According to the WHS Regulations, a boiler means:

  • a vessel, or an arrangement of vessels and interconnecting parts, in which steam or vapour is generated or in which water or other liquid is heated at a pressure above that of the atmosphere by the application of fire, the products of combustion, electrical power or similar high temperature means; and
  • the superheaters, reheaters, economisers, boiler piping, supports, mountings, valves, gauges, fittings, controls, boiler setting and other equipment directly associated with those vessels.

Hazards

Note that the risk of using pressure equipment is determined by their hazard level which relates to the volume, pressure, temperature, location, usage and contents type.

Hazard levels are rated from A through to E, with A being the most hazardous and E the least hazardous. These hazard levels are calculated using Australian Standard - AS 4343 Pressure Equipment - Hazard Levels. The Hazard Level assessment is normally the responsibility of the designer, manufacturer, importer, or supplier.

Boilers can be hazardous as they can seriously injure or kill workers. They are considered to be high risk plant. Common hazards include:

  • Striking Injury: can occur from explosions due to excessive pressure, while burner malfunctions (e.g., fuel-side rich combustion) can lead to fuel explosions or fires.
  • Carbon Monoxide (CO) Poisoning: faulty boilers, particularly those with poor ventilation, can leak odorless, colourless CO gas, which is fatal to occupants.
  • Thermal Exposure: escaping high-temperature steam or contact with hot metal pipes and surfaces can cause severe scalds or burns.
  • Pressure Vessel Failure: poor water treatment can lead to corrosion (scaling), which can cause structural weakness, pitting, and eventual cracking or rupture.
  • Dry Boiler Firing: if a boiler operates without sufficient water, it can overheat, causing structural damage and increasing the risk of a steam explosion
  • Chemical Exposure: workers may be exposed to hazardous chemicals used for water treatment, such as boiler water additives.
  • Electrical Hazards: faulty wiring, pumps, or controls can lead to electric shock or failure of safety shutdowns.
  • Confined Space Hazards: maintenance tasks can occur in confined, poorly ventilated areas.

Safety requirements

  • Training: ensure operators are trained on the specific boiler controls, including emergency procedures, and are licenced and follow SOPs.
  • Operation: ensure daily pre-operational checks are undertaken and emergency stop buttons are functional.
  • Lockout/Tagout: use lock-out/tag-out procedures that go beyond electrical cut-offs. They can require the physical chaining, blanking, and venting of high-temperature steam lines, fuel gas trains, and high-pressure feedwater pipes.
  • Exclusion Zones: create marked pathways and spaces around safety valves, blowdown valves, and electrical control panels that must remain free of debris, storage boxes, or operational blockages.
  • Confined Space Entry Permits: strict multi-signature permit systems required before any worker enters a pressure vessel for cleaning and/or maintenance.
  • Restrict Access: only licensed operators, authorised maintenance staff, and escorted inspectors are permitted inside the boiler room. Doors must be kept locked to the general workforce.

Boiler operation

To achieve compliance for boiler operation you must have:

  • a current plant registration number
  • an operator with a high risk work licence or is trained by an RTO to safely operate the plant without supervision
  • a current boiler inspection certificate stating that the boiler is 'safe to operate'
  • an independent assessment for certificate for attendance category
  • a logbook in place and up to date
  • a procedure for safe operation, testing, cleaning and maintenance displayed
  • completed a hazard and risk assessment.

Dangerous goods and hazardous substances

Workers 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 such as corrosive-resistant flammable liquid storage with a sign

High Risk Work Licence

You will need a high risk work licence to operate specific boilers in South Australia including:

  • standard boilers above 150 kw (unless certified compliant to AS 2593 for unattended operation)
  • advanced boilers above 150 kw (unless certified compliant to AS 2593 for unattended operation)
  • steam turbines over 500KW
  • reciprocating steam engines with piston diameter of 250mm and above.

Registration

Boilers require both design and plant registration.

Registration costs can be found at Registration Fees.

Design registration

Heritage and miniature boilers do not need registration of design.

Plant design registration – Guidance notes

To register or alter the design of plant:

Plant design - New or alteration to design

According to WHS Regulation 243, you must register new designs or alterations of designs of boilers, other than pressure piping, which have a calculated Hazard Level of A, B, C or D according to the criteria in AS 4343.

The boiler can be designed to any internationally recognised published technical standard with the following documents being required for the registration of the plant design:

  • each model must have a separate design registration application form.
  • statement signed by the designer of the plant stating:
  • the designer has complied with their obligations under section 22 of the WHS Act.
  • the published technical standards and engineering principles used in the design.
  • design calculations and drawing(s) in English, as referenced in the designer's statement
  • an independent design verification statement.
  • payment of the fee which lasts for the life of the design (payable on completion of the online application).

Note:

  • design registration applies to all plant items manufactured to the same design.
  • design registration is valid for the life of the plant.
  • manufacturers, importers, and suppliers of plant are prohibited from supplying plant unless the design of that plant is registered.
  • design registration in SA is not required if the plant design is registered in another state under a corresponding WHS law (WHS Act 2012 (SA)).
  • any alteration to the design of registered plant that may affect health, and safety requires an alteration to its design registration.

Importing boilers to South Australia

All boilers coming into South Australia regardless of where they were designed and manufactured are required to be assessed for design registration.

If the design of the boiler has not been registered by the designer or manufacturer, then the responsibility to register it lies with the person who imported the equipment, or the person with management or control of the item of plant in the workplace.

The importer must:

  • conduct a hazard level identification and risk assessment as if they were the designer and manufacturer of the plant. Any risks must be eliminated or minimised
  • provide relevant information relating to the design and safe use of the plant to the end user.

Design registration must be obtained prior to supply or use of the boiler in South Australia. It is an offence to operate or allow someone to operate boilers that is required to be design registered and has not received registration.

Plant registration

Plant registration – Guidance notes

Boilers categorised as hazard level D or E, heritage boilers and miniature boilers do not need to be plant item registered.

To register the item of plant:

Plant design - New or alteration to design

Plant - Variation / Change of ownership

According to WHS Regulation 243, pressure vessels categorised as hazard level A, B or C according to the criteria in Section 2.1 of AS 4343, must be item of plant registered.

Boilers categorised as Hazard level A, B or C must be regularly inspected by a competent person to ensure it is safe to operate in accordance with the Australian Standard AS/NZS 3788: Pressure equipment-in-service inspection.

Once a boiler design is registered, you must permanently mark the design registration number on each boiler manufactured to that registered design.

You must hold a copy of the design registration certificate for item of plant registration. A supplier must share a copy of the design registration certificate with the purchaser.

To register plant for the first time in South Australia or to renew lapsed registration, the following documentation will be required:

  • completed online application form including fee payment.
  • a Design Registration Certificate or a Design Approval Letter issued pre-July 1996, or exemption letter.
  • statement from competent person that the plant is safe to use or operate (issued with 12 months of application date).
  • date when plant item was first commissioned or first registered (whichever occurred first).
  • Commissioning Report (prior to first use in Australia). If the plant being registered has been in service for more than 10 years, attach a copy of the Major Inspection Report (10-yearly) in lieu of a Commissioning Report.
  • photographs of the orientation of the vessel, and the ID / data plate.
  • authorisation letter from the PCBU who will have management or control of plant (where the applicant is a third-party acting on behalf of the PCBU).

If you are applying for transfer of ownership of an existing SafeWork SA issued registration(s) the following documentation will be required:

  • completed online notification form lodged within 14 days of purchase.
  • date when plant item was first commissioned or first registered (whichever occurred first).
  • Statement from competent person that the plant is safe to use or operate (issued within 12 months of application date).
  • if the plant being registered has been in service for more than 10 years, attach a copy of the Major Inspection Report (10-yearly) in lieu of a Commissioning Report.
  • authorisation letter from the PCBU who will have management or control of plant (If applicable where the applicant is a third-party acting on behalf of the PCBU).
  • letter from former owner confirming date that transfer of ownership occurred and that they no longer have management or control of the plant.
  • photographs of the orientation of the vessel, and the ID / data plate.

If you are applying to change the location of an existing SafeWork SA issued registration(s) the following documentation will be required:

  • completed online notification form lodged within 14 days of becoming aware of the change.
  • for plant that is fixed in one location, SafeWork SA requires evidence that it has been commissioned at the new location in order to amend the registration. A copy of statement from competent person that the plant is safe to use or operate in the new location (issued with 12 months of application date).
  • if the plant being registered has been in service for more than 10 years, attach a major inspection report (10-yearly).
  • photographs of the orientation of the vessel, and the ID / data plate.
  • authorisation letter from the PCBU who will have management or control of plant (If applicable where the applicant is a third-party acting on behalf of the PCBU).

If you are applying to make changes to other information of an existing SafeWork SA issued registration(s) the following documentation will be required:

  • completed online notification form lodged within 14 days of becoming aware of change(s).
  • where the change relates to a design alteration, then a copy of the design registration for the alteration and any relevant changes to recorded information
  • statement from competent person that the plant is safe to use or operate reflecting the updated information (if applicable).
  • if the plant being registered has been in service for more than 10 years, attach a copy of the Major Inspection Report (10-yearly).
  • authorisation letter from the PCBU who will have management or control of plant (If applicable where the applicant is a third-party acting on behalf of the PCBU).
  • photographs of the orientation of the vessel, and the ID / data plate.

Note:

  • SafeWork SA will notify plant registration holders in writing around one month prior to renewals being due. In making a decision to grant the renewal of a plant item registration, SafeWork SA will consider whether the plant has been regularly maintained and inspected in accordance with WHS Regulation 213 and 235.

Change of details

You must provide us with written notice within 14 days if:

  • you change your name or address, or any other information stated on your application for registration.
  • the plant design has been altered to an extent where it is subject to new control measures.

Inspection and maintenance

According to WHS Regulation 213 - Maintenance and Inspection of Plant, the person with management or control of plant at a workplace must ensure that the maintenance, inspection and, if necessary, testing of the plant is carried out by a competent person. In addition, the maintenance, inspection and testing must be carried out:

  1. in accordance with the manufacturer's recommendations, if any; or
  2. if there are no manufacturer's recommendations, in accordance with the recommendations of a competent person; or
  3. in relation to inspection, if it is not reasonably practicable to comply with paragraph (a) or (b), annually.

According to WHS Regulation 224 – Pressure Equipment, the person with management or control of plant at a workplace must ensure that the equipment is inspected on a regular basis by a competent person

The inspection must also be in accordance with AS/NZS 3788: In-service Inspection of Pressure Equipment, which outlines the responsibilities for both the inspector and the owner. The Standard incorporates a table that details the periods between routine inspections as well as information that leads the inspector through the inspection process for the various types of boilers.

On completion of the inspection, the inspector will provide you with a Certificate of Inspection and a Report. The certificate must include a statement from the inspector indicating that they have conducted the inspection in accordance with AS/NZS 3788 and that the equipment is Safe to operate (where this is found to be the case).

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.

Boiler inspection and maintenance program

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 2022, 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

Other checks:

  • weekly inspections
  • periodic and yearly maintenance
  • 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.

Record keeping

A record (e.g. logbook) of the service and maintenance history of the plant needs to be kept and made readily available and be written in easy to understand English.

Refer to WHS Regulation 237.

Contact us

Visit: safework.sa.gov.au

Call: SafeWork Licensing Unit on 1300 365 255

Email: licensing.safework@sa.gov.au

Further information

SafeWork SA

Resources

Legislation

  • WHS Act 22 - Duties of PCBUs that design plant, substances or structures
  • WHS Regulation 213 – Maintenance and inspection of plant
  • WHS Regulation 224 – Inspection and management of pressure equipment
  • WHS Regulation 237 – Records of plant
  • WHS Regulation 244 – Altered plant designs to be registered

Australian Standards

  • AS/NZS 1200: Pressure equipment
  • AS 1210: Pressure Vessels
  • AS 1228: Boilers - boilers
  • AS 2593: Boilers – Safety management and supervision systems
  • AS/NZS 3788: Boilers – In-service inspection
  • AS 3873: Boilers – Operation and maintenance
  • AS 4343: Boilers – Hazard levels

Codes of Practice

FAQ – Frequently Asked Questions

Q1. What are the registration requirements?

Boilers require both design registration and item of plant registration

The boiler supplier (who may also be the importer) has the legal duty to ensure that the boiler is design registered, and that they hold a copy of the design registration certificate prior to any distribution and sale.

The design registration number issued by SafeWork SA or an interstate regulator is unique to that model and must be permanently marked on the boiler.

The owner or person with management control of the boiler is responsible for the item of plant registration. They will need copies of the design registration certificate, “Safe to Operate” certificate and commissioning report. They can then attach all the supporting documentation to a completed application form and send it to SafeWork SA along with payment of the fee.

Q2. Are there any registration fees?

Boilers incur a fee when they are first design registered which is valid for the life of the plant.

A design registration fee applies only once for the initial application because upon issue there is no expiry date.

Boilers incur a fee each time they are plant item registered for a 5-year period. The owner will receive an invoice from SafeWork SA before the renewal date. The invoice will have an associated fee.

Plant registration will remain valid for the 5-year period unless the boiler is sold, scrapped, or a design alteration occurs to the level of safety requiring a review of risk control measures.

Q3. Who can apply for design registration?

  • a person conducting a business or undertaking (PCBU) that designs an item of plant may apply to the regulator for the registration of the design of that item of plant.
  • a person with management or control of an item of plant at a workplace may apply to the regulator for the registration of the design of that item of plant.

Q5. Duties of the Designer and Design Verifier.

The designer must undertake a design risk assessment and be satisfied through engineering calculations that the boiler is at the appropriate level of safety in accordance with the published technical standards and/or engineering principles being used. The designer must declare that they “have complied with the designer’s obligations under Section 22 of the WHS Act in respect to the design of the plant.”

For design verification under regulation 252, a Design Verifier is a person who has the skills, qualifications, competence and experience to design the plant or verify the design

The Design Verifier has the important role of determining through their own independent assessment that the design satisfactorily complies with design intent published technical standards, and/or engineering principles. They must also declare that “they were not involved in the production of the design; and that the design was produced in accordance with the published technical standards and/or engineering principles specified by the designer’s statement and documents.”

The boiler original design can be to any internationally recognised published technical standard including calculations and drawings. However, Design verification must declare full compliance with the applicable Australian Standards.

Q6. Can the Designer and/or Design Verifier be located overseas?

Yes. There is no requirement for the Designer and/or Design Verifier to be located in Australia. They must however fully understand their duties under South Australian WHS Legislation. Penalties apply for provision of false or misleading information.

Q7. Can a Designer and Design Verifier be employed by the same business?

Yes, the Designer and Design Verifier can be employed by the same organisation, but the Design Verifier must not have been involved in the production of the design. The design verification process must be independent of the Designer.

Q4. Does each boiler require individual design registration?

No, once the design is registered, there is no restriction on the number of boilers that can be supplied, provided they comply with the registered design. The registration holder must ensure the design registration number is provided with each boiler that is supplied.

Q5. Is interstate design registration recognised in South Australia?

Yes, interstate design registrations issued under a corresponding WHS law (i.e. a law of another Australian jurisdiction corresponding, or substantially corresponding, to the WHS Act 2012 (SA)) are recognised in South Australia. However, it is important to ensure the boiler design also complies with relevant South Australian Approved Codes of Practice.

There may be Australian States or Territories who have introduced specific variations to the WHS model legislation and while the design may comply with the legislation in those jurisdictions, it may no longer fully comply with South Australian requirements. If this is the case, item of plant registration may be refused (i.e. design registration may not be recognised) because the design does not fully comply through a corresponding WHS law equivalent to that in South Australia.

Q10. Are overseas design registrations recognised?

Every boiler installed in South Australia must have an Australian design registration.

Q6. When is an Application for Alteration to a Design of a boiler required?

The WHS Regulations state that “In this regulation a reference to the alteration of a design is a reference to an alteration that may affect health or safety.”

What does that mean?

'Alter' in relation to any plant means to change the design of, add to or take away from the plant where the change may affect health or safety, but does not include routine maintenance, repairs or replacements.

When an boiler is first design registered, the design is based on certain criteria and specifications that set a minimum level of safety. If that level of safety is altered (i.e. structural integrity, capacity, safe operating limits) then an application for the alteration must be submitted to SafeWork SA.

Note: alterations must be compliant to the latest legislative requirements.

Q7. Does each manufactured boiler require item of plant registration?

Yes, each applicable boiler must be individually registered before being placed into service.

The item of plant registration number issued by SafeWork SA is specific to that boiler.

The design registration number issued by SafeWork SA or an interstate regulator is unique to that model of boiler and must be permanently marked on the boiler.

Q8. What happens after I submit an application for plant registration?

After SafeWork SA receives an application and fee payment has been receipted:

  1. SafeWork SA will audit each section of the application form and supporting documentation. It is important that correct information is provided.
  2. If any information is missing, SafeWork SA will contact the applicant. This may cause delays in processing.
  3. Once details are audited and any additional requested information and/or revised documents received the application will be processed and the plant registered.
  4. A registration document (certificate) will be sent to the applicant. The document will contain information as submitted in the application form, the applicant details and the issued item of plant registration number. The registration number must be displayed on the boiler.
  5. The item of plant registration is valid for a 5-year term. When renewal is due, an invoice will be sent about one month before the registration expires to the recorded address of the registration holder.

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