An Extremely Detailed Preventative Boiler Maintenance Checklist

Preventative Boiler Maintenance Checklist: Daily, Weekly, Monthly, Semi-Annual & Annual

Advanced Boiler Maintenance Checklist

Keeping your equipment running efficiently, safely, and reliably is directly related to the preventative maintenance steps you take. At the same time, conducting regular boiler check ups will help reduce downtime, minimize operating costs, and bolster the overall life of your equipment. Simply put, it makes dollars and sense to have your boiler equipment inspected regularly — outside of any mandated annual inspections. 

In fact, you can use ATI of New York's boiler maintenance checklist as a general guide for preventative maintenance. For your convenience, we've broken this checklist down into daily, weekly, monthly, semi-annual, and annual boiler maintenance steps you can take to get the most from your equipment.

Daily Preventative Boiler Maintenance Checklist

  • Blow primary LWCO down while burner is firing and verify proper burner interruption

  • Verify Auxiliary LWCO operation. Verify Burner Shutdown and Manual Reset. 

  • Test All Water Level Controls for Proper Operation

  • Check All Gauges, Monitors and Indicators for Proper Operation

  • Observe Burner Starting Sequence and Flame Characteristics to Verify Normal Behavior

  • Check Furnace for Debris, Sooting or Refractory Cracks

  • Record Operating Pressure/ Temperature Reading

  • Check Safety Valves, Hand Holes nad Manways for signs of leakage

  • Check and Record Fuel Oil tank Level (List Level in Notes Field)

  • Was Picture Taken

  • Check Atomizing Air Compressor Operation

  • Stack Temperature Input (Make Notes)

  • Check & Record Feedwater Temperature

  • Check & Record Water Sample Readings for Proper Chemical Treatment

  • Perform Bottom Blowdown

  • DAILY BOILER PREVENTATIVE MAINTENANCE NOTES

Weekly Preventative Boiler Maintenance Checklist

  • Blow primary LWCO down while burner is firing and verify proper burner interruption

  • Verify Auxiliary LWCO operation. Verify Burner Shutdown and Manual Reset. 

  • Test All Water Level Controls for Proper Operation

  • Check All Gauges, Monitors and Indicators for Proper Operation

  • Observe Burner Starting Sequence and Flame Characteristics to Verify Normal Behavior

  • Check Furnace for Debris, Sooting or Refractory Cracks

  • Record Operating Pressure/ Temperature Reading

  • Check Safety Valves, Hand Holes nad Manways for signs of leakage

  • Check and Record Fuel Oil tank Level (List Level in Notes Field)

  • Was Picture Taken

  • Check Atomizing Air Compressor Operation

  • Stack Temperature Input (Make Notes)

  • Check & Record Feedwater Temperature

  • Check & Record Water Sample Readings for Proper Chemical Treatment

  • Perform Bottom Blowdown

  • Check Operating Control Operation. During This Check, Observe the Operation of the Primary Flame Safeguard to Confirm Proper Operation. 

  • Take Picture Prior to Wipedown of the Unit

  • Wipe Down Entire Unit. Remove All Dust and Oil

  • Take Picture After Wipedown of Unit

  • Verify Operation of Flame Safeguard. 

  • Record Pilot & Main Flame Signals. 

  • Verify Operation of Main Fuel Valves.

  • Verify Proper Setting and Operation of Modulation Control

  • Check Chemical Feed Equipment

  • WEEKLY BOILER PREVENTATIVE MAINTENANCE NOTES

Monthly Preventative Boiler Maintenance Checklist

  • Blow primary LWCO down while burner is firing and verify proper burner interruption

  • Verify Auxiliary LWCO operation. Verify Burner Shutdown and Manual Reset. 

  • Test All Water Level Controls for Proper Operation

  • Check All Gauges, Monitors and Indicators for Proper Operation

  • Observe Burner Starting Sequence and Flame Characteristics to Verify Normal Behavior

  • Check Furnace for Debris, Sooting or Refractory Cracks

  • Record Operating Pressure/ Temperature Reading

  • Check Safety Valves, Hand Holes nad Manways for signs of leakage

  • Check and Record Fuel Oil tank Level (List Level in Notes Field)

  • Was Picture Taken

  • Check Atomizing Air Compressor Operation

  • Stack Temperature Input (Make Notes)

  • Check & Record Feedwater Temperature

  • Check & Record Water Sample Readings for Proper Chemical Treatment

  • Perform Bottom Blowdown

  • Check Operating Control Operation. During This Check, Observe the Operation of the Primary Flame Safeguard to Confirm Proper Operation. 

  • Take Picture Prior to Wipedown of the Unit

  • Wipe Down Entire Unit. Remove All Dust and Oil

  • Take Picture After Wipedown of Unit

  • Verify Operation of Flame Safeguard. 

  • Record Pilot & Main Flame Signals. 

  • Verify Operation of Main Fuel Valves.

  • Verify Proper Setting and Operation of Modulation Control

  • Check Chemical Feed Equipment

  • Check/ Clean Feedwater Strainer

  • Clean Air Filter on Atomizing Air Compressor, Replace Oil Filter and Lubricating Oil

  • Clean Combustion Air Fan and Inlet Assembly

  • Check Rear Door For Flue Gas Leaks. Tighten Bolts As Required. 

  • Manually Blow Down Safety Relief Valves.

  • Clean Scanner Lens. 

  • Test Operation of Low Draft Combustion Air Switches. Verify Burner Shutdown. 

  • Check Low Fire Hold Mechanically and Electrically. Verify Burner Operation

  • Perform Bubble Test on Gas Train

  • Test and Verify Proper Operation of Low Gas Pressure Switch

  • Test and Verify Proper Operation of High Gas Pressure Switch. 

  • Test and Verify Proper Operation of Low Oil & Temperature Pressure Switches

  • Test and Verify Proper Operation of Low Atomizing Medium / Air Pressure Switch

  • Manually Lift and Reseat Safety Relief Valves

  • Check Flue Gas Connector, Vent Connector and Stack for Leaking/ Corrosion

  • Take Picture After Checking Flue Gas Connector, Vent Connector, and Stack for Leaking / Corrosion. 

  • MONTHLY BOILER PREVENTATIVE MAINTENANCE NOTES

Semi-Annual Preventative Boiler Maintenance Checklist

  • Blow primary LWCO down while burner is firing and verify proper burner interruption

  • Verify Auxiliary LWCO operation. Verify Burner Shutdown and Manual Reset. 

  • Test All Water Level Controls for Proper Operation

  • Check All Gauges, Monitors and Indicators for Proper Operation

  • Observe Burner Starting Sequence and Flame Characteristics to Verify Normal Behavior

  • Check Furnace for Debris, Sooting or Refractory Cracks

  • Record Operating Pressure/ Temperature Reading

  • Check Safety Valves, Hand Holes nad Manways for signs of leakage

  • Check and Record Fuel Oil tank Level (List Level in Notes Field)

  • Was Picture Taken

  • Check Atomizing Air Compressor Operation

  • Stack Temperature Input (Make Notes)

  • Check & Record Feedwater Temperature

  • Check & Record Water Sample Readings for Proper Chemical Treatment

  • Perform Bottom Blowdown

  • Check Operating Control Operation. During This Check, Observe the Operation of the Primary Flame Safeguard to Confirm Proper Operation. 

  • Take Picture Prior to Wipedown of the Unit

  • Wipe Down Entire Unit. Remove All Dust and Oil

  • Take Picture After Wipedown of Unit

  • Verify Operation of Flame Safeguard. 

  • Record Pilot & Main Flame Signals. 

  • Verify Operation of Main Fuel Valves.

  • Verify Proper Setting and Operation of Modulation Control

  • Check Chemical Feed Equipment

  • Check/ Clean Feedwater Strainer

  • Clean Air Filter on Atomizing Air Compressor, Replace Oil Filter and Lubricating Oil

  • Clean Combustion Air Fan and Inlet Assembly

  • Check Rear Door For Flue Gas Leaks. Tighten Bolts As Required. 

  • Manually Blow Down Safety Relief Valves.

  • Clean Scanner Lens. 

  • Test Operation of Low Draft Combustion Air Switches. Verify Burner Shutdown. 

  • Check Low Fire Hold Mechanically and Electrically. Verify Burner Operation

  • Perform Bubble Test on Gas Train

  • Test and Verify Proper Operation of Low Gas Pressure Switch

  • Test and Verify Proper Operation of High Gas Pressure Switch. 

  • Test and Verify Proper Operation of Low Oil & Temperature Pressure Switches

  • Test and Verify Proper Operation of Low Atomizing Medium / Air Pressure Switch

  • Manually Lift and Reseat Safety Relief Valves

  • Check Flue Gas Connector, Vent Connector and Stack for Leaking/ Corrosion

  • Take Picture After Checking Flue Gas Connector, Vent Connector, and Stack for Leaking / Corrosion. 

  • Shutdown and Cool Boiler Slowly

  • Remove All Nuts and Clamps Around the Front Door and Flange, Pry Door Loose and Swing Away on Davits

  • Take Picture Prior to Cleaning the Heat Exchanger 

  • Check Refractory and Clean Out Plug

  • Replace Ceramic Fiber Seal or Rope Around Doors

  • Tighten and Cross Torque Front and Rear Door Nuts

  • Clean/Replace Port Sight Glass

  • Flush Air Compressor as Necessary

  • Clean and Adjust Burner Pilot Assembly

  • Re-Calibrate All Indicating and Recording Devices. Record as Completed

  • Steam Boilers, Perform Slow DRain Test of LWCO

  • Check Flame Failure Detection System Components

  • Check Operation of Firing Rate Control

  • Check Piping and Wiring of All Interlocks and Shut Off Valves

  • Check All Wiring Terminations and Wire Insulation Integrity 

  • Disassemble and Clean All Safety Control & Related Piping Including LWCO's, Equalizers, Pressure Control Manifolds & Air Flow Switch Tubes

  • Check and Verify Operation of All Boiler Gauges

Annual Preventative Boiler Maintenance Checklist

  • Blow primary LWCO down while burner is firing and verify proper burner interruption

  • Verify Auxiliary LWCO operation. Verify Burner Shutdown and Manual Reset. 

  • Test All Water Level Controls for Proper Operation

  • Check All Gauges, Monitors and Indicators for Proper Operation

  • Observe Burner Starting Sequence and Flame Characteristics to Verify Normal Behavior

  • Check Furnace for Debris, Sooting or Refractory Cracks

  • Record Operating Pressure/ Temperature Reading

  • Check Safety Valves, Hand Holes nad Manways for signs of leakage

  • Check and Record Fuel Oil tank Level (List Level in Notes Field)

  • Was Picture Taken

  • Check Atomizing Air Compressor Operation

  • Stack Temperature Input (Make Notes)

  • Check & Record Feedwater Temperature

  • Check & Record Water Sample Readings for Proper Chemical Treatment

  • Perform Bottom Blowdown

  • Check Operating Control Operation. During This Check, Observe the Operation of the Primary Flame Safeguard to Confirm Proper Operation. 

  • Take Picture Prior to Wipedown of the Unit

  • Wipe Down Entire Unit. Remove All Dust and Oil

  • Take Picture After Wipedown of Unit

  • Verify Operation of Flame Safeguard. 

  • Record Pilot & Main Flame Signals. 

  • Verify Operation of Main Fuel Valves.

  • Verify Proper Setting and Operation of Modulation Control

  • Check Chemical Feed Equipment

  • Check/ Clean Feedwater Strainer

  • Clean Air Filter on Atomizing Air Compressor, Replace Oil Filter and Lubricating Oil

  • Clean Combustion Air Fan and Inlet Assembly

  • Check Rear Door For Flue Gas Leaks. Tighten Bolts As Required. 

  • Manually Blow Down Safety Relief Valves.

  • Clean Scanner Lens. 

  • Test Operation of Low Draft Combustion Air Switches. Verify Burner Shutdown. 

  • Check Low Fire Hold Mechanically and Electrically. Verify Burner Operation

  • Perform Bubble Test on Gas Train

  • Test and Verify Proper Operation of Low Gas Pressure Switch

  • Test and Verify Proper Operation of High Gas Pressure Switch. 

  • Test and Verify Proper Operation of Low Oil & Temperature Pressure Switches

  • Test and Verify Proper Operation of Low Atomizing Medium / Air Pressure Switch

  • Manually Lift and Reseat Safety Relief Valves

  • Check Flue Gas Connector, Vent Connector and Stack for Leaking/ Corrosion

  • Take Picture After Checking Flue Gas Connector, Vent Connector, and Stack for Leaking / Corrosion. 

  • Shutdown and Cool Boiler Slowly

  • Remove All Nuts and Clamps Around the Front Door and Flange, Pry Door Loose and Swing Away on Davits

  • Take Picture Prior to Cleaning the Heat Exchanger 

  • Check Refractory and Clean Out Plug

  • Replace Ceramic Fiber Seal or Rope Around Doors

  • Tighten and Cross Torque Front and Rear Door Nuts

  • Clean/Replace Port Sight Glass

  • Flush Air Compressor as Necessary

  • Clean and Adjust Burner Pilot Assembly

  • Re-Calibrate All Indicating and Recording Devices. Record as Completed

  • Steam Boilers, Perform Slow DRain Test of LWCO

  • Check Flame Failure Detection System Components

  • Check Operation of Firing Rate Control

  • Check Piping and Wiring of All Interlocks and Shut Off Valves

  • Check All Wiring Terminations and Wire Insulation Integrity 

  • Disassemble and Clean All Safety Control & Related Piping Including LWCO's, Equalizers, Pressure Control Manifolds & Air Flow Switch Tubes

  • Check and Verify Operation of All Boiler Gauges

  • Clean Water Side of Boiler to Include: Open Tri-cocks and Any Vent Valves - (ASME SEC1 Boilers Only)

  • Clean Water Side of Boiler to Include: Drain the Boiler Through Blow Down Valves (ASME SEC1 Boilers Only)

  • Clean Water Side of Boiler to Include: Washdown the Inside of the Boiler with a Hose to Remove Sludge and Scale. (ASME SEC1 Boilers Only)

  • Clean Water Side of Boiler to Include: Remove Hand Hole and Manhole Covers(ASME SEC1 Boilers Only)

  • Clean Water Side of Boiler to Include: Inspect Shell and Tube Surfaces for Corrosion or Scale. Consult Water Treatment Company as Necessary. (ASME SEC1 Boilers Only)

  • Clean Water Side of Boiler to Include: Remove Plugs from LWCO Equalizer Crosses and Clean as Necessary. Remove LWCO Head and Clean Float Chamber: Replace Gasket. 

  • Clean Water Side of Boiler to Include: Replace Hand Hole and Manhole Gaskets. (ASME SEC1 Boilers Only)

  • Clean Water Side of Boiler to Include: Disconnect Feedwater Piping and Inspect for Scale. Check Stop and Check Valve Operation. (ASME SEC1 Boilers Only)

  • Clean Water Side of Boiler to Include: Test Safety Relief Valves. (ASME SEC1 Boilers Only)

  • Clean Water Side of Boiler to Include:  Fill the Boiler with the Feedwater Pump and Reset the LWCO (ASME SEC1 Boilers Only)

  • Temporarily Jumper Operating Control to Test and Verify Operation of Manual Reset High Limit Control. REMOVE JUMPER WHEN FINISHED! 

  • Remove Gas Line Strainer Basket and Clean

  • Conduct Pilot Turndown Test

  • Conduct Intra - Red Refractory Hold Test

  • Check Dual Fuel Changeover Control

  • Replace Scanners and Flame Rods

  • Conduct a Combustion Test Utilize a Flue Gas Analyzer and Tune Burner for Maximum Efficiency

  • Test All Fuel Valve Interlock Switches

  • Perform Leak Test on Pilot and Main Gas and/or Fuel Oil Valves

  • Test Purge Air Switch

  • Test Atomizing Air/Steam Interlock for Proper Operation

  • Test Low Fire Start Interlock

Contact ATI Technical Services Today

When it comes to keeping your boiler running efficiently, safely, and reliably, the experts at ATI Technical Services can help. We're a team of knowledgeable service experts offering the services, resources, and solutions to maximize the life of your equipment while protecting your investment.

Contact ATI Technical Services today.

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