Boiler Maintenance Checklists for Different Boilers

A boiler maintenance checklist is a checklist of a set of inspection and maintenance tasks to be performed to ensure the proper care and maintenance of your boilers. This checklist is an important component of a preventive maintenance system for your boilers which helps you maximize your boilers’ efficiency and elongate their life. There are several checklists for different scheduled times to ensure that the boilers remain in perfect working condition. 

If like many others, you have any use for industrial boilers, you probably know that they are heavy-duty equipment and that they generate steam or hot water by burning fuel. They are essentially closed vessels used to heat fluids and the steam generated is used in various processes. Boilers usually operate under very high temperatures and high pressures. Since they have to operate in these extreme conditions, it is important to make sure that they are regularly and properly maintained. This is where preventive maintenance and boiler maintenance checklists are extremely useful so that regular checking and maintenance can ensure the reliability and safety of the boilers.

Difference between annual and periodic boiler maintenance

The main difference between an annual and a periodic boiler preventive maintenance checklist is simply the time frame and so the tasks are also such that they last for the specified time. Periodic checklists usually refer to the quarterly checklists or those scheduled every few months. 

A periodic boiler maintenance checklist may include tasks such as:

• Inspect the boilers’ hydronic piping for leakages
• Check all the base-mounted pumps for pump alignment
• Check the switches and the condition of the wiring
• Inspect the burner flames for any significant changes in appearance
• Use water cut-off devices to check and make sure that water levels are within recommended levels
• Check and also replace gaskets if necessary

Annual boiler maintenance checklists contain tasks that ensure a more thorough inspection and maintenance of the boilers than those in periodic checklists by dedicated technicians so that nothing is overlooked.

An annual checklist contains tasks like:

• Shut down the boilers in order to open the access doors and properly inspect the boilers
• Inspect the heating system and correct and resolve any issues
• Service and thoroughly clean all the parts including tubes and tube sheets
• Inspect the burner refractory for cracks bigger than ⅛ of an inch
• Ensure that the water pH levels are within the recommended range
• Look out for heavy scaling in the tubes and check for signs of oxygen corrosion
• Check the gas and safety valves and conduct the manufacturer’s recommended safety tests
• Check the insulating materials for any degradation
• Conduct a thorough inspection of all accessories and parts of the boiler system such as deaerators and chemical feed systems
• Inspect the auxiliary and venting systems for any deterioration, corrosions, or blockages.
• Recalibrate all the operating controls

Daily boiler maintenance checklist Vs. monthly inspection boiler checklist

Other than annual and periodic checks there are also short term inspections and tasks which should be performed daily, weekly, or monthly in order to guarantee optimal performance of the boilers. Even though most people think of maintenance as an annual or bi-annual activity, it’s usually the daily inspections that make the biggest difference and prevent any major damage to the boilers.

Daily maintenance checklist

• Inspect boiler and related equipment for water leakages
• Check temperature and pressure readings in order to make sure they are within range
• Keep an eye out for any service codes or error codes on the display panel and keep the service contractor in the loop
• Listen carefully for any unusual noise or vibration from the boiler equipment
• Check and maintain the oil level in the compressor lube tank
• Check the dealkalizer, water softener, and chemical feed system to ensure that it meets the required levels of chemicals and salts

Monthly maintenance checklist

• Execute out a blowdown of the water column via the common drain valves, and the boiler through the bottom blowdown valves
• Inspect the relief valve and the relief valve discharge pipe for leakage
• Inspect and investigate the drain system, drain trap, PVC fittings, and condensate drain line
• Check on the combustion air piping and gas vent piping for any deteriorations, leaks or blockages
• Check the burners’ diffuser, pilot tube, and valves, for wear and deformation
• Inspect alarms and lights to ensure they are functioning properly
• Do an external inspection of the boiler to check for hot spots
• Check gaskets to ensure tight sealing
• Inspect belts for tension
• Examine access openings to look for air leaks

Different types of boiler maintenance checklists

Preventive maintenance for boilers is more or less generic but different types of boilers also may have additional tasks and inspections associated with them. Here are some of the guidelines on how to manage preventive maintenance checklists for different kinds of boilers and any additional inspections that may arise because of the specific kind of boiler it may be. 

Hot water boiler maintenance checklist

A hot water boiler is used to heat water which is then circulated via a closed-loop pipe system for service water and facility heating. The following tasks are a major part of a commercial hot water boiler maintenance checklist:

• Check the hot water boiler for issues like leakages, corrosion, breakage or malfunctioning parts and repair or replace if needed
• Check all the wiring and electric connections
• Test the water pH level in order to maintain an ideal level
• Check the ventilation system in order to make sure that heat is transferred properly
• Inspect the vent terminators and air inlet for debris and dust and clean them
• Inspect and carry a thorough cleaning of the boiler’s heat exchanger
• Inspect the burner and its flame
• Test the igniter and burner assembly and repair or replace as needed.
• Check the condensate system of the boiler for leaks and any debris or chemical buildup so that the system can be cleaned and flushed accordingly
• Examine and test any controls, safety valves, and user control panels, and repair if needed

Steam boiler maintenance checklist

In condensate systems and steam boilers, heat is passed through water in a boiler which makes the water boil and transform into steam. The steam is then piped to the points that require heat and the steam then condenses to form condensate. The steam boiler preventive maintenance checklist includes:

• Inspect the condensate recovery system
• Test the low water cut off in order to maintain water levels and ensure that they don’t fall below the recommended range
• Calibrate the steam control valves according to manufacturer standards
• Check steam pressure
• Recondition and clean feedwater pumps
• Inspect the condensate trap and drain system and make repairs where necessary
• Inspect and clean the combustion chamber

Gas boiler maintenance checklist

Gas boilers work by burning carbon-based fuel and oxygen in order to produce exhaust gases that escape through a chimney of sorts called a flue. A gas boiler checklist includes:

• Inspect and record gas pressure
• Inspect and record temperature
• Check the water level and ensure that it falls within the range
• Inspect and record the flue gas temperature
• Inspect combustion, burner operation and burner controls
• Check air filters
• Inspect safety valves and test them

DIY gas boiler maintenance checklist

If you have a gas boiler there are always some checks you can do for yourself without any technical help so that you don’t need to call a technical team in so often. If your DIY checks help you maintain your boiler well, then it goes a long way and saves you a lot of costs. If your checks highlight some concerns then you can call for maintenance if you can’t manage it by yourself. A DIY checklist includes:

• Inspect your boiler and its surrounding area for any water that may be leaking
• Check and record gas pressure and temperature to make sure they are within range
• Keep a watch on the display panel for any error codes
• Listen very closely for anything different from the norm like any unusual vibration or noise

Home boiler maintenance checklist

If your home has a boiler then it would be beneficial to have at least an annual inspection and maintenance by a licensed professional. For the rest of the time, you can carry out periodic checks for yourself. A checklist for this purpose would include:

• Check if the radiators heat sufficiently. If they don’t then “bleed” them by placing protective cloth onto the floor and opening the radiator valve with a radiator key. Close the valve when water starts to flow out of it.
• Keep a check on the water level to make sure there is always sufficient water.
• Keep a check on the overflow pipe for water dripping.
• Check for blocked air vents
• Keep a check on the flame. Call help if it turns orange or yellow instead of blue.

Conclusion

Preventive maintenance is extremely important if you want your boilers to have their longest possible life while working at their maximum potential. Building boiler maintenance checklists are a crucial part of the preventive maintenance process for boilers. This is because they help organize and record information and ensure better maintenance for your boilers and other assets. Different types of boilers may have unique inspections and tasks which is why different maintenance checklists may be used in order to make maintenance easier and worry-free.