Gas Installer Article Project Specification & Tracking Sheet

Subject: General article looking at the typical servicing requirements of a chip shop fryer. / Reference No:
CL05/09/04
No. of words: 1200
Allocated by: Chris Long / Date: 26.09.05
Allocated to: Andy Durber / Date: 26.09.05
Guidance for the writer: The article can be written in general terms i.e. typical service operations for chip shop fryers or the author may wish to be specific and write an article on a specific manufacturer i.e. Frymaster or a specialist service company.
If the article is written specifically for a manufacturers model, written permission needs to be obtained and provided back to CORGI. Similarly, where the author intends to use images, those images need the permission of the owner(s) to be used in Gas Installer and they need to be of a high resolution i.e. 300dpi.
Deadlinefor completion: 01/06/06
CORGI contact: Chris Long /
Contact details:
0870 401 2482

Date for publication: March 2006
Attachments: None
Other Comments:
Recommend reference material - Gas Safety (Installation and Use) Regulations 1998.
Chris,
This attachment is a little on the long side (approx 1800 words), we have included a section at the front of the article to make installers aware of users responsibilities (shown in dark green) and increased the reference list at the end (also shown in dark green) these could be easily removed if required leaving the article approx 1300 words. Any problems please contact Nick Evans or myself
Regards
Andy
Article management tracking sheet
Please complete the status sheet below at each stage of development.
Subject: General article looking at the typical servicing requirements of a chip shop fryer. / Reference No.
CL05/09/04
Date
/
Name
/
Current Status
19.06.06 / Blueflame Associates / Submitted 1st draft to CORGI publications team
22.06.06 / Chris Long / 1st Proof/edited article

Start Article here:

Maintenance of fish and chip shop ranges by Blueflame Associates Ltd

Maintenance of catering equipment is not only the domain of the gas operative but also all those people involved in the use of the apparatus, . the types of mMaintenance can be broken down into three main areas, includethem being:

  • Cleaning and routine maintenance/inspection (- usually typically carried out by cooking and ancillary staff)
  • Planned Mmaintenance/servicing, which must be - carried out by qualified and experienced CORGI registered Operativesgas operatives.
  • Breakdown/Responsive responsive Maintenancemaintenance, - carried out as a result of component failures, again by CORGI registered gas operatives.

It can be seen from the list above that many routine maintenance (cleaning and inspection) operations are carried out by non non-gas technical persons such as chefs and other kitchen staff. These activities are a crucial and integral component of the maintenance regime and it is therefore important for the Gas gas Operative operative to bring them to the attention of the caterer and to ensure that the caterer is fully conversant with all the requirements of that of the appliance manufacturer.

In this Gas Installer article, Blueflame Associates Ltd will take a closer look at two of these categories, them being maintenance by non-gas personnel and that undertaken by gas operatives.

Additional information, bothfor the caterer and the gas operative can also be found obtained in from the Health and Safety Executive (HSE), via their Free information sheetsi.e. Catering Information Sheet No. 12 ‘Maintenance priorities in catering’

Note: This and other publications/information sheets are available from HSEBooks Tel: 01787 881 165 or alternatively, by visiting

Ongoing cleaning and periodic inspection of fish and chip ranges – caterer responsibilities

Based on the information in HSE Catering Information Sheet No.12 it is extremely important that the caterer establishes a routine for checking and cleaning their catering equipment in order to ensure a safe working environment and to reduce the risks of transmitting diseases.

In addition to this many faults can be identified by the caterer prior to ‘total failure’ of the range; with the required repair work being carried out in a timely and convenient fashion (reducing the down time of the range).

The cleaning operation with probably the greatest potential for accidents isof emptying and changing the fryers cooking oil has probably the greatest potential for accidents. This must operation needs to be carried out safely, in accordance with the appliance manufacturer’s instructions whilst any container used to drain or collect oil must needs to be designed to prevent spillage or possible overflow in areas where there is a risk of ignition.

The caterer should be advised to consult HSE Catering Information Sheet No. 17 ‘Safety during empting & cleaning of fryers’ for detailed guidance on this maintenance activity.

The fish and chip range itself is not the only component that needs attention from the caterer, ; any build build-up of fat within the extraction system will reduce the performance of the range and as well as creating an uncomfortable atmosphere within the premises when the range is in operation, can present a significant could also create a serious fire hazard. It is recommended therefore that the extraction system be periodically cleaned by suitable competent persons and a regime of steam- cleaning adopted to remove deposits of oil and fat.

Parts which may be removed during day day-to to-day routine maintenance should be designed or marked to enable safe and correct reassembly, preferably without the use of any tool.

Planned maintenance and inspection of fish and chip ranges – gas operative responsibilities

Gas Gas-fired fish and chip frying ranges require an annual service/safety check, in accordance with the appliance manufacturer’s instructions and to meet the requirements of many insurance companies.

Warning: It is important to stress to the caterer that if such maintenance work is not carried out in accordance with the appliance manufacturers schedule, including cleaning of any associated ductwork, then any resulting insurance claim(s) may be rejected.If this is not undertaken an insurance company may refuse to honour a claim.

As fish and chip ranges are manufactured by specialists in this field, it is generally accepted that the majority of the servicing and maintenance work is be undertaken by the manufacturer’s own personnel or by approved specialist contractors. However, there are a number of independent companies or individuals who also have the necessary competence, knowledge and experience to operate within this particular sector.

Competence

Gas operatives who undertake this work activity on natural gas installations are required to be CORGI registered and hold current certificates of competence issued under the Nationally Accredited Certification Scheme for Individual Gas Fitting Operatives (ACS) in the following categories: CCCN 1 and COMCAT 4. For LPG installations the operative would also need to hold a fuel changeover category - CoNGLP 1.

It is also recommended that the gas operative to have a sound knowledge and understanding of the current requirements for electrical systems/controls and to have completed a manufacturers training course.

During there their daily activities with fish and chip ranges the, gas operative(s) will normally encounter the following controls:

  • Electric isolator - isolates electric supply to the equipment and should incorporate a facility for ‘locking off’.
  • Applianceisolation valve - isolates gas supply to the equipment.
  • Fan flow/air proving control - a pressure switch and solenoid or a full pressure pressure-proving unit, which initiates the start sequence.
  • Reset button - to initiate start-up in the event of a power failure.
  • Flame supervision device - from a simple manual thermo-electric device to a fully automatic control system.
  • Control thermostat - maintaining oil temperature when frying.
  • Ignition indicator lights - may only show main burner on or include a full ignition sequence.
  • High limit thermostat - ‘backup’ thermostat to shut down the appliance if the frying temperature exceeds dangerous levels (normally 220°C).control thermostat fails
  • Chip-box simmerstat - variable heater control.

Modern equipment will now normally have fully automatic sophisticated control systems.

All servicing and maintenance checks should be carried out strictly in accordance with the ‘mmanufacturer’s instructions’instructions.

In the absence of particular recommendations from the manufacturer the following guidance, presented in the form of tables provide general guidanceis offered:

Initial inspection

Activity / Additional Guidance
Check the general condition and installation of the equipment / Ensure the appliance/flueing provisions have been installed in accordance with manufacturers instructions, legislative requirements and other relevant industry standards. Visually inspect that there are no signs of spillage, etc. that may highlight problems.
Check the ventilation, make-up air and the presence of interlocks.
See Table 1 Note / Older installations with inadequate extract/ventilation systems should be ‘Risk Assessed’ following the information contained in HSE Catering Information Sheet No 23 ‘Gas safety in catering & hospitality’.
Check the general condition and size of the gas supply pipework/meter / The heat input on some units could be quite high and so pipework and meter size should be confirmed as adequate.
Test the operation of the appliance / Do not run the equipment up to temperature,;as the operative will, if everything is operating satisfactory, dismantle the unit.
Inform the responsible person/client if the installation is unsatisfactory, the equipment fails to operate or there is any damage to the equipment / It is important that things such as requirements for remedial work and obviously cost are discussed prior to the commencement of work. Any damage should be pointed out to prevent blame being apportioned afterwards.
Note:Adequate ventilation is required not only for the safe operation of the appliance but to provide a safe environment for any catering staff and any people in an adjoining café or dining area.
Even though some manufacturers stipulate minimum ventilation requirements for their fish and chip ranges dependant upon the heat input of the appliance, they don’t normally take into account other factors such as keeping the working environment comfortable, diluting/removing cooking odours, vapours and steam from the cooking process. The ventilation must also provide ‘make up’ air to replace any air removed by extraction/flue systems, etc.
It is recognised that determining the ventilation requirements should be undertaken by a specialist who is competent in this area.

Note:Adequate ventilation is required not only for the safe operation of the appliance but to provide a safe environment for any catering staff and any people in an adjoining café or dining area.

Even though some manufacturers stipulate minimum ventilation requirements for their fish and chip ranges dependant upon the heat input of the appliance, they don’t normally take into account other factors such as keeping the working environment comfortable, diluting / removing cooking odours, vapours and steam from the cooking process. The ventilation must also provide ‘make up’ air to replace any air removed by extraction / flue systems, etc.

It is recognised that determining the ventilation requirements should be undertaken by a specialist who is competent in this area.

Table 1: Initial InspectionInspection/checks/test

Activity / Additional Guidance
Isolate gas/electricity supplies / Check for let-by of the gas valve and confirm electrical isolation using appropriate test meter/proving unit.
Remove main duct/extractor manifold access panels and clean away any deposits. Refit and reseal with suitable material / On older equipment, it may be necessary to install suitable access panels if not fitted. Filters should be cleaned/replaced. Remember that all sealing materials/tapes must need to be suitable for a catering environment.
Empty and clean all sumps and fat/condensation receptacles
Inspect the fan, dismantle and clean the motor, back plate and the impellor.Re-assemble the fan and check for balance and true running / The fan system shall be interlocked with the gas supply, as required by Regulation 27(4) of the Gas Safety (Installation and Use) Regulations 1998 (GSIUR). Any air pressure tubes should also be checked and cleaned.
Remove and clean the pilot, main burners and injectors / There are primarily three types of burners, ; ‘Davies’ burner system, a “Duoflame” burner or aerated atmospheric burners. Each is unique in their construction and will require special attention.
Check and clean any flame supervision devices (FSD) and thermostats / This allows an operative to identify any deterioration of the sensing devices which may need to be replaced to ensure continued safe operation of the equipment.
Inspect the pans for any pitting or leaks / More modern pans should be CE marked with an individual data badge.
Test the ‘gas train’ for tightness / A gas tightness test need only be carried out from the equipment isolation valve. Pay particular attention to disturbed joints. Only use proprietary jointing compounds/leak detection fluid (LDF) suitable for use in a catering establishment.
Inspect and test electrical wiring/controls for any damage / Pay particular attention to fuse holders, switches, simmerstats/heating elements, dimmer controls and miniature circuit breakers (MCB’s).

Table 2: Maintenance and Cleaning cleaning Operationsoperations

Activity / Additional Guidance
Check that the oil/fat level is within recommended limits
See Table 2 Note / The pan may be marked showing ‘Min’. & ‘Max’. levels. This is important as the thermostats are generally inserted just below the ‘Min’ level and overheating can occur if there is insufficient oil.
Test and re-establish the electrical supply / The electrical connection/wiring within the appliance should be tested for safety and only operatives who are competent to do so should re-establish the electric supply.
Turn on and test the extraction system / The equipment will not ignite until the fan is running. The fan flow proving device will allow the ignition sequence to begin once the extraction system is purged. Test to prove satisfactory operation of the proving device/gas control interlock.
Turn on the control thermostat and carry out a ‘dry run’ / A ‘dry run’ should be carried out on fully automatic systems to ensure that the unit will run through a correct sequence and ‘lock out’ as there is no gas supply.
Re-establish the gas supply / Remember to test all disturbed joints and joints on the outlet of the last safety shut off valve with LDF
Carry out a ‘live run’ on the equipment including checking the:
Flame picture/operating pressure/heat input / Check there is a satisfactory flame picture and cross lighting. If necessary adjust the main burner operating pressure to the requirements of the appliance data plate.
Operation of gas safety controls / Check that the FSD operates satisfactorily. Check the operation and accuracy of the control thermostat. Test the operation of the high limit thermostat, great care must be taken at this point as the fat/oil may be approaching flash point - strictly follow manufacturers instructions.
Settings of dampers and undertaking a combustion analysis / It is a CE requirement that access should be possible to the burner duct below the entry of steam from the storage hoods to record CO/CO2 ratio.
Reassemble any panels that have been removed during servicing / Any loose panels may constitute a danger to catering staff.
Complete necessary documentation. / Completing maintenance record(s) showing CO/CO2 readings, thermostat operating temperatures, electrical checks, tightness test results, etc and report any defects to the responsible person.
Note:Never operate a fish and chip range, even for maintenance purposes, with anything other than the appropriate fat or oil in the pans, as this could lead to inaccurate readings being obtained or damage to the unit.

Andy – I have only deleted the rest due to word count! ChrisNote:Never operate a fish and chip range, even for maintenance purposes, with anything other than the appropriate fat or oil in the pans, as this could lead to inaccurate readings being obtained or damage to the unit..

Table 3: Re-commissioning

Further advice can be obtained from the following documents:

BS 6173 : 2001 - Installation of gas fired catering appliances for use in all types of catering establishments (2nd and 3rd family gases)

HSE Catering Information Sheet No 3 - Precautions at manually ignited gas fired catering equipment

HSE Catering Information Sheet No 9 - Planning for health and safety when selecting and using catering equipment and work places

HSE Catering Information Sheet No 10 - Ventilation of kitchens in catering establishments

HSE Catering Information Sheet No 12 - Maintenance priorities in catering

HSE Catering Information Sheet No 17 - Safety during empting & cleaning of fryers

HSE Catering Information Sheet No 23 - Gas safety in catering & hospitality

Heating and Ventilation Contractors Association (HVCA) DW/172 - Specification for Kitchen Ventilation Systems

British Gas / Catering Equipment Suppliers Association (CESA) Joint Agreed Testing Requirements for Gas-Heated Fish and Chip Frying Ranges.

  • BS 6350 : 1983 - Gas heated fish and chip frying ranges (This standard was withdrawn in 2004 but may be used for reference on older equipment)

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