Understand the core competencies of gas installation with this accessible textbook
Gas operatives in the UK must be Gas Safe registered, suitably qualified and assessed as competent in the aspect of gas work that they wish to undertake. Qualification is gained by means of an industry recognised Managed Learning Programme or a gas aligned National Vocational Qualification (NVQ/SNVQ). Periodic renewal thereafter is by means of the National Accredited Certification Scheme (ACS). Gas Installation Technology is the definitive textbook for students enrolled in any of these courses. Now fully updated to reflect new standards and the most up to date best practices, it remains the indispensable reference for anyone working in the gas industry.
Readers of the third edition of Gas Installation Technology will find:
Coverage of commercial, domestic, and LPG installations New or updated material on 'net zero' targets, climate change, and other aspects of the gas industry's future Notes and examples within each chapter to facilitate learning
Gas Installation Technology is ideal for students in gas installation or plumbing courses, as well as for professional gas installers renewing their certification.
Coverage of commercial, domestic, and LPG installations New or updated material on 'net zero' targets, climate change, and other aspects of the gas industry's future Notes and examples within each chapter to facilitate learning
Introduction xi Acknowledgements xiii 1 The Gas Industry 1 The Gas Industry 1 Nationally Accredited Certification Scheme for Individual Gas Fitting Operatives (ACS) 4 Required ACS Assessments and Flowcharts 9 Legislation Affecting Gas Operatives 10 Specific Legislation Affecting Gas Operatives 15 Industry Documents and British Standards 17 Gas Safety (Installation and Use) Regulations 21 The Future of Gas 24 2 Gas Utilisation 27 Gas: Its Origin 27 Characteristics and Properties of Gases 29 Liquefied Petroleum Gas (LPG) 33 The Combustion Process 34 Air Requirements for Combustion 37 Products of Combustion 39 The Gas Flame 41 Flame Pattern and Characteristics 44 Atmospheric Burners 46 Pre-mix Burners 48 Gas Pressure and Flow 50 Gas Pressure Readings 52 Quick Reference Guide to Taking Pressures 54 Estimating a Suitable Pipe Size 56 Domestic Natural Gas Pipe Sizing 58 Domestic LPG Pipe Sizing 62 Commercial Natural Gas Pipe Sizing 67 Gas Rates and Heat Input 69 Electronic and Smart Meters 72 Quick Reference Tables: Gas Rate/Heat Input 73 The Physical Laws Relating to Gas 76 Measurement of Gas 78 3 Gas Controls 87 Quarter Turn Gas Control Valves 87 Screw Down Gas Control Valves 90 Valve Application 93 Spring-loaded Gas Control Valves 94 Electrically Operated Gas Control Valves 96 Heat-operated Gas Control Valves 98 Pressure-operated Controls Valves 100 Low- and High-pressure Cut-off Devices 102 Pressure Regulators 105 LPG Regulators 108 Flame Supervision Devices 113 Testing Flame Supervision Devices 120 Thermostatic Control 120 Multi-functional Gas Valve 122 Air/Gas Ratio Valve 125 Ignition Devices 127 Vitiation-sensing Devices 129 Pressure and Flow Proving Devices 132 4 Installation Practices 135 Polyethylene Pipe Jointing 135 Copper Pipe Jointing 138 Mild Steel Pipe Jointing 141 Semi-rigid and Flexible Pipe Connections 143 Gas Service and Installation Pipework 145 Connections to High-rise Buildings 150 Gas Meter Installations 153 Commercial Gas Installations 158 Internal Installation Pipework 160 Pipework Laid in Floors 162 Pipework in Walls 165 Pipework Support and Allowance for Movement 168 Timber-framed Dwellings 170 LPG Supply 173 LPG Cylinder Installation 174 Storage and Transportation of LPG Cylinders 176 LPG Bulk Tank Installation 178 Gas Supplies from a Bulk Tank Installation 181 LPG Cylinder Sizing 184 5 Testing and Purging 187 Testing and Purging 187 Tightness Testing With Air (Domestic) 193 Tightness Testing Natural Gas Installations (Domestic) 194 Tightness Testing LPG Installations (Domestic) 199 Purging Domestic Gas Installations 204 Commercial Strength and Tightness Testing (TPCP1A) 209 Commercial Strength and Tightness Testing (TPCP1) 217 Direct Purging Commercial Pipework 230 Indirect Purging Using Nitrogen (N2) 239 6 Flues and Chimneys 243 Flue/Chimney Classification 243 Chimney/Flue Material and Specification 244 Natural Draught Open-Flue Systems 248 Installation of an Open-Flue Chimney 250 Minimum Open-Flue Heights Domestic ≤70 kW 252 Minimum Open-Flue Heights Commercial >70 kW 254 Open-Flue Terminal Design and Location 258 Condensation within Open-Flue Systems 262 Brick Chimneys 264 Flexible Stainless Steel Flue Liners 267 Pre-cast Flue Blocks 270 Pipes Used for Chimneys 272 Fan Draught Open-Flue Chimney Systems 274 Shared Open-Flue Chimney Systems 276 Checking and Testing Open-Flue Systems 279 Room-Sealed Flue Chimneys 282 Fan-Assisted Room-Sealed Flue Appliance 284 Room-Sealed and Fan Flue Terminal Locations ≤70 kW 288 Room-Sealed and Open-Flue Terminal Locations >70 kW 293 Shared Room-Sealed Flue Systems 295 Fan Dilution System 301 Concealed Flues 302 7 Ventilation 305 Need for Ventilation 305 Ventilation Location 308 Effective Ventilation 311 Purge Ventilation (Rapid Ventilation) 315 Ventilation Sizing and Tables 316 Domestic Ventilation Tables 319 Commercial Ventilation Tables 321 Worked Examples for Domestic Premises 325 Worked Examples for Commercial Premises 330 Domestic Ventilation Ready Reckoner 334 8 Gas Installer Responsibility 337 Working on Gas Installations and Appliances 337 Commissioning 339 Servicing Gas Appliances/Installations 346 Installation of Second-hand Appliances 348 Landlords’ Gas Safety Responsibilities 348 Gas Industry Unsafe Situations 351 Gas Escape Procedures 357 Reporting of Injuries, Diseases and Dangerous Occurrences Regulations (riddor) 359 Carbon Monoxide Detection 361 Gas Operative’s Response to an Activated CO Alarm 362 Determining the Ambient Level of CO in a Room (CO Build-up Test) 364 Ambient Air Testing for CO2 in a Non-Domestic Setting 367 Combustion Performance Analysis 368 9 Domestic Appliances 375 Gas Fires and Space Heaters 375 Component Parts of a Gas Fire 377 Open-Flued Radiant Convector Gas Fires 379 Open-Flued Solid Fuel Effect Fires and Heaters 381 Installation of Open-Flued Gas Fires 384 Decorative Fuel Effect (DFE) Gas Fires 391 Fan Flued and Room-Sealed Space Heaters 393 Flueless Space Heaters 396 Commissioning and Servicing Space Heaters 398 Domestic Gas Cookers 401 Installation of Cooking Appliances 406 Domestic Flued Cooking Range 408 Commissioning and Servicing Cookers 410 Instantaneous Gas Water Heaters 413 Instantaneous Water Heater Operation 416 Components and their Operation 419 Installation of Water Heaters 421 Commissioning and Servicing of Water Heaters 422 Domestic Gas Boilers 426 Conventional or Traditional Gas Boilers 428 The Combination Boiler 430 The Condensing Boiler 431 Installation of Domestic Gas Boilers 435 Commissioning and Servicing Gas Boilers 437 Domestic Ducted Warm Air Heaters 441 Installations of Warm Air Heaters 444 Commissioning and Servicing Warm Air Heaters 447 Domestic Tumble Dryers 450 Installation of Domestic Tumble Dryers 453 Domestic Gas Refrigerators 455 Leisure Appliances 456 Greenhouse Heaters and Gas Pokers 460 10 Commercial Appliances 463 Commercial Boilers 463 Commercial Boiler Gas Control Systems 465 Commercial Warm Air Heaters 467 Commercial Direct Fired Air Heaters 470 Commercial Indirect-Fired Air Heaters 471 Commercial Hot Water Storage Heaters 473 Commercial Instantaneous Water Heaters 475 Overhead Radiant Heaters 477 Ventilation for Overhead Radiant Heaters (Type A – Flueless) 482 Gas Boosters 485 11 Commercial Laundry 493 Commercial Laundry Equipment 493 Tumble Dryer and Rotary Ironer 494 Make-up Air 494 Exhaust and Ducting Systems 496 Commissioning and Maintenance 497 Gas Washing Machine 498 12 Commercial Catering 501 Commercial Catering 501 Catering Establishments 503 Ventilation/Extraction in Commercial Kitchens 506 Commercial Catering Appliances 515 Mobile Catering Units 532 13 Educational Establishments 535 Educational Establishments 535 General Considerations 535 Gas Pipework 535 Isolation Valves and Interlocks 537 Boiler Rooms and Plant Rooms 538 Ventilation and Flues 539 Appliances 541 Commissioning, Testing and Maintenance 541 14 Non-permanent Dwellings 543 Residential Park Homes 543 Leisure Accommodation Vehicles – General Requirements 545 Leisure Accommodation Vehicles – Caravan Holiday Homes 548 Leisure Accommodation Vehicles – Caravans and Motor Caravans 551 Gas Supply on Boats 553 Pipework Installation on Boats 556 Tightness Testing on Boats 557 Appliances and Ventilation for Boats 559 15 Electrical Work 563 Electricity 563 Electrical Safety 565 Bonding 567 Safe Isolation 571 Inspection and Testing 576 Fault Diagnosis of Basic Electrical Controls 577 16 The ACS Assessment Process 581 The ACS Assessment Process 581 Matters of Gas Safety Criteria 583 Your ACS Assessment (CCN1) 584 Glossary 591 Appendix A Abbreviations, Acronyms and Units 605 Index 609
Andrew S. Burcham is an Engineering Technician Member of The Institution of Gas Engineers. He has over 40 years of experience in the gas industry, starting as an apprentice Gas Service Engineer with British Gas in 1981. He worked for British Gas for 25 years, later becoming an assessor and trainer. In 2006, he left British Gas and worked as a self-employed heating engineer while also assessing ACS programs at colleges. Since 2014, Andrew has been the ACS Centre Manager at Colchester Institute, delivering training and assessment programs for plumbing and heating engineers. His depth of knowledge and hands-on experience make him an invaluable resource. Stephen J. Denney is a highly respected tutor and assessor in the gas industry, bringing over 30 years of invaluable experience. After graduating as an award-winning plumbing student in 1991, he established a successful business in mechanical services. In 2014, Stephen became a full-time lecturer and assessor and currently holds a pivotal role at Colchester Institute’s Gas and Utilities Department. In this position, he oversees quality assurance and develops industry courses, equipping professionals with essential skills for success in the gas industry. His extensive practical experience, combined with his role as an assessor, enables him to provide valuable insights and real-world perspectives to professionals in the gas and utilities sector.
