Annual Combustion Internal Audit Pre-Flux Burner (Pinkenba)
This procedure outlines the steps for conducting an annual internal audit of the Pre-Flux Burner, focusing on control, protection, operation, maintenance, and combustion records.
Pinkenba QLD - Valmont Coatings APAC
08/14/2025
Annual Combustion Internal Audit Pre-Flux Burner (Pinkenba)
This procedure outlines the steps for conducting an annual internal audit of the Pre-Flux Burner, focusing on control, protection, operation, maintenance, and combustion records.
Preflux Burner Control
Does the control panel have a lockable door in working order?
if the answer is "oneOf [No (Fail)]"
The control panel does not have a lockable door in working order
if the answer is "oneOf [Yes (Pass)]"
Add or drag pictures
Can unauthorised personnel access the Preflux Burner controls?
if the answer is "oneOf [Yes (Fail)]"
Unauthorised Personnel can access the preflux burner controls.
if the answer is "oneOf [No (Pass)]"
Add or drag pictures
Can unauthorised or unqualified personnel access inside of the electrical panel?
if the answer is "oneOf [No (Pass)]"
Add or drag pictures
if the answer is "oneOf [Yes (Fail)]"
Unauthorised/Unqualified personnel can access inside of electrical panel
Are there sufficient exit paths to enable a person to leave the vicinity of the switchboard under emergency conditions?
if the answer is "oneOf [No (Fail)]"
Insufficient exit paths to enable a person to leave the vicinity of the switchboard under emergency conditions.
if the answer is "oneOf [Yes (Pass),No (Fail)]"
Add or drag pictures
Is the lighting in the control panel sufficient for electrical works, without the need for a torch?
if the answer is "oneOf [No (Fail)]"
Insufficient lighting in the control panel.
if the answer is "oneOf [Yes (Pass),No (Fail)]"
Add or drag pictures
Are electrical schematics (line diagrams) available in the control room?
if the answer is "oneOf [No (Fail)]"
Electrical schematics not available in the control room.
if the answer is "oneOf [Yes (Pass),No (Fail)]"
Add or drag pictures
Are air/gas schematics (P&ID diagrams) available in the control room?
if the answer is "oneOf [No (Fail)]"
Air/Gas (P&ID) schematics are not available in the control room.
if the answer is "oneOf [Yes (Pass),No (Fail)]"
Add or drag pictures
Are all control system set points available in the control room?
if the answer is "oneOf [No (Fail)]"
Control system set points not available in the control room.
if the answer is "oneOf [Yes (Pass),No (Fail)]"
Add or drag pictures
Are all schematics free from handwritten markup and additions?
if the answer is "oneOf [No (Fail)]"
Schematics have handwritten markup or additions.
if the answer is "oneOf [Yes (Pass),No (Fail)]"
Add or drag pictures
Are all schematics in the control panel the current revision?
if the answer is "oneOf [No (Fail)]"
Schematics are not the current revision.
if the answer is "oneOf [Yes (Pass),No (Fail)]"
Add or drag pictures
Is there evidence of uncontrolled recording of set points and variables?
if the answer is "oneOf [Yes (Fail)]"
Evidence of uncontrolled recordings of set points and variables.
if the answer is "oneOf [No (Pass),Yes (Fail)]"
Add or drag pictures
Do all indicator lamps function?
if the answer is "oneOf [Yes (Pass),No (Fail)]"
Add or drag pictures
if the answer is "oneOf [No (Fail)]"
Indicator lamp failure
Do all panel displays function correctly including flame sensing ammeter readings and temperature controllers?
if the answer is "oneOf [Yes (Pass),No (Fail)]"
Add or drag pictures
if the answer is "oneOf [No (Fail)]"
Display failure (e.g. flame sensor ammeter, temperature controller, HMI screen)
Do alarms audibly sound when triggered?
if the answer is "oneOf [No (Fail)]"
Alarms do not sound audibly.
if the answer is "oneOf [Yes (Pass),No (Fail)]"
Add or drag pictures
Do Preflux Burner failures trigger remote message and/or a call system?
if the answer is "oneOf [No (Fail)]"
Alarms do not trigger remote messages/call system.
if the answer is "oneOf [Yes (Pass),No (Fail)]"
Add or drag pictures
Are all isolators clearly labelled?
if the answer is "oneOf [No (Fail)]"
Isolators not clearly labelled.
if the answer is "oneOf [Yes (Pass),No (Fail)]"
Add or drag pictures
Is thermocouple wiring fully enclosed in a sheath from the Preflux Burner to outside the area of potential splash?
if the answer is "oneOf [Yes (Pass),No (Fail)]"
Add or drag pictures
if the answer is "oneOf [No (Fail)]"
Thermocouple wiring not protected from splash
Is the thermocouple wiring to the correct specification?
if the answer is "oneOf [No (Fail)]"
Thermocouple wiring not to correct specification
if the answer is "oneOf [Yes (Pass),No (Fail)]"
Add or drag pictures
Is there an overtemperature temperature controller?
if the answer is "oneOf [Yes (Pass),No (Fail)]"
Add or drag pictures
if the answer is "oneOf [No (Fail)]"
Overtemperature temperature controller not installed.
Is the overtemperature temperature controller connected to its own independent thermocouple?
if the answer is "oneOf [No (Fail)]"
Overtemperature temp controller not connected to independent thermocouple.
if the answer is "oneOf [Yes (Pass),No (Fail)]"
Add or drag pictures
Is the overtemperature temperature reading and the controlling temperature reading within 2°C?
if the answer is "oneOf [No (Fail)]"
Overtemp and Control temp readings differ more than 2°C
if the answer is "oneOf [Yes (Pass),No (Fail)]"
Add or drag pictures
Preflux Tank Protection
For a poly tank, or poly lined tank - are group standard heat shields installed between the burner and the wall to a depth of 1m?
if the answer is "oneOf [No (Fail)]"
Heat shields not installed to standard.
if the answer is "oneOf [Yes (Pass),No (Fail),N/A (No Poly in tank)]"
Add or drag pictures
For a poly tank, or poly lined tank - are the heat shields in good condition with steel and fibre blanket wrap?
if the answer is "oneOf [No (Fail)]"
Heat shields or fibre blanket wrap in poor condition.
if the answer is "oneOf [Yes (Pass),No (Fail),N/A (No poly in tank)]"
Add or drag pictures
For a poly tank, or poly lined tank - is a level sensor installed to shut off the burner in the event that the liquid level drops?
if the answer is "oneOf [No (Fail)]"
Level sensor not installed to shut off burner
if the answer is "oneOf [Yes (Pass),No (Fail),N/A (No poly in tank)]"
Add or drag pictures
Does the level sensor shut off the burner when triggered?
if the answer is "oneOf [No (Fail),No Level Sensor (Fail)]"
Level sensor shutoff not functional.
if the answer is "oneOf [Yes (Pass),No (Fail),No Level Sensor (Fail),N/A (No poly in tank)]"
Add or drag pictures
Preflux Burner
Is the preflux burner gas isolating valve painted yellow and easily accessible in an emergency?
if the answer is "oneOf [No (Fail)]"
Preflux gas isolation valve issue with accessibility or visibility.
if the answer is "oneOf [Yes (Pass),No (Fail)]"
Add or drag pictures
Is there appropriate signage marked "Gas Isolation Valve" which can be read from a distance of at least 10m?
if the answer is "oneOf [No (Fail)]"
Gas isolation valve signage not sufficient.
Is the preflux gas isolation valve on the HS-01 isolation register, with the appropriate labeling?
if the answer is "oneOf [No (Fail)]"
Preflux gas isolation not on HS-01
if the answer is "oneOf [Yes (Pass),No (Fail)]"
Add or drag pictures
Do site personnel know where the preflux gas isolation valve is?
if the answer is "oneOf [No (Fail)]"
Site personnel unaware of preflux gas isolation location
if the answer is "oneOf [Yes (Pass)]"
Add or drag pictures
Check all gas valves to ensure they are not siezed closed or open. Are all gas valves free to move?
if the answer is "oneOf [No (Fail),Sticky or difficult to move (Fail)]"
Gas valves siezed or difficult to move
if the answer is "oneOf [Yes (Pass)]"
Add or drag pictures
Has all gas pipework for preflux been inspected in the last 24 months?
if the answer is "oneOf [Partial (Fail),No (Fail)]"
Gas pipework has not been fully inspected
if the answer is "oneOf [Yes (Pass)]"
Add or drag pictures
Is gas pipework in good condition, including coatings in good condition, no pitting or corrosion?
if the answer is "oneOf [No (Fail),Some areas of concern (Fail)]"
Gas pipework requires repair or replacement
Preflux Burner Control Operations
Trigger Preflux Burner 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.
if the answer is "oneOf [No (Fail),Sometimes (Fail)]"
Air control equipment not fully functional.
if the answer is "oneOf [Yes (Pass)]"
Add or drag pictures
Turn off the Preflux Burner completely and start it. Do all burners light first time and reliably?
Turn off the Preflux Burner completely and start it. Does the purge time match the required time marked on the Preflux Burner certification plate and/or drawings?
Does the gas meter operate?
If the gas meter is connected to a recording device, is this fully functional?
If the gas meter is connected to a recording device, is the gas usage at the expected rates for high and low fire?
Combustion Air Fans Maintenance
Is there a preventative maintenance program for the combustion air fans?
Does the preventative maintenance program for the combustion air fans include all of: greasing, filter replacements, vibration analysis, bearing temperature measurement.
Does the condition of the combustion air fans suggest that the preventative maintenance system is being followed correctly?
Is there a spare combustion air blower ready to be operational in the event of a failure of the main unit?
Are there any immediate concerns with the combustion air fans?
Combustion Records and Servicing
Has the combustion workbook been filled out for all known combustion contractor works, including services and breakdowns?
Has the combustion tuning and servicing been completed to the appropriate standard?
Has the combustion tuning and servicing been completed on time at minimum 6 monthly intervals?
Have required safety checks to the local regulations been completed at minimum 12 monthly intervals?
Are the most recent flue gas analysis records for the Preflux Burner consistent with previous records?
Date of Audit
Person Conducting Audit
Click here to sign
Source: Pinkenba QLD - Valmont Coatings APAC (Community Member)