INSTALL SMALL BORE HEATING SYSTEMS Introduction In this unit you will look at gas fired small bore hot water heating systems with a maximum operating pressure and temperature range up to 100 ID: 591862
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Slide1
CPCPMS3003A
INSTALL SMALL BORE HEATING SYSTEMSSlide2
Introduction
In this unit you will look at gas fired small bore hot water heating systems
with a maximum operating pressure and temperature range up to 100C, and pipes up to 25 mm in size. You will also look at how to install them, including the location, support, piping requirements and testing procedures.A range of small bore heating systems are available to suit different environments. You need to be able to select a system that will meet the needs of the job specifications and the environment.
A small bore heating system is one of the most efficient ways of heating a house. Slide3
Components
Hydronic systems
consists of four components.1. The Boiler heats
the water to a thermostatically controlled temperature. Boilers use natural gas, LPG. off-peak electricity or solid fuel. (Wood, coal)2. The Piping usually made of copper and gaining popularity is thermoplastics ( Rehau ) carries the heated water from the boiler to radiators/convectors or into the slab, and back again for re heating
.3. A Pump circulates the water through the piping.4.
Radiators or convectors
transfer the heat to the room. Several types are available.Slide4
Advantages of hydronic systems
Even
, comfortable heat throughout the homeRadiators and or convectors can be added at a later date if the unit is sized adequatelyIndividual control valves to each panel
allow individual rooms or zones to be heated independently, enabling running costs to be substantially lowered. No dust is blown through the house therefore the system is allergy freeResponse time is generally good, and you will feel warm within 30
minuets.Easy installation and control systemUnused rooms can be switched off or kept at a lower temperature by just turning a knob because each radiator or convector can be individually controlled by thermostat
Quiet
operation
.
The proven effectiveness of
hydronic heating
- it has been widely used in Europe for almost a century.Slide5
Heat loss due to air changes
Health
regulations require that the air inside domestic dwellings must be changed at least twice every hour, so that occupants have a good supply of fresh air.The manufacturers of heating products have devised methods for you to calculate the size of the unit used for a particular installation.
Always check with the manufacturer if you need further information. Ask your trainer or supervisor for an example to look atSlide6
Heat emitters
Heat emitters are the devices used to transfer the heat energy from the water into the room or space being heated. This transfer can take place in three different ways
:Conduction (the heat flow in a solid substance where heat is passed from particle to particle)
Convection (the heat flow in liquids or gases via its density).Radiation (the heat is transferred in straight lines in all directions without warming the space through which it passes).
The size of the heat emitters is critical when sizing the system. To select the correctly sized heat emitter for each room the heat load calculations must be used, (refer to manufacturer’s or supplier’s sizing system). Slide7
Choosing a System
If using a
gas-fired system, choose a low water content boiler. Storage boilers have slightly higher running costs due to continual 'standing' heat loss from their tanks. Low water content boilers should be manufactured from a lightweight metal such as steel or copper.
Avoid cast iron or similar heavy materials. Choose panels with low water content. This improves response time and reduces energy use. Response time
- pressed steel panels have a faster response time than cast iron panels. and are around 10-15 minutes quicker heating a room. All piping should be well insulated to guard against heat loss. Slide8
System Design
Materials such as Armaflex, Bradflex or Insulzip
of at least 10m.m. thickness should be used - ordinary pre-lagged copper pipe is insufficient. A thermostat should be installed in the main living area
. This should be located on an internal wall in an area free of draughts, away from sauces of direct heat, such as direct sunlight. Panels in other rooms should have individual valves, allowing rooms to be heated independently.
Individual room heating can substantially lower running costs. Thermostatic valves
are recommended, especially in rooms that gain heat from other sources such as sunlight. Increased comfort levels are achieved as desired temperatures are maintained. Slide9
Fuel options
If you live in an urban area, the cheapest fuel is natural gas
. Solid fuel is an option, but is very pollutant, and costly LPG
is an option in areas without natural gas, but is more than two and a half times more expensive, depending on where you live.Solar Gas Boosted options are also available
Consider mounting an insulating board on any uninsulated walls behind panels to reduce heat loss. Up to 30% of heat produced can be lost through such walls. Thin foil board or foil alone is practical and economical.Slide10
Panel Radiators
The approximate proportions of radiant and convective heat from the different types of panels are as follows:
Diagram No.
Type of
panelRadiant
output %
Convective
Output (%)
1
Single
Panel radiator
70
30
2
Double
Panel radiator
50
50
3
Triple
Panel radiator
30
70
4
Convector
panel
--
100Slide11
hydronic heating system to supply domestic hot water
Many hydronic heating boilers are also able to provide
domestic hot water. These are often referred to as combination boilers, providing hot water will add approximately $400 - $500 to the cost of a storage boiler
.Hydronic systems provide instantaneous domestic hot water similar to that produced by continuous flow hot water systems. but are generally less efficient for this purpose than most domestic hot water systems.
Solar hot water systems can be used to provide hot water for your hydronic system. These combination systems are now commercially available. Slide12
hydronic heating system to supply domestic hot waterSlide13
Heating units
Small bore hot water heating systems may include
panel radiators, skirting convectors, natural convectors and fan convectors.Panel Radiators
A compact panel radiator is made from durable steel. Heat is given off from the panel radiators by way of radiation.
The location of these radiators is critical to the efficient operation of the system. They are best located under or near windows and on external walls, in areas of
greatest heat loss.
The
panels are manufactured in lengths from
400 mm to 3000 mm
in increments of 100 mm. The height varies from
300 mm to 900 mm
.
The pressure loss through a radiator is relatively low and can be calculated by using the manufacturer’s literature. Slide14
Features of panel radiators
Panel radiators have a number of features that are a benefit to the consumer
.Silent, no noise or draughts due to fans blowing hot air.Ideal for allergy or asthma sufferers
.Individual control.Low running cost using an efficiently sized central boiler
Individual flow control at each radiator using a lock shield valve.Slide15
Single panel radiator
Single panel radiator
Lock shield valve
Thermostatic valve
Thermostatic head which controls the temperature of an individual room Isolation & flow control valve Slide16
Skirting convectors
Skirting convectors should be located under windows for maximum benefit
The skirting convectors come in lengths from 900 mm to 3000 mm and heights form 64 mm to 213 mm.Silent, no fans blowing hot air causing in no noise or draughts
Ideal for allergy or asthma sufferersIndividual controlLow running cost using an efficiently sized central boilerSafe for children and senior citizens with low surface temperature
All copper tails with no moving partsCan be made to suit any wall lengthIndividual flow control at each convector using a lock shield valve.Slide17
Natural convectors
Natural convectors provide a means of heating the room by way of
natural air currents (not fan forced). The coolest air enters through the bottom of the convector and as the air flows past the finned copper tubes it is heated and escapes through the top
.The resulting warm air is then gently circulated throughout the room without draughts or noise
.Warm air is less dense than the cold air, which means that the warm air rises rapidly to the ceiling.Slide18
Fan convectors
A fan convector is a fan mounted emitter
with an electric fan built in. The fan switch is mounted on the top of the unit and has an insulated cabinet. They are available with thermostatic two-way valve and lock shield valve for water flow regulation.
Safe for children and senior citizens because of the low surface temperatureCan be combined with panel radiators and skirting convectors for the ideal heating
systemLow maintenance as all waterways are made of copper
Individual
control with two speed fan control, switches off automatically when heating is not
required
Quiet
, state of the art, fan
.Slide19
Planning
To install a small bore heating system safely and effectively you will need to plan your work activities.
Gathering relevant information from building plans or specifications, relevant statutory and authority requirements for installing and commissioning the system.
Referring to the manufacturer’s guidelines for the system specified
Conducting a site inspection to determine where the heating system is to be located.The following sources of information will help you determine whether the installation can be done safely and what you will need to do to ensure that the final job meets all the requirements
.Slide20
Work notices
Relevant state, territory, local regulatory or plumbing and gas fitting authorities may need to be notified. In some cases work notices must be obtained and submitted to the:
Local gas supply authority (prior to installation)Local gas licensing authority (Certificate of Compliance to be lodged at completion
)Local office of gas safety
Local electricity authority (if required).Slide21
Quality assurance
It is critical that the installer of a small bore heating system follows the manufacturers’ instruction
with regard to sizing the system, installation procedures, testing and commissioning the system.
Quality assurance processes that your company uses.Methods used to perform tasks.
Quality of materials used.Quality of the work performed.
Use and maintenance of equipment
.
Attention
to specifications.Slide22
Heating unit
It is important that the unit is installed as economically
as possible and in accordance with to the manufacturers’ installation instructions.Most heating units are
located externally. The unit must be installed clear of the building structure (refer to AS5601 and (AG601) Gas Installations
)Ventilation must be provided for the burner combustion (refer to AS5601 and (AG601) Gas Installations)
Access
for maintenance purposes – most units have an access panel on one
side.
Electrical
connection – units are supplied with a three pin plug
and larger units
must be wired directly by a qualified electrician
.Slide23
Pipe work
There are three systems
that can be used: One pipe system
Two pipe system.
Loop systemSlide24
One pipe system
Advantages
Disadvantages
Cheaper to install.
Only suitable for emitters with low resistance to water flow.
Water gets progressively cooler as it flows around the system.
Radiators near the end of the circuit will have to be lager to emit the same amount as those near the boiler.
The flow and return connections from each appliance are branched into
one
main pipe
as appliance is passed.Slide25
TWO PIPE FORCED SYSTEM
Two separate main pipes
are provided; one to supply the
hot flow water to each radiator the other takes the cooler water
from the radiator and returns it to the boiler via a circulating pump.
Advantages
Disadvantages
Gives a far better distribution of
water throughout
the system.
More efficient.
Greater cost in installation.Slide26
One pipe Looped system
One pipe
looped system is design similar to the one pipe system where only one main pipe is required, this pipe feeds each radiator in turn , all the water passes through each radiator . The system needs to be designed to allow for the extra heat loss as the water is passed through each radiator. Slide27
pipe work
When installing copper heating lines we use copper tails that penetrate into the main lines instead of using tees.
The purpose is to ensure that the flow of water is directed into the tails .The tails can be at right angles or at an angle as shown on the examples .
This method is especially important if you are using a one pipe system where most of the water may by pass the radiator . Slide28
pipe work
Good pipe work design and installation is essential if the whole heating system is to work properly.
There are different types of pipe work that can be used in a small bore installation and this will be covered later in the unit.
Remember, this unit is only up to 25mm installations.
There are many types of pipe clips and supports used in small bore installations. You
will need to choose an
appropriate type and size
of support for the installation you are working on.
A concern in a small bore heating system is allowing for
expansion and contraction
of the pipe work and the
prevention of heat losses
from the pipe circuitSlide29
pipe work
All pipe support systems and installation methods for the gas connection must be in accordance of
Part 4.3 AS5601 (AG601) Gas Installations and in accordance with Table 4.1 of AS/NZS3500.4 National Plumbing and Drainage.
Consumer piping shall be supported by means of brackets, saddles, hooks, straps and hangers. It should be capable of supporting the pipe system.
It should firmly restrain the piping in the intended position and control movement of the piping system.It must be compatible with the consumer piping material.
It should allow for expansion and
contraction
of the pipe work
.Slide30
pipe work
Most small bore pipe work is run using copper tube with silver brazing joints,
brass or copper fittings and flared connections.Most modern small bore installations use the two pipe system incorporating a flow and a return line from the boiler to the heat emitters.
This two pipe system gives a better distribution of heated water through the system than a one pipe system and allows the system to operate more efficiently.Copper tube was
the most popular pipe work used as it is easy to bend and join, is lightweight and resistant to corrosion, but manufactures have now developed light weight cheaper poly alternatives .Slide31
pipe work
When fixing the heating unit you need to ensure:All minimum clearances in relation to distances from open able windows and combustible surfaces are
metA good position for the entry to the access panelThe gas connection is within easy reach
An electrical supply is available and accessibleA water connection is within easy reach.Slide32
Isolation processes and procedures
Some fixtures, appliances and fittings may need to be isolated while you are installing a small bore heating system.
For example when testing the soundness of the pipe work it is critical that all the
heat emitters and the boiler are disconnected.The pipe work system is pressurized to 700
kPa or to manufactures specifications. Once this has been achieved the heat emitters and boiler can be connected and the system can be commissioned.Slide33
Determine system requirements
To be able to determine the system requirements you will need to consider a number of different issues.
These include understanding the properties of water including pressure and flow rates.Your calculations must allow for the rate of flow of the heated water through the heat emitter so that it is able to produce the heat output
requiredManufacturers have design teams & sales representatives that will assist you as it is a complexed task.
In designing the small bore heating system it has to be established whether a one pipe or a two pipe system is to be installed taking into consideration the advantages and disadvantages of both systems, as previously discussed.Slide34
Installation for pipe work and emitters
Obtain the plan of the house which will include the room sizes and type of construction used
.Calculate the area to be heated for each room (as determined by the manufacturer or supplier of the heating system).Select the size of the boiler (heating unit) required (as calculated by the manufacturer or supplier of the heating system
).Select the type of heat emitters to be installed (as calculated by the manufacturer or supplier of the heating system).Calculate the flow rate of water for each heat emitter in litres per second (L/s) (as calculated by the manufacturer or supplier of the heating system
).Size the pipe work (as calculated by the manufacturer or supplier of the heating system).Slide35
Sizing the system
Sizing the system correctly is critical to the efficient operation of the installation
.If the pipes are too large or oversized it will be costly to install and increase the heat losses.
The boiler will run continually if the system has been undersized and this could result in the early breakdown of the system.
The heat given off from the emitters is proportional to the amount of water flowing through the piping system.
A simplified pipe sizing system has been developed and you should
contact your hydronic unit manufacturer or supplier for their sizing programSlide36
Expansion and contraction
As the water is heated, both it and the copper tube it is running through expand.
Your installation needs to allow for the expansion of the copper pipe.Allowing for the increase in pipe length that will occur over long runsdrilling oversized holes where pipes pass through holes in the building.Slide37
Insulation
Because of the high temperature of the water it is vital that the pipes are well insulated
to reduce the amount of heat loss in the piping system. Best results are gained if the insulating materials are at least 20 mm thick. Special attention must be paid to the clipping of pipes that have been insulated.
All clips should be around the outside of the insulation and allow the pipe to move during the expansion and contraction of the pipe.Slide38
Types of pipes
The pipe materials you use must comply with the job specifications and the Australian quality standards
. There are at least four types of pipe you may be required to use.These may include:
SteelCopper
PolyethylenePolybutelene.Slide39
Copper
Copper pipes and tubes are one of the most popular type of piping used in small bore installations
. Most joints and connections are made with flared compression connections or open flamed brazing.
The most popular type of joint is the fabricated joint using silver solder. Copper tube can be pre-insulated (lagged) with close cell polyethylene foam sheathing to
minimise heat loss. Slide40
Cross-linked polyethylene pipes (XLPE)
Cross-linked polyethylene can be used, but it must
not be less than class PN16 polyethylene. It can be joined together by means of electro fusion, butt fusion or mechanical joints.
The electro fusion and butt welding methods require specialist skills. For more information on fusion welding you should refer to BCS3166A – Fusion welding polyethylene pipes.
Tighter manual bending can be achieved for XLPE than for other plastic pipes. Slide41
Polybutelenes
Polybutelene pipes and fittings shall
not be less than Class 16.
The
tubing is flexible but tough and durable.
This
material uses
brass fittings with rings that are crimped
onto the tubing
.
Polybutelene has
low thermal conductivity
and
restricts heat loss so that no lagging is required.
Slide42
Positioning of pipes and heater
The job specifications and plans need to be checked
against the regulatory authority requirements. Your job is to ensure that this occurs and that the positioning of both pipes and the heater will not cause damage or interference to the surrounding structures.
Most heating units will be located externally to the building. This type of unit eliminates the need for the installation of flues if it is gas fired and allows for easier installation. The pipe work installation is dependent on the type of construction and whether it is a suspended timber floor or a slab on ground construction.Slide43
Suspended timber floor installation
In this type of installation the pipe work is fixed to the underside of the bearers or joists.
Once the positions of the emitters are established oversized holes are drilled through the timber flooring for the flow and return pipes to be connected to the emitters. The height above the floor is established from the type of emitter to be installed.Slide44
Concrete slab floor installation
In this type of installation the pipe work is usually fixed inside the walls.
Once the positions of the emitters are established oversized holes are drilled through the stud walls. This is usually completed during the construction of the building. If the building has already been completed you would have to place the pipe work within the roof space and run pipes down the inside of the walls at the positions required.Slide45
Determining quantities of materials and equipment
Identify the size of the heating unit to adequately heat the house (taking into consideration the possibility of future extensions)
Identify the type of emitters to be installedIdentify the type and number of pipes
to be usedCalculate the size and lengths of the tubing required for the installation
Identify
the
position of the heating unit and the
emitters
calculate the number and sizes of the fittings required for the
installation
All this should be done in
consultation with the manufacturer’s specifications
, plans and other information gathered.Slide46
Checking materials
Upon delivery, materials and equipment must be checked for quality and that they correspond with the job specifications.
They must be received in acceptable condition.Set out gas piping systems in accordance with design drawing or instructions and make sure it complies with AS5601 (AG601) Gas Installations and the
local authority’s requirementsSlide47
OH&S requirements
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.
Personal protective equipment In any work situation you can reduce the risk of injury to yourself and others by using appropriate PPE. The PPE that you will need when carrying out the installation of a small bore installation includes:Slide48
Setting out
The installation will be governed by the type of construction.
Selecting pipes, fittings and other components to comply with Section 3 and Section 4 of AS5601 (AG601) Gas Installations and the authority’s requirements.
Installing pipe system in accordance with design drawing, or instruction, to make sure it complies with AS5601 (AG601) Gas Installations and pipe jointing complies with Section 3 of AS5601 (AG601) Gas Installations.
Installing support system (including fixings) to comply with manufacturers’ instructions and section 4 of AS5601 (AG601) Gas Installations.
Selecting testing equipment
and using the equipment in accordance with job requirements in accordance with AS5601 (AG601) Gas Installations
Appendix E,
and if required, leaks located, repaired and installation retested.Slide49
Fixing and supports
Fixings and supports must be installed to manufacturer’s specifications
and also match the job plan or specifications. A further point to consider is the spacing of the pipe clips small diameter piping,
will require the clips close enough together to prevent the pipeline from sagging.All pipe support systems and installation methods must be in accordance of Part 4.3 AS5601 (AG601) Gas Installations and Table 3.1 of AS/NZS3500.4.2 National Plumbing and Drainage.
Consumer piping must be supported by means of brackets, saddles, hooks, straps, hangers or other approved methods. Clips must firmly support the piping in the intended position and control movement of the piping system & be
compatible with the consumer piping material used.Slide50
Installation and jointing
When you have completed the set out you will be able to start the installation. The system needs to be installed according to the job plans and to meet the regulatory authorities’ requirements and standards
Insulating the pipe work
Installing the pipe work
Pressure testing the pipe work installation
Fixing
the emitters in
position
Testing
and commissioning the system (including adding rust inhibitor and bleeding all entrapped air from the system).Slide51
Insulating the pipe work
The first step in installing the pipe work is to apply the insulation material to the pipe work.
Sometimes the pipe work may be supplied with the insulation already attached.
Alternatively you may have to attach the insulation yourself by sliding lengths of foam insulation over the pipe. Make sure you use appropriate PPE.Slide52
Installing the pipe work
Now the pipe work has been insulated you can start installing. The steps you need to remember when installing pipe work includes:
Always follow the work plan and the set out use your personal protective equipment
Use the correct tools and equipment for the jobRemember
to oversize the holes to allow for pipe expansionSlide53
Pressure testing the pipe work installation
With the pipe work in place it is time to test the work completed. The steps you need to remember when testing the pipe work includes
:Work safely
Make sure you do not have any emitters or heating units connected
Pressure test to 700 kPa consult manufactory requirements
Fix
any leaks before you connect the emitters or heating units.Slide54
Installation of heating unit and emitters
The heating unit and emitters can now be installed. The steps you need to remember when installing the heating unit and emitters are as follows.
Use personal protective equipment.Make sure the pipe work has been tested and is working correctly before you start
.Make sure you follow the manufacture’s installation instructions.
Make sure you install the units in their correct position (any errors here can be very expensive to repair).Slide55
Testing and commissioning the system
The heating system is checked and adjusted for correct operations and after testing may be commissioned for use. As manufacturers have specific instructions for their own units, these must be followed carefully.
The steps you need to remember when testing and commissioning the system include:Use the correct testing
equipmentMake any alterations or repairs as required
Retest after making any alterationsRecord the results accurately
Fill
in and submit any documentation accurately and quickly.Slide56
The heating system
There are many different ways of controlling the temperature of a hydronic heating system.
The type of control will depend on the customer and the type of heat emitter used.On domestic hydronic heating units
most of the controls are already built into the unit and require no further attention at the installation stage. If a central thermostat is installed it should be mounted in the main living area, mid-way along an internal wall, clear of draughts and sunlight
and approximately 1500 mm above the floor.Slide57
Controls used in Heating systemsSlide58
The heating system
The thermostatic head
maintains a constant temperature
it opens & closes the valve as the room requires heat.
The
central thermostat controls the whole house temperature
rather than a single emitter .Slide59
Air Bleeding
The major causes of problems in a Hydronic system is
air being trapped in the system.
The air is trapped inside the lines & emitters while being installed or when any alterations that have been done to the system.
The air is circulated throughout the system and gets
trapped at any high points & at the emitters.
The air causes the
cold emitters
& must be allow to escape .
Bleed plugs
are installed by the installer
at the top of a radiator
to allow air to be released .
A special square ended key or screw driver is used to open the bleeder. Slide60
Air Bleeding
Automatic air bleeders
should be installed at the highest point of the system .
As air travels through the system it will always rise to the highest point, by installing an automatic bleed valve at this point you will effectively remove any circulating air .Avoid any dips or troughs in your pipe work as these will trap air in the system.A good method is to rise the pipe work to one area or high point and fall the pipe work downwards from there.Slide61
The End