GAS REFERENCE PACKAGE: Combustion Checks and CO Testing

gb-gas.co.
uk 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
1
gb-gas.co.uk GAS REFERENCE PACKAGE 2010v2 Aim To Pass With Gb-Gas
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 manufacturer’s 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 manufacturer’s 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.
2
BS 7967-3
APPLIANCE TYPE CO/CO2 RATIO
Back boiler unit 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
COMBUSTI C Flueless appliances: On the flue
ON O outlet using the spreader bar tester.
ANALYSER
Natural gas
M
Co…. 21 B The appliance has run for 5 mins.
O2… 4.8 US
Co2...8.9 TI
Monitor the Co reading carefully if
O this starts rising quickly then
N remove the tester as you may
A damage the equipment.
N
A
L
If you don’t get the reading you are
YS looking for let it run for a further 10
IS 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.
3
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 Operate the appliance at full rate until the CO reading stabilizes or begins to fall,
sealed and whichever occurs first.
open flued
appliances
Cookers 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
manufacturer’s 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 Ensure that all permanent ventilation to the space in which the appliance is situated is
water unobstructed.
heaters 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.
Flueless Ensure that all permanent ventilation to the space in which the appliance is situated is
space unobstructed.
heaters
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.
4
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 Incorrect materials
missing to on position missing at meter
Incorrect or no No emergency No governor on Governor not
telephone number procedures label primary meter sealed
Common faults found on pipework installation:

No 10mm² bonding To close to electric To close to electric Pipework
within 600mm of meters or outlets cables or conduits inappropriately
the meter (150mm) (25mm) supported
Incorrect sleaving Incorrect materials Incorrect fittings Unsatisfactory
methods used in pipework used in pipework 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(ft³) = 5x 0.071ft³ = 0.355ft³) (metric meter(M³) = 5x 0.002m³ = 0.010m³)
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. 006m³ = 0.030m³
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 m³ + 0.030 m³ =0.034158 m³.
See page 26 or IGEUP1B FOR MORE DETAIL or visit gb-gas.co.uk
Material and nominal size of pipe Volume of 1m length of pipe
Steel / stainless steel Copper
15mm ½ 0.00024 (m³) 15mm 0.00014 (m³)
20mm ¾ 0.00046 (m³) 22mm 0.00032 (m³)
25mm 1 0.00064 (m³) 28mm 0.00054 (m³)
32mm 1¼ 0.0011 (m³) 35mm 0.00084 (m³)
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
5
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 Reason Test pressure Test time
Let-by test To check if MCV is passing, 10mb 1 min

if greater than (max 0.25mb
or 0.2mb with a digital)
report to supplier. To confirm
let-by spray LDF in valve
Stabilisation to allow for temp. differences 20mb 1 min
Soundness test (No pressure drop or smell 2 min
allowed)
20mb
4. Make sure all appliances are re-connected
5. Turn all valves on including lifting the cooker lid.
Stabilisation To allow for temp. 20mb 1 min

differences
Soundness test (record any drops here) 2 min

20mb
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.
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*********
6
Testing for tightness (Using Gas) Existing Systems

1. Turn the gas off
2. Make sure all appliances are connected
Let-by test To check if MCV is passing, 10mb 1 min

if greater than (max 0.25mb
or 0.2mb with a digital)
report to supplier. To confirm
let-by spray LDF in valve
Stabilisation To allow for temp. 20mb 1 min
differences
Soundness test (see information below) 2 min

20mb
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 E6 meter 8mb over 2min*
2.5 mb if there is 4.5 mb if there is
pipe work greater pipe work greater
than 28mm 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
7
Testing for tightness (Using Gas) Maximum Operating

Pressure (MOP) greater than 75 MB
1. Turn the gas off
2. Make sure all appliances are connected and no pilot lights
Test name How Reason Test Test time

pressure
Let-by test Take the system up to standing To check if MCV is Approx. 1 min
for Meter pressure. passing, if greater than
Control Close meter control valve. (max 0.25mb) report to 2-10mb
Valve (A) Release pressure e.g. (by supplier. To confirm
opening a cooker) let-by spray LDF in
Hold open regulator valve and valve
observe.
Let-by test Release the regulator valve to check if regulator is Approx. 1 min
for pressure should increase passing on lock out, if
Regulator slightly. greater than (max 2-10mb
lock out (B) Open meter control valve and 0.25mb) report to
observe. supplier
Stabilisation Raise pressure to 19 mb close To allow for temp. 19mb 1 min
meter control valve differences
Soundness Observe (No discernable 19mb 2 min

test pressure drop or smell
allowed)
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 E6 meter 8mb over 2min*
2.5 mb if there is 4.5 mb if there is
pipe work greater pipe work greater
than 28mm 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
8
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
OPEN FLUED Advent Top Bottom Outside

ONE Open flued appliance in a room -7kW
MAX net heat input YES * * X 5cm²
ONE Open flued appliance in a
compartment vented to outside * X 5cm² X 10cm² *
MAX net heat input
ONE Open flued appliance in a -7 kW
compartment vented to a room * X 10cm² X 20cm² X 5cm²
MAX net heat input
TWO Open flued appliance in a room ADD two heat inputs together and
MAX net heat input calculate as above
TWO Open flued appliance in a ADD two heat inputs together and
compartment MAX net heat input calculate as above
TWO Open flued GAS FIRES in the additional ventilation may not be
same room (less than 14kW) required
TWO Open flued GAS FIRES in the Add heat inputs together and calculate as
same room (greater than 14kW) for one open flued appliance in a room
IF flue or spillage test fails additional ventilation is required
ROOM SEALED Top Bottom Outside

ONE Room Sealed appliance in a room
MAX net heat input * * *
ONE Room Sealed appliance in a
compartment vented to outside X 5cm² X 5cm² *
MAX net heat input
ONE Room Sealed appliance in a
compartment vented to a room X 10cm² X 10cm² *
MAX net heat input
FLUELESS APPLIANCES OPENABLE ROOM SIZE (M³)

WINDOW OR
SIMILAR <5 5-10 10-15 15-20 >20
COOKER YES 100 CM² 50 CM² * 0 CM² 0 CM² 0 CM²
WATER HEATER YES NOT 100 CM² 50 CM² 50 CM² 0 CM²
TUMBLE DRIER YES 100 CM² 100 CM² 0 CM² 0 CM² 0 CM²
* IF THE ROOM CONTAINS A DOOR TO OUTSIDE THEN A VENT IS NOT REQUIRED
MULTI- APPLIANCE SITUATIONS

SIMILAR flued appliances in a room ADD two heat inputs together and
MAX net heat input calculate as above
DISSIMILAR flued appliances in a room TAKE largest ventilation requirement
Measuring ventilators Calculate the free air area (measure the holes) the hole
MUST be from 5 to 10 mm and not closeable.
if answer is in MM² 100 to get CM²
9
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 APPLIANCE BURNER

WORKING PRESSURE PRESSURE (check against
(max 1mb drop form working appliance data badge)
pressure at the meter)
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 (6m³/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.
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)
10
Heat Inputs And Gas Rates.

The purpose of these tests is to prove how much gas is being burnt by the appliance
IMPERIAL METER (ft³): 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 = 1ft³ of gas
U6 GAS RATE = 100.8 TIME IN SEC FOR 1FT³ OF GAS

=_______________M³/HR
U6 (gross) HEAT INPUT= 1064 TIME IN SEC FOR 1FT³ OF GAS

=_______________kW
U6 (net) HEAT INPUT = 967 TIME IN SEC FOR 1FT³ OF GAS

=_______________kW
4. Compare the reading against the appliance data badge. The reading must be within
the range.
METRIC METER (M³): 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 1 0 0 7 1 3 3 M³
First reading on meter - 1 0 0 7 0 7 2 M³
Amount of gas used = 0 0 0 0 0 6 1 M³
E6 GAS RATE = TWO MINUTES OF GAS X 30

=_______________M³/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.
11
Gas safety devices and Controls

Flame supervision devices or F.S.D s Purpose : To avoid unlit gas entering the appliance
1 Thermoelectric FSD Recognise because it has a push button and
thermocouple
Found in every type of gas appliance
Test 1. Light pilot and establish.
2. Turn gas off time until click
2 Bi-metallic strip FSD Recognise Loop of metal

Found Only found on hot water circulators
Test 1. Light pilot and establish.
2. Turn pilot off time until burner
turns off
3 Vapor pressure FSD Recognise Small probe directly on oven

burner, burner lights on low flame
Found Only found in cookers
Test 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)
4 Flame rectification Recognise Ignition starts automatically to light
FSD the pilot or main burner
(electronic ignition) Found On all appliances
Test 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
FSD shutdown times

* BOILERS 60 SEC
* W / AIR HEATERS 60 SEC
* COOKERS 90 SEC oven
60 SEC other
* WATER HEATERS 90 SEC
* D.F.E. GAS FIRES 120 SEC
* OTHER GAS FIRES 180 SEC
* *Manufacturers instructions may differ from the times stated above. *
12
Thermostats Purpose: to control heat

4 Mechanical Recognise Dial with numbers indicated
thermostat
(Vapor expansion) Found Mostly on cooker ovens
Test 1. Turn oven on and heat up for 15
min.
2. Turn control to lowest setting
flame should drop to by-pass
rate
Mechanical Recognise Dial with numbers indicated
thermostat
(rod type) Found Old cookers and water heaters.
Test Heat up appliance gas should turn
down / or off (depending on
appliance)
5 Electric thermostat Recognise Dial with numbers indicated

Found Boilers etc
Test Heat up appliance thermostat
should turn the solenoid off
6 Solenoid Purpose An electrically operated gas valve

Found Boilers etc
Test 1. Turn electricity on valve opens
2. Turn electricity off valve closes
7 Multi-function Purpose A collection of controls in one unit

control
Found Boilers etc
Test If the FSD, Regulator and solenoid
work then the multi-function
control is working.
8 Relay valve Purpose An automatic gas valve

Found Old boiler, commercial cookers
Test 1. Weep gas of the top of the unit
and the burner should open.
2. Stop the weep and the burner
will go off.
9 Lid safety device Purpose To turn off the burners, when the
lid drops
Mechanical safety Found Cookers, (hotplates)
cut off Test 1. Turn on gas tap to hotplate.
2. Lower lid and gas should turn
off
13
10 Gas tap Purpose To control the flow off gas safely

Found Cooker, fires ,etc
Test 1. tap locks in the off position
2. tap functions correctly
11 Atmospheric Purpose To close down the open flued

Sensing appliance automatically, if the
Device appliance and flue operate
(ASD) (VSD) incorrectly
Found All open flued appliances after 1998
Test 1. light pilot.
2. Close air inlet hole and observe
flame (turn yellow)
12 Atmospheric Purpose To close down the open flued

Sensing appliance automatically, if the
Device / over heat appliance and flue operate incorrectly
Thermocouple Found On water heaters, Flued water heaters
interrupter this is usually a overheat safety
device. Flueless used as an ASD
Test Visual inspection to check wiring to thermocouple (no
links) and check FSD
13 Regulator Purpose Adjuster screw to alter burner

pressure
Found Boilers etc
Test 1. Attach manometer to test point
2. Adjust screw to alter pressure
14 Zero governor Purpose To compensate for the negative

pressure caused by the fan, on the
gas valve (this could pull more gas
into the burner than intended)
Found New fan flued room sealed
appliances
Test 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.
15 Medium to low Purpose To lower incoming gas pressure from

pressure Regulator 2 bar to 21mb
Found Above the meter control valve, fitted
with a reset handle
Test 1. make sure working pressure is 21mb

make sure the regulator lockout does not let-by
14
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
15
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)
16
Unsafe situations
To find out if a situation is NCS AR or ID consult the unsafe situations document
Category Action taken Label used Notice used
N.C.S. Inform responsible person, and repair fault if None Fill in the NCS
NOT TO possible. Fill in (notice) and give copy to section of
CURRENT responsible person warning notice
STANDARDS
form
A.R. Inform responsible person, and repair fault if Warning label do Fill in the A.R.
AT RISK possible. If not turn appliance off attach not use section of
(label) and fill in (notice) and give copy to warning notice
responsible person. form
I.D. Inform responsible person, and repair fault if Warning label do Fill in the I.D.
IMEDIATELY possible. If not DISCONNECT appliance not use section of
DANGEROUSE
and attach (label) and fill in (notice) and warning notice
give copy to responsible person. form
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 Catchment area not Catchment area has Incorrect flue for
small sealed letterbox opening appliance
Flue not sealed to the Flue damaged Flue upside down Signs of spillage
appliance
Joints leaking Joints not sealed Flues not clipped Minimum of 600mm
between draught
diverter and first bend
Bend no greater than Flue too small for To close to Incorrect terminal
45 appliance. combustible material.
Terminal not high Copex liner not fixed Copex not sealed to Incorrect material or
enough through the at the top or bottom appliance methods used.
roof.
Room sealed flues

Flue not sealed Appliance seals Terminating in wrong No terminal guard
damaged or missing position.
Flue length to long Flue damaged Incorrect material or Appliance or flue
methods used leaking.
17
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 IMPORTANT

from cold while completing the test;
↓
All smoke must be drawn into the flue.
Pre-test with → Heat the flue The smoke must terminate at the correct point.
a smoke for 10 min and The flue must not leak into any other flue, room or dwelling
match FAIL retest
↓ ↗ ↓
Test with a Pre-test with a → Heat the flue If the flue is
smoke pellet smoke match for further 10 condemned it may
FAIL min and retest require repair or
cleaning further
↓ ↓ ↗ ↓ investigation is
required. Follow
OK Test with a Pre-test with a → Heat the flue the unsafe
smoke pellet smoke match for further 10 situations
FAIL min and retest procedures
↓ ↓ ↗ ↓
OK Test with a Pre-test with a → CONDEMN
smoke pellet smoke match
FAIL
↓ ↓ ↗
If heating the flue with a blow torch, it OK Test with a
may require as much as 30 min to heat smoke pellet
properly
↓
OK
18
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 IMPORTANT

appliance for 5 while completing the test;
minutes
All smoke must be drawn
↓ into the appliance.
Leave the
appliance on and → Heat the
appliance for
The appliance must be left
on at maximum setting.
place smoke
FAIL further 10 min
match in the
desired area
↓ ↗ ↓
Is all the
smoke drawn
Leave the
appliance on and → CONDEMN
place smoke
into the match in the FAIL
appliance desired area
↓ ↓ ↗
OK Is all the If the appliance fails then
smoke drawn further investigation may be
into the required
appliance The appliance may be;
1. Over gassed.
↓ 2. Sooted up.
3. Blocked flue or flue ways.
OK 4. Bad flue design.
5. Faulty appliance.
19
gb-gas.co.uk GAS REFERENCE PACKAGE 2008.1 Aim To Pass With Gb-Gas
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 300 [#] 75 [@]

sanitary pipe work
E Below the eaves 300 [#] 200
F Below a balcony or 600 200
carport roof
G Above ground, roof or 300 300
balcony level
H From vertical drain/soil 75 [@] 75 [@]
pipe work
J From an internal or 600 300
external corner
K From a surface or 600 600 [+]
boundary facing the
terminal
L Vertically from terminal 1500 1500
on same wall
M Horizontally from 300 300
terminal on same wall Notes:
N From a terminal facing 600 1200 @. a terminal serving a natural draught and fanned draught appliance
the terminal more than 5kW heat input should be at least 300mm and 150mm
P From an opening in a 1200 1200 respectively from combustible material.
carport (e.g. door, #. Where a natural draught flue terminates not more than 1m below a
window) into the building plastic projection or not more than 500mm below a projection with a
R From a vertical n/app n/app painted surface, then a heat shield at least 1m long should be fitted.
structure on the roof +. The distance from a fanned draught appliance terminal installed at
[Note $] right angles to a boundary may be reduced to 300mm
S Above an intersection n/app n/app $. Vertical structure includes a chimney-stack, dormer window, tank
with the roof room, lift motor room or parapet.
20
Minimum distance to terminal in millimetres

Balanced flue, room-sealed appliance
Natural Fanned draught
draught
A Directly below an (0-7 kW) 300 300
opening, air brick, (>7-14 kW) 600 300
opening window, etc
(>14-32 kW) 1500 300
(>32-70 kW) 2000 300

B Above an opening, air (0-32 kW) 300 300
brick, opening window, (>32-70 kW) 600 300
etc
C Horizontally to an (0-7 kW) 300 300
opening, air brick, (>7-14 kW) 400 300
opening window, etc (>14-70 kW) 600 300
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
21
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.
22
Typical Gas Component Faults On

Central Heating Boilers And Circulators
Devices;

Faulty FSD

Over gassed (Long flames with possible yellow tips)
Cracked burners
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

a FSD,
a Solenoid
a Regulator
23

Cookers

Devices;

Faulty FSD shut down in (90sec)
Faulty ignition system
 Unstable Flame Picture at Full or Simmer

Over gassed ( Long flames with possible yellow tips)
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
24

Space Heating (gas fires)
Devices;

Faulty FSD

Cracked burners
 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

25

Warm Air Units.
Devices;

Faulty FSD

Cracked burners CRACKED HEAT EXCHANGER/
NO RETURN AIR DUCT
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.

a FSD,
a Solenoid
a Regulator
26

Instantaneous Water Heaters
Devices;

Faulty FSD

Cracked burners
 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)
27
Volume and purge calculations for large installations

With pipework greater than 28mm or a meter bigger than a 6m³ capacity.
Installation volume Purge volume
Meter type
LENGTH 15mm
LENGTH 22mm
LENGTH 28mm
LENGTH 35mm
Pipe volume m³ A Total pipe volume F

Multiply the lengths by the This is the same as B
volumes from table 1
Fittings +10% B Pipework purge volume G

Multiply A by 1.1 to add the x 1.5
10% on
Multiply F by 1.5
Meter volume C Meter purge volume H

Look up the meter volume (cyclic volume x5)
Total installation D Total purge volume J
volume Add G and H together
Add B and C together
If the volume is greater than 0.035m³ or the meter capacity is If the purging volume is less than If the purging volume is greater
greater than 16m³/hr then the (commercial) IGE UP 1 or 1A 0.02m ³ purging is conducted from than 0.02m ³ purging is
document and qualification must be used. the furthest practical point well conducted from the furthest
ventilated and no source of ignition. practical point and the appliance
must be continually ignited until
a flame is established.
Steel / stainless steel Copper
15mm ½ 0.00024 (m³) 15mm 0.00014 (m³)
20mm ¾ 0.00046 (m³) 22mm 0.00032 (m³)
25mm 1 0.00064 (m³) 28mm 0.00054 (m³)
32mm 1¼ 0.0011 (m³) 35mm 0.00084 (m³)
Type of meter FOR VOLUME CALCS FOR PURGE CALCS B

Meter volume (m³) for pipe work Meter cyclic volume x 5 =Meter purge volume in (m³)
volume calculations
G4 / U6 0.008 0.002 x 5 = 0.010m³
U16 0.025 0. 006 x 5 = 0.030m³
E6 0.0024 N/A =0.0036m³
28
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
A GAS FLOW REQUIRED M³/HR

THIS IS THE GAS RATE OF THE
APPLIANCES THAT THIS PIPE IS
FEEDING
Pipework
B LENGTH (how many meters of pipe) M
C FITTINGS (0.5m for each elbow or M

tee going round the corner)
D ACTUAL LENGTH (add B+C M

together)
E ASSUMED PIPE DIAMETER MM

Make an assumption on the pipe
diameter or use the table to find a
diameter
F CHART ALLOWABLE LENGTH M

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
G PRESSURE DROP mb
Chart allowable length D divided by
the actual length F. if this is greater
than one you have divided the wrong
number first.
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
29

GAS REFERENCE PACKAGE: Combustion Checks and CO Testing

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GAS REFERENCE PACKAGE: Combustion Checks and CO Testing

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gb-gas.co.

uk GAS REFERENCE PACKAGE 2010v2 Aim To Pass With Gb-Gas

This document is free to download and copy from www.gb-gas.co.uk

Combustion See www.gb-gas.co.uk for more details.

1. Carry out the service as per manufacturer’s instructions

2. If the appliance is range rated turn to maximum setting

3. Take flue gas analysis

4. Complete job documentation

If using a flue gas analyser acceptable readings vary depending on the

Make sure the probe is placed

Pipe work inspection See www.gb-gas.co.uk for more details.

Common faults found on the meter installation:

Common faults found on pipework installation:

Re-establishing gas supplies

A visual check on the pipework installation

Steel / stainless steel Copper

15mm ½ 0.00024 (m³) 15mm 0.00014 (m³)

20mm ¾ 0.00046 (m³) 22mm 0.00032 (m³)

25mm 1 0.00064 (m³) 28mm 0.00054 (m³)

32mm 1¼ 0.0011 (m³) 35mm 0.00084 (m³)

Testing for tightness (Using Gas) NEW SYSTEMS

After visually inspecting the installation

Test name Reason Test pressure Test time

Let-by test To check if MCV is passing, 10mb 1 min

Test name Reason Test pressure Test time

Stabilisation To allow for temp. 20mb 1 min

Soundness test (record any drops here) 2 min

******** Test all testpoints with leak detector fluid*********

Testing for tightness (Using Gas) Existing Systems

Test name Reason Test pressure Test time

Let-by test To check if MCV is passing, 10mb 1 min

Soundness test (see information below) 2 min

* in any situation if the recorded drop is in the pipework it is an immediate fail

******** Test all testpoints with leak detector fluid*********

Testing for tightness (Using Gas) Maximum Operating

Test name How Reason Test Test time

Soundness Observe (No discernable 19mb 2 min

No discernable drop is any drop greater than 0.25mb

Maximum drop allowed

* in any situation if the recorded drop is in the pipework it is an immediate fail

******** Test all testpoints with leak detector fluid*********

OPEN FLUED Advent Top Bottom Outside

ROOM SEALED Top Bottom Outside

FLUELESS APPLIANCES OPENABLE ROOM SIZE (M³)

WATER HEATER YES NOT 100 CM² 50 CM² 50 CM² 0 CM²

MULTI- APPLIANCE SITUATIONS

APPLIANCE INLET APPLIANCE BURNER

Meter Standing and Working Pressure

******** Test all testpoints with leak detector fluid*********

Heat Inputs And Gas Rates.

1 revolution = 1ft³ of gas

U6 GAS RATE = 100.8 TIME IN SEC FOR 1FT³ OF GAS

U6 (gross) HEAT INPUT= 1064 TIME IN SEC FOR 1FT³ OF GAS

U6 (net) HEAT INPUT = 967 TIME IN SEC FOR 1FT³ OF GAS

METRIC METER (M³): E.G. E6, G4

E6 GAS RATE = TWO MINUTES OF GAS X 30

E6 (gross) HEAT INPUT = TWO MINUTES OF GAS X 317

E6 (net) HEAT INPUT = TWO MINUTES OF GAS X 288

Gas safety devices and Controls

2 Bi-metallic strip FSD Recognise Loop of metal

3 Vapor pressure FSD Recognise Small probe directly on oven

FSD shutdown times

* *Manufacturers instructions may differ from the times stated above. *

Test all testpoints with leak detector fluid*

Test all testpoints with leak detector fluid*

Test all testpoints with leak detector fluid*

Test all testpoints with leak detector fluid*

* Manufacturers instructions may differ from the times stated above.