BCPGS3010A INSTALL A ‘TYPE B’ APPLIANCE FLUE

PLUMBING AND SERVICES

TRAINING PACKAGE

BCPO3

BCPGS3010A

Staff

INSTALL A ‘TYPE B’ APPLIANCE FLUE

LEARNING GUIDE

This unit of work has been produced /revised by the Plumbing Department Staff of Chisholm Institute Frankston Campus

September 2006

This unit of work has been prepared with due care and every effort has been made to ensure the information contained within the unit is in accordance with current regulatory requirements and technology. However, it is not intended to be an exhaustive statement of all relevant requirements, as successful completion of the module depends on a number of factors outside the scope of the materials provided. Therefore, Chisholm Institute of TAFE disclaims all and any liability to any person, whether a subscriber to the unit of work or not, in respect of anything and the consequences of anything done or omitted to be done by any such person in reliance, whether total or partial, upon the whole or any part of the contents of the unit of work.

This unit may contain ANTA, Energy safe Victoria, Australian standards and other material.

What do I have to do?

To demonstrate competence in this unit you will be required to show the level of skills and knowledge for each of the elements involved in BCPGS30010A – Install Type B appliance flue.

You need to understand the unit note book information & be able to answer questions to demonstrate underpinning knowledge to required standard.

You need to install a flue in the workshop to comply with drawings & specifications. (Assessment)

You will have to clean upthe work area to required standard.

How will I be assessed?

Your assessment activity will be the practical task of Installing a flue in the workshop to comply with drawings & specifications set by your assessor.The assessment will be the final requirement needed for you to demonstrate that you have the skills and knowledge required to meet this competence requirement.

This unit may be assessed in conjunction with other units of competence. Your trainer or supervisor will tell you if you are to be assessed this way.

BCPGS3010A / Install a Type B appliance flue
Unit Descriptor / This unit covers the competency to install flue systems for Type B gas appliances.
Work associated with this unit is undertaken within the plumbing and services sector in accordance with relevant Australian Standards. It has application in the gas services stream.
Element / Performance Criteria
Elements define the essential outcomes of a unit of competency. / Performance criteria specify the level of performance required to demonstrate achievement of the element.
1Prepare for work / 1.1Work plans or specifications and any special instructions are obtained
1.2OH&S requirements associated with the installation of flues for Type B gas appliances, and the workplace environment, are adhered to throughout the work
1.3Quality assurance requirements for company operations are identified and adhered to
1.4Any required approval of the system design is obtained in accordance with authorities’ and workplace requirements
1.5Tasks are planned in conjunction with others involved or affected by the work
1.6Sequence of work is prioritised to suit job requirements
1.7Tools and equipment are selected consistent with installing a Type B appliance flue and checked for serviceability
2Determine flue requirements / 2.1Details of dimensions and loads are checked for compliance with plans or specifications
2.2Size of flue is calculated in accordance with authority requirements and is appropriate for the type of appliance burner
2.3Flue is selected for the type of appliance and its determined route in compliance with standards
2.4Quantity and type of materials for the installation are calculated from plans or specifications
3Install flue / 3.1Preparatory work, including any penetration of walls and rooves, is performed in accordance with industry and workplace requirements
3.2Installation is completed without damage or distortion to the surrounding environment or other services
3.3Flue is installed in compliance with standards and authority requirements
4Clean up / 4.1Work area is cleared and materials disposed of or recycled in accordance with State or Territory legislation and workplace procedures
4.2Tools and equipment are cleaned, checked, maintained and stored in accordance with manufacturers’ recommendations and workplace procedures
4.3Documentation is completed in accordance with workplace requirements
Specific knowledge required to achieve the performance criteria /
  • A knowledge of:
the properties of gas, gas safety, combustion principles, pressure and flow rates
electrical safety and the requisite precautions
the relevant statutory and authority requirements related to the installation of flues for Type B appliances
the Standard International system of measurements
the sources of information including the appropriate standards
the material requirements determination process
procedures for installing Type B appliances, including roof and wall penetration and flashing
workplace and equipment safety requirements
JSA’s/Safe work method statements

Resourcesthat have relevant information for this unit include.

Texts resources

Australian Standard Gas Installations AS 5601- 2004

Australian Standard Pressure equipment-Installation AS3892-2001

Australian Standard Industrial & commercial gas-fired appliances AS3814-2005

Australian Standard Boilers-Safety management & supervision systems AS 2593-2004

Victorian Gas Safety Act No. 99/1997

Victorian Gas Safety (Gas Installation) Regulation 1999 Statutory Rule No. 6/1999

VictorianBuilding act 1993 Act No. 126/1993 Part 12A-Plumbing Work

Victorian Plumbing Regulations 1998 Statutory Rule No. 148/1998

Web sites

Victorian Plumbing Industry

Energy safe Victoria

Victorian environment protection agency

Work Safe Victoria

Safety

Occupational health and safety (OH&S) requirements need to be observed in accordance with legislation.. You need to know the OH&S laws governing your job. Revision of BCPCM2003A - Carry out OH&S requirements, before commencing this unit is advisable

In any work situation you can reduce the risk of injury to yourself and others by using appropriate personal protective equipment (PPE). The types of PPE that you will need include:

overalls – used for the protection of the installer when working in different conditions

boots – it is recommended that soft soled footwear is worn while working on roofs, as deep grooved footwear pick up small stones and debris that might damage or scratch the roof sheets

safety glasses or goggles to protect the eyes from injury when cutting the sheets with a power saw

ear plugs or muffs to protect the installer’s hearing from excessive noise

dust masks or respirators to protect the user from breathing in dust or fine particles when cutting the sheets with a power saw

gloves, for the protection of the installer’s hands when working with different types of pipes, tools and equipment.

Workplace environment and safety

Handling of materials / Manual lifting and handling techniques must always be followed according to OH&S requirements. You should move materials into position by hand where possible. Excessive manual handling should be avoided and cranes and other mechanical lifting devices should be employed when necessary.
Limited height scaffolds and elevating work platforms (EWP) / Operators must ensure they are familiar with all operating procedures detailed by manufacturers in the elevated working platforms operators’ manual. Personal protective equipment must be worn at all times by the person working in the basket of the EWP. This consists of safety harnesses, safety helmets, rubber soled shoes, safety vests and suitable clothing.

Introduction

In this unit you will learn how to identify a type A & B appliance the qualification requirements needed to work on type A & B appliances and the qualification requirements needed to install a Type B appliance flue.

You will also learn who the relevant authorities are in regards to installing a type B appliance flue and what regulations govern the design requirements for Type B flues.

In this unit you will learn about what determines a flue size, flue materials, flue terminals, and design principals for type B flues.

You will also be required to install a type B appliance flue from a simulated boiler as per plans and specifications.

What is a type A & type B appliance & who can work on them?

Type B appliances are defined in AS5601 – 2004 clause 1.4.3.2, as: 'An appliance, with gas consumption in excess of 10MJ/h, for which an AGA/ALPGA approval scheme does not exist.

A Type B appliance is also an appliance which is rated at more than 500Mj/hr.

A “Type A” appliance is an appliance which has a certification scheme in place from the Australian Gas Association. The certification scheme for “Type A” appliances is limited to 500 mega joules per hour therefore an appliance which is rated at more than 500 Mj/hr is a type B appliance.

Type B appliance commissioning, installation & repair may only be carried out by people with specialized qualifications which are set out in the Victorian Plumbing Regulations 1998 under:

Statutory Rule No. 148/1998.

Part 3- Qualification & experience requirements for license or regulation.

Division 3 & 4-Requirements for Plumbing (Type B Gasfitting) work.

25. Qualifications required.

The Victorian Plumbing Industry Commission is the organization empowered by Victorian parliament to regulate and enforce the relevant Acts of Victorian parliament in relationship to Plumbing works carried out. Licensing and Registration of Plumbers also comes under their jurisdiction.

Energy Safe Victoriais the organization empowered by Victorian parliament to regulate and enforce the relevant Acts of Victorian parliament in relationship to standards of Gasfiiting work which also includes Type A & B Gasfitting work.

On successfully completing a 4 year apprenticeship in Plumbing & Gasfitting in Victoria a person can apply to the Victorian Plumbing Industry Commission to become a registered person in “Type A” Gasfitting Plumbing work. A Registered Plumber is allowed to work under a Licensed Plumber on “Type A” appliances and consumer piping. Additional requirements and qualification are required for a registered plumber to become a licensed plumber.

Energy Safe Victoria and the Victorian Plumbing Industry Commission allow a person registered or Licensed in “Type A” Gasfitting Plumbing work to install a type B appliance flue, however no other type B work can be done unless Registered or Licensed in “Type B” Gasfitting work.

The Victorian Plumbing Regulations 1998 states that any other part of the Type B installation with the exception of the consumer piping that leads up to the gas isolation valve can not be worked on without the required type B qualification.

A Type A Registered or Licensed Plumber & Gasfitter can only apply for “Type B” Gas Registration or Licence after additional qualifications and other criteria required by the Plumbing Industry Commission are met.

Examples of Type B appliances are:

  • Fire tube and water tube steam or hot water boilers that usually have mild steel flues either fabricated on site or fabricated off site and erected on site with flanged joints
  • Small package hot water boilers that require either stainless steel or fibre cement (synthetic fibre free) flues
  • Rotary clothes dryers that require either stainless steel or fibre cement (synthetic fibre free) flues
  • Pottery kiln dryers that require either stainless steel, masonry or fibre cement (synthetic fibre free) flues
  • Some commercial kitchen equipment that have gas consumptions in excess of 10 MJ/h. (However, these appliances usually do not require flues as they are installed beneath hoods with mechanical ventilation that also exhausts flue gases).

Student Worksheet No 1

  1. Can a plumber Registered or Licensed in Type A Gasfitting install a Type B appliance flue?

Yes□

Reference pg7

  1. Can a plumber Registered or Licensed in Type A Gasfitting work carry out appliance commissioning, installation & repair on Type B appliances?

No□

Reference pg7

  1. Who is the organization that plumbers are licensed or registered with?

The Victorian plumbing industry commission

Reference pg7

  1. Who is the organization empowered to regulate Type B Gasfitting work?

Energy safe Victoria

Reference pg7

  1. Type B appliance commissioning, installation & repair may only be carried out by people with specialized qualifications. What is the name of the regulations that state this?

The Victorian Plumbing regulations 1998

Reference pg7

Before installing a type B appliance flue!

Before installing a type B appliance flue you should contact:

  • Environmental Protection Authority
  • Energy safe Victoria should also be consulted before installing type B appliance flues.

The EPAhave an investigative & enforcement role to ensure flues are operating within there specified Environmental Protection Authority Act guidelines. The EPA mayrequire special requirements in regards to flue outlet discharges.

This may mean that a flues’ size and design may have to be changed to comply with the EPA, such as the discharge height of the flue in atmosphere.

The EPA may require a higher discharge point for the flue to allow natural air currents to adequately remove flue gases and odours without causing a nuisance to surrounding residents. (Refer to As5601-2004 clause 5.13.3.3)

The EPA may also require after burners to be fitted to the flue to burn of flue odours.

This picture shows a small after burner fitted in the flue of a coffee roaster type B appliance.

The rectangular box that the coffee roaster flue connects to with the components fitted to the end of it is the after burner.

The flue products from the coffee roaster are drawn into the after burner where they are refired to burn off any odour.

Any residual from the after burning process is collected in the cylinder below the after burner and removed to waste.

Types of flues

Gas appliances may have any one of a number of different flues types connected to them whether they are type A or Type B appliances.

The type of flue attached to an appliance doesn’t determine wether the appliance is a type A or type B appliance. Both type A & B appliances use the same range of flue types (Refer to AS5601-2004 Definitions).

Flue types include:

  • Natural draught flues (Atmospheric)
  • Forced or induced draught burner flues
  • Power flues
  • Open flues

Natural draught flues(Atmospheric)

The principal of hot gases always rising in an atmospheric climate is the scientific physics of how a natural draught flue removes products of combustions (flue gases) away from the appliance burner and out to the atmosphere.As long as the appliance products of combustion remain hotter than the surrounding air they will move up through the flue and out to atmosphere, providing the flue is correctly sized.

Natural draught flued appliances have atmospheric burners which mean the air for combustion is not provided by mechanical means, such as a fan. The air for combustion to aNatural draught flued applianceis provided by the inspirating effect of the gas or the natural draught in the combustion chamber. See AS5601 clause 1.4.14.1

Natural draught flues may be connected individually to an appliance or they may connect more than one appliance using the same flue which is known as a common natural draught flue. Australian Standard 5601-2004 appendix H & clause 5.13 provides information for natural draught flue design and sizing.

Natural draught flues used on Type B appliances are generally found on smaller commercial & industrial appliances. Natural draught flued appliances generally use a 50% burner excess air for combustion. Using excess air for combustion ensures complete combustion of the fuel gas takes place. Complete combustion results in no carbon monoxide occurring in the flue products (Carbon monoxide is a dangerous poisonous gas). Excessive air used for combustion is a safety measure.

Although excess air provides safety from carbon monoxide being produced by the combustion process the down side to excess air is the loss of efficiency in the appliance. In a large industrial appliance this loss of efficiency may costs thousands of dollars in fuel annually.

Air for combustion in a forced or induced draught burner can be more accurately adjusted which enables the type B qualified person to reduce excess combustion air resulting in a more efficient cost saving appliance.

Natural draught flues continued

One of the disadvantages with a natural draught flue is that compared to forced, induced or power flues the diameter of the flue is generally considerably larger if comparing an appliance with the same Mega joule per hour rating.

All natural draught flues must include a down draught divert except where clause 5.13.3.10 specifies otherwise.

A forced, induced or power flue does not require a down draught diverter which can result in a cost savingto manufacture the appliance. A forced or induced draught unit can be made smaller as adown draught diverter is usually integral to a natural draught appliance which increases its size.

Flues on atmospheric appliances require an A.G.A. approved cowl unless otherwise stated in AS5601-2004 clause 5.13.3.14.

Flue gas heat loss is another major fact to take into consideration when designing a natural draught flue. Ideally low heat loss flues are desirable. Low heat loss flues are smaller in diameter and produce less condensation than high heat loss flues

Flues maybe regarded as either high or low heat loss flues depending on the environment which the flue is to be installed in.

Long exposed single skin or uninsulated outdoor fluesare regarded as high heat loss flues.

Internally installed fluesare regarded as low heat loss.

The type of material the flue is made from as listed in AS5601 appendix H1.2.1 also determines whether the flue may be high or low heat loss, for instance certified twin-wall or insulated flue is regarded as low heat loss.

High heat loss flues will result in larger flue sizes and high heat loss flues will result in more flue condensation.

Information for general design and sizing requirements for natural draught flues can befound in As5601-2004 clause 5.13 and appendix H.

Natural draught flues continued