Lesson 1Safe removal of old boiler and radiators: mechanical fixing removal, managing old materials (corroded steel) and temporary supportsDis describe safe isolation and dismantling of old boilers and radiators, including supporting pipework, handling corroded components, and segregating waste. E emphasize manual handling, dust control, and protection of 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 fixingDis explain how to plan and install radiator pipework, select suitable jointing methods, orient valves correctly, and apply proper support and fixing techniques to ensure reliable operation, quiet running, and long-term system durability.
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 checksDis detail correct flue routing, terminal siting, and support, with emphasis on sealed joints, condensate management, and compliance checks. E explain how to verify flue integrity, draft, and performance during commissioning and handover.
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 resultsDis cover gas pipe sizing, routing, and support, correct use of fittings and torque, and tightness testing. Include documenting results, dealing with test failures, and ensuring compliance with relevant gas safety standards.
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 fallDis describe selecting suitable boiler location, fixing wall brackets, lifting and hanging de appliance, and maintaining clearances. E cover condensate trap connection, pipe fall, and provision for future servicing and maintenance.
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 pressureDis explain controlled system filling, use of automatic and manual air vents, correct venting sequence, and setting cold fill pressure. Include checks for hidden air pockets and re-pressurization after initial heat-up.
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 readingsDis explain how to label valves, circuits, and appliances, provide user-friendly operating stickers, and record key data such as pressures, serial numbers, and combustion results to create clear, auditable installation record.
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 waterDis cover safe isolation of gas, water, and electrical supplies before work, stepwise draining of heating circuits, managing trapped water, and environmentally compliant disposal, while preventing damage to property and existing components.
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 checkDis guide de first firing of de boiler, including purging air from gas and water circuits, starting at low load, and stabilizing temperatures. E introduce basic flue gas analysis, CO checks, and documenting commissioning 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 requiredDis focus on pre-installation tasks, including site survey, identifying hidden services, assessing ventilation and access, and confirming permits or notifications. Ensure work can proceed safely, legally, and with minimal disruption.
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 valveDis address hydraulic connections to de boiler, including flow and return, filling loop, expansion vessel, safety valves, filters, and check valves. E emphasize correct orientation, isolation, and service access for each component.
Connecting primary flow and returnInstalling filling loop and isolationMounting expansion vessel correctlyFitting safety valve and discharge pipeIntegrating filter and non-return valve
