Boiler commissioning: when "start up" does not mean "forget"
Many people believe that the installation of the boiler is completed at the moment of its first ignition. In fact, this is just the beginning. Without proper commissioning and mode settings, even the most modern equipment will run out of fuel, increased wear and risk of failures. And in the worst cases — in violation of industrial safety requirements.
Commissioning is not "just a test", but a point—by-point engineering adjustment that allows the boiler to work as intended by the manufacturer. And regime adjustment is the art of maintaining this balance in all possible operating conditions.
What is the commissioning — on the fingers?
This is a set of measures carried out after installation, but before commissioning. It includes:
- checking the tightness of pipelines and fittings;
- setting up safety automation (thrust, flame, pressure sensors);
- setting up the burner for a specific type of fuel (gas, fuel oil, pellets);
- calibration of temperature and pressure control systems;
- strength and density tests (hydraulic and pneumatic);
- development of emergency modes and shutdown scenarios.
All this is recorded in the report of the commissioning organization, which becomes part of the technical documentation of the boiler house and can be requested by Rostechnadzor during the inspection.
And what is regime adjustment — and why is it needed?
The commissioning is the "start". And the mode adjustment is the adjustment to real conditions.
Each boiler operates in a unique system: its own loads, temperature schedules, heating network features, and consumption schedules. The mode adjustment answers the main question: how to achieve maximum efficiency with minimal fuel consumption?
For this purpose, it is carried out:
- Thermal engineering analysis — measurements of temperature, pressure, and composition of combustion products (including O₂ and CO).
- Construction of operating mode charts showing optimal operating parameters under different loads.
- Setting the excess air ratio is one of the key energy efficiency factors. Is there too much air? Heat is lost with flue gases. Too little? Incomplete combustion and risk of CO formation.
- Debugging automation — so that the system does not "over-heat" on warm days and does not "under-heat" in frosts.
Why are regime maps not a bureaucracy, but a working tool?
Imagine: you have 10 modes of operation depending on the time of day, day of the week and weather. Without a regime card, the staff acts on the eye — "somehow it warmed up, so it's fine." With the card, it strictly adheres to the settings set by the engineers.
As a result:
- Reducing gas consumption by 5-15% is an easily achievable effect even on modern boilers.;
- reducing NOₓ and CO emissions is relevant