CPCPGS3050A - INSTALL ‘TYPE B’ GAS APPLIANCE FLUES
CONSTRUCTION, PLUMBING AND SERVICE
INTEGRATED FRAMEWORK
TRAINING PACKAGE
CPC08
CPCPGS3050A
INSTALL ‘TYPE B’ GAS APPLIANCE FLUES
LEARNING GUIDE
ACKNOWLEDGEMENTS
National Plumbing Services Training Advisory Group
Plumbing Industry Commission Victoria
© Commonwealth of Australia 2015
Construction and Property Services Industry Skills Council
PO Box 151
Belconnen ACT 2616
Tel: 02 6253 0002
This work is copyright, but permission is given to trainers and teachers to make copies and contextualise the resources for use within their own training organisation or in a workplace where training is being conducted. This permission does not extend to making copies for use outside the immediate training environment for which they are made, or the making of copies for hire or resale to third parties.
This work was first published in 2004 with the assistance of funding provided by the Commonwealth Government through the Australian National Training Authority (ANTA). The2015 publication has been updated to reflect changes to the national units of competency.
The views expressed in this work do not necessarily represent the views of the Commonwealth of Australia or CPSISC. In addition, the Commonwealth of Australia and CPSISC do not give warranty or accept any legal liability in relation to the content of this work.
The website addresses and other contact information provided in this publication were compiled in good faith and were correct at the time of printing.
The updating of these resources was completed by:
National Plumbing and Services Training Advisory Group, with funding and support provided by the Construction and Property Services Industry Skills Council (CPSISC):
This guide was developed in consultation with representatives of the Plumbing Industry by NPSTAG and CPSISC to support the implementation of the CPC08 Construction, Plumbing and Services Training Package.
Contents
What is this resource about?......
How do I use this resource?......
Flexible delivery
What do I have to do?......
Unit Descriptor......
Element......
Performance Criteria......
Required knowledge...... 4
What other resources will I need?......
Safety......
Workplace environment and safety......
Introduction......
Type B appliances......
Handling hazardous materials......
Planning
Prepare for work......
Gas safety
Fixing, fastening and joining techniques......
Measuring and calculating flue size......
Regulations......
Quality assurance......
Determine flue requirements......
Checking the dimensions and load of the design......
Selecting the flue material......
Calculating the flue size......
Tools and equipment......
Selecting a development method......
Install a Type B Appliance Flue......
Clean up......
Worksheet
Practical application......
Assessment checklist......
© Commonwealth of Australia 2015 1
CPCPGS3050A - INSTALL ‘TYPE B’ GAS APPLIANCE FLUES
What is this resource about?
Welcome to CPCPGS3050A – Install Type B gas appliance flues. This resource will help you gain the skills and knowledge necessary to demonstrate competence in this unit.
How do I use this resource?
This resource is divided into four main sections:
- A learning unit, which contains background information on CPCPGS3050A – Install Type B gas appliance flues
- Worksheets, which prepare you for the practical application
- Practical application, which allows you to experience installing a Type B appliance flue
- Assessment materials, which help you demonstrate competency.
To complete this unit of competence you will need to:
- read the information contained in the learning unit
- complete the worksheets as instructed
- have your answers checked by your trainer or supervisor
- work with your trainer or supervisor to practice fabricating installing a Type B appliance flue
- read the assessment checklist together with the assessment sheets
- complete the assessment.
Learning Resources are not intended to be the only source of information nor are they intended to be an exhaustive form of instruction.
Flexible delivery
The Trainer or Supervisor may adapt and deliver this Learning Resource to suit people from diverse backgrounds to meet equity principles and conform to Legislative Policies.
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 CPCPGS30050A – Install Type B gas appliance flues:
- Prepare for work
- Determine flue requirements
- Install and commission flue
- Clean up.
If you are unsure of the meaning of these elements you should read the performance criteria on the following pages.
To be competent in this unit you will need to demonstrate:
- a knowledge of :
the Standard International system of measurement
hazardous materials – insulation material
relevant WHS regulations and AS/NZS5601 – Relevant Version - Gas Installations, and AS1375
relevant statutory and authority requirements
types of fasteners, fixings and joining techniques and their application to the fabrication and installation of flues
properties of gas, gas safety, combustion principles, pressure and flow rates, electrical safety.
- the ability to:
organise work
use tools and equipment
communicate effectively, in written and verbal form
select, fit and use appropriate personal protective equipment for the job
read and interpret drawings, specifications and AS/NZS5601 – Relevant Version
(AG601) Gas Installations and AS1375
apply mathematical skills required to measure and calculate flue size and various configuration requirements
measure and calculate quantities of flue materials required for the job
use testing or commissioning procedures and equipment in accordance with AS1375.
CPCPGS3050A / Install Type B gas appliance fluesUnit Descriptor / This unit of competency specifies the outcomes required to install flue systems for Type B gas appliances.
Work may also involve the installation of power flue applications.
The design requirements of this unit are limited to the application of the design to layout and installation.
Element / Performance Criteria
Elements describe the essential outcomes of a unit of competency. / Performance criteria describe the performance needed to demonstrate achievement of the element. Where bold italicised text is used, further information is detailed in the required skills and knowledge section and the range statement. Assessment of performance is to be consistent with the evidence guide.
1Prepare for work / 1.1Work plans, specifications and any special instructions are obtained
1.2Work health and safety (WHS) and environmental requirements associated with installing flues for Type B gas appliances are adhered to throughout the work
1.3Quality assurance requirements for company operations are identified and adhered to
1.4Approval of system design is obtained according to statutory and regulatory authority and workplace requirements
1.5Tasks are planned in conjunction with others involved in or affected by the work
1.6Sequence of work is prioritised to suit job requirements
1.7Tools and equipmentare selected consistent with installing a Type B appliance flue and checked for serviceability
2Identify flue requirements / 2.1Details of dimensions and loads are checked for compliance with plans and specifications
2.2Size of flue is calculated according to authorities’ requirements and is appropriate for type of appliance burner
2.3Flue is selected for type of appliance and its determined route, in compliance with relevant Australian standards
2.4Quantity and type of materials for the installation are calculated from plans and specifications
3Install flue / 3.1Preparatory work, including any penetration of walls and rooves, is performed according to industry and workplace requirements
3.2Installation is completed without damage or distortion to surrounding environment or other services
3.3Flue is installed in compliance with relevant Australian standards and authorities’ requirements
3.4Sustainability principles and concepts are applied throughout the installation
4Clean up / 4.1Work area is cleared and materials disposed of, reused or recycled according to legislation, regulations, codes of practice and job specification
4.2Tools and equipment are cleaned, checked, maintained and stored according to manufacturer recommendations and workplace procedures
4.3Informationis accessed and documentation completed according to workplace requirements
Required knowledge / Required knowledge for this unit is:
- electrical safety and requisite precautions
- how to access relevant information, including codes and technical standards
- job safety analysis (JSA) and safe work method statements (SWMS)
- material requirements determination process
- procedures for installing Type B appliances, including roof and wall penetration and flashing
- properties of gas, gas safety, combustion principles, pressure and flow rates
- relevant statutory requirements related to installing flues for Type B appliances
- SI system of measurements
- workplace and equipment safety requirements
An up to date version of the ‘Unit Descriptor’ may be located on the Australian Government web site training.gov.au
How will I be assessed?
Your trainer or supervisor will decide with you how you will be assessed. Your assessment activity may include completion of the student worksheet and practical task selected by your trainer or supervisor. Your assessment should allow you to demonstrate all the skills and knowledge required to install a Type B appliance flue.
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.
Are there any pre-requisites?
Prior to commencing CPCPGS3050A – Install Type B gas appliance fluesyou must have successfully completed the following pre-requisite:
- CPCPCM2043A - Carry out WHS requirements
It is also recommended that prior to commencing CPCPGS3050A – Install Type B gas appliance flues you should have successfully completed the following competencies:
- CPCPCM2048A - Cut and Join Sheet metal
- CPCPCM3021A – Flash penetration through roves and walls
- CPCPGS3049A – Install type A appliance flues
- CPCPGS3054A – Calculate and install natural ventilation for type A gas appliances
- CPCPCM2041A – Work effectively in the Plumbing and Services sector
- CPCPCM2059A – Carry out interactive workplace communications
- CPCPCM2043A – Carry out WHS requirements
- CPCPCM2045A – Handle and store plumbing materials
- CPCPCM2046A – Use plumbing hand and power tools
- CPCPRF2055A – Work safety on roofs.
Project work may also group pre-requisite and or co requisite competencies together to carry out such projects. It is recommended that the following competencies are grouped with this unit of competency:
- Nil.
What other resources will I need?
To assist you the following resources have been suggested and should be available to you to do this competency:
Texts
- Standards Australia/Australian Gas Association. AS/NZS5601 – Relevant Version /AG601 – 2002, Redfern NSW.
- State or Territory regulations may override this learning guide.
Web sites
Video/audio cassettes
Safety
Workplace health and safety (WHS) requirements need to be observed in accordance with legislation. You need to know the WHS laws governing your job. Revision of CPCPCM2043A - Carry out WHS 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 WHS 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 look at installing a flue system for Type B appliances. Type B appliances are defined in AS/NZS5601 – Relevant Version, as: 'An appliance, with gas consumption in excess of 10mJ/h, for which an AGA/ALPGA approval scheme does not exist.'
The aim of this unit is to assist you to determine the size of the required flue, determine the quantity and type of fabrication materials required, assemble the components and install the flue. Erection of the flue must comply with Section 5 of AS/NZS5601 – Relevant Version. You will also need to determine the requirements of the Environmental Protection Authority (EPA) in your state. These people have an investigative role if flues are not operating within the guidelines of their Act.
Before you can install a flue system for Type B appliances, you must know about:
- handling hazardous materials–insulation material
- properties of gas, gas safety, combustion principles, pressure and flow rates, electrical safety
- types of fasteners, fixings and joining techniques and their application to the fabrication and installation of flues
- applying mathematical skills to measure and calculate flue size and various configuration requirements
- testing and commissioning procedures and equipment in accordance with AS1375
- relevant WHS regulations and AS/NZS5601 – Relevant Version - Gas Installations, Section 5 and AS1375.
Type B appliances
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 has a gas consumption 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).
Handling hazardous materials
Flues, particularly for steam and hot water boilers are often covered with insulation materials and sheathed with sheetmetal products. This practice is aimed at preventing heat loss within the flue as this affects the ability of the flue to provide a motive draft to remove the products of combustion. Loss of heat inside the flue can also cause condensate to form. This condensate can produce an acid, which reduces the life of the flue.
Insulation materials to cover sheetmetal or mild steel flues are made from mineral wool (yellow) or fiberglass (pink). This may cause problems to soft tissues eg eyes, nose and mouth. It may cause industrial dermatitis (Inflammation of the skin) if handled by some people.
NoteSome early boilers are lagged with asbestos and should be removed by specialist personnel.
Planning
Prepare for work
Before you begin the installation of flue systems for Type B appliances you need to obtain the plans and specifications from the job supervisor. Gathering information about the job will help you make informed decisions about the nature of the job and how to plan and sequence the entire process. Also, before beginning any work, you may need to obtain work notices and submit them to the relevant authorities.
The table below shows some information sources and the type of information each source can provide.
Authorities /
- Standards and installation requirements.
Plans or specifications /
- Location of flue.
- Type of appliance.
- Materials to be used.
- Commissioning requirements.
Company’s quality assurance /
- Workplace operations and procedures.
- Control of handling procedures.
Regulatory requirements /
- Installation.
- Operation criteria for flue.
Site inspection /
- Size and length of flue.
- Height above parapet.
- Location of appliance and pipe duct.
In some States or Territories, a plan of the flue must be forwarded to the Environmental Protection Authority for their requirements with regards to height, size and materials used to fabricate the flue. This is vital when the appliance is a boiler. Some local government Authorities have specific requirement for the installation of pottery kilns and should be contacted prior to commencing installation. Authorities are concerned that the flue does not reduce the building's strength or fire resistance. The gasfitter must submit a certificate of compliance upon completion of gas installation and any other relevant forms applicable to your state authority.
You need to consider how the task you are about to do affects others. You should plan the task with the others involved or affected by the work. Your company may have procedures regarding this that you will need to take into account.
Large steel flues are usually fabricated off site and erected after the components arrive on site. This usually involves the use of a crane located on the site.
You will also need to:
- prepare a chart outlining the fabrication dates, arrival on site and installation period for the principal contractor
- advise the bricklayer, plasterer and painter of your plans to install the support brackets at the specified distances for the flue
- brackets should be positioned with a plumb bob to ensure the flue is plumb
- you need to discuss with the roofing contractor where the flue penetrates the roof
- you need to arrange for this person to prepare and install a soaker in the roof for this penetration
- you need to discuss with this contractor your plans to flash the flue penetration and seek approval for your design
- work closely with the personnel operating the crane, to ensure that the flue components are safely lifted into position and fixed by your brackets.
Note
Your company may have additional procedures regarding planning and working with others. You will also need to take these into account.
Gas safety