposal of condensate from condensing boilers
commission boiler systems. T h e Code represents
standards of good practice which are presented in the form - control of the heating system other than the boiler
of recommendations a n d guidance for t h e building controls required by BS EN 3030.
services industry.

Compliance with the Code does not confer immunity from B0.2 Termin oIogy
relevant statutory and legal requirements.
The term ‘boiler’ used in the title of this Code is a generic
With the issue of the 2002 edition of Building Regulations term used to describe equipment to burn fuel and produce
Approved Document L2(’), commissioning is a require- hot water. The terms ‘boiler’, ‘boiler body’ and ‘burner’
ment for all building services works approved under the a r e used t h r o u g h o u t t h i s Code with t h e following
Regulations. Compliance with this Code should satisfy definitions:
Building Control Officers that the relevant requirements
of the Building Regulations in respect of commissioning - A boiler is the assembly of a burner and boiler
of the boiler systems have been met. body designed to convert the energy of a com-
bustible fuel into heated water.
T h e Code is applicable to individual hot water boilers - A boiler body comprises the heat exchanger, water
(including those of the condensing type) burning natural carrying passages, combustion gas passages,
gas and/or BS 2869 Class D gas oil with rated inputs of insulation and jacket of a boiler.
between 60 kW and 2 MW (gross calorific value), installed
i n h y d r o n i c heating systems of t h e low/medium - A burner comprises the equipment for producing,
classifications of pressure/temperature. A plant room may controlling and maintaining a stable and safe
contain a number of boilers to provide a heating system flame from the fuel.
rating in excess of 2 MW.
The terms ‘should’, ‘shall’ and ‘must’ are used in this Code
The Code is equally applicable to new-build and retrofit with t h e following meanings (adopted by o t h e r
applications. The Code may be applied to boilers equipped organisations). Notwithstanding sub-section B0.3:
to burn other gaseous or liquid fuels by appropriate
- The term ‘must’ identifies a statutory requirement
adaptation.
in force in the UK at the time of publication.
T h e Code is not intended for application to normal - The term ‘shall’ prescribes a procedure which, it is
domestic installations. T h e Code does not cover steam intended, will be complied with i n full a n d
raising plant, air heaters and electric heaters. The Code without deviation.
does not cover solid fuel fired boilers.

T h e Code does not cover hydronic heating systems Table 1 Classification of hydronic heating systems as defined in CIBSE
classified as ‘high’ pressure/temperature. Note: hydronic Guide B1(2)
heating system classifications are defined in CIBSE Guide Classification System design water Operating static
B1(*) and HVCA TR20(3); these definitions are sum- temperature / “C pressure / bar (absolute)
marised in Tables 1 and 2. LPHW 40 to 85 1to3
MPHW 100 to 120 3 to 5
The following items and/or equipment are not included in HPHW > 120 5 to 10
this Code but nevertheless, where they are present in a
system, require commissioning before boiler commission-
ing can proceed:
Table 2 Classification of hydronic heating systems as defined in HVCA
- power supplies ~~20(3)
- fuel supply up to the appliance isolating valve Classification Maximum Maximum pressure
temperature / “C / bar (gauge)
- flue and chimney including leak testing
LTHW 90 10
- ventilation system MTHW 90 to120 10
HTHW > 120 10
- pressurisation equipment
 2 Boilers

- The term 'should' prescribes a procedure which, it B0.6 The importance of

is intended,' will be complied with unless, after
prior consideration, deviation is considered to be commissioning
acceptable.
T h e proper commissioning of a boiler is essential to
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ensure safe and correct operation and compliance with

In certain circumstances, a departure from the procedures various statutory requirements relating to boilers and fuel
in this Code may be considered. The responsibility for burning apparatus, e.g. Gas Safety (Installation and Use)
such a departure is wholly the responsibility of the client Regulation#).
or the agent acting on their behalf. Any such departure
needs to be supported and confirmed in writing by either
a specialist manufacturer or approved consultant/design T h e issue of the 2002 edition of Building Regulations
house. Approved Document L2(') requires the commissioning of
all building services works approved u n d e r t h e
Regulations.
B0.3 New technologies T h e Government's commitment t o international
initiatives to reduce emissions of 'greenhouse' gases
This Code does not attempt to make use of any method or requires owners of carbon fuel burning equipment to
specification obligatory against the judgement of the ensure that plant is commissioned correctly, maintained
responsible engineer. Where new and better techniques regularly and operated at its highest possible efficiency.
are developed and proved, they should be adopted without
waiting for modification to this Code. Amendments to this
Code will be issued when necessary and its publication 80.7 Other guidance
will be announced by the Institution as appropriate.
Guidance concerning the commissioning of building
services systems is contained in the following CIBSE
B0.4 Purpose publications :
- Commissioning Code A: Air distribution systems(6)
The Code is intended to be used as: - Commissioning Code C: Automatic controls(7)
- a guide to good practice for the commissioning of - Commissioning Code R: Refigerating systems@)
boiler system(s)
- Commissioning Code W: Water distribution systemd9)
- a tool to assist the definition of commissioning
- CIBSE Guide H: Building control systems(lo).
procedures to be performed
- a basis for the preparation of commissioning Additional commissioning guidance is provided in the
specifications. following BSRIA publications:
- AG 02/89.3: Commissioning water systems -
It is not intended that contracts or specifications should application principles(' I )
refer to the Code in its entirety, but that direct references
may be made to specific appropriate sections of the Code - AG 03189.3: Commissioning air systems - application
when specifying requirements for commissioning boilers. procedures for buildingdl2).

Additional commissioning guidance for gas fired boilers is

provided in the following IGEM publications:
B0.5 Summary of commissioning
requirements - IGEMlUP/4: Commissioning of gas-fired plant on
industrial and commercialpremises(13)
T h e following summarises the key requirements for a - IGEMlUP/lO: Installation of gas appliances in
successfully commissioned boiler system: industrial and commercialpremises(14).
- Building services plant and control system to be Guidance relating to the design of hydronic heating
inherently commissionable. This is most likely to systems is provided in CIBSE Guide B1: Heating(z).
be achieved if the requirement is in the brief from
the outset and specialist commissioning advice
sought early in the design process. B0.8 Definitions
- Boiler plant and associated equipment to be
For the purposes of this Code the following definitions
inherently commissionable.
apply:
- Contractor and client to allow sufficient time for
the complete commissioning process. Boiler
- Formation of a commissioning management team. The boiler is the assembly of a burner and boiler body
designed to convert the energy of a combustible fuel into
- Adoption of thorough commissioning procedures. heated water.
 Introduction 3

Boiler body Control panel

The heat exchanger, water carrying passages, combustion T h e enclosure and equipment providing temperature
gas passages, insulation and jacket of a boiler. regulating and limiting devices for the boiler.
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Boiler log book Controlled shut-down

T h e p e r m a n e n t record of calibration settings a n d T h e process by which the power to t h e gas shut-off
performance test results that is initiated by commission- valve(s) is removed before any other action takes place,
ing engineers and maintained thereafter by responsible e.g. as a result of the action of a controlling function.
persons.
Damper
Burner
A restriction in a flue system or chimney that may be
T h e e q u i p m e n t for producing, controlling a n d manually adjusted or mechanically controlled.
maintaining a stable flame from the fuel.
Draught stabiliser
Calibration
A mechanical device designed to control the natural
The adjustment of control devices to meet the require- draught generated by a chimney or flue.
ments of the heating system specification.
Energy sources
CDM Regulations
All fuels and forms of motive power supplies to the
Construction (Design and Management) Regulations system.
1994('5 ) .
Flame failure
Chimney
The loss of flame from the normally detected position by
T h e purpose-designed vertical duct to convey exhaust any cause other than the action of de-energising the safety
gases from a flue system to the discharge them safely to shut-off system.
the outside atmosphere.
Flue spigot
Commissioning engineer
The purpose-designed connection for attachment of the
The person undertaking the commissioning procedure. boiler to a flue system.

Commissioning Flue
The advancement of an installation from the state of static T h e system of purpose designed ducts to convey
completion to full working order to the specified require- combustion products from a boiler or combination of
ments. It includes the setting-to-work of an installation, boilers to a chimney.
the regulation of the system and the fine tuning of the
system.
Fuel supply system
That part of the pipework associated with the fuel system
Commissioning management
that lies between the entry point or storage vessels and the
The planning, organisation, co-ordination and control of appliance isolation valves for each burner. The fuel supply
commissioning activities. system may include a flow measuring device a n d
automatic safety shut off devices.
Commissioning manager
Gas train
T h e person appointed to manage the commissioning
process. The assembly of equipment to control and regulate the
supply of a gaseous fuel to the burner.
Condensing boilers
Heating system
Boilers with heat exchanger arrangements that allow the
recovery of latent heat as well as sensible heat from the A system which includes pumped pipe circuits, heat
combustion gases when boiler water temperatures are emitters and hot water storage vessel charging coils that
below the dew point of the exhaust gas. contain the treated water heated by the boiler(s) but
excludes potable water supplies.
Control device
HPHW
Any valve or component which regulates the supply of
fuel, air, water, products of combustion and process High pressure hot water heating system, see Table 1 and
throughput. CIBSE Guide B1(2).
 4 Boilers

HTHW PPE
High temperature hot water heating system, see Table 2 Personal protective equipment.
and HVCA TR20(3).
Responsible engineer
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Interlock device The suitably qualified and competent engineer appointed

to be responsible for the application of all or part of these
Any component which operates independently o r i n
procedures or a suitably qualified, experienced a n d
conjunction with other devices to monitor prescribed
competent person acting under his or her supervision.
operating conditions and ensure appropriate action if
conditions deviate from the normal operating levels.
Safety shut-down
Isolating valves The process which is effected immediately following the
response of a safety limiter or the detection of a fault in
Valves provided in fuel supply lines and water connec- the automatic burner control system, and which puts the
tions that are provided to permit isolation of boiler bodies burner out of operation by immediately removing the
and burners for the purpose of inspection, maintenance power to the fuel shut-off valve(s) and the ignition device.
and/or removal.
Note: safety shut-down can also occur as a result of an
interruption or decrease of the power supply.
Leak tight
The positive condition of a pneumatic or hydraulic test at Safety shut-off valve
a defined pressure over a defined period of time that A valve that is actuated by the safety control so as to admit
verifies that any leakage from the pipework or system is and stop fuel flow automatically.
within defined limits.

Specification
Lock-out
T h e document that prescribes the system design and
See volatile lock-out and non-volatile lock-out. requirements for commissioning by reference to drawings,
information schedules and relevant codes, manuals, guides
and standards.
LPHW
Low pressure hot water heating system, see Table 1 and Shut-down
CIBSE Guide B1(2).
See controlled shut-down and safety shut-down.
LTHW
Testing
Low temperature hot water heating system, see Table 2
The measurement and recording of system parameters to
and HVCA TR20(3).
assess specification compliance.

MPHW Volatile lock-out

Medium pressure hot water heating system, see Table 1 The safety shut-down condition of the system such that
and CIBSE Guide B1(2). restart can only be accomplished by either the manual
reset of the system, or an interruption of the main power
MTHW
and its subsequent restoration.

Medium temperature hot water heating system, see

Table 2 and HVCA TR20(3).
Safety issues
Non-volatile lock-out Before commissioning work is commenced a risk
The safety shut-down condition of the system such that assessment shall be carried out and appropriate safety
restart can only be accomplished by a manual reset of the precautions shall be observed.
system and by no other means.
Note: where no document exists the spirit of the Gas
Safety Regulations and Codes should be adopted.
Operating levels
T h e set points of all contro1,devices under operating 61 . I Legislation
conditions.
Applicable legislation may include, but is not limited to,
Performance testing the following:
- Building Regulations 2000('6)
T h e testing of a system, or a grouping of systems, to
determine if certain performance criteria are met. - Boiler (Efficiency) Regulations 1993(17)
 Design for ease of commissioning 5

- Where possible use two-person working. In certain

Health and Safety at Work etc. Act 1974('*)
conditions two-person working is mandatory, e.g.
Management of Health a n d Safety at Work working on live equipment.
Regulations 1999(19)
- Ensure that a responsible person on site is aware of
Construction (Design a n d Management)
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the location of the commissioning personnel and

Regulations 1994(15) the nature of their work.
Workplace (Health, Safety a n d Welfare) - Smoking is prohibited during commissioning due
Regulations 1992(20)
to the presence of highly combustible fuels.
The Working Time Regulations 1999(2')
- Combustion air and the environment surrounding
The Working Time Regulations 1998(22) the boiler(s) to be commissioned shall be free of
Electricity at Work Regulations 1989(23) chlorinated hydrocarbons.

Personal Protective Equipment at Work - The commissioning manager should be provided

Regulations 1992(24) with the calculations which determined the design
of the flue, chimney and ventilation systems.
Health and Safety (Display Screen Equipment)
Regulations 1992(25)
Confined Spaces Regulations 1997(26)
Gas Act 1995(27)
B2 Design for ease of
commissioning
Gas Safety (Installation and Use) Regulations
1998(5)
It is important that the system specifier is aware of the
Noise at Work Regulations 1989(28) requirements to ensure that boiler(s) and the associated
building services systems are inherently able to be
Pressure Equipment Regulations 1999(29) commissioned. Involvement of a commissioning engineer
Pressure Systems Safety Regulations 2000(30) at the design stage should be considered where in-house
experience is not sufficiently comprehensive. Some issues
Provision a n d Use of Work E q u i p m e n t which impinge on the ease of commissioning of a boiler
Regulations 1998(31) are considered in the following sections.
Reporting of Injuries, Diseases and Dangerous
Occurrences Regulations 1995(32).
B2.1 Appropriate boilers and
B1.2 Good practice burners

Good practice safety procedures include the following: Boilers must be appropriate for the building heating
system(s) (having regard for the requirements of the
- Risk assessments should be performed a n d Building Regulations(16)), must comply with the Boiler
resulting method statements produced. (Efficiency) Regulations(I7), and should be CE-marked.
- Personnel shall receive adequate training in safety Where the boiler does not have an integral burner, the
matters before working on site. boiler supplier's recommendation(s) in respect of burner
selection shall be observed (see B7.1.1).
- Site personnel shall be issued with, and be trained
to use, appropriate safety equipment e.g. hard hat,
safety boots, PPE, eye protection, ear defenders and 82.2 Access to boilers and burners
overalls etc. where appropriate.
- Wherever possible electrical equipment should be Adequate access for the assembling, commissioning and
isolated before working using locked-off and local maintenance of boilers and burners shall be provided.
isolators. Live work should only be carried out Manufacturer's recommendations shall be incorporated in
when there is no reasonable alternative. the planning and layout of the plant room.
- Cordon off live electrical panels and display
warning notices.
B2.3 Cleanliness in plant room
- Ensure that remotely controlled plant or other
equipment is clearly labelled and made safe during For safety, the plant room shall be clean and tidy for the
testing. commissioning procedures.
- Personnel should stand on rubber mats when
working on live panels.
- B2.4 Adequate boiler and burner
Use of adequate safety barriers when working on
live equipment. specification details
- Use a 'permit to work' system.
I t is essential for the commissioning process that the
- Ensure that authority to proceed is granted before details listed in section B3.3 are obtained by the commis-
starting work involving rotating plant. sioning manager.
 6 Boilers

62.5 Means of isolation from fuel can be performed correctly. Specialist commissioning
input at this stage will be beneficial to the process.
supply
Adequate means of isolation of the burner and all sources 63.2 Building Regulations
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of fuel supply must be provided. This includes the ability

to physically lock the appliance isolating valves in the T h e commissioning manager (see B4.1) shall ascertain
shut position to prevent the possibility of fuel being that the relevant approvals under Building Regulations
delivered. have been obtained including any required by t h e
Environmental Health Officer in respect of chimney
termination and height.
B2.6 Means of isolation from water
circuits In addition helshe shall ascertain whether the site falls
within the scope of the Pollution Prevention and Control
Valves shall be fitted in the flow and return pipework to (PPC Act) and the Pollution Prevention and
each boiler to enable it to be isolated and drained without Control Regulations(34)that relevant approvals have been
de-commissioning the heating system. granted.

Note: a site may fall within the scope of the PPC Act
62.7 Means of isolation from because of the process(es) being carried out on the site.
electricity supplies
B3.3 Boiler specification details
Isolating switches must be provided for each boiler.
required for commissioning

B2.8 Other requirements The commissioning manager (see B4.1) shall obtain the
following plant specification details from the specifier:
In addition to the above issues, it is essential that the - heating system type (e.g. LPHW, MPHW, LTHW,
boiler systems are inherently controllable in terms of their MTHW)
fundamental design, sizing and commissioning. T h e -
following are examples of items that can simplify system control system type (e.g. compensating etc.)
commissioning: - boiler sequencing controls
Use specialist commissioning engineers trained - fuel type(s)
and approved by the burner manufacturer.
- boiler model(s) (e.g. manufacturer’s model
Provide correct design information to allow the reference)
selection of appropriate devices. - boiler type (e.g. cast iron, steel, condensing etc.)
Use reverse return pipework layouts to balance -
hydraulic circuits through multi-boiler systems. boiler combustion efficiency claimed by supplier
- burner type (e.g. forced draught, atmospheric, pre-
Use independent flues and chimneys for each
boiler. mix)
- burner mode of operation (e.g. onloff, highllow,
Provide independent fuel meters for each boiler.
modulating)
Use automatic valves to balance hydraulic losses - b u r n e r model(s) (e.g. manufacturer’s model
through multi-zone heating systems.
reference)
Use variable speed drives for burners and pumps - burner fuel consumption rates and operating
where appropriate.
pressures
Provide read out signals for fault indication. - require inlet gas pressure required (if applicable)
- operating temperatures
- operating water flow rates and temperature
Specification issues differences
- suitabilitv of boiler for sealed systems
B3.1 General - operating system pressures
In order properlv to commission a boiler, the commission- - method for boiler filling
ing engineer-shail be provided with comprehensive details - system pressurisation details a n d operating
relating to its design and specification. This Code assumes pressures
that the installation is DroDerlv constructed to an anreed
1 - I Y

specification, stating how the plant is designed to operate - flue system type and draught requirements
and giving permissible tolerances. In addition, commis- - ventilation system details, minimum open area of
sioning shall be clearly specified and the needs of the grilles andlor air flow rates
commissioning process addressed during initial design to
ensure that the-commissioning of the boiler installation - alarms, warnings and remote indicators required
 Commissioning project management 7

- interfaces with interlocks and heating system T h e commissioning manager shall be competent and
controls (building
- management
- system etc.) qualified and if necessary shall appoint commissioning
engineer(s) who are qualihed and competent to carry out
- occupant interfaces the commissioning work.
- hard wire interfaces
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It is the commissioning manager’s responsibility to verify

- accuracy and stability.
that the installation conforms to the design specification,
collect relevant documents, certificates etc., and propose
and agree the commissioning procedure with the specifier,
B3.4 Specifying requirements for commissioning engineer(s) and other parties concerned.
commissioning The commissioning manager should call for the assistance
of the commissioning engineer(s) in the estimation and
The commissioning manager (see B4.1) shall prepare a allocation of manpower resources and the creation of a
commissioning specification which should incorporate the schedule of commissioning work.
requirements detailed in this Code. The commissioning
specification requirements s h o u l d be tailored, as
appropriate, to reflect the particular type and scope of the B4.2 Commissioning engineer
installation.
More than one commissioning engineer may be required
In summary, details relating to the following should be to e n s u r e t h a t t h e necessary level a n d breadth of
included in the specification: competence is available. This may also be necessary for
- clear description of the division of responsibility reasons of safety and/or practicality.
between the various parties
Where appropriate the commissioning engineer(s) or
- pre-commissioning procedures his/her employer should assist t h e commissioning
- commissioning procedures manager particularly in the estimation and allocation of
manpower resources and the creation of a schedule of
- requirements for the control system to be used to commissioning work.
assist in the commissioning of the boiler(s)
- arrangements for management of delays Individual commissioning engineer(s) engaged to work on
commercial gas fired installations must be competent to
- phased completion requirements carry out the required work to comply with the Gas Safety
- requirements for demonstration/witness testing on (Installation and Use) regulation^(^). They must hold a
the basis of a point-by-point basis; the witnessing current certificate of competence in accordance with
requirements should include the identification of Health and Safety Commission (HSC) COP 20(35),issued
those responsible under the HSC’s Approved Code of Practice (ACoP)
arrangements or a certification body accredited by the
- involvement in complete system and sub-system United Kingdom Accreditation Service (UKAS), and they
performance testing must be registered with the Council for Registered Gas
- burner and boiler documentation including the Installers (CORGI).
endorsement of boiler log books
- It is the responsibility of the commissioning engineer(s) to
operator training requirements before and during e n s u r e that, before commencing work, they have
the commissioning period familiarised themselves with, and understand completely,
the detailed commissioning instructions provided by the
- post handover operator training. manufacturer(s) for the boiler(s) and for the burner(s).

B4 Commissioning project B4.3 Commissioning management

management team

The commissioning manager should form a commission-

B4.1 Commissioning manager ing management team to co-ordinate and oversee the
commissioning process. Communication between the
A commissioning manager shall be appointed who shall be various parties is vital and it is important that the M&E
responsible for planning and programming the com- contractor, consulting engineer, commissioning engineers
missioning. T h e responsibility for the commissioning and project management team meet on a regular basis.
manager’s duties may lie with a senior engineedmanager
responsible for the safety of the site/premises.
B4.4 Responsibilities
T h e commissioning manager should also have respon-
sibility for the commissioning of the heating system and It is important that the respective roles of the various
heating controls and thereby ensure integration of the parties involved in the installation and commissioning of
specific requirements for boiler commissioning with the boiler(s) are clearly defined. Any ambiguity is likely to
overall programme for commissioning the heating services result in contractual problems which may ultimately
to the building. impact on the effectiveness of the installed plant.
 8 Boilers

This Code assumes that the boiler(s), burner(s), new

flue(s), new chimney(s), ventilation, heating circuit(s),
B5 Sequence of
heating control(s), power supplies, wiring and all associ- commissioning
ated equipment shall have been procured and installed by,
or on behalf of, the main contractor.
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B5.1 Manufacturers’ instructions

B4.5 Commissioning management: In general, commissioning of individual parts of plant

shall be carried out in accordance with specific manufac-
general considerations turers’ and/or suppliers’ instructions, in a series of logical
steps which shall also comply with applicable parts of this
Code. However it is necessary to consider the interaction
The following commissioning management actions and of those parts with the rest of the plant.
considerations should be observed:

A detailed commissioning programme shall be B5.2 Commissioning periods

written and agreed with the main contractor. The
programme should be based on the sequence of The sequence of operations to achieve successful commis-
commissioning defined in section B5 of this Code. sioning is divided into five, distinct, consecutive periods.
Each period shall be completed satisfactorily before
The commissioning programme shall take account moving on to the next period. A typical commissioning
of commissioning activities for associated plant sequence is described below and illustrated in Figure 1.
and controls. The programme shall note and take
account of the requirements of CIBSE, BSRIA,
and IGEM publications as detailed in B0.7. B5.2.1 Planning and programming period

Appropriate health and safety method statements This is the period in which the commissioning procedure
and risk assessments for t h e tasks shall be is created. It includes the establishment of verification of
completed a n d submitted to t h e planning plant design, t h e collection of related documents,
supervisor. (Some small-scale installations may not certificates etc. and the agreement of a commissioning
be within the scope of the CDM Regulations(I5).) procedure with relevant persons (see B6).

A means of monitoring the progress of commis- B5.2.2 Pre-commissioningverification and

sioning activities should be established a n d inspection period
integrated into the commissioning programme.
Checklists should be used to monitor and record
how the commissioning job progresses. Source I n this period t h e installation a n d its individual
information for such checklists is provided in components is examined visually and, as appropriate,
sections B5 to B11 of this Code. Proper progress physically, with all energy sources isolated (see B7).
monitoring procedures will help ensure that
commissioning and testing actions are performed B5.2.3 Activation (dry and live runs) period
correctly, in the correct sequence, and not unnec-
essarily repeated.
This period is concerned with the systematic search for,
and elimination of, any fault which could result in a
All parties involved in the commissioning process dangerous condition. At the start of the period, the
shall have documentation procedures for dealing engineer will not be aware if such a condition exists and
with variations to contract. A change control hence the period starts with the dry run when fuel is
mechanism should be set up which includes isolated. Once the engineer is satisfied that any potentially
documentary backup of what has been changed, dangerous condition has been revealed and eliminated, the
how and why. live run is carried out when the fuel is admitted and safe
operating levels are established (see B8).
A consistent numbering system should be used to
identify individual work items.
65.2.4 Operation and calibration period

T h i s period is concerned with the establishment of

Off-site pre-commissioning satisfactory performance and the setting of controls to
work achieve correct operation (see B9).

Off-site pre-commissioning of boilers and burners shall B5.2.5 Reporting, training and recording
always be checked during commissioning. Commissioning period
shall take account of the operating conditions prevailing
at the time of commissioning and subsequently expected T h i s period is concerned with completing t h e
to prevail at the installation. These conditions cannot be commissioning and handing the plant over to its operators
replicated off-site. (see BlO).
 Sequence of commissioning 9

1 Planning and programming period Design verification:

0 Ensure design has been verified - boiler location, fuel supply, ventilation,
(See section B6) fluekhimney system, heating system, controls and power supply
Documentation:
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0 Compile specifications, instructions, drawings and certificates

Programme:
0 Plan and aqree work proqramme with the commissioning manager
~

2 Pre-commissioning verification and Fuel(s):

inspection period 0 Confirm isolation, availability and type
0 For gas, confirm testing and purging of supply, confirm supply pressures
(See section B7) 0 For oil, confirm correct storage, bunding, testing and purging of supply system
Safety checks:
0 Examine documentation
0 Confirm energy sources isolated
0 Confirm installation of fire valves, fuel safety shut off and leak detection system
(if applicable)
0 Examine plant and components
0 Check electrical earthing
0 Test and purge fittings, tools, instruments and safety equipment
0 Check water supply, venting and pressure relief
Confirm warning notices in place
0 Confirm adjacent plant is safe
0 Confirm associated plant is available

3 Activation period Dry run (gas):

0 Check pipework and valves proved sound
(See section B8)
0 Set controls and interlock devices
0 Check interlocks and power operated equipment
0 Check air purge rate and time
Dry run (oil):
0 Check pipework and pump proved sound
0 Set control and interlock devices
0 Check interlocks and power operated equipment
0 Check air purge rate and time

Ensure complete faultless dry run before proceeding

3 Activation period (continued) Live run (gas):

(See section 88) 0 Check fuel available
0 Check start gas ignition and shut-down
0 Check main flame ignition and shut-down
0 Ensure flame failure shut-down
0 Check other burners
0 Establish safe operating levels
0 Check gas pressure at maximum demand
Live run (oil):
0 Fuel made available
0 Check low flame ignition and shut-down
0 Check main flame ignition and shut-down
0 Ensure flame failure shut down
0 Check other burners
0 Establish safe operating levels

Ensure complete faultless live run before proceeding

~

4 Operation and calibration period Under normal operating conditions:

0 Check combustion, correct operation of flue(s)/chimney(s) including operation of
(See secton B9)
mechanical systems, plant condition and hot water generation
0 Re-check from cold
Boiler over-heat:
0 Verify operation of boiler safety devices
Trials:
0 Water heating and acceptance trials for each fuel
Reporting:
0 Modifications t o original design
0 Operating levels
0 Settings
0 Instructions and drawings
Training:
0 Nominated operatives
0 Supervisory and maintenance personnel
Recording:
0 Boiler loa books

Handover plant

Figure 1 Sequence of commissioning periods

 10 Boilers

B6 Planning and affect other items, e.g. cements and ceramics of under-
floor heating systems.
programming
Any need for specialist monitoring equipment shall be
taken into account.
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B6.1 Planning

B6.1. I Design B6.2 Programming

The planning of the commissioning shall establish that B6.2.1 Programme

the design of the installation has been verified and that
the likely effect of operating the plant on surrounding A commissioning programme shall be agreed by the
plant and the working environment has been taken into commissioning manager with those personnel directly
account. concerned with the running of the plant, including, where
appropriate:
B6.1.2 Resources - the customer and/or the customer’s agent
- t h e main contractor and/or appropriate sub-
All the resources required for the commissioning shall be
verified, for example specialist personnel and equipment. contractors
- consultants and/or insurers
B6.1.3 Documentation - fuel supplier(s).
Prior to commissioning, all relevant documents shall be It is important that the contractual responsibilities of the
available to those concerned with the commissioning, various parties involved over the period of commissioning
including, where appropriate: activity are stated, acknowledged and understood.
- plant performance specification
Commissioning engineers shall comply with any permit to
- schedule of hardware and manufacturer’s instal- work system that is in operation.
lation instructions
- plant drawings and pipework layouts B6.2.2 Timing
- electrical logic and wiring diagrams
T h e programme shall include details of t h e project
- certificates confirming satisfactory completion of completion times of such activities as installation,
such procedures as pressure testing, soundness modification, availability of fuel and services, soundness
testing, purging, electrical safety tests, etc. tests, purging of the installation pipework and electrical
- commissioning, operating a n d maintenance safety tests.
instructions for the plant, including the fuel firing
and ancillary equipment
- certificates confirming correct calibration of ancil-
lary equipment, for example emissions measuring
B7 Pre-commissioning
equipment verification and inspection
- log books for boilers and burners. T h e commissioning manager a n d commissioning
engineer(s) must ensure that the installation is in a safe
B6.1.4 Manufacturers’ instructions state before commissioning is commenced. T h i s
requirement shall include the adequate lagging of hot
The availability and correctness of manufacturers’ instruc- pipes, components and vessels.
tions shall be verified and be issued to commissioning
engineers for reference. T h e commissioning manager shall n o t p e r m i t part
commissioning of boilers but may authorise commission-
ing of individual boilers in a plant room comprising
B6.1.5 Other plant and equipment multiple boilers providing that adequate steps are taken to
ensure that by so doing no hazard will ensue.
An important consideration to be addressed, before
commissioning, is the interaction of all plant on the The following activities are typical of the items that shall
premises. It should therefore be established that the be addressed.
operation of the plant, other than that to be commis-
sioned, will not affect adversely the operation of the plant
to be commissioned and, equally, that the commissioning B7.1 Verification
and subsequent operation of the plant to be commissioned
will n o t have a n adverse effect on o t h e r plant a n d
equipment. B7.1.1 CE-marking

In particular, it shall be verified that the thermal effect of New boilers must comply with the Boiler (Efficiency)
heating the system for the first time will not adversely Regulations(17)and should be CE-marked.
 Pre-commissioningverification and inspection 11

CE-marking may be based on demonstration of compli- supply must be verified. Mechanical ventilation systems
ance with a relevant European Standard, including: must be provided with interlocks to prevent burners being
- BS E N 303(4) for boilers with forced draught fired unless the correct volume of air is being supplied.
burners up to 1 MW output
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-
B7.1.5 Adequate exhaust discharge system
BS EN 656(36)for Type B boilers with nominal
heat inputs not exceeding 300 kW. The commissioning manager shall obtain verification that
all boilers are fitted to an exhaust extract system that
New forced draught burners should be CE-marked. conforms with the requirements of the Clean Air
Relevant standards are: the Pollution Prevention and Control and the
- BS EN 267(37)for oil burners Pollution Prevention and Control Regulations(34).
- BS EN 676(38)for gas burners. The chimney height and the position of the termination
shall be validated against design calculations a n d
New boilers, burners and other equipment may also need environmental health officer’s requirements.
to demonstrate compliance with other statutory require-
ments, the detailing of which is beyond the scope of this The flue and chimney components shall have purpose
Code. designed seals and have been tested for soundness relative
to their design. The flue and chimney ducts must be leak
B7.1.2 Boiler access tight, clean and free from obstruction. Where a boiler is
not in position the connection point in the flue system
The configuration of the boiler door hinges and the fuel shall be capped.
isolation valve shall allow the boiler door to be opened
without obstruction for inspection, boiler cleaning and Note: it is generally advisable that a condensate drain is
burner head maintenance. The routing of water pipes, fuel fitted in an appropriate position to dispose of liquid
supplies, flues etc. shall not impair removal of any boiler condensate, rain or snow that may enter an open chimney.
inspection and cleaning port covers nor shall it impair
access for cleaning and/or servicing of the boiler or Mechanical exhaust systems with fans shall have been
burner. commissioned by others and must be provided with
interlocks to prevent burners being fired unless the
designed volume of gases is flowing though the system.
B7.1.3 Boiler pressure test
The design of flue dilution systems shall conform with the
The commissioning manager shall verify that the boiler requirements of IGEM/UP/10(’4) and have been commis-
bodies have been pressure tested. Factory assembled sioned by others. Interlocks must be provided to prevent
boilers shall have been tested by the manufacturer in
burners being fired unless the designed volume of diluting
accordance with the relevant design standard. Boiler
air is flowing though the system. Inlet and exhaust grilles
bodies built on-site shall be tested and certified by the must be clean and free of obstruction.
assembling engineer.
Draught stabiliser(s) and damper(s), if fitted, must operate
Note: the test pressure for the boiler should be at least 1.3
correctly.
times the system operating pressure or 4 bar, whichever is
the higher.
The static draught in the flue system, or provided by a
mechanical extract system, adjacent to the connection to
B7.1.4 Adequate ventilation the boiler should be measured and verified to be adequate
and in accordance with the boiler and burner manufac-
The commissioning manager shall confirm the maximum turers’ recommendations.
heat input (kW) of the total number of boilers and fuel
fired equipment in the plant room and the total heat Note: the level of draught required will be stated in the
dissipation from ancillary equipment such as p u m p boiler supplier’s literature and will be either suction (i.e.
motors, etc. i n t h e plant room. By reference to t h e negative to atmosphere) or negative (i.e. positive to
appropriate standard he/she shall obtain verification that atmosphere). Typically boilers in this market sector
the ventilation system is adequate for the plant room. require a suction in the range 0 to 0.25 mbar.

Note: IGEM/UP/10(14)provides requirements for gas fired Where a draught stabiliser is installed it should be
boilers with a heat input in excess of 60 kW (gross). adjusted to provide the maximum draught permitted by
the boiler supplier.
For oil fired boilers, the safety recommendations of
BS 5410-2(39)shall be observed. The ventilation provisions Manual dampers should be set to the provisional oper-
of IGEM/UP/10(14)should be adopted, with the agreement ating position.
of the architect or specifier, as being the most informed
advice on the subject. Mechanical dampers must be provided with interlocks to
prevent burners being fired unless they are open and
The ventilation grilles and ducts must be clean and free should be set to the provisional operating position whilst
from obstruction. the exhaust extraction system is in operation.

Mechanical ventilation systems with fans shall have been Where required, provision shall be made for explosion
commissioned by others and the correct volume of air relief.
 12 Boilers

67.1.6 Adequate means of dissipating heat process) may require treatment, as may other effluents
from a boiler from t h e building. T h e treatment of effluent from
commercial buildings is a ‘grey area’ and guidance shall be
The commissioning manager shall obtain verification that sought from the local water authority.
the heating system has been flushed, filled with treated
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water, tested and commissioned, has adequate provision

67.1 .% Fuel supply
for the expansion of the heated water and has sufficient
capacity to dissipate the maximum heat output of the
The commissioning manager shall obtain verification that
boilers to be commissioned, taking account of prevailing
the fuel supply has been commissioned and is purged up
weather conditions.
to the appliance isolating valve for each individual burner.
Flushing and filling of the system shall be in accordance
Gas supplies must be adequate in respect of gas pressure,
with BSRIA AG l/ZOOl(41).
meter capacity and pipework sizing. Where a boosted gas
supply is required the booster shall be fitted with flexible
Leak testing of the system shall be in accordance with inlet connections and be provided with an inlet pressure
HVCA TR6(42). interlock.
Note: where only a proportion of the boilers in a plant Note: for gas supplies the following publications are
room are being commissioned, it is sufficient to provide relevant: IGEM/UP/1(44),IGEM/UP/1A(45),IGEM/UP/2(46),
only an equivalent proportion of the total heating system CIBSE Guide B1(2),HVCA TRZO(3).
to dissipate heat.
Oil storage sites must be safe and secure. Oil storage tanks
The heat emission from a system will be considerably shall be bunded, an overfill alarm, fire valves and isolation
reduced during hot summer days and such factors should valves shall be provided. All oil supplies shall be filtered.
be considered when making the assessment. Oil supply pipes shall not be exposed to conditions of low
temperature which could cause waxing of the oil supply.
In particular all pumps, automatic valves and manual
valves shall be proved to operate correctly. Hot water Single or two pipe systems with or without a ring main
isolating valves shall be in the open position. and with or without transfer pump(s) may be required
according to the relative positions of the burner(s) and the
S h u n t p u m p s t h a t are necessary to e n s u r e correct fuel storage tank(s). The burner supplier’s recommend-
hydraulic conditions i n t h e boiler shall operate ations should always be observed.
satisfactorily and sensors shall be adjusted to achieve the
temperatures advised by the boiler supplier during start Note: for oil supplies t h e following publications are
up and normal operation of the boiler(s). relevant: CIBSE Guide B1(2), HVCA TR20(3), OFTEC
Code of Practice OCP/l(47), O F T E C also publishes
Pressurisation unit(s), if installed, shall have been relevant Technical Information sheets.
commissioned by others and proved to be operating
satisfactorily.
67.1.9 Safety interlocks
Pressure relief valves a n d discharge pipes shall be
correctly sized and adjusted and have been tested and The commissioning manager shall obtain verification that
confirmed to operate correctly. Open vents shall have been all system interlocks operate correctly. Interlocks shall not
verified as free from obstruction and of adequate size, as be adjusted to operate at any level below the prescribed
specified in BS 6644(43). safety level. Interlocks are required with all ancillary
equipment that must be working correctly to enable safe
and correct working of the boiler. Examples of such
67.1.7 Condensate disposal equipment equipment are:
Where boilers are of the condensing type they shall be - mechanical ventilation systems
provided with means of condensate disposal. All - mechanical exhaust extract systems
condensate pipes shall be made from a material that is
chemically inert to condensate, be adequately sized and be - plant room doors in plant rooms that are balanced
routed so as to be free from frost or seasonal freezing. compartments
- flue dilution systems
Note: condensate is acidic, with a pH of 3.5 to 5.5 under
normal working conditions. A fully condensing 1 MW - fuel supply solenoid valves
rated boiler at maximum output will produce approx- - gas boosters
imately 50 litres per hour of condensate.
- hydraulic pressurisation units
T h e commissioning manager shall ascertain whether - smoke detectors, fusible links and/or fire alarm
regulations are i n force t h a t require treatment of
systems.
condensate effluent and ensure that treatment provisions
are appropriate.
67.1.10 Burner installation
Note: condensate from domestic boilers (i.e. up to 60 kW)
does not require treatment. Condensate from boilers in The commissioning manager shall obtain verification that
industrial premises (i.e. associated with a manufacturing the burner has been assembled to the boiler.
 Pre-commissioning verification and inspection 13

Atmospheric a n d pre-mix b u r n e r s are normally a n The boiler(s) to be commissioned shall be isolated from
integral part of the boiler and will be either factory fitted the fuel and electricity supplies.
or site assembled according to the characteristics of the
boiler model. Burners of this type will not be CE-marked The commissioning engineer shall confirm that the fuel is
as they are an integral part of the boiler. available up to the plant isolation valve(s) and that the
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fuel(s) are of the correct type and being supplied at the

Forced draught burners are normally supplied as complete correct pressure.
assemblies for fitting to the front door of the boiler.
Burners of this type (for all fuels) must be CE-marked.
B7.2.1 Starting equipment
Condensing boilers may have burners of either type.
Any item of equipment shall not be started prior to
confirming that it has been installed correctly and that the
All manufacturer’s instructions relating to the installation, components are satisfactory, either by checking written
commissioning and adjustment of the burner shall be records of work carried out andlor by visual andlor
given to the commissioning engineer for hislher exam- physical examination, as appropriate.
ination and reference.

Note: many boilers and burners are manufactured by B7.2.2 Safety checks
overseas suppliers. As a condition of CE-marking all
equipment must be supplied with adequate installation, P r i o r to commencing work, t h e commissioning
commissioning and maintenance literature and these engineer(s) shall identify and carry out safety checks and
instructions must be in the native language of the Member safety procedures. This should include, in sequence, the
State of sale, i.e. English in the UK. following:
(a) Checking appropriate documentation confirming
Gas burners that are not commissioned must be labelled as satisfactory safety checks which include soundness
being unsafe to use and isolated from the fuel supply by testing and purging of installation pipework up to
disconnecting or physically locking the appliance isolating the isolation valve and electrical safety checks (at
valve in the shut position. least on the general plant supply). .
(b) Carry out safety procedures including:
B7.1. I 1 Electricity supply
(i) a visual examination of the plant, ensuring
The commissioning manager shall obtain verification that that all required components have been
the electricity supply has been commissioned and that included a n d t h a t t h e pipework a n d
each boiler has an independent protective device and electrical connections have been made;
isolating switch. T h e burner and boiler body must be any explosion reliefs, ventilation openings
correctly earth bonded. etc., should be checked for freedom from
obstruction
B7.1.12 Heating system control (ii) electrical earthing checks, including cross
bonding of services
The commissioning manager shall obtain verification that familiarisation with the physical layout of
the heating system control has been commissioned and is
(iii)
the plant and the location of the emer-
set to allow safe and effective dissipation of the heat that gency isolation valve(s)
will be generated during commissioning.
(iv) confirming that all manually operated fuel
Compensating control systems should be set to manual valves are capable of operation, for
control and adjusted to provide the maximum heating example are fitted with handwheels or
service. handles and are clearly marked with ‘OFF’
and ‘ON’ positions, are leak tight and in the
Thermostatic valves on heat emitters should be set in the ‘OFF’ position
fully open position. (v) confirming that the pressure rating of any
safety valve is appropriate to the boiler and
Shunt pump sensors should be adjusted to the settings system and that the discharge pipe is led to
required by the boiler supplier. a safe place with free drainage
(vi) confirming that all other plant energy
B7.1 . I 3 Warning notices sources, for example electrical, hydraulic
and pneumatic, are isolated
Warning notices must be observed and permits to work
issued in accordance with site management requirements. (viz) ensuring that operation of the plant will
not damage electrical cable, earthing, cross
bonding etc.
B7.2 Inspection (viii) giving regard to t h e ventilation a n d
exhaust requirements of the plant to be
The commissioning engineer shall inspect the boiler(s) commissioned, paying particular attention
that helshe is to commission together with the plant and to the requirements of any other plant
equipment that is associated with the boiler(s). sharing the same ventilation space
 14 Boilers

(ix) checking the provision of certain ancillary - A record shall be kept i n the commissioning
fittings which are required for the com- report of all settings, and changes to settings, of
missioning procedure to be undertaken, system operating levels
such as test and purge points - If, during the activation period, a temporary
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(x) ensuring that any warning notice appro- change has been made to t h e plant to aid
priate to the commissioning procedure is commissioning, the plant shall be restored to the
in place correct design condition before proceeding to the
operational period.
(xi) confirming that the operation of adjacent -
plant and machinery will not constitute a If, during the activation period, a fault is found, it
hazard to the personnel involved with shall be rectified before proceeding. T h i s is
commissioning particularly important for interlocks. Faulty
interlocks that comprise part of the primary safety
(xii) e n s u r i n g t h a t associated plant a n d controls shall not be by-passed.
machinery required for correct operation
of t h e p l a n t to be commissioned, is
available and ready for use B8.2 Dry run
(xiii) ensuring that any integral fire protection Note: for gas fired burners the recommendations for dry
system is operative. and live run activation contained in IGEM/UP/4(13)shall
be observed. In general terms the advice for dry and live
activation contained in this publication is suitable for
B7.3 Boiler log book adoption on oil fired plant, having regard for the different
fuel characteristics.
The commissioning engineer should complete the ‘Pre-
commissioning checks’ section of the boiler log book as a The purpose of the dry run is to ensure that control and
record of the checks that have been made (see B9.3). interlock devices are set to provisional operating levels
that are considered safe for commissioning, that the
burner controls operate correctly and that the flame
supervision control detects the absence of a flame and
B8 Activation, dry and live signals ‘lock-out’.

runs For multi-fuel burners, where all fuels are available for
commissioning, the order in which fuels are commis-
sioned should be considered, with a preference being for
B8.1 General the least finely adjustable fuel being commissioned first.

The commissioning engineer is responsible for carrying Note: for typical dual-fuel burners for natural gas and oil,
out the dry and live runs. At this point, satisfactory, safe, it is recommended that oil firing is completed first and gas
operation of the plant being commissioned shall not be firing rates adjusted to match the input data achieved for
assumed. oil. This is because gas controls are typically capable of
finer adjustment than their oil counterparts.
The commissioning engineer shall ensure that:
The manufacturer’s instructions for the adjustment of
- All instruments are calibrated, comply with the controls for fuel regulation and flame supervision and the
specified levels of accuracy and resolution and are setting or positioning of components such as restrictors,
ready for use. Specifications for instruments are baffles, flame dishes, etc. shall be followed exactly.
detailed in Appendix BA1 to this Code.
The burner shall be inspected to ascertain that the correct
- A complete, faultless dry run shall be achieved size of fuel injector(s) idare fitted.
before the live r u n is commenced and before
fuel(s) idare admitted to the plant. Note: for atmospheric gas burners, sizes m u s t be
-
permanently marked on burner injectors and shall be
On multi-burner boilers a faultless dry run shall verified. However, verification of these markings
be carried out on every burner before carrying out potentially requires dismantling part of the boiler. An
a live run on any burner. examination of the boiler data label, with reference to the
- On multi-fuel burners, a dry run should be carried boiler commissioning instructions, to verify that the
out on t h e control system for all fuels before correct specification has been supplied shall suffice to
admitting any fuel. If this is not possible, then satisfy this inspection.
other fuels shall be positively isolated during the
dry r u n of the control system of any particular For forced draught gas burners, fixed restrictor sizes shall
fuel, even if those other fuels have been fully be verified and variable restrictors shall be set according
commissioned. to the manufacturer’s instructions.

Note: it is unlikely that multi-fuel burners in For oil burners, oil nozzles must be marked. The nozzle
commercial applications will cater for more than manufacturer, size (usually expressed as US gal/h), spray
two fuel types and are therefore commonly known angle (expressed in degrees) and the spray style (solid,
as dual-fuel burners. hollow etc.) of oil nozzle(s) shall be verified. The nozzle(s)
 Activation, dry and live runs 15

fitted to the burner(s) must conform with the make, size (f> non-return valves operate correctly
and style specified by the burner supplier.
(g) timing devices are set correctly

88.2.1 Control and interlock devices (h) before an air pre-purge, the air switch proves ‘no
airflow’ a n d switches to ‘airflow confirmed’
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position when .the burner fan starts

Control and interlock devices shall be set to provisional
operating levels considered safe for commissioning. These (i) an air purge of the combustion space is carried out
include: at the required rate for the appropriate time
- pressure, flow, level and position switches 0’) safe-start check function(s) of the flame guard
system(s) is/are proved for at least two consecutive
- regulators operations
- pressure relief valves
(k) the main flame ignition rate is as required
- dampers (where manually adjustable) (1) ignition source(s) is/are operational; this should be
- flow control systems (including fuel/air ratio checked under the ignition air flow conditions, the
where manually adjustable) correct quantity of which should be checked
- heating system controls and interlocks. (m) flame safeguard systems detect the presence of a
simulated flame or, where permissible, a n
independent flame source
B8.2.2 Burner controls and flame supervision
(n) flame safeguard systems go to the correct shut-
Provided t h a t the plant conditions allow, a n d with down condition, for example lock-out, within the
auxiliary energy supplies available, all power equipment specified time period when a simulated flame is
and interlocks shall be checked for correct operation. The removed
controls shall be proved to execute the correct sequence, (0) for gas fired burners, the sequence of ignition
including t h e appropriate response to all interlock source, start gas and the opening of the main safety
operations. shut-off valves is correct and that the safety shut-
off valves remain leak tight after operation; for oil
Some of t h e following checks may entail electrical fired burners, the sequence of ignition source and
alterations of a temporary nature, for example by linking- low flame valve opening is correct and that the
out of interlocks. In such cases, care shall be taken to valve remains leak tight after operation
ensure that the safety of the plant is not affected adversely
and that hazard is not caused to the engineer or other (p) t h e required cooling medium is provided as
parties. necessary, for example air cooling for uv flame
detector heads
Voltages higher than normal plant voltages are used in (4) the shut-down sequence, including any water
electrical control equipment, such as flame safeguard heating run on requirements, is correct.
circuits and high-tension ignition sources. In addition,
these circuits often include large capacitances which can All interlocks shall be reinstated prior to the live run.
present an electrical shock hazard, even after t h e
equipment has been switched off. I n view of this, care
shall be taken in making temporary connections. 68.3 Live run
A purge of the combustion space shall be carried out Fuel shall now be made available to the burner. For gas,
before checking of any ignition source. pipework shall be purged. For oil, pipework shall be
purged up to the pump vent point. Freedom of movement
of the isolation valve(s) shall be checked at this time.
B8.2.3 Checks

Checks shall be carried out, where appropriate, to ensure B8.3.1 Start up

that:
(a) motor drives rotate in the correct direction B8.3.1.1 For gas: start-gas verification
(b) dampers and associated interlocks operate satisfac- With the main gas and other fuels prevented from flowing
torily into the main burner and provided the heating system
(c) flow control systems and interlocks operate satis- conditions allow, start-gas should be made available and
factorily the start-gas ignition and shut-down system shall be
checked in the following order:
(d) remaining interlocks operate satisfactorily
(a) Ensure t h a t t h e combustion space is purged
(e) valve proving systems operate appropriately, adequately.
including the manual checking for gas tightness of
the system with: (b) Check that all fan controls, air dampers, flue
dampers and throughput controls are correctly set
- all valves closed and leak tight and/or activated to provide safe ignition.
- a valve open or with a deliberately induced (c) Ensure the establishment of a stable start-gas
leak flame. Any temporary alteration made to enable
 16 Boilers

setting up of a start-gas flame shall be reinstated A purge of the combustion chamber and flueways shall be
prior to making main gas available. carried out prior to every attempt at first-stage ignition of
the first burner in a combustion chamber.
Confirm t h a t t h e start-gas flame is of t h e
designated size/start-gas rate and in a position
B8.3.2 Main flame
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which would allow satisfactory ignition of the

main gas flame.
Care shall be taken to ensure that cold boilers are not
Confirm the leak tightness of any pipework joints subjected to heating up rates that exceed the maximum
downstream of the start-gas safety shut-off valve(s) rate stated by the boiler supplier.
using a suitable leak detection fluid o r gas
detector. Note: this is especially true of both welded steel and cast
Confirm that the strength of signal to the start-gas iron boilers.
flame detector is satisfactory.
When new hydronic heating systems are being heated for
Ensure that the failure of the start-gas flame is the first time, care shall be taken to meet any system
detected and that this results in the correct shut- limitations such as the thermal effect on cements and
down condition, for example lock-out. ceramics of underfloor heating circuits.
Ensure that, with the burner shut-down, the safety
A purge of the combustion chamber space and flueways
shut-off valve(s) remain(s) leak tight.
shall be carried out whenever the main flame ignition
Prove the sequence by repetition of procedures to attempt on the first burner in a common combustion
check for reliable ignition shut-down of the start- chamber is unsuccessful or whenever the main flame is
gas flame. extinguished, even though the start gas may have ignited.

A purge of the combustion chamber and flueways shall be In addition, where multiple burners fire into a common
carried out prior to every attempt at start-gas ignition of combustion chamber, a check shall be made on any
the first burner in a combustion chamber. interaction between burners following commissioning, for
example stability, firing rate or aidfuel ratio.

B8.3.1.2 For oil: first-stage verification

88.3.2.1 For gas: main gas verification
With the main flame oil and other fuels prevented from
flowing into the main burner and provided the heating With main gas available and controls restricted to the
system conditions allow, oil should be made available and main flame ignition rate and provided that the heating
the first-stage ignition and shut-down system shall be system conditions allow, ignition and shut-down of the
checked in the following order: main flame shall be checked in the following order:
Ensure that the combustion space is adequately
Ensure t h a t t h e combustion space is purged
purged.
adequately.
Check that all fan controls, air dampers, flue
Check that all fan controls, air dampers and flue dampers and throughput controls are correctly set
dampers are correctly set and/or activated t o andlor activated to provide safe ignition.
provide safe ignition.
Ensure that the burner is set to give excess air
Ensure the establishment of a stable first-stage prior to main gas ignition.
flame. Any temporary alteration made to enable
setting up of a first-stage flame shall be reinstated Establish a start-gas flame.
prior to making main gas available.
Establish a safe, stable main gas flame at t h e
Confirm that the pump pressure is adjusted to the designated main flame ignition rate.
designated level and the size of the first-stage Adjust burner for correct flame shape, size, colour
flame would allow satisfactory ignition of the main etc. as specified by the manufacturer.
flame.
Confirm the leak tightness of any pipework joints
Confirm the leak tightness of any pipework joints downstream of the main gas safety shut-off valve(s)
downstream of the pump. using a suitable leak detection fluid o r gas
Confirm that the strength of signal to the first- detector.
stage flame detector is satisfactory. Confirm that the strength of the signal to the main
Ensure that the failure of the first-stage flame is flame detector is satisfactory.
detected and that this results in the correct shut- Ensure that failure of the main flame is detected
down condition, for example lock-out. and that this results in the correct shut-down
condition, for example non-volatile lock-out.
Ensure that, with the burner shut-down, the safety
shut-off valve(s) remain(s) leak tight. Ensure that the main gas is re-established as in (b)
to #I above.
Prove the sequence by repetition of procedures to
check for reliable ignition shut-down of the first- Ensure that all appropriate interlocks operate
stage flame. correctly.
 Operation and calibration 17

B8.3.2.2 For oil: main flame (second stage) (g) Setting up any additional combustion controls,
verification such as oxygen trim, boiler temperature controls,
etc, as detailed in the supplier's instructions.
With oil fuel available and controls restricted to the main After shut-down, checking that the safety shut-off
flame ignition rate and provided that the heating system (h)
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valves remain leak tight.

conditions allow, ignition and shut-down of the main
flame shall be checked in the following order: Important: a complete, faultless live run shall be
Ensure that the combustion space is adequately achieved before proceeding to the operation and
purged. calibration period.
Check that all fan controls, air dampers and flue
dampers are correctly set and/or activated to
provide safe ignition. Operation and calibration
Ensure that the burner is set to give excess air
prior to main flame ignition. T h e commissioning manager shall be responsible for
ensuring the completion of the operation and calibration
Establish a first-stage flame. period.
Establish a safe, stable main flame a t t h e
On completion of a faultless activation period the plant
designated pump pressure. shall be brought up to the specified operating conditions
Adjust burner for correct flame shape, size, colour and, provided that the heating system conditions allow,
etc. as specified by the burner supplier. acceptance trials shall be carried out, during which final
adjustments shall be made.
Confirm the leak tightness of any pipework joints
downstream of the pump.
Confirm that the strength of the signal to the main B9.1 Establishment of operating
flame detector is satisfactory. levels
Ensure that failure of the main flame is detected
and that this results in the correct shut-down By appropriate adjustment of the heating system controls,
condition, for example lock-out. the plant shall be brought up to operating conditions and
the following checks and adjustments shall be made:
Ensure that the main flame is re-established as in
(b) to (f) above. (a) The flue draught at the outlet of the boiler shall be
measured and the settings of draught stabilisers,
Ensure that all appropriate interlocks operate manual dampers and/or mechanical extract
correctly. systems calibrated to provide the level of draught
recommended by the boiler supplier. Manual
dampers shall be locked at the position required
B8.4 Further checks by calibration tests. In a multi-boiler installation
and where necessary this calibration shall be
With the main flame established and provided that the
'
repeated for each permutation of boilers operating
heating system conditions allow, other operating levels and on standby.
shall be established (see B9). The prescribed tests shall be (b) The calibration of the boiler control device shall
carried out across the operating range of the heating be validated by comparison with water temper-
system, for example in terms of temperature, rating, ature measurements made at the outlet of the
pressure, etc. boiler.

These shall include where appropriate: (c) T h e boiler thermometer calibration shall be
validated by comparison with temperature
Setting up of the aidfuel ratio controls as detailed measurements made at the outlet of the boiler.
in the supplier's instructions. The heat input to each burner shall be validated at
(d)
Ensuring a safe and stable main flame across all full and part rates.
b u r n e r stages a n d rates, especially where With the boiler(s) operating at full and part rates,
modulating burners are being used. (e)
the draught in the flue and chimney system shall
Checking burner combustion characteristics, flue be validated and within the range(s) prescribed by
draught conditions and boiler efficiency data. the boiler manufacturer.
F o r gas boilers, checking t h a t t h e inlet gas (f) Combustion characteristics shall be validated and
pressure to individual appliances is adequate with satisfactory in each boiler at full and part rates.
the system and all other building gas requirements For flame reversal boilers, the same tests shall be
at full demand. made at the first hot gas return point adjacent to
the burner.
Checking the correct operation of any remaining
interlocks, including heating system interlocks. (g) Oxygen/carbon dioxide levels shall be those
recommended by the boiler supplier at full and
Re-checking and recording the level of operation part rates. Harmful and noxious emission in each
of all interlocks. boiler shall be validated and be within permitted
 18 Boilers

limits at full and part rates. For flame reversal T h e combustion efficiency shall be calculated a n d
boilers, the same tests shall be made at the first hot recorded (see BA1.ll and BA1.12). T h e record shall
gas return point adjacent to the burner. identify the boiler being tested and include the date and
time of the test. A print-out from an electronic analyser is
The temperature rise through each boiler shall be
preferred but not essential.
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validated and not exceed the maximum value

prescribed by the boiler manufacturer.
The combustion efficiency value shall have reasonable
The return water temperature to each boiler shall correspondence with the value declared by the boiler
be validated and remain above the minimum value manufacturer for the operating conditions prevailing. In
prescribed by the boiler manufacturer, except assessing the degree of correspondence the commissioning
during the initial start-up phase. manager shall take note and account of the requirements,
selection of instruments and likely error factors described
Validation of return water temperatures(s) shall be in BS 7190(48).
made at all permutations of system heating zone
availability and especially during the transient
conditions created when a cold zone is opened to a Note: on-site conditions relating to boiler water temper-
heated boiler. atures and chimney draught can never be controlled to
reproduce 'laboratory' conditions. It is therefore unlikely
The flow water temperature from each boiler shall that the combustion efficiency value calculated from a
be validated and not exceed the maximum value measured flue loss will achieve exact correspondence with
prescribed by the system designer. the 'laboratory' values declared by the boiler manufac-
turer. Variation from the declared value may be upward or
When new hydronic heating systems are being downward.
heated for the first time, care shall be taken to
meet any system limitations such as the thermal
A permanent record of the values of combustion efficiency
effect on cements and ceramics of underfloor
measurements shall be made in the boiler log book.
heating circuits.

With the boiler(s) and heating system at or near equilib-

rium conditions and close to their intended operating B9.2 Boiler over-heat test
temperatures the heat input and combustion efficiency
shall be measured for each boiler. Each individual boiler shall be tested to ensure that its
water temperature over-heat device is correctly calibrated
Heat input and combustion efficiency measurements shall and operates correctly.
be made at the maximum input rate of each boiler and at
part load with reduced firing rates. For boilers equipped The boiler temperature control device shall be temporarily
with modulating burners, at least one intermediate setting disabled and, using the boiler isolating valves, the water
between maximum and minimum firing rates shall be flow through the boiler shall be restricted so that the
checked for combustion efficiency. At each setting the boiler water temperature increases at a rate not exceeding
system shall be at or close to equilibrium conditions. A one degree Celsius per 30 seconds. The boiler over-heat
permanent record of the values of combustion efficiency device shall operate a t t h e maximum p e r m i t t e d
measured shall be made in the boiler log book. temperature to shut off the burner. The over-heat device
must be of the manual re-set type and it shall be possible
to reset the device when the system has cooled to below
B9.1.1 Heat input the normal boiler operating temperature.

For gas burners, gas flow rates shall be measured and On completion of the boiler over-heat test the boiler
recorded (see BA1.4). control device operation and normal water flow conditions
shall be reinstated.
For oil burners, oil flow rates shall be calculated and
recorded (see BA1.5). Note: boiler over-heat thermostat calibrations are usually
as follows:
The calorific value of the fuel should be obtained from the
fuel supplier and recorded (see BA1.6). - LPHW and LTHW boilers: 100 "C (+O/-6 "C)
- MPHW and MTHW boilers: 120 "C (+O/-6 "C).
Heat inputs shall be recorded and shall be calculated by
multiplying the flow rate by the declared calorific value of
the fuel being used (see BA1.7). B9.3 Boiler log book
B9.1.2 Combustion efficiency T h e boiler log book is t h e definitive record of t h e
commissioning and servicing histories of a burner and
The values of the oxygen (or carbon dioxide) concen- boiler. It provides a permanent historical record of the
tration, carbon monoxide concentration, exhaust gas pre-commissioning checks and commissioning data that
temperature and the ambient air temperature shall be are to be used as a benchmark for re-calibration at the
measured simultaneously and recorded. Where i t is time of maintenance, service or repair.
required that other exhaust components are measured, for
example nitroudnitric oxide, sulphur dioxide, particu- T h e boiler log book should be made available as a
lates, etc. the measurements shall be made of the same reference document for engineers on every occasion that
combustion gas sample (see BA1.8, BA1.9 and BA1.lO). the burner and/or boiler is inspected.
 Recording data, reporting and training 19

On-going endorsement of the boiler log book by service - confirmation of operating levels including a
and maintenance personnel provides a permanent record comparison with design requirements
of the maintenance and service histories of a burner and -
boiler. settings of all control and safety devices associated
with the boilers
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Note: the correct use of t h e boiler log book may be - details of a m e n d m e n t s and/or alterations to
included as a condition of enhanced guarantee by the original drawings including confirmation that the
suppliers of boilers and burners. It is often the case that a drawings are a true record of t h e completed
manufacturer of equipment will require a duplicate copy installation.
of the pre-commissioning and commissioning reports in
the boiler log book to be lodged with them as proof of
correct commissioning B10.4 Training
Note: the creation of and maintenance of a comprehensive T h e commissioning manager shall be responsible for
boiler log book should be regarded as evidence of good ensuring the comprehensive training of nominated
housekeeping by property insurers. operators, supervisory and maintenance staff. Instruction
shall include:
Guidance on’ the minimum information which shall be
recorded in a boiler log book is included in this Code as - identification of all components comprising the
Appendix BA2. Additional information on boiler log installation and explanation of their functions
books may be obtained from the British Combustion - the correct lighting-up and shut-down procedures
Equipment Manufacturers Association (BCEMA)*.
- the adjustment of operating variables
- the action(s) to be taken under fault conditions
B10 Recording data, reporting - the checking of interlock devices, in that they
function correctly, with particular reference to the
and training frequency of such checks (see B10.5)
T h e commissioning manager shall be responsible for - the regular trial firing on the alternative fuel of
e n s u r i n g t h e recording of data, completion of t h e dual fuel systems
commissioning report and training responsible persons in -
procedures for operation and maintenance of the boiler(s). advice on the method and frequency of main-
tenance and servicing, the life of replaceable items
and allied maintenance and servicing aspects.
B1O.l Recording - recording of data in the boiler log book.

T h e commissioning manager shall be responsible for

ensuring that the boiler log book for each boiler and B10.5 Interlocks
burner is completed and handed on to the appropriate
nominated operative (see B9.3 and B10.4). The frequency of checking interlocks will depend on the
nature of the heating system and the operational pattern.
Some checks are subject to existing Codes and require-
B10.2 Labe1ling ments, e.g. pressure relief valves. As a general principle,
t h e operation of each interlock shall be checked as
T h e commissioning manager shall be responsible for frequently as possible, compatible with plant operating
ensuring that clear lighting-up a n d shut-down etc. and maintenance schedules.
procedures are displayed permanently on each boiler in an
accessible position and in a way that can be easily read in
the prevailing lighting conditions.
B11 System handover
He/she shall further ensure that there is provision for the
clear identification of all pipes, valves and switches in T h e commissioning manager o r h i d h e r appointed
order that their function can be readily understood. nominee shall assist the main contractor at the time of
handover.

B10.3 Reporting
B11 .I Witnessing
T h e commissioning engineer shall be responsible for
ensuring that a written report is made to t h e main A programme for witnessing shall be included in the
contractor detailing the following: commissioning programme and should include:
- modifications and/or variations to the original - audit of equipment
design required by t h e constructors and/or
commissioning engineer(s) - verification of boiler operation
- verification of records
* British Combustion Equipment Manufacturers Association (BCEMA),
58 London Road, Leicester, LE2 OQD - verification of log books
 20 Boilers

- verification of labelling and placement of light-up 8 Refngerating systems CIBSE Commissioning Code R (London:
instruction for each burner Chartered Institution of Building Services Engineers) (2002)

- verification of operating manuals and system W a t e r distriburion systems CIBSE Commissioning Code W
( L o n d o n : . Chartered I n s t i t u t i o n of Building Services
documentation
Engineers) (2002)
Licensed copy from CIS: giovani.tauckoor@bdsp.com, BDSP Partnership, 23/04/2012, Uncontrolled Copy.

- verification of operator training. 10 Building control systems CIBSE Guide H (London: Chartered
Institution of Building Services Engineers) (2000)
61 1.2 0perat ion 11 Commissioning water systems - application principles BSRIA
Application Guide AG2B9.3 (Bracknell: Building Services
Research and Information Association) (2002)
At the time of handover the commissioning manager or
hislher nominee shall demonstrate that the boilers operate 12 Commissioning air systems - applications procedures in buildings
correctly. This shall include: BSRIA Application Guide AG3/89.3 (Bracknell: Building
Services Research and Information Association) (2002)
the faultless light-up of every burner
13 Commissioning of gas-fired plant on industrial and commercial
the faultless operation of every boiler individually premires IGEMIUPI4 (2nd edition) (London: Institution of Gas
and in association with others Engineers and Managers) (1999)
the safe exhaust of all combustion gases 14 Installation of gas appliances in industrial and commercial premises:
P a r t l : Flued appliances IGEM/UP/10 (London: Institution of
the achievement of correct operating temperatures Gas Engineers and Managers) (2001)
conformity with manufacturer’s technical specifi- I5 Construction (Design and Management) Regulations 1994
cation and installation requirements Statutory Instrument 1994 No. 3140 (London: The Stationery
Office)
the safe shut-down to lock-out of each individual
boiler in the event of over-heat of other plant 16 The Building Regulations 2000 Statutory Instrument 2000 No.
malfunction. 2531 (London: The Stationery Office) (2000)
Boiler (Efficiency) Regulations 1993 Statutory Instrument 1993
Where required by the witness, the following measure- No. 3083 (London: The Stationery Office) (1993)
ments shall be demonstrated:
Health a n d Safety a t Work etc. Act 1974 ( L o n d o n : T h e
- t h e combustion efficiency of each boiler Stationery Office) (1974)
individually and in association with others Management of Health and Safety at Work Regulations 1999
- t h e levels of harmful a n d / o r noxious gases Statutory Instrument 1999 No. 3242 (London: The Stationery
components of the exhaust gases. Office)
20 Workplace (Health, Safety and Welfare) Regulations 1992
Statutory Instrument 1992 No. 3004 (London: The Stationery
Office)
References 21 T h e Working Time Regulations 1999 Statutory Instrument
1 Conservation of fuel and power in buildings other than dwellings The 1999 No. 3372 (London: The Stationery Office)
Building Regulations 2000 Approved Document L2 (London:
22 T h e Working Time Regulations 1998 Statutory Instrument
The Stationery Office) (2001)
1998 No. 1833 (London: The Stationery Office)
Heating CIBSE Guide B1 (London: Chartered Institution of
23 Electricity at Work Regulations 1989 Statutory Instrument
Building Services Engineers) (2002)
1989 No. 635 (London: T h e Stationery Office)
Installation and testing of pipmork systems HVCA TR20 (London:
24 Personal Protective Equipment at Work Regulations 1992
H e a t i n g a n d Ventilating Contractors’ Association) (in
Statutory Instrument 1992 No. 2966 (London: The Stationery
preparation)
Office)
4 BS EN 303: Heating boilers. Heating boilers with forced draught
25 Health and Safety (Display Screen Equipment) Regulations
burners: Part 1: 1999: Terminology, general requirements, testing
1992 Statutory I n s t r u m e n t 1992 No. 2792(London: T h e
and marking; Part 2: 1999: Special requirements for boilers with
Stationery Office)
atomizing oil burners; Part 3: 1999: Gas-fired central heating boilers.
Assembly comprising a boiler body and a forced draft burner; Part 4: 26 Confined Spaces Regulations 1997 Statutory Instrument 1997
1999: Special requirements for boilers with forced draught oil burners No. 713 (London: The Stationery Office)
with outputs up to 70 k W and a maximum operating pressure of
3 bar. Terminology, general requirements, testing and marking; Part 27 Gas Act 1995 (London: The Stationery Office)
5 : 2000: Heating boilers for solid fuels, hand and automatically fired, 28 Noise at Work Regulations 1989 Statutory Instrument 1989 No.
nominal heat output of u p to 300 k W ; Part 6 : 2000: Specific 1790 (London: The Stationery Office)
requirements for domestic hot water operation of combination boilers
with atomizing oil burners of nominal heat input not exceeding 70 29 Pressure Equipment Regulations 1999 Statutory Instrument
k W ( L o n d o n : British Standards I n s t i t u t i o n ) (dates as 1999 No. 2001 (London: The Stationery Office)
indicated)
30 Pressure Systems Safety Regulations 2000 Statutory Instrument
5 T h e Gas Safety (Installation a n d Use) Regulations 1998 2000 No. 128 (London: The Stationery Office)
Statutory Instrument 1998 No. 2451 (London: The Stationery
31 Provision and Use of Work Equipment Regulations 1998
Office) (1998)
Statutory Instrument 1998 No. 2306 (London: The Stationery
Air distribution systems CIBSE Commissioning Code A (London: Office)
Chartered Institution of Building Services Engineers) (1996)
32 Reporting of Injuries, Diseases and Dangerous Occurrences
Automatic controls CIBSE Commissioning Code C (London: Regulations 1995 Statutory I n s t r u m e n t 1995 No. 3163
Chartered Institution of Building Services Engineers) (2001) (London: The Stationery Office)
 Biblioqraphy 21

33 Pollution Prevention and Control Act 1999 (London: T h e

Stationery Office) Bibliography
34 Pollution Prevention and Control Regulations 2000 Statutory BS EN 304: 1992: Heating boilers. Test code for heating boilers for atomising
Instrument 2000 No. 1913 (London: The Stationery Office) oil burners (London: British Standards Institution) (1992)
Licensed copy from CIS: giovani.tauckoor@bdsp.com, BDSP Partnership, 23/04/2012, Uncontrolled Copy.

35 Standards of training in safe gas installation HSC Approved Code BS 7671 : 1992: Requirements for electrical installations. IEE Wiring
of Practice COP 20 (Sudbury: HSE Books) (1987) Regulations (London: British Standards Institution) (1992)

36 BS EN 656: 2000: Gas-fired central heating boilers. Type B boilers Essential gas safety (Council of Registered Gas Installers) (2001)
of nominal heat input exceeding 70 k W but not exceeding 300 k W
Working in confined spaces IGEM/SR/S (London: Institution of Gas
(London: British Standards Institution) (2000)
Engineers and Managers)
37 BS E N 267: 1999: Forced draught oil burners. Definitions,
requirements, testing and markings (London: British Standards Code ofpractice for gasfired process plant BG/IM/30 (London: Institution of
Institution) (1999) Gas Engineers and Managers) (1993)

38 BS EN 676: 1997: Automatic forced draught burnersfor gaseous fuels Oil fired commissioning and service technicians manual for pressure jet burners
(London: British Standards Institution) (1997) (2nd edition) (Banstead: Oil Firing Technical Association) (2002)

39 BS 5410-2: 1978: Code of practice for oil firing. Installations of 44 The professional’s guide to safe working practices for oil firing and delivery
k W and above output capacity for space heating, hot water and stem technicians (2nd edition) (Banstead: Oil Firing Technical Association)
suppb purposes (London: British Standards Institution) (1978) (2001)

40 T h e Clean Air Act 1993 (London: T h e Stationery Office) Installation requirementsfor oil fired boilers and oil storage tanks (9th edition)
(1993) (Banstead: Oil Firing Technical Association) (2002)
41 Pre-commission cleaning of pipework systems BSRIA Application The professional’s guide to commissioning and servicing oil fired systems -
Guide AG1/2001 (Bracknell: Building Services Research and Book 2: Pressure jet appliances: commissioning and servicing requitremenis for
Information Association) (2001) technicians (Banstead: Oil Firing Technical Association) (2002)
42 Guide to Good Practice - Site pressure testing of pipework HVCA Design and operating principles (4th edition) (Banstead: Oil Firing
T R 6 ( L o n d o n : H e a t i n g a n d Ventilating Contractors Technical Association) (2002)
Association)
Successful health and safety management HS(G)65 (Sudbury: HSE Books)
43 BS 6644: 1991: Specification for installation of gas-fired hot water (1997)
boilers of rated inputs between 60 k W and 2 M W (2nd and 3rd
familygases) (London: British Standards Institution) (1991) Safety in the installation and use ofgas systems and appliances - Gas Safety
(Installation and Use) Regulations - Approved Code of Practice and
44 Soundness testing and purging of industrial and commercial gas Guidance HSE L56 (Sudbury: HSE Books) (1998)
installations IGEM/UP/l (London: Institution of Gas Engineers
and Managers) (1995) prEN 50379- 1 : Specification for portable electrical apparatus designed to
measure combustion flue gas parameters of heating appliances. Part I : General
45 Soundness testing and direct purging of small low pressure industrial
requirements and test methods Document no. 02/203341 DC (London:
and commercial gas installations I G E M / U P / l A ( L o n d o n :
British Standards Institution) (draft)
Institution of Gas Engineers and Managers) (1998)
prEN 50379-2: Specification for portable electrical apparatus designed to
46 Gas installation pipework, boosters and compressors on industrial and
measure combustion flue gas parameters of heating appliances. Part 2:
commercial premises IGEM/UP/2 (London: Institution of Gas
Performance requirements for apparatus used in statutory inspections and
Engineers and Managers) (1994)
assessment Document no. 02/203342 DC (London: British Standards
47 Code ofPractice for the safe installation, commissioning, maintenance Institution) (draft)
and fault rectification of oil firing equipment O F T E C OCP/1
(Banstead: Oil Firing Technical Association) (1999) prEN 50379-3: Specification for portable electrical apparatus designed to
measure combustion flue gas parameters of heating appliances. Part 3:
48 BS 7190: 1989: Assessing thermal performance of low temperature Performance requirements for apparatus used in non-statutory servicing of gas
hot water boilers using a test rig (London: British Standards fired heating appliances Document no. 02/203343 DC (London: British
Institution) (1989) Standards Institution) (draft)
 22 Boilers

Additional sources of technical

advice
Advice on technical and design requirements may be
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obtained from the following organisations.

General advice on building services:

Building Services Research and Information
Association (BSRIA)
Old Bracknell Lane West
Bracknell
Berkshire
RG12 7AH
Telephone: 01344 42651 1
e-mail: bsria@bsria.co.uk
Web site: www.bsria.co.uk

Advice on gaseous fuel supplies design and gas appliance

installation requirements:
Institution of Gas Engineers and Managers (IGEM)
12 York Gate
London
NW14QG
Telephone: 0207 487 0650
e-mail: general@igem.0rg.uk
Web site: igem.0rg.uk

Advice on oil fuel supplies design and oil appliance

installation requirements:
Oil Firing Technical Association (OFTEC)
Century House
100 High street
Banstead
Surrey
SM7 2”
Telephone: 01737 37311
e-mail: enquiries@oftec.org
Web site: www.oftec.org
 Appendix BA1 : Instrumentation and calculations 23

Appendix BA1: Instrumentation and - *" X

@bar + P g a s )
(273 + tgas)
qv(STP) - qv(measured)
calculations 1013

where qV(STP)is the volumetric flow rate at standard

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BA1. I General temperature and pressure (m3/h), q, measured) is the measured

volumetric flow rate (m3/h), pbaris the barometric pressure
(mbar), pgasis the gas pressure (mbar) and tgas is the gas
Instruments selected shall be appropriate for the type and temperature ("C).
range of measurements to be made.

BA1.5 Oil flow rate

BA1.2 Water temperatures
Oil flow rates should be quoted in kilograms per hour
Immersion thermometers shall be used to obtain (kg/h) and shall be calculated from the measurement of
temperatures for recording in the boiler log book etc. the nozzle pressure (bar) and the declared nozzle size
Surface temperature probes, optical (infra-red) ther- using t h e t h r o u g h p u t data provided by t h e nozzle
mometers etc. sensing the temperature of external surfaces manufacturer.
do not provide sufficiently accurate data to be admitted as
records but may used as indicators to inform an engineer Note: practical advice on the measurement of oil flow rates
of trends in operation. Temperatures shall be quoted as is contained in OFTEC publication: The professional's
degrees Celsius ("C). guide to commissioning and servicing oil fired systems - Book
2: Pressure j e t appliances: commissioning and servicing
requirements for technicians (see Bibliography).
BA1.3 Pressures
(a) Gas supply pressures should be measured with
electronic instruments or liquid filled manometers
BA1.6 Calorific values
and shall be quoted as millibars (mbar).
T h e calorific value for the fuel being used should be
(b) Flue draught should be measured with electronic obtained from the supplier. A declaration of tolerance of
instruments or liquid filled slope gauges and shall such information should be obtained and recorded.
be quoted as pascals (Pa).

(c) Oil pressures should be measured with Bourdon or BA1.7 Heat input
similar mechanical gauges and shall be quoted as
bars (bar).
Heat input rates should be stated in kilowatts (kW). The
(d) Water pressures should be measured with Bourdon heat input shall be calculated by multiplying the measured
or similar mechanical gauges and shall be quoted flow rate by the declared calorific value of the fuel.
as bars (bar).
Note: where gas calorific values are quoted as MJ/m3 the
conversion from MJ/h to kilowatts is 1 MJ/h = 3.6 kW.
BA1.4 Gas flow rate
The gross heat input shall be stated in the commissioning
The standard conditions of temperature and pressure for report. Where boilers are of the condensing type, the net
the sale a n d testing of gas i n the UK are 15 "C a n d heat input shall also be stated.
101.3 kPa. Gas flow rates should be quoted in cubic metres
per hour (m3/h) at these conditions and shall be calculated
from the timing of a fixed volume of gas flowing through a BA1.8 Combustion gas analysis
calibrated gas meter using a calibrated timer. T h e gas
temperature and gas pressure in the metering device shall Combustion gas analysis measurements shall be made
be measured whilst the flow rate measurement is being using purpose designed electronic instruments. T h e
made. The barometric pressure shall be recorded. measurement of oxygen, carbon monoxide, exhaust gas
temperature and ambient temperature values shall be
Note: practical advice on the measurement of gas flow made simultaneously from the same sample. Where
rates using a gas meter are contained i n the CORGI required by the specification, the concentrations of other
handbook Essential gas safety (see Bibliography). combustion gases such as nitroushitric oxides, sulphur
dioxide, etc. shall be measured from the same gas sample.
Note: where gas meters are calibrated in cubic feet, the
factor for conversion from cubic feet to cubic meters is T h e values of carbon dioxide concentration and com-
1 m3 = 35.31 ft3. bustion efficiency shall be computed from the recorded
measurements.
The measured gas flow rate shall be corrected to standard
temperature and pressure (STP) conditions (i.e. 15 "C, A print out of the measurements, computations, date and
101.3 kPa) using the following formula: time of test should be made as a permanent data record.
 24 Boilers

BA1.9 Measurement tolerances Table BA1.2 provides a guide to the specification of

performance of electronic exhaust gas analysers; this
Only instruments capable of measuring within t h e should be regarded as a minimum specification
tolerance specified in Table BA1.l shall be used. These
tolerances are selected such that the error in determining
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the boiler efficiency does not exceed 2%, see BS 7190(A1-1). BA1. I 1 Calculation of exhaust loss
The exhaust loss is a measurement of the heat being lost
Table BA1.l Measurement tolerances (wasted) via the exhaust of the boiler. The exhaust loss is
Measurement Tolerance
calculated from the combustion gas analysis (see BA1.7)
and may be calculated in terms of either the gross or the
Atmospheric air pressure -c 0.05 mbar* net calorific values. The resulting figure shall be stated as
'gross' or 'net' as appropriate.
Chimney draught -c 0.05 mbar*
Gas fuel pressure f 0.05 mbar* The definitive reference document for the calculation of
exhaust gas heat losses based upon carbon dioxide
Oil fuel pressure -c 0.03 bar concentration and temperature shall be BS 7190(A1-1),
section 11.4 et seq.
Fuel flow rate (at nominal t 0.5% by volume
boiler rating)
Notwithstanding, it shall be acceptable to use purpose
Time 0.5 s up to 1 hour
rfr designed commercial electronic instruments that display a
? 1% over 1 hour report of the chemical concentrations and temperature of
an exhaust gases sample and uses these values to compute
Temperatures:
- water f 0.1 "C
combustion efficiency using factors compatible with
- exhaustgas f 5 "C BS 7190.

CO, CO, and 0, rfr 0.2 %

* 1 mbar = 100 N/mZ = 100 Pa BA1.I2 Calculation of combustion

efficiency
BA1. I 0 Electronic combustion gas The combustion efficiency is calculated by subtracting the
percentage exhaust loss from 100 and shall be stated as
a naIys is ins t rument s 'gross' or 'net' as appropriate.

T h e performance levels specified for modern heating The combustion efficiency represents the percentage of
installations by the Building Regulations(A1-2),require the energy not being lost to the exhaust. The commissioning
use of reliable and accurate instrumentation for the report and boiler log book records shall unambiguously
analysis of exhaust gas samples. The use of CO, chemical state t h e basis of calculation (gross o r net) and t h e
absorption instruments and helical bi-metal thermometers operating state of the boiler (full fire, low fire, etc.). The
are unlikely to provide the accuracy and repeatability values obtained represent the instantaneous values of the
required by today's standards. Electronic instruments plant operation at the time of measurement.
based on the measurement of oxygen concentrations using
a conductivity cell and temperatures measured in the same
gas sample using calibrated sensors should be used. BA1 .I3 Calculation of thermal efficiency
Note: at the time of publication of this Code, no standard The thermal efficiency of a boiler may be expressed in
specific to commercial installations is available for terms of the gross or net calorific value of the fuel and is
reference. However, draft European standard p r E N the combustion efficiency minus the boiler case emission
50379(A1-3-A1'5)has been issued for consultation. losses. The measurement of boiler case emission losses is
Notwithstanding, analysers conforming with BS 7927(A1-6) n o t a requirement of commissioning a n d where a n
are commonplace and are accepted as suitable for use in estimate of the thermal efficiency is required the boiler
commercial installations. supplier's data should be used.

Table BA1.2 Minimum performance specification for electronic gas analysers

Measurement Range Accuracy Resolution
Temperature -40 to +600 5 1.0 "C (0-99.9
"C) 0.1 "C
f1.0% of measured value (> 100 "C) 0.5 "C
Draught/pressure -c 100 mbar 0.01 mbar ~ 1 mbark0.l
0 mbar
>10 mbar-cl.0 mbar
Grosshet efficiency 0 to 120% By calculation/computation 0.1%
Oxygen 0 to 21% by vol. f0.2% by vol. (absolute) 0.1% by vol.
Carbon dioxide 0 to CO, max. By calculation/computation 0.01% by vol.
Carbon monoxide 0 to 2000 ppm 220 ppm (to 400 ppm) 1 ppm
CO/CO, ratio - - 0.001
 Appendix BA1 : Instrumentation and calculations 25

BA1 .I 4 Seasonal efficiency A1-3 p r E N 50379-1 : Specification for portable electrical apparatus
designed to measure combustion f l u e gas parameters of heating
appliances. P a r t I : General requirements a n d test methods
Seasonal efficiencies can only be assessed by measuring Document no. 02/203341 D C (London: British Standards
the fuel consumption over a protracted period of time, e.g. Institution) (draft)
a 12-month period, and comparing these with records of
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heat being supplied to the heating system as measured by A1-4 prEN 50379-2: Specification f o r portable electrical apparatus
heat meters installed i n t h e heating system. T h e designed to measure combustion f l u e gas parameters of heating
appliances. Part 2: Performance requirements for apparatus used in
measurement of seasonal efficiency is not a requirement of
statutory inspections and assessment Document no. 02/203342 DC
commissioning. (London: British Standards Institution) (draft)
A1-5 prEN 50379-3: Specification for portable electrical apparatus
designed to measure combustion f l u e gas parameters of heating
References (Appendix BAI) appliances. Part 3: Performance requirements for apparatus used in
non-statutory servicing of gas fired heating appliances Document no.
Al-1 BS 7190: 1989: Method for assessing thermal performance of low 02/203343 DC (London: British Standards Institution) (draft)
temperature hot water boilers using a test rig (London: British
A14 BS 7927: 1998: H e a t i n g appliances f o r heating applications.
Standards Institution) (1989)
Portatble apparatus designed to detect a n d measure specific
AI-2 The Building Regulations 2000 Statutory Instrument 2000 No. combustion f l u e gas products. Requirements (London: British
2531 (London: The Stationery Office) (2000) Standards Institution) (1998)
 26 Boilers

Appendix BA2: Guidance on the - a record of site measurements of parameters that

concern the owner and the supplier.
design of boiler log books
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- The log book is the first document in an on-going

- blown oil or gas fired low or medium pressure historical record of the boiler.
boilers
- gas fired atmospheric low and medium pressure - A pre-commissioning report i n which t h e
boilers. commissioning person is required to be identified
(legibly) and to respond to questions with replies
The documents are divided into two principal sections: ‘yes’, ‘no’ or ‘not applicable’.
- a pre-commissioning checklist - A commissioning report in which the commission-
- a commissioning record. ing person is required to record all measurements
of commissioning data, not only the results of
A third section relating to servicing is outside the scope of calculations or computations.
this Code.
- T h e principal copy of t h e boiler log book is
The guidance document recommends that there should be retained with the plant and available for inspec-
two copies of the pre-commissioning and commissioning tion by servicing engineers.
reports. T h e first copy should be kept with the boiler
equipment, in the plant room and always available to - The equipment supplier is provided with a copy of
engineers carrying out work on the plant; the second copy each report.
should be returned to the supplier for inclusion in their
records and reference in case of malfunction of the plant.
Guidance on typical items to be addressed in the pre-
The documents have been prepared from the point of view commissioning inspection and commissioning procedures
of the burner and/or boiler supplier and are intended as: are given in the example reports shown below as Figures
BA2.1 a n d BA2.2. T h e s e are presented so as to be
- a n aid to e n s u r i n g a smooth commissioning applicable to all types of burner - forced draught oil or
procedure gas, gas pre-mix or atmospheric.
 Appendix BA2: Guidance on the design of boiler loq books 27

PRE-COMMISSIONING RECORD
On completion, please send a copy of this pre-commissioning report t o [manufacturer's name]
record system a t address shown.
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The boiler log book shall be made available t o the service engineer and a record of the work carried
out made for every visit.
Statistics
Manufacturer's address

Engineer's CORGl registration number I

Customer's add ress I
Customer's telephone number I
Site address I
Site telephone number I
Date of commissioning I
Report number I
Date of insoection I
Engineer's name I
I Boiler specification I
Fuel(s)
Electrical supply (single phase or 3-phase)

Plant room check list Yes No NIA

Correct fuel types for burner($
1 Local gas meter fitted I
System fuel appliance isolating v x e accessible ~

, Fuel pipework clean, sound and purged I I I I

1 Fuel isolating valve($ for each burner I
Fuel available at burner
l Suitably rated protective device and isolator for each boiler
and burner
Earth bonded supplies to each boiler and burner
~~
I
Main electric isolator accessible
Safety circuits operate correctly I
System controls operational
Flue system clear and functional
Plant room ventilation conforms to relevant Standard I
Boiler clean and clear of obstructions I
System filled and sound I I I I
Pumps operational and isolating valves open

Figure BA2.1 Example pre-commissioning report pro-forma

 2% Boilers

Boiler system checklist Yes No NIA

Open vented system

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Vent clear and correctly sized

Closed system
Pressurisation unit operational
Pressure relief valve fitted
I Safety relief valve lift pressure I bar
System pressure (static) bar
Water connections correctly fitted
Flow and return isolating valves for each boiler
Shunt pumps for each boiler
Primary loop with shunt pump
Pump overrun control fitted

Flue system check list 1 Yes 1 No I NIA I

Flue type (refer IGEM/UP/I0): I
0 conventional I
0 fan-assisted I I I I
0 fan dilution system I
0 room sealed I I I I
0 balance compartment system
Individual flues
5 hared header
I Header internal diameter mm
Chimney internal diameter mm
Chimney height from floor level (approx) m
Draught stabiliser installed
Manual dampers fitted

Ventilation check list Yes No NIA

Natural venti tat ion

Mechanica I ventilation
I Ventilation interlock functions correctly I

Figure BA2.I Example pre-commissioning report pro-forma -continued

 Appendix BA2: Guidance on the design of boiler log books 29

Other equipment Yes No

Do all other appliances connected to the same chimney have the same
type of burner (e.g. nozzle mix forced draught, atmospheric, pre-mix, etc.)
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If 'NO', has the design been authorised by the commissioning manager?

Add itionaI cornments:

Engineer's declaration: Yes No

This system satisfies the basic requirements of safety and is ready for
commissioning

I Engineer's signature
~ ~
I I
Customer's representative name
Customer's representative signature

Figure BA2.1 Example pre-commissioning report pro-forma -continued

 30 I Boilers

COMMISSIONING RECORD (separate report for each boiler)

On completion, please send a copy of this pre-commissioning report to [manufacturer's name]

commissioning records. Leave the duplicate copy in the boiler log book for future reference.
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Statistics
Manufacturer's address
I Engineer's CORGI registration number I
I Customer's address I
Customer's telephone number
Site address
-phone number
Date of commissioning
Contract number
Report number
Engineer's name

I Single or multi-boiler system I I

Number of boilers
Boiler model reference (manufacturer's product code)
I Boiler serial number I I
I Plant room location reference
I Burner model type
I Fuel type (e.g. natural gas, 35 sec. class D oil)
I Burner operation (e.g. on/off, high/low, modulating)
Fuel consumption Units 1 Low fire High fire

Gas inlet pressure (static) mbar I

Gas inlet pressure - sinqle boiler firing
Gas inlet pressure - all equipment firinq
Gas head pressure (gas forced draught)
Burner manifold pressure (gas atmospheric) mbar
~

Gas flow rate (1 m3/h = 35.31 ft3/h) f?/h

Oil pressure (at oil pump) bar

Nozzle make
Nozz Ie a ng Ie/s p ray pattern
Nozzle capacity kg/h
Heat input kW

Figure BA2.2 Example commissioning record pro-forma

 Appendix BA2: Guidance on the design of boiler log books 31

Combustion gas analysis Units Low fire High fire

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Flow water temperature "C

Return water temperature "C

I Functional checks I Units I Low fire I High fire I

I Gas inlet pressure switch setting I mbar I
I 1'' stage boiler control checked and set to: I "C I
Pdstage boiler control checked and set to: "C
Over-heat device operation checked and set to operate at: "C
Exhaust gas thermostat(s) checked and set to operate at: "C
~~

u)t and safety functions checked I YIN I

I Internal gasloil pipework checked I Y/N I
Additional comments (use separate sheets to record flue dilution system settings and burner head
settings):

Engineer's declaration: I Yes I NO

This boiler has been commissioned in accordance with the manufacturer's
instructions and statutory safety regulations and is ready for use
If the boiler and system CANNOT be commissioned in accordance with the manufacturer's
instructions and statutory safety regulations, state reasons on a separate sheet and inform the
commissioning manager.
Date work carried out
Time started
Time finished I
E nqineer's siq nat ure I
Customer's representative name
Customer's representative signature

Figure BA2.2 Example commissioning record pro-forma -continued

 Index 33

reporting duties 19 Flues 1, 5,6, 11,28

Index safety checks 13-14 Flushing, heating systems 1, 12
Access 5,ll Commissioning manager and management, Forced draught burners 11, 13, 14
Activation period 8,1417 definitions 3 Fuel consumption 30
Airlfuel ratio 16,17 Commissioning managers and management Fuel injectors 14
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Atmospheric burners 13,1415 7-8,lO Fuel meters 6

Automatic valves 6, 12 documentation and labelling 7, 19,26 Fuel supply 1, 3,6, 12, 13
information requirements 5,&7 - see also Gas supplies and pressures
Boiler, definition L2 operation and calibration duties 17, 18 Fuel valves 11, 12, 13
Boiler body, definition 123 pre-commissioning duties 10, 11-13 Fusible links 12
Boiler (Efficiency) Regulations 1993 4,5, 10 system handover 19-20
Boiler log books 3, 10, 14, 18-19, training duties 19 Gas Act 1995 5
24,26-3 1 verification of approvals 6 Gas boosters 12
Boilers Commissioning programme 8, 10 Gas fired boilers and burners 11, 13, 14,
system checklist 28 Commissioning report 14, 19,26, 15-17
- see also Condensing boilers; Flame 30-31 Gas flow rates 18,23
reversal boilers; Gas fired boilers and Commissioning sequence 8-9,14 Gas Safety (Installation and Use) Regulations
burners; Multiple boilers; Oil fired Condensate disposal 1, 11, 12 1998 2,4,5,7
boilers and burners Condensing boilers 3, 12, 13,23 Gas supplies and pressures 12, 17, 23
British Combustion Equipment Manufacturers Confined Spaces Regulations 1997 5 Gas tightness 15
Association 19,26 Construction (Design and Management) Gas train, definition 3
BS 5410-2 11 Regulations 1994 3,598 Gases 18,23-24,31
BS 6644 12 Contract variations 8
BS 7190 18,24 Control device, definition 3 Handover 19-20
BS 7927 24 Control panel, definition 3 Health and safety - see Safety
BS EN 267 11 Controlled shutdown, definition 3 Health and Safety at Work etc. Act 1974 5
BS EN 303 1,ll Controls 1, 13, 14, Health and Safety (Display Screen Equipment)
BS EN 656 11 15, 16, 17 Regulations 1992 5
BS EN 676 11 Council for Registered Gas Installers (CoRGI) Heat dissipation 11, 12, 13
BSRIA AG 112001: Pre-commissioning cleaning 7 Heat inputs 1 I, 17, 18, 23
of pipework systems 12 Cross-bonding 13 Heat losses 24
BSRIA AG 2189.3: Commissioning water systems Heating, effect of commissioning on plant and
1
L Dampers 3, 11, 15, equipment 10, 16, 17
BSRIA AG 3189.3: Commissioning air systems 2 16,17 Heating systems 1, 12, 13, 15, 16
Building Regulations 2000 4,5,6,24 Design 5-6,lO - see also High pressure and high-
Building Regulations 2000: Approved Diagrams - see Documentation temperature hot water systems; Low
Document L 42 Discharge pipes 12,13 pressure and low-temperature hot water
Building Services Research and Information Documentation systems; Medium pressure and medium-
Association 22 combustion efficiency 18,23, 24 temperature hot water systems
Burner, definition 193 heat inputs 18,23 Heating up rates 16
Burner controls 14,15 planning and programming 8, 10 High pressure and high-temperature hot water
Burners 5-6,11,12-13, pre-commissioning 13-14,26-29 systems 1,394
14-17.18 safety checks 13 Hinges, boiler access 11
water temperatures 23 HSE Approved Code of Practice 20 7
Calculations 23-25 - see also Boiler log books; HVCA TR6: Guide to good practice: site pressure
Calibration 3, 8, 14, 17-19 Commissioning report testing of pipework 12
Calorific values 18,23 Door hinges, boiler access 11 HVCA TRZO: Installation and testing of pipework
Carbon dioxidelcarbon monoxide - see Draught and draught stabilisers 3, 11, 17,23 systems 1,4, 12
Combustion Drawings - see Documentation
CE-marking 5,lO-11,13 Dry runs 8,1615 IGEMIUPIl: Soundness testing and purging of
Certificates - see Documentation Dual-fuel burners 14 industrial and commercial gas installations 12
Checklists - see Documentation IGEMfUPIlA: Soundness testing and direct
Chimneys 1, 3, 5 6 , 11 Electricity and electrical safety 1,5,6, purging of small 1020 pressure industrial and
Chlorinated hydrocarbons 5 13,15 commercial gas installations 12
CIBSE Commissioning Code A: Air distribution Electricity at Work Regulations 1989 5 IGEMIUPIZ: Gas installation pipework, boosters
systems 2 Electronic combustion gas analysis and compressors on industrial and commercial
CIBSE Commissioning Code C: Automatic instruments 23,24 premises 12
controls 2 Energy sources 3, 13 IGEMfUPl4: Commissioning of gas-fred plant on
CIBSE Commissioning Code R: Refigeration -see also Fuel supply industrial and commercial premises 2, 14
systems 2 Essential gas safety 23 IGEM/UP/lO: Installation of gas appliances in
CIBSE Commissioning Code W: Water Exhaust systems and gases 11, 18,23, 24 industrial and commercial premises 2, 11
distribution systems 2 Explosion relief 11,13 Inspection 8,13-14
CIBSE Guide BI: Heating 1,2,3,4, 12 - see also Pressure relief valves Institution of Gas Engineers and Managers 2,
CIBSE Guide H: Building control systems 2 11, 12, 14,22
Clean Air Act 1993 11 Filling, heating systems 12 Instrumentation 23-25
Cleanliness 1, 5, 11 Fire protection and alarm systems 1,12, 14 Interlock device, definition 4
Combustion 17-18,20,23-24,31 Flame failure, definition 3 Interlocks
Commissioning 2, 3, 5-10 Flame reversal boilers 17,18 activation 14, 15, 16, 17
Commissioning engineer, definition 3 Flame safeguards and supervision controls 14, checking 12,19
Commissioning engineers 7 15, 16,17 gas boosters 12
activation duties 14 Flue, definition 3 ventilation and exhaust systems 11
information requirements 6, 13 Flue dilution systems 11,12
Isolation and isolation valves 4,6
Flue draught - see Draught and draught boiler access 11
involvement in design 596
permits to work 10 stabilisers dry runs 14
pre-commissioning duties 10 Flue spigot, definition 3 fuel supply 12
 34 Boilers

heat dissipation 12 Oil supply and storage 12 Seasonal efficiency 25

inspection 13 Operating levels 4,17-18 Sensors 12,13
live runs 15 Operation 8,17-19,20 Sequence of commissioning 8-9,14
safety checks 13 Over-heat tests 18 ‘Shall’, definition 1
uncommissioned gas burners 13 Oxygen -see Combustion ‘Should’, definition 2
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-see also Electricity and electrical safety Shunt pumps 12,13

Performance testing, definition 4 Shut-down 3,4,5,15,
Labelling 5, 13, 19 Permits to work 5, 10, 13 16, 17,20
-see also Warning notices Personal protective equipment 4,s Shut-off valves 4, 15, 16, 17
Leak tightness and testing 4, 11, 12, Personal Protective Equipment at Work Smoke detectors 12
15, 16,17 Regulations 1992 5 Smoking 5
Legislation +5 Pipework 6, 11, 12, 13, Soundness testing 11,13
Live runs 8,15-17 16, 17 Specification 4,6-7
Lock-out Pipework layouts - see Documentation Start-gas verification 15-16
definitions 4 Planning and programming 8, 10 Start up 15-16
-see also Shut-down Plant and equipment, effect of commissioning Starting of equipment 13
Log books 3, 10, 14, 18-19, on 10, 16, 17 Sulphur dioxide - see Combustion
24,26-31 Plant rooms 5, 12, 27 System handover 19-20
Low pressure and low-temperature hot water Pollution Prevention and Control Act 1999 6,
. systems 1,4,18 11 Temperatures 18,23
Pollution Prevention and Control Regulations
Test points 14
Main flame 16-17 2000 6, 11 Testing
Management of Health and Safety at Work Pre-commissioning 8, 10-14,26-29
definition 4
Regulations 1999 5 Pre-mix burners 13
-see also Leak tightness and testing;
Manufacturers instructions prEN 50379 24
Over-heat tests; Pressures and pressure
boiler log books 19 Pressure Equipment Regulations 1999 5 testing; Soundness testing
boi1ers 12,16 Pressure relief valves 12,15
Thermal efficiency 24
burners 5, 13, 14, 15 - see also Explosion relief
Thermometers 17,23
combustion efficiency 18 Pressure Systems Safety Regulations 2000 5
Thermostatic valves 13
commissioning 7,8 Pressures and pressure testing 11, 13, 17,23
planning and programming period 10 Timing 10
Pressurisation equipment 1, 12
plant room design 5 Professional’s guide to commissioning and seruicing Tolerances 24
shunt pump sensors 13 Training 5,8, 19
oilfired systems 23
Measurement tolerances 24 Programming 8, 10 Treatment of water 1, 12
Mechanical exhaust, extract and ventilation Project management 7-8 Two-person working 5
systems 11, 12, 17 Provision and Use of Work Equipment
Medium pressure and medium-temperature Regulations 1998 5 Uncommissioned gas burners 13
hot water systems 1,4, 18 Pumps 12 United Kingdom Accreditation Service 7
Method statements 5,s Purging 13, 14, 15,
Modulating burners 18 16,17 Valves 4, 12, 13, 15,
Monitoring 8, 10 16,17
Multi-fuel burners 14 Qualifications 7 - see also Automatic valves; Fuel valves;
Multiple boilers 6, 10, 17 Isolation and isolation valves
Multiple burners 14,16 Records - see Documentation Variable speed drives 6
‘Must’, definition 1 Remotely controlled plant 5 Variations to contract 8
Reporting of Injuries, Diseases and Dangerous Vents and ventilation 1,5, 11, 12,
Nitrous/nitric oxide - see Combustion Occurrences Regulations 1995 5 13,28
Noise at Work Regulations 1989 5 Reports and reporting - see Commissioning Verification 8,lO-13
Non-volatile lock-out, definition 4 report; Documentation Volatile lock-out, definition 4
Nozzles, oil fired burners 14-15 Responsible engineer
definition 4 Warning notices 5, 13, 14
OFTEC OCP/l: Code of practice for the safe -see also Commissioning engineer -see also Labelling
installation, commissioning, maintenance Risk assessments 5,s Water and water circuits 1,6, 12, 18, 23
and fault rectification of oil firing Rotating plant 5 Wiring diagrams - see Documentation
equipment 12 Witnessing 19-20
Oil fired boilers and burners 11, 1415, Safety 1,4-5,8, Working Time Regulations 1998 5
16,17 13-14 Working Time Regulations 1999 5
Oil Firing Technical Association 12,22 - see also Explosion relief; Pressure Workplace (Health, Safety and Welfare)
Oil pressures and flow rates 18,23 relief valves; Shut-down; Shut-off valves Regulations 1992 5