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G3 Study Notes
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Study notes for the Ontario G3 Gas-Fitter final exam administered by the TSSA. Full description

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Furnaces
Furnace types:
Flue Temperature Type of Vent
Conventional (Cat. 1) > or = 350ºF Single wall or B-vent
(max efficiency = 60%) (metal because the temperatures
are so hot)
Mid-Efficiency (Cat. 1) 275ºF to 350ºF Single wall or B-vent
(max efficiency = 80%)
High-Efficiency (Cat. 4) 80ºF to 120ºF System 636
(min efficiency = 90%)

Module 1
Personal Safety:
-attitudes that will help:
1) Courtesy
2) Attention
3) Safe Conduct
4) Posture
-factors that will affect a safe working environment:
1) Temperature and humidity conditions
2) Noise
3) Lighting
-safety aspects:
1) eye protection
-CSA-approved glasses or goggles
2) hearing protection
3) head protection
-must be CSA-approved
4) foot protection
-CSA-approved
5) respiratory protection
6) hand protection
*types:
-thermally-insulated gloves = hot surfaces
-rubber/approved plastice treated gloves = acids and cleaning
chemicals
-approved rubber gloves = electrical
-neoprene gloves = LPG (liquid propane gas)
-when using a ladder: 1 ft horizontal for every 4 ft vertical
-protective equipment:
-fire extinguishers
-ventilation equipment
-vacuum systems
-exhaust systems
-special ventilating equipment
-electrical safety:
-use grounded plugs or double-insulated power tools

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-lockout:
Lockout-Tagout (LOTO)
-general safety rules:
1) No horseplay You're Reading a Preview
2) Clean up
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3) Do not place things yourthey
where documents
can fall to download.
4) Work with adequate lighting
5) Lift correectly
OR
6) Use protective equipment
7) Tag and remove defective items
8) Report accident
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9) Be aware of the state of your health
10) Do not work while impaired first 30bydays are free.
alcohol or medication
11) Correct or report unsafe conditions immediately
-fire hazards: Continue for Free
-fire is also called combustion
*for it to exist: need three things:
1) oxygen
-remove it = starvation
2) fuel
-remove it = cool
3) heat for ignition
-remove it = smother
-Fire extinguishers:
-aim at base of fire
-inspect every year

Symbol Colour and Class
A (green)
e.g. water ext. / halon ext. /
dry chemical ext.
B (red)
e.g. halon ext. / dry chemical
ext. / C02 ext.
C (blue)
e.g. halon ext. / dry chemical
ext. / C02 ext.
Fire Extinguishers
Type of Fire Type of Extinguisher
-involving ordinary -ones that use the
combustibles (wood, cloth, heat-absorbing effects of
paper, rubber, most plastics) certain chemicals that slow
combustion
-involving flammable -ones that prevent vapours
vapours from being released
-ones that interrupt
combustion
-involving energized -ones that use
electrical equipment non-conductive
extinguishing agents
-A or B extinguishers can
be used when electrical
equipment is de-energized

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D (yellow) -involving combustible -ones that use

metals (magnesium, heat-absorbing
You're Reading a Preview
titanium, zirconium,
sodium, potassium)
extinguishing medium not
reactive w/ burning
materials
Upload your documents to download.
-sand can also be used

WHMIS: OR
-supplier WHMIS label must have following info.:
1) Product identifier (name of product)
Become(name
2) Supplier identifier a Scribd member for
of company thatfull
soldaccess.
it) Your
3) statement that an MSDSfirst 30 days are free.
is avail.
4) hazard symbols
5) risk phrases
6) precautionary measures (how Continue
to be for
safeFree
when using the product)
7) first aid measures
8) all text in English and French
9) WHMIS hatched border
-classes:
Class A: Compressed Gas
Class B: Flammable and Combustible Material
Class C: Oxidizing Material
Class D: Poisonous and Infectious Material
Division 1: Immediate and Serious Toxic Effects
Division 2: Other Toxic Effects
Division 3: Poisonous and Infectious Material

Module 2
Screws:
-identification:
1) outside thread diameter
2) number of threads per inch
3) length of screw
4) type of point
5) type of head

6 - 20 x 1/2 Type AB, slotted hex

Cotter pins:
-used to secure circular shafts (keep something on an axle
(look kind of like bobby pins)
Bits:
-carbon bits = to drill into steel
-carbide bits = to drill into concrete
Temperature calculations:
Cº to Fº = (Cº x 9) + 32 Fº to Cº = (Fº – 32) x 5
5 9

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Module 3: Propane and Natural Gas

PROCESSING You're Reading a Preview

COMPRESSOR CITY GATE
PLANT STATION STATION
(separates methane, Upload your documents to download. (mercaptan added)
butane, water,
odourless odourless
petroleum, etc.)
natural gas (1500 to
OR
2000 PSI)

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7”WC
first 30 days are free.to
60PSI

Continue for Free

GAS WELL COMMERCIAL INDUSTRIAL

(methane plus a lot AND
of other stuff) RESIDENTIAL

Distro. of Natural Gas:

-through pipeline
-City Gate Station:
-gas reduced in pressure for local distro.
-ethyl mercaptan is added
-stored in subterranean caverns when there is low demand
*delivered locally at three different pressures:
Low pressure = 7”WC to 14”WC (older areas of cities w/ low-pressure systems)
Intermediate pressure = 2 to 60 PSI (residential and commercial)
High pressures = 60 to 125 PSI (industrial)
Distro. of Propane:
-in containers by rail, truck, etc.
-process:
Well head
Well head processing plant: gas is liquified and mercaptan is added
Shipped in containers to distributors
Uses of Natural Gas and Propane:
1) Residential
-space heating
-water heating
-ranges
-dryers
-fireplaces
-pool heaters
2) Commercial/Institutional
-space heating

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-commercial cooking and laundry

-temp. heating at construction sites (propane)
3) Industrial/Agricultural
-space heating You're Reading a Preview
-process ovens and dryers
-power generationUpload your documents to download.
-welding
-crop drying and milk processing
OR
Physical Properties:
-natural gas and propane = hydrocarbons (compounds of H and C)
-propane distilled fromaoil
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-natural gas is naturally occurring => drawn out of the well as a substance containing
mostly methane first 30 days are free.
-90% methane
-5% ethane Continue for Free
-other stuff
-characteristics of propane and natural gas:
1) colourless
2) odourless
3) tasteless
4) non-toxic
-propane also known as liquid petroleum gas (L.P.G.)
Mercaptan:
Natural gas: butyl mercaptan added at City Gate Station
Propane: ethyl mercaptan added at processing plant
*one pound of mercaptan is added to every 1 million cubic feet of gas
Chemical composition:
Natural gas:
-composed primarily of methane
METHANE is CH4
-H is lighter than C
Propane:
Propane is C3H4
-additional C atoms is what makes it heavier than natural gas
*the more C and H = the heavier the molecule
= the more heat value (greater BTUs/greater calorific
value)
= the more air you need for complete combustion
Properties of Natural Gas and Propane:
A) Relative Density (Specific Gravity)
= weight of a substance as compared to the known weight of another substance
Gaseous state: compare to air (specific gravity of air is 1)
Specific gravity of N.G. = 0.6 (lighter than air)
Specific gravity of Propane gas = 1.52 (heavier than air)
Liquid state: compare to water (specific gravity of water is 1)
Specific gravity of N.G. liquid = 0.4 (lighter than water)
Specific gravity of Propane = 0.5 (lighter than water)
B) Boiling Point
= temperature at which a liquid turns into a vapour

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-water boils at 212ºF

Propane: boiling point is -44ºF
N.G.:
C) Expansion Factors You're Reading a Preview
boiling point is -258ºF

= when the temp. of a liquid increases, it changes to a vapour and expands

Upload
= this results in anyour documents
increased to download.
pressure and volume (amount of a substance)
-liquid propane containers only partially filled to allow for expansion
*when you let vapour escape from a propane container, the pressure inside
OR
changes which causes the remaining liquid to boil/vapourize
N.G. Expansion Factor: expands 1 to 600 times
Propane Expansion
Become Factor:
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member1 to
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access. Your
D) Heating Value (Heat Content)
first 30 from
= amount of heat energy released days the
are burning
free. of one cubic foot of gas
(Calorific value)
(BTUs/ft3) Continue for Free
*1 BTU = amount of heat required to raise 1lb of water 1ºF
Propane heat content: 2520 BTUs per cubic foot
N.G. heat content: 1000 BTUs per cubic foot
(natural gas has fewer carbon and hydrogen atoms => it produces less heat
content per cubic foot of gas)
E) Minimum Ignition Temp.
= temperature at which an air/gas mixture will start combustion
Propane: 1200ºF
N.G. 900ºF
F) Limit of Flammability
= upper and lower ranges of the amount of gas in an air/gas mixture that will support
combustion (keep the fire burning)
Propane: 2.5% to 9.5%
N.G.: 4% to 15%
G) Air to Fuel Ratio
= the ratio of air to gas required for complete combustion
Propane: 23.5 to 1 (23.5 cubic feet of air for 1 cubic feet of propane gas)
N.G.: 10 to 1
H) Max. Flame Temperature
= the maximum flame temperature that a gas can produce
*only occurs at perfect combustion
Propane: 3600ºF
N.G.: 3500ºF
I) Max. Flame Speed
= speed at which the flame front moves towards the air/gas mixture issuing from the
burner port
*depends on the amount of air
Propane: 32” per second
N.G.: 12” per second
Combustion Properties:
*combustion = the rapid oxidization of a fuel gas to produce light and heat
*oxidation = process where oxygen combines chemically with other atoms to form
oxides (e.g. rust = iron oxides -> slow form of oxidation)
-three components for ideal combustion:

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1) Air (80% N, 20% O)

2) Fuel
3) Heat for ignition
-types of combustion: You're Reading a Preview
1) Perfect Combustion (not the real world) of methane and air
Upload
(air is 2 parts your
O2 and documents
8 parts N2) to download.
Flue Gases
Air-Gas Mixture Carbon Dioxide
Methane (CH4) OR (CO2)
ignition causes
Air (2O2 + 8N2) COMBUSTION
Become a Scribd member for full access. Your Water vapour (2H2O)
first 30 days are free.
Nitrogen (8N2)

-all products of combustion/flue

Continue forgases
Free hold heat
-N is not part of the reaction b/c it is inert (just passes through and holds heat)
2) Complete Combustion of methane and air Flue Gases
Carbon Dioxide (CO2)
Air-Gas Mixture
Methane (CH4) ignition causes
Water vapour (2H2O)
COMBUSTION
Air (2O2 + 8N2)
Nitrogen (8N2)
Excess Air (O2 + 4N2)
Excess Air (O2 + 4N2)

-the excess air is not needed for complete combustion

*it is a safety factor to avoid CO
-passes through combustion but still holds heat SECONDARY
-residential burners = 50% excess air AIR
-in a furnace burner:

PRIMARY AIR

GAS -->

THROAT
AIR/GAS INNER CONE
ORIFICE MIXING -incomplete OUTER
ZONE MIXING combustion (CO, CONE
PRIMARY MIXER TUBE/ BURNER etc. is present) -2ndary air is
AIR HEAD VENTURI PORT drawn in to
SHUTTER complete
combustion

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3) Incomplete combustion of methane and air

Flue Gases
You're Reading a Preview Carbon Monoxide (CO)
Air-Gas Mixture
Methane (CHUpload
4)
your documents tocauses
ignition download. Water vapour (2H2O)
COMBUSTION
Incomplete Air (O2 + 4N2) Hydrogen (H2)
OR

Nitrogen (4N2)
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first 30 days
-air (and therefore oxygen) are free.
has been cut in half => not enough air for complete
combustion
-Combustion Air: Continue for Free
1) Primary Air
= air mixed w/ the fuel prior to actual combustion
2) Secondary Air
= air added after combustion to allow complete combustion
-Excess Air
= air added but not required for combustion
*buffer added to make sure there is enough air supplied for complete
combustion
*too much excess air...
...can carry away heat and therefore decrease efficiency
... can lower flame temperature and cause some incomplete combustion
-Dilution air is added at the draft hood for venting appliances
-products of combustion:
Complete combustion: CO2 + Water vapour + heat + excess air
Incomplete combustion: CO + Soot + Aldehydes
*the CO has carbon atoms which aren't completely burnt = will create soot
-unburned carbon seen as:
-yellow or white in a flame
-white residue on a heat exchanger
*aldehydes: have an acrid smell and create irritation in eyes and throat
-carbon monoxide (CO)
= the great imitator
-displaces oxygen in the blood
= similar to common flu, headaches, dizziness, nausea w/out fever
*characteristics
-colourless
-tasteless
-odourless
-combustible and explosive (flammibility range is b/t 12 and 74%)
-specific gravity is 0.96
-if CO concern is raised:
1) evacuate the area and/or
2) sample the air at a 5ft height as you approach potential source

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Air Supply Requirements

(theoretical to complete combustion)
*the requirements:
1) Combustion Air You're Reading a Preview
-required to complete combustion process
Upload your documents to download.
*two aspects:
I) Primary Air
-air that is mixed w/ fuel prior to ignition
OR
-enters through air shutter around orifice
II) Secondary Air
Become -air supplied
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*Primary Air + Secondary Air = COMPLETE COMBUSTION
2) Excess Air first 30 days are free.
-air supplied to combustion process in excess of combustion air to ensure
complete combustion Continue for Free
3) Dilution Air
-air which enters the draft control device to cool the hot flue gases
Total Air Requirement:
-Natural Gas: theoretical air requirements for a natural draft furnace:
For every cubic foot of gas that is burned (producing 1000 BTUs of heat), the air
required is...
1) Combustion Air = 10 cubic feet of air
Ratio = 10 air : 1 gas
2) Excess Air = 5 cubic feet of air
Ratio = 5 air : 1 gas
3) Dilution Air = 15 cubic feet of air
Ratio = 15 air : 1 gas
Total air requirement = 30 CUBIC FEET OF AIR
-Propane: requires much more air
Flame types:
-determined by: (1) type of burner used and (2) type of fuel burned
-liquid fuels (oil) and solid fuels (coal, wood) can't mix the fuels as thoroughly as fuel
gases
-fuel gases can produce two types of flames:
1) Yellow or luminous flame
= when air is partially or not premixed w/ the fuel gas
*so: too much fuel gas and not enough air
-the yellow in the flame = result of glowing carbon particles
2) Blue or bunsen flame
= when fuel is premixed with air
*two cones are present, each a different shade of blue
-if orange is present = dirt in the combustion zone
Outer cone: where complete combustion occurs
-oxygen in the secondary air mixes w/ the incomplete products of
combustion
-if outer cone touches a cold surface = no quenching of combustion
process, b/c complete combustion has already occurred
-if inner cone touches a cold surface = incomplete combustion will result
because the temperature has decreased

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Flame Lifting:
*occurs when:

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1) the burner is over-fired (max. gas input exceeds the burner design)
2) too much primary air is used
-can be noisy
-flame cones may rupture, Upload your
causing documents
incomplete to download.
combustion
-more likely to occur when the burners are cold
Flashback:
OR
= when gas/air mixture burns back towards the burner
*the flame burns back through the burner port to ignite the mixture in the burner head
-occurs when: gas/airBecome
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Propane:
*also called Liquefied Petroleum Gas first (LP
30 days are free.
Gas/LPG) b/c it is stored and transported as a liquid
-is stored in 2 types of containers:
1) Cylinder Continue for Free
-designed, tested, fabricated by: Transport Canada, Department of Transport,
Canadian Transport Commission
-are filled by weight, measured in “water capacity” or pounds of water
e.g. WC240 = “water capacity 240”
= the capacity of the cylinder when filled w/ water
-to determine how much propane can be safely stored: mutiply by 0.42
-the largest cylinder manuf.ed = 1000lbs WC (420 lbs propane)
-relief pressure = 375PSI
2) Tank
-designed, tested, fabricated under the Boiler and Pressure Vessels Act (overseen
by TSSA)
-are filled by volume given in US gallons of water
-propane tanks are made for withdrawing both liquid and vapour
*vapour = left hand threads
*liquid = right hand threads
-relief pressure = 250 PSI
-filling a propane container:
-when heated, propane liquid expands
-propane liquid at 60ºF, filled to 80% will expand to 100% at 130ºF
-1 gallon of propane weights 5.1lbs

Module 4: Codes
Technical Standards and Safety Act:
-MCBS: Minister of the Consumer and Business Services = provincial minister ultimately
responsible for the admin. of the TSS Act
*monitors the TSSA
-TSSA: Technical Standards and Safety Authority
-Director's role = ensure the act, regulations and standards are administered
Testing Agencies:
1) Canadian Gas Association (CGA)
-test and certify appliances, equipment, components, and accessories
2) International Approval Services (IAS)
-test appliances, equipment, components, and accessories on behalf of AGA and CGA
3) Canadian Standards Association (CSA)

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-accredited to test and certify appliances, equipment, components, and accessories

-can develop standards and codes

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-has purchased CGA and IAS
4) Underwriter's Laboratories of Canada (ULC)
-approves venting in addition to other related things
Upload your
5) Underwriter's Laboratories documents to download.
Inc. (UL)
-only approved if it says Ulc
6) Warnock Hersey (WH) and Equipment Testing Laboratories (ETL)
OR
-both are operated by Inchscape Testing Services

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