Understand the core competencies of gas installation with this accessible textbook
This fully revised third edition is an essential on-site resource and an indispensable training guide for both qualified gas engineers and new entrants to the industry. Comprehensively updated to align with the latest standards and developments, it provides unrivalled coverage of all aspects of gas installation work in the United Kingdom.
This new edition features a full-colour layout, additional dedicated chapters on commercial catering, commercial laundry, educational establishments, and the ACS assessment process. With all topics consolidated into one convenient volume, gas operatives have all relevant information at their fingertips.
Key Highlights:
- Coverage of commercial, domestic and LPG installations along with emergency service provider and meter installation details.
- Comprehensive index and section-numbered text for easy topic identification by trainers and learners.
- Detailed discussion of UK gas installation standards, practices and procedures.
- New and updated material on net zero targets, climate change, and other aspects of the gas industry's future.
Gas Installation Technology is an invaluable training aid for students in gas installation or plumbing courses, as well as for professional gas installers renewing their certification.
Andrew S. Burcham is an Engineering Technician Member of The Institution of Gas Engineers and Managers. 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.
Roy D. Treloar was, until his retirement, curriculum development manager for the Professional Training Centre at Colchester Institute.
Understand the core competencies of gas installation with this accessible textbook This fully revised third edition is an essential on-site resource and an indispensable training guide for both qualified gas engineers and new entrants to the industry. Comprehensively updated to align with the latest standards and developments, it provides unrivalled coverage of all aspects of gas installation work in the United Kingdom. This new edition features a full-colour layout, additional dedicated chapters on commercial catering, commercial laundry, educational establishments, and the ACS assessment process. With all topics consolidated into one convenient volume, gas operatives have all relevant information at their fingertips. Key Highlights: Coverage of commercial, domestic and LPG installations along with emergency service provider and meter installation details. Comprehensive index and section-numbered text for easy topic identification by trainers and learners. Detailed discussion of UK gas installation standards, practices and procedures. New and updated material on net zero targets, climate change, and other aspects of the gas industry's future. Gas Installation Technology is an invaluable training aid for students in gas installation or plumbing courses, as well as for professional gas installers renewing their certification. Andrew S. Burcham is an Engineering Technician Member of The Institution of Gas Engineers and Managers. 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. Roy D. Treloar was, until his retirement, curriculum development manager for the Professional Training Centre at Colchester Institute. Understand the core competencies of gas installation with this accessible textbook This fully revised third edition is an essential on-site resource and an indispensable training guide for both qualified gas engineers and new entrants to the industry. Comprehensively updated to align with the latest standards and developments, it provides unrivalled coverage of all aspects of gas installation work in the United Kingdom. This new edition features a full-colour layout, additional dedicated chapters on commercial catering, commercial laundry, educational establishments, and the ACS assessment process. With all topics consolidated into one convenient volume, gas operatives have all relevant information at their fingertips. Key Highlights: Coverage of commercial, domestic and LPG installations along with emergency service provider and meter installation details. Comprehensive index and section-numbered text for easy topic identification by trainers and learners. Detailed discussion of UK gas installation standards, practices and procedures. New and updated material on net zero targets, climate change, and other aspects of the gas industry's future. Gas Installation Technology is an invaluable training aid for students in gas installation or plumbing courses, as well as for professional gas installers renewing their certification. Andrew S. Burcham is an Engineering Technician Member of The Institution of Gas Engineers and Managers. 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. Roy D. Treloar was, until his retirement, curriculum development manager for the Professional Training Centre at Colchester Institute.Table of Contents
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
