Boiler Combustion Analysis Tune-Up Report

This template captures the boiler ID, fuel type, burner model, operating status, analyzer calibration, and safe test access before any readings are taken. It then records pre-adjustment and post-adjustment O2, CO, NOx, stack temperature, excess air, and estimated combustion efficiency. The final sections document burner changes, observed deficiencies, and sign-off so the tune-up is traceable.

Use this report when the work includes combustion analysis and burner tuning, not just a visual walk-through. It is the right fit after maintenance, during seasonal startup, after fuel changes, or when you need to document performance changes from an adjustment. If you only need to record housekeeping, leaks, or general condition, a broader boiler inspection form is a better match.

The cadence depends on the site’s maintenance program, equipment criticality, and any applicable local or insurance requirements. Many facilities document tune-ups during scheduled preventive maintenance, after burner service, and whenever combustion readings drift outside target ranges. If the boiler supports a critical process, you may also want a record after any control, fuel train, or burner component change.

A qualified boiler technician, combustion service contractor, or in-house maintenance professional with the right training should complete it. The person performing the test should understand analyzer use, burner adjustment, and safe access around energized or hot equipment. If your site requires it, a competent person or supervisor can review the report before it is closed out.

Yes, it helps document safe work practices and maintenance records that support OSHA general industry expectations, lockout-tagout controls, and safe access to equipment. It also aligns well with fire-life-safety and mechanical maintenance programs that reference NFPA codes, and with quality systems that require corrective-action tracking. It is not a substitute for jurisdiction-specific permits, manufacturer procedures, or AHJ requirements.

A common mistake is recording only the final readings and skipping the pre-adjustment baseline, which makes the tune-up hard to verify. Another is failing to note analyzer calibration status or test-port conditions, which can undermine the data. Teams also sometimes document a burner change without stating what was adjusted, making it difficult to repeat the setup later.

Yes, the template is meant to be adapted for fire-tube, water-tube, packaged, or process boilers and for natural gas, propane, oil, or dual-fuel systems. You can add fields for draft, flue gas temperature, smoke number, fuel pressure, or manufacturer target ranges if those are part of your program. Keep the core before-and-after readings so the report stays comparable across jobs.

Ad hoc notes and invoices usually do not capture the full before-and-after combustion picture or the safety checks around the work. This template gives you a repeatable record of what was measured, what was changed, and what condition the boiler was left in. That makes it easier to trend performance, defend maintenance decisions, and hand the work off to the next technician.