Lesson 1Safe removal of old boiler and radiators: mechanical fixing removal, managing old materials (corroded steel) and temporary supportsDescribes safe shut-off and taking down old boilers and radiators, holding pipes, handling rusted bits, and sorting waste. Stresses safe lifting, dust control, and guarding finishes.
Supporting pipework before disconnectionRemoving wall fixings and bracketsHandling corroded radiators and sludgeProtecting floors and wall finishesSegregating scrap metal and wasteLesson 2Radiator installation and valve connections: pipework layout (surface vs concealed), valve orientation, compression vs soldered joints, supports and wall fixingExplains planning and fitting radiator pipes, picking joint methods, right valve angles, and good support and fixing for reliable work, quiet run, and long system life.
Surface vs concealed pipework routingValve orientation and flow directionCompression vs soldered joint selectionBracket positioning and wall anchorsAllowing for expansion and movementLesson 3Flue installation and commissioning: correct flue route, sealing, condensate trap, and flue performance checksDetails right flue paths, end places, and support, stressing sealed joints, condensate handling, and rule checks. Shows how to check flue strength, pull, and work during testing and hand-over.
Selecting compliant flue routeClearances to openings and boundariesSealing joints and wall penetrationsCondensate trap and fall requirementsFlue integrity and draft verificationLesson 4Gas connection and testing: sizing and routing gas pipe, torque and fitting standards, performing gas tightness test and documenting resultsCovers gas pipe sizing, paths, support, right fittings and torque, and tightness tests. Includes noting results, fixing test fails, and meeting gas safety rules.
Calculating gas pipe size and lossesRouting and supporting gas pipeworkApproved fittings and torque valuesTightness and let-by test stepsRecording and interpreting test dataLesson 5Boiler siting and mounting: wall-hung bracket installation, clearances, service access, condensate trap and correct fallDescribes picking good boiler spot, fixing wall brackets, lifting and hanging, and keeping spaces. Covers condensate trap link, pipe slope, and room for future service.
Assessing boiler location and clearancesFixing and leveling wall bracketLifting and hanging boiler safelyRouting condensate with correct fallMaintaining service access zonesLesson 6System filling, venting and pressurization: controlled fill, automatic air vents, manual venting sequence, setting system pressureExplains controlled filling, auto and manual air vents, right venting order, and cold fill pressure. Includes checks for trapped air and re-pressurising after first heat.
Pre-fill checks and valve positionsControlled filling rate and monitoringUsing automatic air vents effectivelyManual venting of radiators and coilsSetting and verifying cold fill pressureLesson 7Documentation and labeling: labelling valves, providing operation stickers, recording pressures, serial numbers, and commissioning readingsExplains labelling valves, circuits, appliances, user stickers, and noting pressures, serials, combustion results for clear, checkable install records.
Labelling isolation and control valvesCircuit and radiator identification tagsUser operating and safety stickersRecording serials and set pressuresStoring commissioning certificatesLesson 8Isolation and safe draining of existing system: sequence to isolate gas, water, electricity; draining procedures and safe disposal of waterCovers safe shut-off of gas, water, power before work, step-by-step draining, trapped water, and green disposal, without harming property or parts.
Locking off gas and verifying isolationIsolating cold feed and heating circuitsElectrical lockout and safe confirmationLocating and opening drain-off pointsCollecting and disposing of waste waterLesson 9Commissioning and first fire: purge procedure for air removal, low-load start, checking flow temperatures and return temperatures, flue gas analysis basics and CO checkGuides first boiler light, purging air from gas and water, low-load start, steady temps. Introduces basic flue gas check, CO test, and noting readings.
Filling, venting, and leak recheckGas purge and ignition sequenceLow-load warm-up and balancingMeasuring flow and return temperaturesBasic flue gas and CO checksLesson 10Pre-work checks and preparations: site survey, locating services, permits, notifications to gas supplier/authority where requiredFocuses on before-work tasks like site check, finding hidden services, ventilation access, permits. Ensures safe, legal work with little bother.
Reviewing drawings and specificationsLocating gas, water, and cablesAssessing ventilation and access routesConfirming permits and notificationsPlanning waste removal and storageLesson 11Plumbing and hydraulic connections: flow/return connection, system filling loop, fitting expansion vessel and safety valves, integrating magnetic filter and non-return valveHandles water links to boiler, flow return, fill loop, expansion vessel, safety valves, filters, check valves. Stresses right way round, shut-off, service access.
Connecting primary flow and returnInstalling filling loop and isolationMounting expansion vessel correctlyFitting safety valve and discharge pipeIntegrating filter and non-return valve
