COMMISSIONING OF BOILER ( PART -V) PNEUMATIC VALVE ,PIPIING CHECKS

Pneumatic valve.

Check the valve position with reference to PID.

Check the availability of secure platform , operation flexibility etc.

Consult manufacturer’s manual to know the detail of the valve

Check the basic characteristic of the valve whether it is air to open /air to close.

Check the damage of the valve controller box and other small items like air filter regulator ,

air lock relays ,small gauges connected with controller box ,position transmitters ( if available) and 

limit switches.

Study the system requirement of the valves in the process.

Check the power air supply ( 0 to 7Kg/cm2 ) and control air supply ( 0.2 to 1.0 Kg /cm2)

Check the function of EP (electro –pneumatic) controller before mounting.

Check the cu-tube /ss –tube connection at different places by charging air . Checking should be done by 

soap solution. Control air piping to be checked thoroughly as signal strength is less and can give 

erroneous reading during calibration.

Charge the air for commissioning. Test jig having ( 0.2 to 1.0 Kg/cm2) to be connected otherwise DCS 

to charge for signal. Before charging of air please flush the line well to remove dirt specially of 

control air line.

Valve operation to  be done five to six times to set the open- close limit switches.

Check the valve in different position through  control air supply jig. Calibrate the valve with zero and 

span . Calibrate the valve position transmitters.

Check the valve stay put condition on failure.

Check the manual operation of the valve ( if available)

Protocol all the checks and readings for future reference.  

Keep the valve in close position.

Checking of Pipelines   :-  General checks

The installation is complete and correct in accordance with the latest approved drawings and 

specification.

Check that all bosses, flanges and tapping points have been adequately made off.

Check that all cold pulls, if required, have been made and records completed.

Check that all pipe falls to drainage points are satisfactory.

Confirm that all blanks still required in the system are identified and recorded in the Blanks Schedule

Check that drains are provided at all points on the steam range where water may collect.

Check that steam traps are fitted with bypass and test connections.

Confirm that all pipework that can be touched from walkways etc, and that reaches a temperature of 60 

deg C or over is adequately lagged.

Check that adequate number of vents are provided on the pipe at highest points.

Check that all supports are undamaged, fixed and mounted vertically, (Except where design requires the support 

at a specified angle).

Check that all support loadings have been correctly set and recorded.

Confirm, where possible, that there is a radial clearance between the pipe and the support clip.

Check that all roller and sliding supports are clean, free to move and so constructed that dirt and water 

cannot accumulate.

Check that all thrust/anchor points are correctly installed.

Check that all the supports as required as per the drawing.

Flush the pipe line properly to open drain to clear of all debris from pipe.

Test the pipeline hydraulically to the relevant standard in presence of Boiler Inspector if required.

Check that all temporary supports have been withdrawn.

Confirm adequate support for small bore, horizontal pipes that may be stood upon (or adequate 

protection for the pipes and supports for system not strong each to withstand additional loads).

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