Annual service - steam and hot water boilers (gas and oil fired)
Estimated duration: 6 - 10 hours (plus cool-down time) • Frequency: every 12 months
Equipment Details
| # | Service Action (Annual Additional Items) | Type | Done | Notes |
|---|---|---|---|---|
| Internal Inspection | ||||
| 1 | Full internal inspection (open manhole / handhole, inspect tubes, shell, fireside, waterside for scale, corrosion, pitting) | INSPECT | ☐ | |
| 2 | Inspect refractory and insulation (cracks, spalling, hot spots) | INSPECT | ☐ | |
| Pressure Testing | ||||
| 3 | Hydrostatic pressure test (1.5x working pressure per AS 3788) | TEST | ☐ | |
| Burner Service | ||||
| 4 | Burner service (clean / replace nozzles, adjust air / fuel ratio, combustion efficiency test with flue gas analyser) | CLEAN | ☐ | |
| 5 | Efficiency test (combustion analysis - O2, CO, CO2, stack temperature) | TEST | ☐ | |
| Gaskets and Seals | ||||
| 6 | Replace all gaskets (manhole, handhole, inspection covers) | REPLACE | ☐ | |
| Electrical and Controls | ||||
| 7 | Full electrical test (safety controls, limit controls, flame safeguard, ignition sequence) | TEST | ☐ | |
| 8 | Calibrate all safety controls and operating controls | CALIBRATE | ☐ | |
| Ancillary Systems | ||||
| 9 | Inspect economiser (if fitted) | INSPECT | ☐ | |
| 10 | Inspect condensate return system | INSPECT | ☐ | |
| Compliance | ||||
| 11 | Compliance inspection per AS 3788 (Boilers and Pressure Vessels) | INSPECT | ☐ | |
| 12 | Update boiler log book and compliance certificate | RECORD | ☐ | |
Fluid Specifications (General Guide)
| System | Type / Grade | Notes |
|---|---|---|
| Water treatment chemicals | Oxygen scavenger, pH control, anti-scale | Per water treatment provider |
| Fuel (gas) | Natural gas or LPG as applicable | Check supply pressure |
| Fuel (oil) | Diesel or light fuel oil as applicable | Check supply pressure |
Specifications are general guidelines. Always refer to the boiler manufacturer's service manual for your specific make and model. All pressure testing must comply with AS 3788.
Parts / Consumables Required (Annual Additional)
| # | Part / Consumable | Part Number | Qty | Ready |
|---|---|---|---|---|
| 1 | Manhole / handhole gaskets | 1 set | ☐ | |
| 2 | Burner nozzles | As req. | ☐ | |
| 3 | Refractory cement (if patching) | As req. | ☐ | |
| 4 | Flue gas analyser calibration gas | 1 | ☐ | |
| 5 | Water treatment chemicals | As req. | ☐ | |
| 6 | Boiler water test kit (reagents) | 1 | ☐ |
Notes / Defects Identified
Next Service Due
Technician
Facilities Manager