Date last updated

Wednesday 19 Feb 2020

Industries and topics
  • Cleaning
  • Manufacturing
  • Dangerous goods
Click here to view more industries and topics
View more

On this page

  • Your legal duties
  • Boiler inspection and maintenance
  • Keeping records
  • Dangerous goods and hazardous substances
  • Further information

Your legal duties

Employers, self-employed persons, employees, designers, manufacturers and suppliers all have legal obligations to workplace safety under the Occupational Health and Safety Act 2004 (OHS Act) and Occupational Health and Safety Regulations 2017 (OHS Regulations).

Find out about your occupational health and safety obligations relating to plant on WorkSafe's Plant and your legal duties page.

Plant and your legal duties

Boiler inspections and maintenance

Without maintenance and inspection, the safety and reliability of a boiler cannot be ensured and may expose employees and other people to risks to their health and safety. For example, scale formation can cause hot spots inside boilers which can lead to an explosion.

Employers, including self-employed persons, have a duty to ensure plant such as boilers is inspected to an extent that monitors any risks associated with the plant's use. As an employer you should have a competent person carry out periodic internal and external inspections of unattended boilers, including operational tests and necessary maintenance to ensure boilers are safe and reliable. Periodic inspections should assess the soundness of the boiler and its suitability for service, in line with design conditions and normal use.

A certificate or report of inspection should state that the boiler is safe to operate before it returns to use after being cleaned, inspected, serviced or repaired.

An effective boiler inspection and maintenance program should include:

  1. A daily/routine check and operation test to:
    • ensure a pre-operation check is carried out
    • perform blowdown of water gauge glasses to remove impurities which may affect their accuracy
    • check the operation of any water-level security equipment, such as a low-water device
    • check the boiler pressure and water gauge level to ensure it is within the recommended parameters
    • ensure that any steam leak is rectified immediately
    • carry out blowdown as recommended by the boiler water treatment company to ensure chemicals are within recommended ranges to prevent scale formation inside the boiler
    • ensure exposed hot surfaces including piping, are insulated and/or guarded
    • ensure safety data sheets (SDS) for boiler chemicals are current and readily accessible to any person on the premises
    • ensure appropriate personal protective equipment (PPE) is provided
    • ensure no flammable substances are stored in the boiler's vicinity. Under the Dangerous Goods (Storage and Handling) Regulations 2012, an occupier of premises where dangerous goods are stored and handled must ensure that, so far as is reasonably practicable, ignition sources are not present in any hazardous area within the premises
    • ensure fire extinguishers are available and serviced at 6-monthly intervals
  2. weekly inspections
  3. periodic and yearly maintenance
  4. three-monthly boiler water treatment and testing

Employers also have a responsibility to make sure, so far as is reasonably practicable, that plant that is not in use, including boilers, is left in a state that does not create a risk to any person.

For more information about boiler inspection and maintenance, refer to Australian Standards AS/NZS 3788:2006 (R2017) Pressure equipment – In-service inspection and AS 2593-2004 (R2016) Boilers – Safety management and supervision systems.

Keeping records

As an employer or self-employed person, you must keep a record of any inspection and maintenance on boilers with a hazard level A, B or C as determined by the Australian Standard AS 4343:2014 Pressure equipment—Hazard levels. You must keep the inspection and maintenance records for the period you have management or control of the plant.

Dangerous goods and hazardous substances

Employees who inspect or maintain boilers may be exposed to hazardous substances such as perchloroethylene and hydrofluoric acid, which are common in dry cleaning chemicals, and dangerous goods that can create risks such as fire, explosion, corrosion and poisoning.

Employers can use a range of measures to control risks from the use of hazardous substances and dangerous goods. Control measures include:

  • undertaking regular maintenance to repair leaks in a timely manner
  • providing mechanical ventilation
  • displaying signs warning of the hazards
  • ensuring all personnel are trained and supervised
  • providing current SDSs and a dangerous goods register
  • enforcing strict hygiene and ensuring PPE is worn
  • ensuring an emergency eyewash facility is in the immediate vicinity
  • ensuring flammable liquids are separated from ignition sources
  • providing storage cabinets and shelving designed for the hazards associated with the substance. For example, corrosive-resistant flammable liquid storage with a sign

Further information

Australian Standards

AS/NZS 1200:2015 – Pressure equipment

AS 2593-2004 (R2016) Boilers – Safety management and supervision systems

AS/NZS 3788:2006 (R2017) Pressure equipment – In-service inspection

AS 3873-2001 Pressure equipment – Operation and maintenance

AS 4343:2014 Pressure equipment – Hazard levels

Boiler designers, suppliers, manufacturers and service organisations may also be able to provide information on safe inspection, maintenance and use of specific boiler models.