Boiler Maintenance Checklist

A Boiler Maintenance Checklist is essential for ensuring the safe and efficient operation of boilers. This checklist can be used in eAuditor Audits & Inspections to digitize inspections, making it easier to manage, record, and track boiler maintenance activities. Below is a template for a Boiler Maintenance Checklist you can implement in eAuditor Audits & Inspections.

Boiler Maintenance Checklist

For use with eAuditor Audits & Inspections

Section 1: General Information

1. Facility Name:
2. Location:
3. Date of Inspection:
4. Inspector Name:
5. Boiler Type/Model:
6. Boiler Serial Number:
7. Operating Hours:

Section 2: Daily Maintenance

1. Visual Inspection:
   • Check for any visible signs of leakage or damage.
   • Ensure all gauges are operating correctly and are within normal ranges.
   • Inspect the burner flame for proper color and consistency.
2. Water Levels:
   • Verify that the water level is within the acceptable range.
   • Ensure that low-water cutoff devices are functioning properly.
   • Test water-level alarms.
3. Pressure Checks:
   • Check boiler pressure and compare it to the recommended operating range.
   • Ensure the pressure relief valves are functioning.
4. Temperature Checks:
   • Record boiler water temperature.
   • Verify proper temperature differential between the inlet and outlet.
5. Fuel Levels:
   • Check fuel levels (for oil or gas-fired boilers).
   • Inspect fuel lines for any leaks or signs of damage.

Section 3: Weekly Maintenance

1. Burner Inspection:
   • Inspect the burner for cleanliness and proper operation.
   • Check for soot or debris buildup.
2. Boiler Room Ventilation:
   • Ensure proper ventilation in the boiler room.
   • Check that ventilation openings are clear and unobstructed.
3. Blowdown Procedures:
   • Perform blowdown to remove sediment and impurities from the boiler.
   • Record the blowdown frequency and amount.
4. Check Safety Valves:
   • Test the pressure relief valve manually.
   • Ensure safety valves are not blocked or tampered with.

Section 4: Monthly Maintenance

1. Combustion Air Settings:
   • Check the combustion air intake to ensure it’s unobstructed.
   • Ensure the air-to-fuel ratio is optimized for efficiency.
2. Water Treatment Program:
   • Test water for pH levels and chemical concentrations.
   • Ensure proper treatment of boiler water to prevent scaling and corrosion.
3. Control System:
   • Verify that all control systems, including the thermostat, are working properly.
   • Check that the flame detector or sensor is functioning correctly.
4. Inspect Valves and Piping:
   • Inspect feedwater, blowdown, and other valves for proper operation.
   • Check piping for leaks, corrosion, or damage.

Section 5: Quarterly Maintenance

1. Boiler Shutdown and Full Inspection:
   • Shut down the boiler and allow it to cool for a full inspection.
   • Inspect the interior of the boiler for scale buildup or damage.
   • Clean the boiler’s combustion chamber, tubes, and heat exchanger.
2. Inspect Electrical Components:
   • Inspect all electrical connections for loose wires or corrosion.
   • Check the condition of the control panel and its components.
3. Gasket Inspection:
   • Inspect gaskets on all doors and covers.
   • Replace any gaskets that show signs of wear or leaks.
4. Recalibrate Gauges and Thermostats:
   • Calibrate pressure and temperature gauges for accuracy.
   • Recalibrate thermostats as necessary.

Section 6: Annual Maintenance

1. Complete System Overhaul:
   • Perform a full boiler shutdown and inspection.
   • Disassemble and clean the boiler completely.
   • Test and replace all worn or defective parts.
2. Fire Tube/Water Tube Inspection:
   • Inspect all fire tubes (or water tubes) for scaling or blockages.
   • Clean or replace tubes if necessary.
3. Chimney/Flue Inspection:
   • Inspect the chimney or flue for blockages or buildup.
   • Ensure proper airflow and combustion gas exit.
4. Safety Valve Certification:
   • Verify the certification of safety valves.
   • Replace safety valves that are out of certification or damaged.

Section 7: Record Keeping and Documentation

1. Log Maintenance Activity:
   • Record all maintenance tasks performed.
   • Document any parts replaced, adjustments made, or corrective actions taken.
2. Boiler Performance Log:
   • Record fuel consumption and efficiency.
   • Monitor any changes in boiler performance over time.
3. Inspection Certifications:
   • Ensure that the boiler inspection certificate is up to date.
   • Attach any relevant documents, certifications, or reports to the inspection log.

Section 8: Corrective Actions

1. Non-Compliance Findings:
   • Note any issues found during inspection.
   • Assign corrective actions with due dates.
2. Action Taken:
   • Document any corrective actions taken.
   • Verify the resolution of issues and update the maintenance log.

Section 9: Final Comments and Sign-Off

1. Inspector Comments:
   (Include any final comments or concerns about the inspection)
2. Inspector Signature:
3. Date:

Notes for eAuditor Audits & Inspections Integration:

• Automated Notifications: Set up alerts for upcoming maintenance tasks based on the daily, weekly, monthly, quarterly, and annual schedules.
• Custom Fields: Use custom fields in eAuditor Audits & Inspections for boiler-specific details such as model, serial number, and operating conditions.
• Attach Photos: Use the option to attach photos for visual documentation of any findings.
• Signature Field: Include a signature field to sign off on completed inspections.

This checklist ensures all key aspects of boiler maintenance are covered, improving safety, efficiency, and the longevity of your boiler system.