Annual Combustion Internal Audit - Kettle

Does the control room have a lockable door in working order?

• Yes
• No
• N / A

Can unauthorized personnel access the control room?

• Yes
• No
• N / A

Does the control panel have a lockable door in working order?

• Yes
• No
• N / A

Can unauthorised personnel access the furnace controls?

• Yes
• No
• N / A

Does the electrical panel have a lockable door in working order?

• Yes
• No
• N / A

Can unauthorised or unqualified personnel access inside of the electrical panel?

• Yes
• No
• N / A

Are there sufficient exit paths to enable a person to leave the vicinity of the switchboard under emergency conditions?

• Yes
• No
• N / A

Are there any items or equipment other than the switchboard and furnace control equipment in the control room?

• Yes
• No
• N / A

Is the lighting in the control room sufficient for general access, viewing and adjusting the controls?

• Yes
• No
• N / A

Is the lighting in the control panel sufficient for electrical works, without the need for a torch?

• Yes
• No
• N / A

Does control room temperature control equipment achieve the required set point if present?

• Yes
• No
• N / A

Is there any evidence of water ingress to the control room?

• Yes
• No
• N / A

Is there any evidence of corrosive fume ingress to the control room?

• Yes
• No
• N / A

Are electrical schematics available in the control room?

• Yes
• No
• N / A

Are air/gas schematics available in the control room?

• Yes
• No
• N / A

Are all control system set points available in the control room?

• Yes
• No
• N / A

Are all schematics free from handwritten markup and additions?

• Yes
• No
• N / A

Are all schematics the current revision?

• Yes
• No
• N / A

Is there evidence of uncontrolled recording of set points and variables?

• Yes
• No
• N / A

Do all indicator lamps function?

• Yes
• No
• N / A

Do all panel displays function correctly including flame sensing ammeter readings and temperature controllers?

• Yes
• No
• N / A

Do alarms audibly sound when triggered?

• Yes
• No
• N / A

Do all furnace failures trigger remote message and/or a call system?

• Yes
• No
• N / A

Are all isolators clearly labelled?

• Yes
• No
• N / A

Are all inputs, outputs and relays labelled in the control panel/switchboard?

• Yes
• No
• N / A

Is there any evidence of marker pen or handwritten labelling in the control panel/switchboard?

• Yes
• No
• N / A

Are Variable Speed Drive Cooling fans operational?

• Yes
• No
• N / A

Are the Variable Speed Drive cooling fans filtered?

• Yes
• No
• N / A

Are the Variable Speed Drive cooling fan filters clean?

• Yes
• No
• N / A

Is there a program to replace the Variable Speed Drive cooling fan filters on a regular basis?

• Yes
• No
• N / A

Is thermocouple wiring fully enclosed in a sheath from the furnace to outside the area of potential zinc splash?

• Yes
• No
• N / A

Is the thermocouple wiring to the correct specification?

• Yes
• No
• N / A

Is the overtemperature temperature reading and the controlling temperature reading within 1°C?

• Yes
• No
• N / A

Is there appropriate signage marked "Gas Isolation Valve" which can be read from a distance of at least 10m?

• Yes
• No
• N / A

Is the gas isolation valve on the HS-01 isolation register, with the appropriate labeling?

• Yes
• No
• N / A

Do site personnel know where the main gas isolation valve is?

• Yes
• No
• N / A

Are all gas valves free to move?

• Yes
• No
• N / A

Has all gas pipework been inspected in the last 24 months?

• Yes
• No
• N / A

Is gas pipework in good condition, including coatings in good condition, no pitting or corrosion?

• Yes
• No
• N / A

Trigger furnace to engage high and low fire by changing the set point. Do all air control motors, solenoids, or Variable Speed Drive's actuate/control as required?

• Yes
• No
• N / A

Turn off the furnace completely and start it. Do all burners light first time and reliably?

• Yes
• No
• N / A

Turn off the furnace completely and start it. Does the purge time match the required time marked on the furnace certification plate and/or drawings?

• Yes
• No
• N / A

Does the gas meter operate?

• Yes
• No
• N / A

If the gas meter is connected to a recording device, is this fully functional?

• Yes
• No
• N / A

If the gas meter is connected to a recording device, is the gas usage at the expected rates for high and low fire?

• Yes
• No
• N / A

Is there a preventative maintenance program for the combustion air fans?

• Yes
• No
• N / A

Does the preventative maintenance program for the combustion air fans include all of: greasing, filter replacements, vibration analysis, bearing temperature measurement?

• Yes
• No
• N / A

Does the condition of the combustion air fans suggest that the preventative maintenance system is being followed correctly?

• Yes
• No
• N / A

Is there a spare combustion air blower ready to be operational in the event of a failure of the main unit?

• Yes
• No
• N / A

Are there any immediate concerns with the combustion air fans?

• Yes
• No
• N / A

Are air pressure switches free of any zinc/ash, in working condition, undamaged, and readable?

• Yes
• No
• N / A

Are air pressure switch set points marked and correct?

• Yes
• No
• N / A

Is the pit easily accessible?

• Yes
• No
• N / A

Does the pit entry access method include hand railing around the entrance?

• Yes
• No
• N / A

Does the pit entry access method include fixed ladders or stairs without obstruction?

• Yes
• No
• N / A

Is the pit entry access free from slip and trip hazards?

• Yes
• No
• N / A

Are alternative arrangements available to inspect the pit to avoid confined space entry?

• Yes
• No
• N / A

Is the furnace pit air temperature less than 45 degrees?

• Yes
• No
• N / A

Is there evidence of chemicals leaking into the furnace pit?

• Yes
• No
• N / A

Is there evidence of stormwater or groundwater entering the furnace pit?

• Yes
• No
• N / A

Is there evidence of zinc spills in the furnace pit?

• Yes
• No
• N / A

Comments on zinc spills

Are there records in the safety management system of all known zinc spills?

• Yes
• No
• N / A

Is there excessive ash buildup in the pit?

• Yes
• No
• N / A

Is there adequate risk control for zinc spills coming in contact with electrical wiring?

• Yes
• No
• N / A

Is there adequate risk control for zinc spills coming in contact with gas pipework, gas valves, and gas equipment?

• Yes
• No
• N / A

Is all electrical field wiring intact, and protected from heat, zinc, and water?

• Yes
• No
• N / A

Is there any damage to pit electrical wiring from zinc, chemical overflow/fume, or heat?

• Yes
• No
• N / A

Is there evidence of ash, zinc splatter, or moisture on any of the gas equipment?

• Yes
• No
• N / A

Is there evidence of physical damage or corrosion on any of the gas equipment?

• Yes
• No
• N / A

Is there any redundant electrical wiring in the furnace pit?

• Yes
• No
• N / A

Is there any redundant equipment in the furnace pit?

• Yes
• No
• N / A

If the furnace is fuelled by LPG, are LPG sensors installed?

• Yes
• No
• N / A

If LPG sensors are installed, are they operational?

• Yes
• No
• N / A

If LPG sensors are installed, are they tested frequently with records kept?

• Yes
• No
• N / A

Is there any burnt paint or areas with heavier corrosion evident on the furnace wall?

• Yes
• No
• N / A

Check these areas with a temperature device, are any spots over 100C?

• Yes
• No
• N / A

Are viewing ports available to observe all operating burners?

• Yes
• No
• N / A

Are viewing ports clean so that the flame can be seen clearly?

• Yes
• No
• N / A

Are all furnace top plates in good condition?

• Yes
• No
• N / A

Are all furnace top plates fully sealed to adjacent top plates, the furnace wall, and the kettle top plate?

• Yes
• No
• N / A

Is there a zinc leak detection system in place?

• Yes
• No
• N / A

Test the zinc leak detection by removing the probes from the furnace and shorting them together in the field. Does every zinc leak detection zone trigger the alarm?

• Yes
• No
• N / A

Has the annual ultrasonic (KID) test been completed?

• Yes
• No
• N / A

Has the annual ultrasonic (KID) test report been reviewed by plant management?

• Yes
• No
• N / A

Have all recommended actions from the previous KID test report been actioned and closed out?

• Yes
• No
• N / A

Is the thermocouple located at least 80mm away from the wall and clear of ash and zinc buildup?

• Yes
• No
• N / A

Is the thermocouple secure inside its tube or sheath?

• Yes
• No
• N / A

Does the thermocouple use the required "standard" plug with round pin connectors?

• Yes
• No
• N / A

Is all thermocouple cabling at the kettle area fibreglass coated?

• Yes
• No
• N / A

Are the thermocouples inserted the entire way into the tube or sheath and making good contact with the kettle wall?

• Yes
• No
• N / A

Are insulated covers available for use and comply with the Valmont Standard?

• Yes
• No
• N / A

Are insulated covers used for EVERY off shift?

• Yes
• No
• N / A

Observe the kettle covers when on the kettle, is there any heat loss due to damage, bowing, condition, or poor use?

• Yes
• No
• N / A

Has the combustion workbook been filled out for all known combustion contractor works, including services and breakdowns?

• Yes
• No
• N / A

Has the combustion tuning and servicing been completed to the appropriate standard?

• Yes
• No
• N / A

Has the combustion tuning and servicing been completed on time at minimum 6 monthly intervals?

• Yes
• No
• N / A

Have required safety checks to the local regulations been completed at minimum 12 monthly intervals?

• Yes
• No
• N / A

Does the flue gas analysis for the furnace meet the required standards?

• Yes
• No
• N / A

Response: Is there a documented plan with escalation for furnace alarms after hours?

• Yes
• No
• N / A

Date of procedure completion

Signature of auditor