Annual Combustion Internal Audit - Caustic Burner (Pinkenba)

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

• Yes
• No
• N / A

Can unauthorised personnel access the Caustic Burner controls?

• 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

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

• Yes
• No
• N / A

Are electrical schematics (line diagrams) available in the control room?

• Yes
• No
• N / A

Are air/gas schematics (P&ID diagrams) available in the control room?

• Yes
• No
• N / A

Are all control system set points (e.g. Variable Speed Drive settings) 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? (Refer electronic register)

• Yes
• No
• N / A

Is there evidence of uncontrolled recording of set points and variables? (e.g. not in the electrical schematics or workbook)

• Yes
• No
• N / A

Do all indicator lamps function? Note alarm conditions may be needed to test all lamps.

• 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 Caustic Burner failures trigger remote message and/or a call system?

• Yes
• No
• N / A

Are all isolators clearly labelled?

• Yes
• No
• N / A

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

• Yes
• No
• N / A

Is the thermocouple wiring to the correct specification - fibreglass coated wiring and round pin plugs (not flat blade)?

• Yes
• No
• N / A

Is there an overtemperature temperature controller?

• Yes
• No
• N / A

Is the overtemperature temperature controller connected to its own independent thermocouple?

• Yes
• No
• N / A

Is the overtemperature temperature reading and the controlling temperature reading within 2°C?

• Yes
• No
• N / A

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?

• Yes
• No
• N / A

For a poly tank, or poly lined tank - are the heat shields in good condition with steel and fibre blanket wrap?

• Yes
• No
• N / A

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?

• Yes
• No
• N / A

Does the level sensor shut off the burner when triggered? (remove the level sensor from the tank to trigger it)

• Yes
• No
• N / A

Is the main gas isolating valve painted yellow and easily accessible in an emergency? (e.g. not blocked in or keyed access)

• 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 labelling?

• Yes
• No
• N / A

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

• Yes
• No
• N / A

Check all gas valves to ensure they are not seized closed or open. Are all gas valves free to move? (note: no need to fully shut off)

• Yes
• No
• N / A

Has all gas pipework been inspected in the last 24 months? (Frequency TBC)

• Yes
• No
• N / A

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

• Yes
• No
• N / A

Trigger Caustic 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.

• Yes
• No
• N / A

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

• Yes
• No
• N / A

Turn off the Caustic Burner completely and start it. Does the purge time match the required time marked on the Caustic Burner certification plate and/or drawings? (10min if not labelled)

• 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?, including greasing, vibration analysis, and filter replacements.

• 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? (quiet, clean filters, not running hot)

• 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 (noisy, dirty, unbalanced fan, excessive heat)?

• 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 (flue gas analysis, air/gas pressures, safety checks, condition report, adjustments)

• 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? Testing to AS3814 required for AU, and recommended for all sites.

• Yes
• No
• N / A

Are the most recent flue gas analysis records for the Caustic Burner consistent with previous records?

• Yes
• No
• N / A