Gas Reference Package: This Document Is Free To Download and Copy From WWW - Gb-Gas - Co.uk

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GAS REFERENCE PACKAGE 2010v2
Aim To Pass With Gb-Gas
GAS REFERENCE PACKAGE
This document is free to download and copy from www.gb-gas.co.uk
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Combustion See www.gb-gas.co.uk for more details.

Visual inspection The main reasons for incomplete combustion 1. Lack of oxygen (soft yellow flames) 2. Incorrect burner pressure (over gassed / under gassed) 3. Flame impingement (flame chilling) A good pre-aerated flame should be bright blue with a strong inner and outer cone, and above all will have a roar. If there is any yellow in the flame then it is incorrect. (Do not mistake yellow for orange, as orange flames are usually dust being burnt.) Procedure for carrying out a service with the aid of a Combustion Analyser. 1. Carry out the service as per manufacturers instructions Tightness test, clean and inspect. 2. If the appliance is range rated turn to maximum setting Traditional boilers adjust to max burner pressure. Combination boiler on hot water mode or chimney sweep mode. Condensing boilers check manufacturers instructions. All other appliances burner(s) on full.**
**Be aware that checking a eye level grill when the hob burners are on will cause incomplete combustion on the grill.
3. Take flue gas analysis If acceptable: Reset to original burner pressure / gas rate and retest if ok Then conduct: Flue and spillage test Check safety controls. Ventilation. Confirm safe operation
If unacceptable: If possible rectify fault(s) then re test If not possible follow the unsafe situations guidelines. At Risk for flued appliances Immediately Dangerous for Flueless appliances. 4. Complete job documentation If using a flue gas analyser acceptable readings vary depending on the appliance type. Consult manufacturers instructions. If the manufacturer supplies a Co2 reading only then make sure you are very close to that reading.
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BS 7967-3 APPLIANCE TYPE Back boiler unit
CO/CO2 RATIO Boiler 0.008 In combination with fire 0.020 Central heating boiler 0.008 Hot water circulator 0.010 Flued space heater 0.020 (check man instructions) Flueless space heater 0.001 Water heater flued and Flueless 0.020 Warm air heater 0.008 Flueless cooker Oven 0.008 Hob Visual inspection of flames Grill (CE marked) 0.010 Grill (No CE mark) 0.020 Range oven flued 0.020 Refrigerator (LPG) 0.007 Tumble drier Flued 0.010 flueless 0.001 Gas lights (LPG) 0.020 Any ratios above these readings maybe through, misuse, lack of maintenance, damage or aging. Make sure the probe is placed correctly: Open flued: centre of the flue, or 200mm inside the draught diverter. Room sealed: From the manufacturers test point or 200mm inside the flue duct from outside Flueless appliances: On the flue outlet using the spreader bar tester. The appliance has run for 5 mins. Monitor the Co reading carefully if this starts rising quickly then remove the tester as you may damage the equipment. If you dont get the reading you are looking for let it run for a further 10 mins and retest. A full clean and check or repair of the appliance is essential and then re-tested. If it is not possible to achieve these levels then the appliance should be regarded as at risk for flued appliances and immediately dangerous for Flueless appliances.
COMBUSTI ON ANALYSER Natural gas Co. 21 O2 4.8 Co2...8.9
C O M B US TI O N A N A L YS IS
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Carrying out a room test for carbon monoxide with a Combustion Analyser. General 1. Position an open ended sampling probe approximately 2 m above floor level in the centre of the room and at least 1 m away from any suspect appliance installation. 2. Close all external doors, windows and customer adjustable ventilation. 3. Record the level of CO over a 15 min period. If the indoor level of CO starts to rise during this period, check for CO migration from other sources. 4. If there is no rise then proceed to test the appliance. Room sealed and open flued appliances Cookers
Operate the appliance at full rate until the CO reading stabilizes or begins to fall, whichever occurs first.
Ensure that all permanent ventilation to the space in which the appliance is situated is unobstructed. Place a saucepan on each of the pan-supports above the two largest hotplate burners and put approximately a litre of water in each and cover with a lid. Use a saucepan with a flat base and a base diameter of between 160 mm and 220 mm. Place the grill pan in its highest position under the grill. Open/operate the customer adjustable ventilation in accordance with the cooker manufacturers instructions, e.g. window or extractor fan. Light the grill, oven and the two hotplate burners at their maximum setting. Turn the oven down to gas mark 5 (or mid-range if not calibrated in gas mark numbers). Record the CO levels at 1 min intervals. Turn the hotplate burners down to simmer when the water boils. Turn the grill off after 30 min. If during the test the CO reading: begins to fall without exceeding 30 ppm, stop the test; the installation and cooker are satisfactory; does not exceed 30 ppm for longer than 20 min and begins to fall and does not exceed 90 ppm at any time, stop the test; the installation and cooker are satisfactory; Exceeds 90 ppm at any time, stop the test, ventilate the room, identify the cause, rectify and repeat the test.
Flueless water heaters
Ensure that all permanent ventilation to the space in which the appliance is situated is unobstructed. Close all customer adjustable ventilation to the space in which the appliance is situated. Light the appliance and operate it at maximum gas rate for 5 min recording the CO levels at 1 min intervals. Ensure that all permanent ventilation to the space in which the appliance is situated is unobstructed. Close all customer adjustable ventilation to the space in which the appliance is situated. Light the appliance and operate it at maximum gas rate for 30 min recording the CO levels at 1 min intervals.
Flueless space heaters
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Pipe work inspection See www.gb-gas.co.uk for more details. Common faults found on the meter installation: Valve handle Valve handle drops On / off label missing to on position missing Incorrect or no No emergency No governor on telephone number procedures label primary meter Common faults found on pipework installation: No 10mm bonding To close to electric To close to electric within 600mm of meters or outlets cables or conduits the meter (150mm) (25mm) Incorrect sleaving Incorrect materials Incorrect fittings methods used in pipework used in pipework Incorrect materials at meter Governor not sealed
Pipework inappropriately supported Unsatisfactory workmanship
Re-establishing gas supplies

This checklist should be conducted every time the gas has been turned off. Even if only conducting a tightness test.
A visual check on the pipework installation A visual check of the appliances should be made Calculate the ventilation requirements for the installation Test for soundness Purge the meter from the furthest practical point
Purge volume = 5x the meter badge capacity for installations with pipe up to 28mm e.g. ( imperial meter(ft) = 5x 0.071ft = 0.355ft) (metric meter(M) = 5x 0.002m = 0.010m)
If there is pipework greater than 28mm or a meter bigger than a 6m capacity a calculation must be used
U16 meter 5 x 0. 006m = 0.030m

Purge volume = pipework length x volume of 1m length x 1.1 (for fittings) x 1.5 plus meter purge volume. Eg 3 m of 35mm pipe plus a U16 meter... 3 x 0.00084 x 1.1x1.5 =0.004158 m + 0.030 m =0.034158 m.
See page 26 or IGEUP1B FOR MORE DETAIL or visit gb-gas.co.uk

Material and nominal size of pipe Steel / stainless steel 15mm 20mm 25mm 1 0.00024 (m) 0.00046 (m) 0.00064 (m) 0.0011 (m) Volume of 1m length of pipe Copper 15mm 22mm 28mm 35mm 0.00014 (m) 0.00032 (m) 0.00054 (m) 0.00084 (m)
32mm 1
Purge the remaining sections of the installation (light and detect method) Re-light each appliance in turn checking that all user controls are working satisfactorily Check all open flued appliances for spillage Inform customer on appliance use and gas safety
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Testing for tightness (Using Gas) NEW SYSTEMS

See www.gb-gas.co.uk for more details.
After visually inspecting the installation 1. Turn the gas off 2. Make sure all appliances are disconnected 3. Turn all valves on pipework on. Connect a zeroed manometer to the meter test point and start the test procedure Test name Let-by test Reason To check if MCV is passing, if greater than (max 0.25mb or 0.2mb with a digital) report to supplier. To confirm let-by spray LDF in valve to allow for temp. differences (No pressure drop or smell allowed) Test pressure Test time
10mb
1 min
Stabilisation Soundness test
20mb 20mb
1 min 2 min
4. Make sure all appliances are re-connected 5. Turn all valves on including lifting the cooker lid. Connect a zeroed manometer to the meter test point and start the test procedure Test name Stabilisation Reason To allow for temp. differences (record any drops here) Test pressure Test time
20mb 20mb
1 min 2 min
Soundness test
Gas test for pipework and appliances in new installations NO DISCERNABLE DROP ALLOWED (max 0.25mb or 0.2mb with a digital) The test pressure must never be greater than 23mb as the governor may lock up, if so you will have to spray all the inlet pipework to check for leaks.
Air testing
Connect a zeroed manometer to the TEST TEE and start the test procedure. Test name Reason Test pressure Test time Stabilisation to allow for temp. differences 20mb 1 min Soundness test (record any drops here) 20mb 2 min Air test would be used for pipework in new installations NO DISCERNABLE DROP ALLOWED -(max 0.25mb or 0.2mb with a digital)
******** Test all testpoints with leak detector fluid*********
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Testing for tightness (Using Gas) Existing Systems

After visually inspecting the installation 1. Turn the gas off 2. Make sure all appliances are connected 3. Turn all valves on pipework on. Connect a zeroed manometer to the meter test point and start the test procedure Test name Let-by test Reason To check if MCV is passing, if greater than (max 0.25mb or 0.2mb with a digital) report to supplier. To confirm let-by spray LDF in valve To allow for temp. differences (see information below) Test pressure Test time
10mb
1 min
Stabilisation
20mb 20mb
1 min 2 min
Soundness test
If there is no discernable pressure drop in the system and no smell of gas then the system has passed. If there is a drop in the system then all the appliances must be isolated and the pipework tested on its own (no discernable drop is allowed in the pipework) If the drop is at an appliance and within the limits set (below) and no gas can be smelled, then the system may be passed. The test pressure must never be greater than 23mb as the governor may lock up, if so you will have to spray all the inlet pipework to check for leaks.
Maximum drop allowed U6 meter 4mb over 2min* or 2.5 mb if there is pipe work greater than 28mm E6 meter 8mb over 2min* 4.5 mb if there is pipe work greater than 28mm
U16 meter 1mb over 2 min* even if the pipe is greater than 28 mm * in any situation if the recorded drop is in the pipework it is an immediate fail * if there is a sell of gas the installation is an immediate fail
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Testing for tightness (Using Gas) Maximum Operating Pressure (MOP) greater than 75 MB
After visually inspecting the installation 1. Turn the gas off 2. Make sure all appliances are connected and no pilot lights 3. Turn all valves on pipework on. Connect a zeroed manometer to the meter test point and start the test procedure Test name Let-by test for Meter Control Valve (A) How Reason To check if MCV is passing, if greater than (max 0.25mb) report to supplier. To confirm let-by spray LDF in valve to check if regulator is passing on lock out, if greater than (max 0.25mb) report to supplier To allow for temp. differences (No discernable pressure drop or smell allowed) Test pressure Test time
Take the system up to standing pressure. Close meter control valve. Release pressure e.g. (by opening a cooker) Hold open regulator valve and observe. Let-by test Release the regulator valve for pressure should increase Regulator slightly. lock out (B) Open meter control valve and observe. Stabilisation Raise pressure to 19 mb close meter control valve Soundness test Observe
Approx. 2-10mb
1 min
Approx. 2-10mb 19mb 19mb
1 min
1 min 2 min
No discernable drop is any drop greater than 0.25mb The test pressure must never be greater than 19mb as the governor may lock up, Because the inlet pipework is subjected to pressures up to 2 bar you must spray all the inlet pipework to check for leaks.
Maximum drop allowed U6 meter 4mb over 2min* or 2.5 mb if there is pipe work greater than 28mm E6 meter 8mb over 2min* 4.5 mb if there is pipe work greater than 28mm
U16 meter 1mb over 2 min* even if the pipe is greater than 28 mm * in any situation if the recorded drop is in the pipework it is an immediate fail * if there is a sell of gas the installation is an immediate fail

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Ventilation
When checking ventilation requirements always observe manufacturers instructions Calculate MAX NET heat input Take MAX GROSS heat input from the appliance DATA BADGE and by 1.1 Advent YES * Top * X 5cm Bottom * X 10cm Outside -7kW X 5cm * -7 kW X 5cm
OPEN FLUED ONE Open flued appliance in a room MAX net heat input ONE Open flued appliance in a compartment vented to outside MAX net heat input ONE Open flued appliance in a compartment vented to a room MAX net heat input TWO Open flued appliance in a room MAX net heat input TWO Open flued appliance in a compartment MAX net heat input
X 10cm X 20cm
ADD two heat inputs together and calculate as above ADD two heat inputs together and calculate as above
TWO Open flued GAS FIRES in the additional ventilation may not be same room (less than 14kW) required Add heat inputs together and calculate as TWO Open flued GAS FIRES in the for one open flued appliance in a room same room (greater than 14kW) IF flue or spillage test fails additional ventilation is required ROOM SEALED ONE Room Sealed appliance in a room MAX net heat input ONE Room Sealed appliance in a compartment vented to outside MAX net heat input ONE Room Sealed appliance in a compartment vented to a room MAX net heat input FLUELESS APPLIANCES COOKER WATER HEATER TUMBLE DRIER
OPENABLE WINDOW OR SIMILAR
Top * X 5cm
Bottom * X 5cm
Outside * *
X 10cm
X 10cm
<5
100 CM NOT 100 CM
ROOM SIZE (M) 5-10 10-15 15-20

50 CM * 100 CM 100 CM 0 CM 50 CM 0 CM 0 CM 50 CM 0 CM
>20
0 CM 0 CM 0 CM
YES YES YES
* IF THE ROOM CONTAINS A DOOR TO OUTSIDE THEN A VENT IS NOT REQUIRED
MULTI- APPLIANCE SITUATIONS SIMILAR flued appliances in a room MAX net heat input DISSIMILAR flued appliances in a room Measuring ventilators
ADD two heat inputs together and calculate as above TAKE largest ventilation requirement
Calculate the free air area (measure the holes) the hole MUST be from 5 to 10 mm and not closeable. if answer is in MM 100 to get CM
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Pressure testing
STANDING PRESSURE at the meter (APPROX. 25mb) Test method (see below) WORKING PRESSURE (must be 21 2 mb) AT THE METER Test method (see below) Multifunction control BURNER APPLIANCE INLET WORKING PRESSURE (max 1mb drop form working pressure at the meter) APPLIANCE BURNER PRESSURE (check against appliance data badge)
Meter Standing and Working Pressure

1. Connect a zeroed manometer to the meter test nipple.** 2. Turn on gas slowly and record STANDING PRESSURE (APPROX. 25mb) 3. Then turn on ONE appliance: Cooker 3 hotplates. Fire on full rate. Boiler on full rate.* Other appliance full rate. *a range rated boiler may cause a problem, if using a combi. Use hot water mode 4. Record reading on the WORKING PRESSURE (must be from 19mb to 23mb) if to high or to low contact gas supplier for primary meter, if it is a secondary meter adjust (screw down clockwise to increase pressure.) **To read the manometer correctly add both legs together and divide by 2** If the meter is running at full rate (6m/hr), with an inlet pressure of 19mb at the governor. The drop or (absorption) through the meter will be as much as 4mb.
Inlet working pressure

This test is prove the pipework is suitable in size and length with no blockages. 1. Connect a zeroed manometer to the boiler inlet test point. 2. Turn on the appliance and record the reading( only 1mb drop allowed through the pipeline) see page 27 for more details e.g. working pressure at the meter : 21mb inlet working pressure : 20mb installation acceptable. **To read the manometer correctly add both legs together and divide by 2**
Burner pressure
This test is to prove that the appliance is burning within the limitations set by the manufacturer. 1. Connect a zeroed manometer to the boiler BURNER PRESSURE test point. 2. Turn on the appliance and record the reading (compare the reading against the appliance data badge. The reading must be within the range) **To read the manometer correctly add both legs together and divide by 2**
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Heat Inputs And Gas Rates.

The purpose of these tests is to prove how much gas is being burnt by the appliance
IMPERIAL METER (ft): E.G. U6

1. Make sure only the appliance to be tested is on (turn up full) 2. Got to the gas meter and time one complete revolution of the red dial on the meter. 3. Convert the time into seconds and apply into the calculation. 1 revolution = 1ft of gas
U6 GAS RATE = 100.8 TIME IN SEC FOR 1FT OF GAS =_______________M/HR U6 (gross) HEAT INPUT= 1064 TIME IN SEC FOR 1FT OF GAS =_______________kW U6 (net) HEAT INPUT = 967 TIME IN SEC FOR 1FT OF GAS =_______________kW
4. Compare the reading against the appliance data badge. The reading must be within the range.
METRIC METER (M): E.G. E6, G4

1. Make sure only the appliance to be tested is on (turn up full) 2. Go to the gas meter and record the reading and at the same time start the stop watch. 3. Two minutes later (on the stop watch) record the second reading. 4. Subtract the first reading from the second reading and apply into the calculation. EXAMPLE Reading after two minutes First reading on meter Amount of gas used = 1 1 0 0 0 0 0 0 0 7 7 0 1 0 0 3 7 6 3 2 1 M M M
E6 GAS RATE = TWO MINUTES OF GAS X 30 =_______________M/HR E6 (gross) HEAT INPUT = TWO MINUTES OF GAS X 317 =_______________Kw E6 (net) HEAT INPUT = TWO MINUTES OF GAS X 288 =_______________Kw
Compare the reading against the appliance data badge. The reading must be within the range.
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Gas safety devices and Controls

Flame supervision devices or F.S.D s Recognise Thermoelectric FSD Found Test
Purpose : To avoid unlit gas entering the appliance because it has a push button and thermocouple in every type of gas appliance 1. Light pilot and establish. 2. Turn gas off time until click Loop of metal Only found on hot water circulators 1. Light pilot and establish. 2. Turn pilot off time until burner turns off Small probe directly on oven burner, burner lights on low flame Only found in cookers 1. Light burner (should light on low flame) after approx. 30sec rising to high flame. 2. Turn gas tap off, wait for 90 sec and re-light (should light on low flame) Ignition starts automatically to light the pilot or main burner On all appliances 1. turn appliance on make sure flame lights and establishes 2. Keep the demand on the appliance and turn the gas off. The appliance should go into lockout or keep sparking
Bi-metallic strip FSD
Recognise Found Test
Vapor pressure FSD
Flame rectification FSD (electronic ignition)
FSD shutdown times

* BOILERS * W / AIR HEATERS * COOKERS * WATER HEATERS * D.F.E. GAS FIRES * OTHER GAS FIRES * 60 SEC 60 SEC 90 SEC oven 60 SEC other 90 SEC 120 SEC 180 SEC
*Manufacturers instructions may differ from the times stated above. *
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Thermostats
4 Mechanical thermostat (Vapor expansion) Recognise Found Test
Purpose: to control heat Dial with numbers indicated Mostly on cooker ovens 1. Turn oven on and heat up for 15 min. 2. Turn control to lowest setting flame should drop to by-pass rate Dial with numbers indicated Old cookers and water heaters. Heat up appliance gas should turn down / or off (depending on appliance) Dial with numbers indicated Boilers etc Heat up appliance thermostat should turn the solenoid off
Mechanical thermostat (rod type)
Electric thermostat
Solenoid
Purpose Found Test
An electrically operated gas valve Boilers etc 1. Turn electricity on valve opens 2. Turn electricity off valve closes A collection of controls in one unit Boilers etc If the FSD, Regulator and solenoid work then the multi-function control is working. An automatic gas valve Old boiler, commercial cookers 1. Weep gas of the top of the unit and the burner should open. 2. Stop the weep and the burner will go off. To turn off the burners, when the lid drops Cookers, (hotplates) 1. Turn on gas tap to hotplate. 2. Lower lid and gas should turn off
Multi-function control
Purpose Found Test
Relay valve
Purpose Found Test
Lid safety device Mechanical safety cut off
Purpose Found Test
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10
Gas tap
Purpose Found Test
To control the flow off gas safely Cooker, fires ,etc 1. tap locks in the off position 2. tap functions correctly To close down the open flued appliance automatically, if the appliance and flue operate incorrectly All open flued appliances after 1998 1. light pilot. 2. Close air inlet hole and observe flame (turn yellow) To close down the open flued appliance automatically, if the appliance and flue operate incorrectly On water heaters, Flued water heaters this is usually a overheat safety device. Flueless used as an ASD Visual inspection to check wiring to thermocouple (no links) and check FSD Adjuster screw to alter burner pressure Boilers etc 1. Attach manometer to test point 2. Adjust screw to alter pressure To compensate for the negative pressure caused by the fan, on the gas valve (this could pull more gas into the burner than intended) New fan flued room sealed appliances 1. Attach manometer to burner pressure test point Turn appliance on when the fan comes on the manometer reads negative pressure, quickly going to positive pressure when the burner comes on. To lower incoming gas pressure from 2 bar to 21mb Above the meter control valve, fitted with a reset handle 1. make sure working pressure is 21mb make sure the regulator lockout does not let-by
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Atmospheric Sensing Device (ASD) (VSD)
Purpose
Found Test
12
Atmospheric Sensing Device / over heat Thermocouple interrupter
Purpose
Found
Test
13
Regulator
Purpose Found Test
14
Zero governor
Purpose
Found Test
15
Medium to low pressure Regulator
Purpose Found
Test
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Flame rectification / conductance

Sequence of events for an electronic ignition fan flued boiler yes no 1 Demand on the system turns pump then fan on. 2 Fan turns on fan pressure switch 3 Pressure switch turns on ignition system. Proving AC to AC through electrodes 4 Ignition system turns on power to the solenoid via the control stat and high limit stat. 5 Ignition spark ignites the gas 6 Ignition system proves the flame by rectification of the current through the ionized layer of the flame AC to DC 7 Ignition system monitors flame by DC current
To test the flame rectification system
1 Put a demand on the system and make sure it fires up and stays lit 2 Turn the gas off system should start sparking again then go into lockout or keep sparking
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Cooker Controls
FSD Vapour pressure

Test procedure
Light the oven burner, it should light on the low flame After approx. 30 seconds it should rise to the high flame Turn oven gas tap off After 90 seconds re-light the oven burner, it should light on low flame If it lights on the high flame then the FSD is faulty
OR
Thermoelectric
Test procedure
Push the control handle in and turn to a setting. Light the burner hold in the control handle for 30 seconds Release the control handle the flame should stay on the burner. If the flame goes out the thermocouple or thermoelectric valve is faulty Turn the gas off, at the meter or appliance isolation valve, after the flame goes out at the burner time until a click is heard or the time limit is reached. Turn the gas back on without pushing in the control knob in ,the gas should not come back through the burner If the gas comes back on thermoelectric valve is faulty
Oven thermostat Test Procedure

Light the oven burner and turn to high setting Shut the door and leave for 15 min Open the door to see the flames and turn to the lowest possible setting The flame should drop to the bypass rate If flame goes out (faulty bypass) If flame does not drop (faulty thermostat)
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Unsafe situations
To find out if a situation is NCS AR or ID consult the unsafe situations document
Category N.C.S.
NOT TO CURRENT STANDARDS
Action taken
Inform responsible person, and repair fault if possible. Fill in (notice) and give copy to responsible person
Label used
None
Notice used
Fill in the NCS section of warning notice form Fill in the A.R. section of warning notice form Fill in the I.D. section of warning notice form
Inform responsible person, and repair fault if Warning label do A.R. not use AT RISK possible. If not turn appliance off attach (label) and fill in (notice) and give copy to responsible person.
I.D.
IMEDIATELY DANGEROUSE
Inform responsible person, and repair fault if possible. If not DISCONNECT appliance and attach (label) and fill in (notice) and give copy to responsible person.
Warning label do not use
Flue inspection
When visually inspecting a flue start at one end and work methodically to the other end making a note of all the problem areas Common faults to look for are
Open flues
Catchment area too small Flue not sealed to the appliance Joints leaking Catchment area not sealed Flue damaged Joints not sealed Catchment area has letterbox opening Flue upside down Flues not clipped Incorrect flue for appliance Signs of spillage Minimum of 600mm between draught diverter and first bend Incorrect terminal Incorrect material or methods used.
Bend no greater than 45 Terminal not high enough through the roof.
Flue too small for appliance. Copex liner not fixed at the top or bottom
To close to combustible material. Copex not sealed to appliance
Room sealed flues

Flue not sealed Flue length to long Appliance seals damaged or missing Flue damaged Terminating in wrong position. Incorrect material or methods used No terminal guard Appliance or flue leaking.
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FLUE TESTING
The purpose of a flue test is to prove a few points about the flue: 1. Flue draws all the products of combustion up the flue. 2. The flue does not leak from any joints or connections. 3. The flue terminates in the correct position. 4. The flue does not leak through any other flue system. Before carrying out the test a few points MUST be covered. 1. Explain to the customer what you are about to do (in case they panic) 2. Close doors and windows (put the flue under its worst conditions) 3. When testing a flue with a fan in the area (it may not be necessary to turn the fan on as the problems that may occur with back pressure are checked when conducting a spillage test)
Test the flue from cold Pre-test with a smoke match FAIL Heat the flue for 10 min and retest IMPORTANT while completing the test; All smoke must be drawn into the flue. The smoke must terminate at the correct point. The flue must not leak into any other flue, room or dwelling
Test with a smoke pellet
Pre-test with a smoke match FAIL Heat the flue for further 10 min and retest If the flue is condemned it may require repair or cleaning further investigation is required. Follow the unsafe situations procedures
OK
Pre-test with a smoke match FAIL Heat the flue for further 10 min and retest
OK
Pre-test with a smoke match FAIL CONDEMN
If heating the flue with a blow torch, it may require as much as 30 min to heat properly OK
OK
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SPILLAGE TESTING
The purpose of a spillage test is to prove a few points about the appliance: 1. The appliance draws all the products of combustion into the flue. 2. The appliance and flue design are working correctly. 3. The appliance has no fumes entering the room 4. The appliance is safe to use Before carrying out the test a few points MUST be covered. 1. Explain to the customer what you are about to do (in case they panic) 2. Close doors and windows (put the flue under its worst conditions) 3. Turn the extractor fans on in the room and test 4. Turn extractor fans on in any other room in the house and leave the door between the rooms open. And re test 5. When testing a flue with a fan in the area test with the fan on and with the fan off.
Heat the appliance for 5 minutes
IMPORTANT
while completing the test;
Leave the appliance on and place smoke match in the desired area
All smoke must be drawn
FAIL
Heat the appliance for further 10 min
into the appliance. The appliance must be left on at maximum setting.
Is all the smoke drawn into the appliance
Leave the appliance on and place smoke FAIL match in the desired area
CONDEMN
OK
Is all the smoke drawn into the appliance
If the appliance fails then further investigation may be required

The appliance may be; 1. Over gassed. 2. Sooted up. 3. Blocked flue or flue ways. 4. Bad flue design. 5. Faulty appliance.
OK
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GAS REFERENCE PACKAGE 2008.1
Spillage Testing for room sealed appliances

This to make sure the appliance is sealed form the room. Remove the outer case if its not part of the seal. Visually inspect for any corrosion, distortion and problems with seals While the appliance is turned on Move a lighter or match around 1. All the case seals, 2. Viewing windows, 3. All Pipes and wires entering the pressurised case 4. Around the flue seals If the lighter flame is distorted or blows out then this is a fail.
D Below a gutter, or sanitary pipe work E Below the eaves F Below a balcony or carport roof G Above ground, roof or balcony level H From vertical drain/soil pipe work J From an internal or external corner K From a surface or boundary facing the terminal L Vertically from terminal on same wall M Horizontally from terminal on same wall N From a terminal facing the terminal P From an opening in a carport (e.g. door, window) into the building R From a vertical structure on the roof [Note $] S Above an intersection with the roof
300 [#] 75 [@] 300 [#] 200 600 300 200 300
75 [@] 75 [@] 600 600 300 600 [+]
1500 300 600 1200
1500 300 1200 1200 Notes: @. a terminal serving a natural draught and fanned draught appliance more than 5kW heat input should be at least 300mm and 150mm respectively from combustible material. #. Where a natural draught flue terminates not more than 1m below a plastic projection or not more than 500mm below a projection with a painted surface, then a heat shield at least 1m long should be fitted. +. The distance from a fanned draught appliance terminal installed at right angles to a boundary may be reduced to 300mm $. Vertical structure includes a chimney-stack, dormer window, tank room, lift motor room or parapet.
n/app
n/app
n/app
n/app
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Minimum distance to terminal in millimetres Balanced flue, room-sealed appliance Natural draught 300 600 1500 2000 300 600 300 400 600 Fanned draught 300 300 300 300 300 300 300 300 300
A Directly below an opening, air brick, opening window, etc
(0-7 kW) (>7-14 kW) (>14-32 kW)
(>32-70 kW) B Above an opening, air (0-32 kW) brick, opening window, (>32-70 kW) etc C Horizontally to an (0-7 kW) opening, air brick, (>7-14 kW) opening window, etc (>14-70 kW)
Condensation and pluming.

Facing properties and points of possible extensions in the future must be a consideration. A distance of 2m is recommended where pluming may be a nuisance. To openings or other properties
POSSIBLE EXTENSION
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Simple gas faultfinding on appliances Typical Gas Component Faults on Central Heating Boilers and Circulators
Unsatisfactory Ignition Of Burners / Flame Supervision Devices;

Flames not igniting, Explosive ignition due to a range of possible faults; Pilot flame to small Pilot flame not in correct position Faulty FSD To much gas at the main burner Not enough gas at the main burner
Unstable Flame Picture

Incorrect flame due to a range of possible faults Over gassed (Long flames with possible yellow tips) Lack of oxygen (Yellow flames) Cracked burners Blocked burners (Choked with soot)
Signs Of Spillage
Sooting in or around the appliance or appliance seals Pattern staining from the draught diverter
Inoperative Thermostats
Inoperative operating thermostats giving temperature problems (to hot or to cold) If operating thermostat fails on a system boiler. The high limit stat will lock the boiler out (requires to be manually reset) If high limit stat also fails steaming hot water will discharge from the pressure relief valve. This will drop the pressure from the boiler. (requires to be manually reset)
Inoperative Air Pressure Switch Symptoms on a fan flued boiler would be

The boiler fan starts up but the ignition sequence does not start ( The fan pressure switch starts the ignition sequence)
Inoperative Multifunction Control Valve

a multifunction control valve contains three main components a FSD, a Solenoid a Regulator all three components must work correctly.
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Typical Gas Component Faults On Central Heating Boilers And Circulators

Flames not igniting, Explosive ignition due to a range of possible faults;
Pilot flame to small Pilot flame not in correct position Faulty FSD To much gas at the main burner Not enough gas at the main burner

Incorrect flame due to a range of possible faults Over gassed (Long flames with possible yellow tips) Lack of oxygen (Yellow flames) Cracked burners Blocked burners (Choked with soot)
Signs Of Spillage
Inoperative operating thermostats giving temperature problems (to hot or to cold) If operating thermostat fails on a system boiler. The high limit stat will lock the boiler out (requires to be manually reset) If high limit stat also fails steaming hot water will discharge from the pressure relief valve. This will drop the pressure from the boiler. (requires to be manually reset)


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Typical Gas Component Faults On
Cookers
Flames not igniting, Explosive ignition due to a range of possible faults; Pilot flame to small Pilot flame not in correct position Faulty FSD shut down in (90sec) To much gas at the main burner Not enough gas at the main burner Faulty ignition system
Unstable Flame Picture at Full or Simmer

Incorrect flame due to a range of possible faults Over gassed ( Long flames with possible yellow tips) Lack of oxygen (Yellow flames) Cracked or warped burners Blocked burners (Choked with grease)
Faulty Thermostat or Oven By-pass

Thermostat out of calibration and undercooking or overcooking food Oven burner goes out when the oven reaches temperature (blocked by-pass)
Stiff Burner Control Tap

A control tap that is too loose or too tight may require re-greasing A control tap must also lock itself in the off position so that it cannot be turned on by accident check the spring and locking collar
Inoperative Lid Closure Device Lid safety Device must turn the gas of to the burners when the lid is lowered
Some devices turn all the gas taps off others have a reset button to push when the lid is lifted again. Check that the device operates correctly
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Typical Gas Component Faults On Space Heating (gas fires)

Flames not igniting, Explosive ignition due to a range of possible faults;
Pilot flame to small Pilot flame not in correct position Faulty FSD To much gas at the main burner Not enough gas at the main burner

Incorrect flame due to a range of possible faults Over gassed ( Long flames with possible yellow tips) Lack of oxygen (Yellow flames) Cracked burners Blocked burners (Choked with soot)
Signs Of Spillage
Incorrect position of fuel on the fuel bed

If the wrong size of radiant or the incorrect amount of coals are used on a gas fire the result could be Flame impingement Incomplete combustion In either case the burner will not operate correctly, with the appliance becoming sooted
Inoperable or Stiff control tap

Check that the gas tap is easy to work and that it controls the full range of settings on the appliance

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Warm Air Units. Unsatisfactory Ignition Of Burners / Flame Supervision

Devices;

Incorrect flame due to a range of possible faults Over gassed ( Long flames with possible yellow tips) Lack of oxygen (Yellow flames) Cracked burners CRACKED HEAT EXCHANGER/
Blocked burners (Choked with soot) NO RETURN AIR DUCT
Signs Of Spillage
Sooting in or around the appliance or appliance seals Pattelkj ;oinern staining from the draught diverter
Warm air units have a low temperature thermostat this lets the burner turn on and heat, the heat exchanger before the fan unit turns on. and a high temperature thermostat this turns the burner off when the heat exchanger gets too hot, but lets the fan keep running. If it does not operate in this sequence then the thermostat(s) may be faulty.
Faulty Heat Exchanger Symptoms of a cracked heat exchanger would be

The flame picture is very poor (flames blown side ways) Products of combustion entering all warm air ducting Pilot flame blowing out. Fail spillage test at burner.

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Instantaneous Water Heaters Unsatisfactory Ignition Of Burners / Flame Supervision

Devices;

Incorrect flame due to a range of possible faults Over gassed ( Long flames with possible yellow tips) Lack of oxygen (Yellow flames) Cracked burners Blocked burners (Choked with soot)
Signs Of Spillage
Scaled Heat Exchanger

A scaled heat exchanger usually results in a noisy unit due to the reduction in flow rate. Also may cause the appliance to over heat

Defective Gas Valve Assembly

Will result in the main burner failing to light or the main burner staying on after the water has been turned off. The problem may be: Defective Diaphragm Blocked Venturi Failure of the mechanism (push rod sticking)
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Volume and purge calculations for large installations

With pipework greater than 28mm or a meter bigger than a 6m capacity.
Installation volume
Meter type LENGTH 15mm LENGTH 22mm LENGTH 28mm LENGTH 35mm
Purge volume
Pipe volume m
Multiply the lengths by the volumes from table 1
A B C D
Total pipe volume

This is the same as B
F G
Fittings +10%
Multiply A by 1.1 to add the 10% on
Pipework purge volume x 1.5

Multiply F by 1.5
Meter volume
Look up the meter volume
Meter purge volume (cyclic volume x5) Total purge volume

Add G and H together
If the purging volume is less than 0.02m purging is conducted from the furthest practical point well ventilated and no source of ignition.
H J
Total installation volume

Add B and C together
If the volume is greater than 0.035m or the meter capacity is greater than 16m/hr then the (commercial) IGE UP 1 or 1A document and qualification must be used.
If the purging volume is greater than 0.02m purging is conducted from the furthest practical point and the appliance must be continually ignited until a flame is established.
Steel / stainless steel 15mm 20mm 25mm 1 0.00024 (m) 0.00046 (m) 0.00064 (m) 0.0011 (m)
Copper 15mm 22mm 28mm 35mm 0.00014 (m) 0.00032 (m) 0.00054 (m) 0.00084 (m)
32mm 1
Type of meter
FOR VOLUME CALCS

Meter volume (m) for pipe work volume calculations
FOR PURGE CALCS B

Meter cyclic volume x 5 =Meter purge volume in (m)
G4 / U6 U16 E6
0.008 0.025 0.0024
0.002 x 5
= 0.010m
0. 006 x 5 = 0.030m N/A =0.0036m
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Pipe work sizing

Resistance table: Discharge in straight horizontal table x copper tube with 1.0 mb differential pressure between the ends, for gas of relative density 0.6 (air = 1).
When estimating the gas flow rate in pipework of a known length this length must be increased by 0.5 m for each elbow and tee branch fitted.
Draw a plan of your pipe routs SPLIT THE PIPE WORK INTO SECTIONS and number them 1,2,3,4 etc. details on the plan the number of actual or estimated elbows and tees required.
Appliance / appliances 1 2 3 4 5 6 M/HR
GAS FLOW REQUIRED

THIS IS THE GAS RATE OF THE APPLIANCES THAT THIS PIPE IS FEEDING Pipework
B C D
LENGTH (how many meters of pipe) FITTINGS (0.5m for each elbow or tee going round the corner) ACTUAL LENGTH (add B+C together)
M M M
ASSUMED PIPE DIAMETER Make an assumption on the pipe diameter or use the table to find a diameter CHART ALLOWABLE LENGTH Use diameter E in the table read to the right until you find close to or just greater than A. then run up to the top of the table to find the allowable length
MM
PRESSURE DROP Chart allowable length D divided by the actual length F. if this is greater than one you have divided the wrong number first.
mb
Total Pressure drop Adding the pressure drops from the meter to the appliances and all pipework it passes must total less than one to pass eg. (From the meter to the first tee). + (From the tee to the appliance) = must equal less than 1mb. See www.gb-gas.co.uk for more details. Meter to appliance 1 Meter to appliance 2 Meter to appliance 3 Meter to appliance 3
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