CONTRACT

SPECIFICATION TECHNICAL
BOILERS
MAINTENANCE TYPE:

STATUTORY

1.0

SCOPE OF SERVICES
The Contractor shall provide maintenance services for the Boilers covered by this Contract. Boilers
include gas fired boilers, oil fired boilers, electric boilers, and steam generators.
The Services shall be carried out at the intervals stated below unless otherwise stated in the
Equipment and Pricing Schedule.

2.0

MINIMUM STANDARD
The minimum standards for periodic inspection and servicing shall be as stated below and in
accordance with the manufacturers recommendations and with the current editions of:

Work Health & Safety Act and Regulation

AS 2593 Boilers - Safety management and supervision systems

AS/NZS 3788 Pressure equipment - In-service inspection

AS 3873 Pressure equipment - Operation and maintenance.

3.0

MINIMUM QUALIFICATIONS
The Contractor must provide evidence to the satisfaction of the Principal that staff performing the
Services have sufficient experience and expertise in this field to competently carry out the Services
required to be considered a conforming offer.
The Contractor shall also ensure that relevant to each activity, only competent persons, such as those
defined by the current editions of the Electrical Safety Act and Regulations (for performing
maintenance servicing on electrical equipment and Electric Boilers), Work Health and Safety Act and
Regulation, and AS 2593 Appendix B, carry out required tests, Services or make logbook entries.

4.0

MAINTENANCE SERVICE AND FREQUENCY

4.1

Frequency of Services
Maintenance and inspection activities shall be carried out according to the attendance type, boiler type
and power and/or pressure ratings shown in the Equipment and Pricing Schedule.
In the absence of any details in the Equipment and Pricing Schedule the following intervals shall
apply:

Periodic Checks and Tests

Monthly

Preventive Maintenance

Yearly

External Inspection

Yearly

Internal Inspection

Yearly

ATTENDANCE
TYPE

Unattended
Operation

BOILER TYPE

a) Water-tube steam and hot

water boilers, excluding
electrical elements
b) Forced circulation coil
steam boilers
c) Combined water-tube,
fire-tube steam boilers
d) Fire-tube hot water boilers

Document: TSW00729

MAXIMUM
POWER
OUTPUT AND
MAXIMUM
DESIGN
PRESSURE

MAXIMUM INTERVALS
Periodic
Checks &
Tests
(Clause 4.2)

Preventive
Maintenance

External
Inspection

Internal
Inspection

(Clause 4.3)

Clause 4.4)

(Clause 4.5)

10 MW
6 MPa

Monthly

Yearly

Yearly

Yearly

10 MW
10 MPa
10 MW
2.5 MPa
5 MW
2.5 MPa

Monthly

Yearly

Two-yearly

N/A

Monthly

Yearly

Yearly

Yearly

Monthly

Yearly

Yearly

Yearly

Date Issued:
The State of Queensland (Department of Housing and Public Works)

Page 1 of 5

CONTRACT

ATTENDANCE
TYPE

BOILER TYPE

e) Electrode or electric
steam boilers (electric
element fails on low
water)
f) Electric element steam
boiler (electric element
may not fail on low water)
g) Boilers all types except f(i)
Limited
Attendance
Operation

a) Water-tube boilers
b) Combined water-tube,
fire-tube boilers
c) All other types including
fire-tube steam and hot
water boilers

Attended
Operation

4.2

All types

MAXIMUM
POWER
OUTPUT AND
MAXIMUM
DESIGN
PRESSURE

f (i)
f
(ii)

MAXIMUM INTERVALS
Periodic
Checks &
Tests
(Clause 4.2)

Preventive
Maintenance
(Clause 4.3)

External
Inspection

Internal
Inspection

Clause 4.4)

(Clause 4.5)

No MW
limit
2.5 MPa

Yearly

Yearly

Two-yearly

Four-yearly

250 MW
2.5 MPa
6 MW
2.5 MPa
500 MW
1.2 MPa

Yearly

Yearly

Two-yearly

Four-yearly

Monthly

Yearly

Two-yearly

Four-yearly

Threemonthly

Yearly

Yearly

Yearly

20 MW
6 MPa
20 MW
2.5 MPa
5 MW
2.5 MPa

Threemonthly

Yearly

Yearly

Yearly

Threemonthly

Yearly

Yearly

Yearly

Threemonthly

Yearly

Yearly

Yearly

No limits

N/A

Yearly

Yearly

Yearly

PERIODIC CHECKS AND TESTS

(a) Check Boiler Log and ensure that daily and weekly checks have been carried out by the owners
representative and note any items requiring attention.
The daily checks shall include the following:
(1) Visually check operation of the water level controls on steam boilers.
(2) Test boiler water for the levels of total dissolved solids.
(3) Check operation of each automatic blowdown system, where appropriate.
(4) Examine all glands, flanges and connections to ensure that there are no substantial leaks.
(5) Examine all locks and seals to ensure that there has been no unauthorized tampering.
(6) Blow down water gauge glasses and check for correct water level all in accordance with AS
3873, where appropriate.
The weekly checks shall include the following:
(1) Check operation of flame failure detection system to shutdown energy input and boiler in
correct order.
(2) For each boiler other than water-heating boilers, operate intermittent (manual) blowdown
while the boiler is off-line.
NOTE: Waterwall headers should only be blown down while the boiler is off-line.
(3) For boilers other than water-heating boilers, blow down any external water level safety
device and check operation of interlock.
(4) Reset any manual reset interlocks, check water level in gauge glasses and restart boiler.
(5) Check start-up sequence and visual sequence indicator operation.
(6) Check that all management systems are operating, all valves are correctly set and water
level is correct before leaving boiler.
(7) Check that feedwater pump operating sequence has changed in accordance with AS 2593
Clause 3.5.3.3.
(8) For hot water boilers incorporating a pressurized expansion system, check that the system
is functioning correctly and check levels in the expansion system are in accordance with the
manufacturers recommendations.
(b) Lower the boiler water level to check the operation of the low water and extra low water devices.
(c) Check the operation of fan and airflow interlocks.
(d) Check safety shut-off valve(s) for leakage.
(e) Check fire start interlock.
(f)
Check steam pressure interlock.

Document: TSW00729

Date Issued:
The State of Queensland (Department of Housing and Public Works)

Page 2 of 5

CONTRACT

(g)
(h)
(i)
(j)
(k)
(l)
(m)
(n)
4.3

For oil: check fuel pressure and temperature interlocks.

For gas: check main gas filter, and high and low fuel pressure interlocks.
Clean and check fuel filters.
Clean and check water filters.
Check the effectiveness of the water treatment.
Check combustion efficiency and flue gas analysis through the normal operating range.
Check flame failure detection system whilst boiler is operational to shutdown the energy input
and the boiler in a correct sequence, then clean the flame detection sensors.
Any other examinations and tests as required by the contractor or authority having jurisdiction.

PREVENTIVE MAINTENANCE
The boiler and its operating and safety systems shall be thoroughly checked and overhauled in
accordance with the procedure for yearly maintenance specified in AS 2593. The procedure shall
include the inspection of all pressure parts, valves and fittings, and in particular the following:

4.3.1 Safety Valve

(a) Overhaul safety valves.
(b) Reset safety valves for correct lifting pressure.
4.3.2 Blowdown Valve
(a) Overhaul blowdown valve.
(b) Remove blowdown leg and carry out inspection.
4.3.3 Gauge Glass Assemblies
(a) Supply and replace gauge glasses.
(b) Supply and replace gauge glass rubbers, cones and balls.
(c) Supply and replace cock glands.
(d) Check cock valves and seats for sealing capabilities.
(e) Remove and clean bottom mount.
(f)
Check protector glass for soundness.
4.3.4 Feedwater
(a) Check feedwater tank operation and float valve operation.
(b) Check feedwater pump and strainer.
(c) Check feedwater pipe and valves for correct operation, corrosion and leaks.
4.3.5 Man and Hand Holes
(a) Supply and replace gaskets.
(b) Check surfaces for sealing capabilities and soundness.
(c) Check bolts.
4.3.6 General
(a) De-soot boiler.
(b) Vacuum clean boiler
(c) Hose out where possible.
(d) Brush out tubes.
(e) Overhaul main steam stop valve.
(f)
Dismantle and check water level controls for correct settings.
(g) Check explosion doors for correct operation.
(h) Check refractory work for soundness.
(i)
Check expansion slides.
(j)
Check boiler - house cleanliness.
(k) Check all reducing, non return, stop valves for correct operation.
(l)
Open boiler for periodic inspection as required by AS/NZS 3788, when appropriate.
Document: TSW00729

Date Issued:
The State of Queensland (Department of Housing and Public Works)

Page 3 of 5

CONTRACT

(m)
(n)
(o)
(p)
(q)
(r)

Clean and examine boiler internally (where appropriate to the type of vessel) for scale or
corrosion (forced circulation boilers normally cannot be inspected internally).
Clean and test every interlock and safety system.
Check electric equipment and wiring.
Check all instruments.
Carry out hydrostatic test before starting-up boiler.
After start-up, check and rectify operation of all components for:
(i)
Correct operation and sequence
(ii) Leaks or loose connections, and
(iii) Correct calibration and adjustment.

4.4

EXTERNAL INSPECTION OF PRESSURE VESSELS

The minimum standards for periodic inspection and servicing shall be as stated below and in
accordance with the current requirements of AS/NZS 3788.
Perform all of the service requirements as detailed under:
(a) Inspect externals of pressure vessel for pitting.
(b) Inspect externals of pressure vessel for cracks or splitting.
(c) Inspect pressure vessel for bulging.
(d) Inspect pressure vessel for corrosion. Repair as required.
(e) Remove all deposits and debris from on and around boiler.
(f)
Inspect condition of welds.
(g) Inspect condition of all sockets, studs and flanges.
(h) Inspect covers for damage and sealing integrity.
(i)
Inspect pressure vessel and unit for leaks.
(j)
Inspect all gaskets.
(k) Supply a complete and concise report on internal/external inspection.
(l)
Contact the Principal's Representative if further work is required.
(m) On completion of inspection the Contractor shall fix an aluminium tag (business card size) to the
equipment. The tag shall indicate Date Tested and Next Test Date Due for both internal and
external inspections.

4.5

INTERNAL INSPECTION OF PRESSURE VESSELS

The minimum standards for periodic inspection and servicing shall be as stated below and in
accordance with the current requirements of AS/NZS 3788.
Perform all of the service requirements as detailed under:
(a) Inspect internals of pressure vessel for pitting. Report as required.
(b) Inspect internals of pressure vessel for cracks or splitting.
(c) Inspect pressure vessel for bulging.
(d) Inspect pressure vessel for corrosion. Repair as required.
(e) Remove all deposits from vessel interior.
(f)
Inspect condition of welds.
(g) Inspect condition of all sockets, studs and flanges.
(h) Inspect covers for damage and sealing integrity.
(i)
Inspect pressure vessel and unit for leaks.
(j)
Check condition of fire tubes, water tubes and tube plates.
(k) Inspect all gaskets.
(l)
Supply a complete and concise report on internal/external inspection.
(m) Contact the Principal's Representative if further work is required.
(n) On completion of inspection the Contractor shall fix an aluminium tag (business card size) to the
equipment. The tag shall indicate Date Tested and Next Test Date Due for both internal and
external inspections.

Document: TSW00729

Date Issued:
The State of Queensland (Department of Housing and Public Works)

Page 4 of 5

CONTRACT

5.0

RECORDS
All maintenance work on the boiler and its systems shall be recorded in the Boiler Log as follows:
(a) The names of the persons and organizations performing the maintenance and testing and the
work date where required by relevant Standards and regulations.
(b) Details of any maintenance work performed in conjunction with daily or periodic testing shall be
recorded on the documentation for the relevant testing.
(c) Details of yearly maintenance or any additional maintenance shall be recorded in a separate
report.
(d) Particulars of any malfunction.

Document: TSW00729

Date Issued:
The State of Queensland (Department of Housing and Public Works)

Page 5 of 5