Boiler, Steam System and Steam User Audit

Did the Auditor find the Boiler House secure?

Is the Boiler House functionally adequate?

Does the Boiler House provide adequate security to inhibit interference by unauthorised personnel?

Does the Boiler House provide a safe working environment?

Is the Boiler House acceptable to the OH&S Committee?

Does the Auditor consider that all platforms, stairs, walkways, and ladders conform to AS1657?

Is the Boiler clearly marked as a Confined Space fireside and waterside?

Is there clear space to provide safe access, operation and maintenance to all equipment?

Is there the required access and clear space for all electrical panels?

If the noise level is above exposure standard is there a procedure in place to minimise sound levels?

Is Hearing Protection signage in place?

Is PPE available?

Is there adequate ventilation for the Boiler's operation and safety and comfort of the operators?

Are all accessible hot surfaces adequately guarded or insulated and signed?

Is all machinery correctly guarded with guards in place?

Is signage in place on all removable machine guards requiring Isolation prior to removal?

Is signage in place on all removable machine guards warning of entanglement hazard?

Is signage in place on all removable machine guards warning plant starts automatically?

Is there adequate PPE considering heat, steam and chemical hazards?

Is there adequate permanent lighting for the normal operation of the Boiler and it's Auxiliaries, including any necessary outside facilities?

Is there emergency lighting in place?

Is emergency portable (Torch) lighting available?

Is there adequate and suitable fire fighting equipment available considering the fuel and hazard risks?

Is there an operating maintenance program for the fire fighting equipment in place?

Is the fire detection equipment adequate?

Is the equipment and the general maintenance/ housekeeping of the Boiler House done in a manner conducive to fire prevention?

Is there adequate Emergency Exit signage in place?

Do the Exit Doors comply with the Building Code of Australia?

Is the Boiler House kept in a clean and tidy condition, with equipment properly adjusted and maintained to facilitate a safe working environment?

Does the Boiler House have adequate communications available, including outside call access to Emergency Services?

Is the Emergency Shutdown Procedure clearly displayed?

In the opinion of the Auditor, does the electrical installation comply with AS3000?

Is the Main Isolator on the electrical supply lockable?

Are all cables and switchgear legibly labelled?

Is all single insulated wiring enclosed in panels, ducts or conduits, and all double insulated wiring suitably protected from damage?

Are all motors fitted with lockable isolators?

Does the Facility have on site electrical schematics which include wiring marking?

Does the Facility have on site technical data sheets for the electrical components?

Does the Auditor consider that the Boiler House generally complies with AS3892?

Are all floors fire resistant?

Are all floors adequately drained for steam and water and directed away from Boiler and supports?

Is there a minimum clearance for any explosion relief devices, and is it adequately signed or protected so that personnel would not be injured if it operates?

Is the Boiler House within operational temperature limits?

Are the flues designed to withstand wind and earthquake forces?

If a common flue is used, is a partition installed?

With the best knowledge of the Facility, would the Boiler House comply with all Council requirements?

Has there been any additions or alterations to the Boiler House since its original erection?

Does the Auditor believe that the components in the steam plant have been well maintained and operated?

Does the Auditor consider that the Boiler complies with the relevant Australian Standards?

Does the Auditor consider that all valves and fittings (including flanges) are appropriate for the intended use and pressure rating?

To your knowledge, if the Boiler has been altered, modified or repaired by welding, has the work been carried out under supervision of an inspector in accordance with AS3788?

Are Safety Valve seals intact?

Are exhausts vented clear to atmosphere in s safe manner?

Are the Safety Valve exhausts drained to a safe place?

Can the Hand Easing Gear be operated safely if required?

Are the Safety Valves checked regularly to ensure they have not been tampered with and the seals are in place?

Are the Gauge Glasses well lit and visible for the operating position?

Are Protective Safety Shields in place for Gauge Glasses the require them?

Are the Protective Safety Shields made of hardened glass?

Are the Gauge Glasses marked with the operation and alarm points?

Is the Pressure Gauge of a suitable range for the Boiler Pressure?

Is the Pressure Gauge marked with the correct safe working pressure?

Has the Pressure Gauge been correctly fitted with a siphon?

Has the Pressure Gauge been calibrated?

Does the Pressure Gauge appear to be working correctly?

Can the Pressure Gauge be seen from the operating position?

Are the Blowdown Valves in a safe position for operation?

Does the Boiler Blowdown terminate in a safe manner?

Is a Blowdown Tank employed?

Is the Blowdown Tank of suitable design?

Is Automatic Blowdown fitted?

Does the Automatic Blowdown terminate in a safe manner?

Is the Boiler fitted with two Feed Pumps?

Is the Boiler of Unattended or Limited Attendance design?

Do the Feed Pumps change over as per AS2593?

Can each Feed Pump be individually isolated?

Is/are the Feed Water Pump/s protected by an inline suction strainer?

Is there a regular cleaning schedule suitable for the installation?

Are Feed Pumps protected to prevent cavitation, vapour lock or overpressure due to low flow?

Is this achieved by a relief system?

Is the Pressure Relief Valve set to the correct pressure above Boiler Pressure?

Is there sufficient flow to avoid cavitation, vapour lock and overpressure?

Does the relief system return to the Feed Water Tank?

Does the Feed Water Check Valve hold?

Is a Feed Water Control Valve fitted?

Is its operation checked on a regular basis?

Is it fitted with a Manual By-pass Valve and Isolation Valves?

Does the Feed Water Control Valve fail safe to the 'Open' position?

Are Sootblowers fitted?

Is there adequate provision for isolation of Sootblowers?

Can the Sootblower's steam supply be adequately drained before operation?

Are the alignment of Sootblowers checked at the time of Boiler Inspection?

Is there a procedure clearly displayed for operation and time of use for the Sootblowers?

Are Air Heaters fitted?

Are differential pressures recorded regularly and confirmed to be within operation limits?

Are differential temperatures recorded regularly and confirmed to be within operation limits?

Is Gas Outlet Temperature maintained above 'Dew Point'?

Are the Draft Fans inspected at the time of Boiler Inspection?

Do the Operators regularly check the fans for abnormal vibration indicating out of balance situations?

Do the Operators regularly check the fan vanes and dampers for correct operation?

Are Dampers, Ducting and Windbox checked regularly by the Operators to ensure correct operation, no leakages and appropriate operation?

Is a Firing Grate employed?

Indicate the type of Grate

Is the Grate cleaned regularly?

Are moving/actuating components inspected for wear and clinker build-up regularly?

Is the dumping mechanism for emergency shutdown checked for operation regularly?

Is an Economiser employed?

Is there an Economiser Safety Valve fitted?

Is the Economiser Safety Valve serviced at the time of Boiler Inspection?

Are water differential temperatures recorded regularly by Operators and confirmed to be within operational limits?

Is the Economiser inspected at time of Boiler Inspection?

Is the Stack and Duct Work regularly inspected?

Are Stack Stays fitted?

Are Stays checked they are secure at both ends and correctly tensioned?

Where the Stack is considerably higher than the surrounding structure, is there Lighting Strike protection fitted?

Is there a system of instrument checking and calibration that covers all critical instruments on the boiler?

Is there a system in place to prevent alteration to the control system?

Are control loops checked for correct operation on a regular basis?

Is the incoming feed water tested?

Is the water in the feed tank heated?

Is the feed tank size appropriate?

Is the feed tank mounted high enough to prevent feed pump cavitation?

Is there a Deaerator included as part of the Feed Tank?

Is the Deaerator operational?

Is the Deaerator inspected in conjunction with the Boiler?

Is there adequate access to the Feed Tank (and Deaerator if fitted) fo cleaning and inspection?

Is the Feed Tank inspected annually and cleaned out if required?

Are Pressure Reducing Stations installed to good industry standards?

Is all equipment downstream of Pressure Reducing Stations rated for the upstream pressure or protected by adequately sized relief valves?

Has the Steam Distribution System been inspected in the last five years?

Can major steam users be adequately isolated?

Does the isolation of one user isolate other users?

Are there adequate condensate drains to ensure the steam traps are operating correctly and to allow safe steam plant start-up?

Do all steam traps and drains operate?

Is there a planned testing and maintenance system in place for steam traps/pumps?

Select the frequency.

Has there been any alterations or additions to the Steam Distribution System since installation?

Have alteration and additions been considered for total stress on the system?

Have alterations and additions requiring welding been performed by suitably qualified personal?

Have alterations and additions been documented setting out the design, welding procedure notification, Non-Destructive Testing results etc?

Is pipe work adequately labelled and colour coded with flow direction, pressure and contents?

Is all pipe work free from apparent mechanical damage?

Is there a steam system warming valve?

Does the Steam Distribution System seem to be adequately maintained?

Are all Pressure Vessels connected to the Steam Distribution System registered? (If required)

Are all Pressure Vessels inspected in accordance with AS3788 by a qualified inspector at the frequency required?

Are all Pressure Vessels operating within their design limits with respect to Pressure and Temperature?

Can all equipment be isolated for both safety and maintenance?

Are there exposed sections of plant, in the contact zone, that are operating at temperatures above 50 degrees Celsius?

In the opinion of the Auditor is all steam equipment installed, maintained and operated in accordance with good engineering practices?

Is there a suitable water treatment program in place for the boiler?

Is there a reputable feed water treatment company represented on site?

Are standard tests being carried out on Boiler Water, Feed Water, Softened Water, Condensate Return?

Are boiler attendants conducting the tests?

Is there a laboratory on site that confirms water tests?

Does the Chemical Treatment Company audit water tests?

At what frequency is auditing occurring?

Is there adequate stocks of all boiler chemicals on site considering lead time for delivery and normal usage levels?

Is chemical storage suitable?

Is chemical storage dry?

Is chemical storage well ventilated?

Is chemical storage safe?

Is chemical storage adequately signed?

Are the chemicals listed within the site's Dangerous Goods Register?

Are Safety Data Sheets located with the chemicals?

Are chemical drums fit for purpose?

Are chemical drums marked with the chemical name and strength?

Is there a written procedure on the correct method to make-up any chemicals?

What is the frequency of inspection?

Is the history of each Pressure Vessel available including the Manufacturer's Data Sheet?

Are all appropriate inspection certificates available?

Are copies of all Boiler Attendant's Licences held on file and are they all in date?

Is the Boiler of Unattended or Limited Operation?

Is the Registration suitably endorsed?

Is the Registration displayed in the Boiler House?

Is there a current Log Book available in the Boiler House?

Does the Log Book meet the requirements of AS3873?

Is the Log Book being filled-out correctly?

Are all water tests being logged?

Are there Operations Manuals in the Boiler House?

Are there current Process & Instrumentation Drawings available?

Are there current Electrical Drawings & Schematics available?

Are Maintenance Schedules clearly documented?

Are there comprehensive maintenance history records of alterations and repairs available?

Are all Protection Device test records available?

Are there consistent minimum safety standards available and enforced for the control of all work associated with steam equipment by both employee and contractors?

Do only qualified Boiler Attendants Start-up, Operate and Shut Down steam plant?

Are other Operators adequately trained to use the steam plant?

Do other Operators understand the importance of communicating with the Boiler Attendants before altering Steam demand?

Are there regular house keeping inspections by the Services Engineer?

Are all logs/records analysed by the Services Engineer?

Are all out of normal parameters/problems highlighted to the Services Engineer?

Is there a formal documented procedure to report and follow up of plant defects?

Is this system effective to ensure that appropriate corrective action is taken in the appropriate time frame?

Are there pre-printed check sheets (daily & weekly) used to direct operators

Is there an established formal, documented procedure for authorising and recording changes to the system (controls, flow arrangement, equipment etc.)?

Is this system strictly followed?

When components (piping, valves, vessels, materials, etc.) are repaired/replaced, are they actually checked and documented to ensure that they meet the appropriate specification for intended service?

Are Welders tested and certified prior to carrying out welding operations on the system?

Is all welding carried out on the system accompanied by documentation?

Is there a documented procedure for isolation, draining, flushing, and testing/inspection the system prior to commencing work on the system and after completion of work?

Does this procedure include provision for X-ray testing, welds pressure testing, leak testing?

Is a Hot Work Permit system, with provision for after inspection, established and strictly followed for welding, grinding and open flame work?

Are electrical and mechanical lockout procedures strictly followed when it is required to carry out maintenance or modification to the system?

Is Flue Gas tested regularly and the combustion system adjusted to provide efficient combustion?

Is fuel consumption tracked and reviewed against steam product to monitor efficiency?

Does the Auditor consider the boiler is operating efficiently?

Are all boiler attendants certified for the appropriate boilers?

Do all personnel responsible for working with the steam system have appropriate training?

Are all Boiler Attendants trained for the boiler they are using?

Is there ongoing training for boiler room staff?

Are all the operators of major steam consumers trained in the use of steam and their equipment?

Has the maintenance staff been trained for minor breakdowns?

Is the Boiler of Unattended or Limited Attendance status?

Do maintenance staff hold the appropriate qualifications as per AS2593?

Have the Boiler Attendants been provided with detailed duty statements?

Have all Boiler Attendants and maintenance staff been trained in the use of fire-fighting equipment?

Is the Boiler House inspected regularly (daily) by the Service Engineer?

Is there a Third Party inspection of the Boiler to AS3788 annually?

For Unattended and Limited Attendance boiler installations is there a maintenance contract in place in accordance with AS2593?

Are all inspection intervals adequate for the conditions the plant is operating under?

Have all modifications to steam pressure equipment (if any), been carried out in accordance with Australian Standards and the appropriate regulatory authority?

Are Contractors used for work on the system?

Are the Contractors carefully checked for competence and experience prior to hiring?

Is there a single company representative on site who has control of all liaisons with the Contractors that work on steam plant?

Are there other pressure vessels on site?

Are all vessels being inspected by a qualified independent inspector in accordance with AS3788?

Are records of inspection available?

Do all vessels appear to be installed and operated in accordance with legislative requirements?