BRITISH STANDARD BS 779:1989

Incorporating
Amendment No. 1

Specification for

Cast iron boilers for

central heating and
indirect hot water
supply
(rated output 44 kW
and above)

UDC 697.3:696.4:621.1:669.13
BS 779:1989

Committees responsible for this

British Standard

The preparation of this British Standard was entrusted by the Refrigeration,

Heating and Air Conditioning Standards Policy Committee (RHE/-) to
Technical Committee RHE/10, upon which the following bodies were
represented:

Associated Offices Technical Committee

Association of British Solid Fuel Appliances Manufacturers
Association of Shell Boilermakers
Boiler and Radiator Manufacturers’ Association Limited
British Coal Corporation
British Combustion Equipment Manufacturers’ Association
British Foundry Association
British Gas plc
Building Services Research and Information Association
Chartered Institution of Building Services Engineers
Department of Energy (Energy Efficiency Office)
Department of the Environment (Property Services Agency)
Domestic Solid Fuel Appliances Approval Scheme
Engineering Equipment and Materials Users’ Association
Health and Safety Executive
Institute of Domestic Heating Engineers
Institution of Chemical Engineers
Society of British Gas Industries
Waterheater Manufacturers’ Association

This British Standard, having

been prepared under the
direction of the Refrigeration,
Heating and Air Conditioning
Standards Policy Committee,
was published under the
authority of the Board of BSI
and comes into effect on
31 October 1989

© BSI 07-1999

First published February 1938 Amendments issued since publication

First revision July 1961
Second revision January 1976 Amd. No. Date of issue Comments
Third revision
7704 July 1993 Indicated by a sideline in the margin
The following BSI references
relate to the work on this
standard:
Committee reference RHE/10
Draft for comment 88/70535 DC

ISBN 0 580 17835 8

 BS 779:1989

Contents

Page
Committees responsible Inside front cover
Foreword ii
Section 1. General
1.1 Scope 1
1.2 Definitions 1
1.3 Performance 1
Section 2. Materials
2.1 Boiler pressure bearing parts 2
2.2 Refractory materials 2
2.3 Pulling-up bolts and tie rods 2
Section 3. Construction and workmanship
3.1 Testing 3
3.2 Repairs to castings by welding 3
3.3 Boiler openings 3
3.4 Dampers, doors and observation ports 3
Section 4. Mountings and fittings
4.1 Safety valves 5
4.2 Vent pipes 5
4.3 Emptying valves or cocks 6
4.4 Pressure gauges 6
4.5 Temperature gauges 6
Section 5. Combustion equipment
5.1 General 7
5.2 Solid fuel firing 7
5.3 Liquid fuel firing 7
5.4 Gas firing 7
Section 6. Automatic controls and electrical installation
6.1 Automatic controls 9
Section 7. Inspection and marking
7.1 Inspection 10
7.2 Marking 10
Appendix A Installation provisions 11
Appendix B Electrical installation 11
Appendix C Information to be supplied by the purchaser 13
Appendix D Information to be supplied by the manufacturer 13
Figure 1 — Heating system categories 8
Table 1 —Tapping sizes for safety valves 5
Table 2 — Sizes for safety valves (open vented systems only) 5
Table 3 — Tapping sizes for vent pipes 6
Table 4 — Minimum open vent pipe sizes 11
Publications referred to Inside back cover

© BSI 07-1999 i
BS 779:1989

Foreword

This British Standard has been prepared under the direction of the Refrigeration,
Heating and Air Conditioning Standards Policy Committee. It supersedes
BS 779:1976 which is now withdrawn. As well as re-editing and updating the
information to comply with current practice the requirements for type, works and
site testing have been clarified together with a reappraisal of the parameters for
test pressures and specification of materials of construction.
Appendix A includes information on those items which are essential inclusions on
a boiler plant but which may not necessarily form part of the supply by the
manufacturer.
Appendix B gives recommendations for electrical wiring of boiler installations;
however reference should be made to the 15th Edition of the Institution of
Electrical Engineers (IEE) “Regulations for Electrical Installations” for electrical
distribution in buildings and to the appropriate British Standards for the
equipment, cables, controls and components of an electrical installation.
It has been assumed in the drafting of this British Standard that the execution of
its provisions is entrusted to appropriately qualified and experienced people.
This standard forms one of a series of standards used in boiler construction, the
others being:
BS 855, Specification. Welded steel boilers for central heating and indirect hot
water supply (rated output 44 kW to 3 MW).
BS 1113, Specification for design and manufacture of water-tube steam generating
plant (including superheaters, reheaters and steel tube economizers).
BS 1894, Specification for electrode boilers of riveted, seamless, welded and cast
iron construction for water heating and steam generating.
BS 2790, Specification for design and manufacture of shell boilers of welded
construction.
BS 1971, Specification for corrugated furnaces for shell boilers.
This standard is included in the list of “Standards significant to health and safety
at work”1) published by the UK Health and Safety Executive (HSE) and is also
referred to by HSE in giving guidance.
In order not to conflict with the work of CEN in the field of oil fired boilers it has
been necessary to restrict the scope of this standard. However, pending the
publication of a European standard covering oil fired boilers up to 300 kW rated
heat output, users of this standard will find the information contained useful
when determining the specific requirements for such boilers.
A British Standard does not purport to include all the necessary provisions of a
contract. Users of British Standards are responsible for their correct application.
Compliance with a British Standard does not of itself confer immunity
from legal obligations.

Summary of pages
This document comprises a front cover, an inside front cover, pages i and ii,
pages 1 to 14, an inside back cover and a back cover.
This standard has been updated (see copyright date) and may have had
amendments incorporated. This will be indicated in the amendment table on the
inside front cover.

1) Available from the HSE through any of its offices.

ii © BSI 07-1999
 BS 779:1989

Section 1. General

1.1 Scope 1.2.3

1.1.1 This British Standard specifies requirements
for the design and construction including materials,
workmanship, inspection testing and marking of
cast iron boilers for central heating and indirect hot
water supply.
1.1.2 This standard applies to boilers for hot water
with rated heat output of 44 kW or above when used
with one or more of the following fuels:
a) smokeless solid fuels, e.g. furnace coke, low
temperature coke or anthracite;
b) bituminous coal fired by means of mechanical
stokers;
c) gaseous fuels of the 2nd and 3rd families
(see BS 4947);
and with rated heat output of 300 kW and above
when used with liquid fuels of the classes specified
in BS 2869.
1.1.3 This standard does not apply to steam boilers
or boilers pressurized by steam.
NOTE The titles of the publications referred to in this standard
are listed on inside back cover.
1.2 Definitions
For the purposes of this British Standard the
definitions given in BS 1179:1967, BS 1179-6:1980
and BS 1846 apply, together with the following.
safety valve
a spring-loaded automatic valve fitted to a boiler for
relieving the build-up of excess pressure by means of
discharge to atmosphere
1.2.4
inspecting authority
the body or association which checks the design,
materials and construction to ensure that they are
in accordance with this standard
1.3 Performance
The manufacturer shall declare the rated heat
output in kW and the efficiency of the boiler for the
appropriate fuel or fuels under normal conditions of
operation. The declared values shall be based on
values determined in accordance with BS 7190 or
BS 845-1, when the boiler is fired with combustion
equipment either supplied or recommended by the
manufacturer (see Appendix D). For combustion
equipment giving cyclic variations in heat release
rate due to periodic refuelling or de-ashing
operations, the period for which the rated output is
obtainable shall also be stated.
NOTE 1 The manufacturer should supply, on request, a copy of
the boiler performance test report (see Appendix D).
NOTE 2 The purchaser should disclose to the manufacturer, at
the time of enquiry, the information listed in Appendix C.

1.2.1
design pressure
the pressure used for safety valve sizing (in bar)2).
It is equivalent to the works test pressure specified
in 3.1.3.1 divided by 1.8. It is also the maximum
permissible setting pressure of any safety valve
(see 4.1.2.1)
1.2.2
operating pressure
the maximum pressure measured in the boiler
under normal operating conditions
NOTE The pressure will be dependent on static head,
pressurizing equipment (where fitted) and the effect of the
circulating pump. The static head, and pressurizing equipment
in the case of pressurized systems, determine the maximum
water temperature permissible at the point of lowest pressure.
This temperature is not to exceed a predetermined level below
the saturated steam temperature for the lowest pressure
(see 6.1.2).

2) 1 bar =105 N/m2 =105 Pa.

© BSI 07-1999 1
BS 779:1989

Section 2. Materials

2.1 Boiler pressure bearing parts 2.2 Refractory materials

The minimum grade of grey cast iron used for the Refractory materials used in the construction and
manufacture of the boiler pressure bearing parts assembly of the boiler or boiler components shall be
shall be grade 180 of BS 1452. suitable for the temperatures to which they will be
NOTE 1 As an alternative to grey cast iron a grade of spheroidal subjected when the boiler is fired and operated as
graphite or nodular graphite cast iron complying with BS 2789 intended by the manufacturer.
may be used at the discretion of the manufacturer.
NOTE 2 The chemical composition of the cast iron is to be at the
discretion of the manufacturer, but should in general be in
2.3 Pulling-up bolts and tie rods
accordance with the guidance given in Appendix A of Pulling-up bolts and tie rods shall be of steel having
BS 1452:1977.
a minimum tensile strength of 430 N/mm2 and in
The tensile test frequency for grey cast iron castings which neither sulphur nor phosphorus content
shall be as given in BS 1452, except in the event of exceeds 0.05 %. They shall be threaded in
metal being transferred from small melting units accordance with BS 3643-1 and BS 3643-2 or
and accumulated as batches in large holding alternatively in accordance with BS 1580.
furnaces, when at least one test bar representative
of that sample shall be cast.
The tensile test frequency for spheroidal or nodular
graphite cast iron castings shall be as given in
BS 2789.

2 © BSI 07-1999

Section 3. Construction and workmanship
3.1 Testing
NOTE It is important that erection and site testing is in
accordance with A.1; see also BS 6880-3 for low temperature hot
water heating systems.
3.1.1 General
Type tests, carried out before production, on boilers
or boiler sections shall be in accordance with 3.1.2
and production tests on these items shall comply
with 3.1.3.
3.1.2 Type tests
3.1.2.1 At least one of each type of section of the
same design, series and material, shall be subjected
to a type test and shall withstand for a period
of 30 min hydraulic pressure of 14 bar or four times
the maximum operating pressure declared by the
manufacturer, whichever is the greater. This test
shall be repeated at least annually. Sections used in
this test shall be discarded.
3.1.2.2 At least one assembled boiler of each design,
made up to the maximum number of sections offered
by the manufacturer, shall be subjected to a type
test and shall withstand for a period of 30 min a
hydraulic pressure of 10.5 bar or twice the
maximum operating pressure declared by the
manufacturer plus 3.5 bar, whichever is the
greater. Sections used in this test shall be discarded.
3.1.3 Production tests
3.1.3.1 Each boiler casting or boiler section shall
withstand a hydraulic pressure test of 7 bar or twice
the maximum operating pressure, declared by the
manufacturer, whichever is the greater. The
duration of the pressure test shall be 1 min plus the
time taken to complete a visual inspection. There
shall be no signs of leakage or weakness.
3.1.3.2 Where the boiler sections have been tested in
accordance with 3.1.3.1, the boiler, if finally
assembled at the manufacturer’s works, shall be
tested at a pressure of 1.5 times the maximum
operating pressure declared by the manufacturer,
for sufficient time to enable a full visual inspection
to be made, and in any case for not less than 5 min.
The boiler, during this test, shall show no signs of
leakage or weakness.
3.2 Repairs to castings by welding
The welding of defects in castings in positions
subjected to pressure, or of lugs securing sections,
shall not be permitted.
© BSI 07-1999
BS 779:1989
3.3 Boiler openings
3.3.1 All boilers shall have suitable openings for
flow and return connections and for mountings and
fittings as specified in section 4.
3.3.2 Openings for screwed connections or fittings
shall have threads in accordance with BS 21.
The minimum length of internal thread into which
connections or fittings are screwed shall be in
accordance with 5.1 of BS 21:1985.
NOTE Mountings with male ends not exceeding R3 size
(in which the screwed portion is an integral part of the mounting)
and screwed pipe connections not exceeding R3 size may be
screwed into tapped bosses on the boiler.
3.3.3 Adequate access shall be provided to permit
the cleaning of combustion surfaces and flue ways.
3.4 Dampers, doors and observation
ports
3.4.1 Solid fuel boilers
3.4.1.1 Air control damper. In order to control the
combustion of the fuel in the boiler at varying rates
of burning, boilers which are hand-fired shall be
provided with an adjustable air inlet below the
grate.
3.4.1.2 Secondary air. Provision shall be made for
the admission of secondary air above the fuel bed for
hand fired boilers.
3.4.1.3 Doors at front and above grate level. The
clearance between any door and the surface against
which it closes shall not exceed 1 mm except in the
case of firing doors for hand fired boilers for which
the clearance shall not exceed 2 mm.
3.4.1.4 Flue or chimney damper. Hand-fired boilers
shall be fitted with a sliding or butterfly damper at
the outlet.
Sliding dampers shall be clearly graduated to
facilitate accurate setting. Butterfly dampers shall
have a handle, indicating clearly the position of the
blade, which is to be capable of being held in position
to prevent movement. Dampers of either type shall
be so shaped that when in the fully closed position
the free area to permit the passage of flue gases is
not less than 12 % of the area of the flue in the plane
of the damper.
In the case of boilers supplied for automatic stoking,
where a damper is fitted, provision shall be made for
it to be locked in the correct position.
3
BS 779:1989

3.4.2 Boilers for gaseous or liquid fuels

3.4.2.1 A boiler using gaseous or liquid fuels shall
not be fitted with a manually-operated damper. In
the case of a solid fuel boiler being converted to use
gaseous or liquid fuel, any damper shall be removed
or permanently fixed in the open position.
3.4.2.2 Any automatic flue or combustion air
damper fitted on a boiler using gaseous fuel shall
comply with the requirements of BS 5978 and
BS 5885 as applicable.
3.4.2.3 Any automatic flue or combustion air
damper fitted on a boiler using liquid fuel shall be
provided with interlocking equipment to prevent
the combustion equipment from operating if the
damper is not in the correct position.
NOTE In the case of combustion equipment supplied or
recommended by the boiler manufacturer, provision should be
made for flame observation during the commissioning operation.

4 © BSI 07-1999
 BS 779:1989

Section 4. Mountings and fittings

4.1 Safety valves Table 2 — Sizes for safety valves

(open vented systems only)
4.1.1 Tappings for safety valves
Valve rating Nominal size Minimum flow
A tapping for a safety valve shall be provided on the area A
boiler of a size not less than that specified in
Table 1. For a sectional boiler, the tapping size shall kW mm mm2
be that appropriate to the maximum number of 44 to 264 20 314
sections offered by the manufacturer. For boilers 265 to 352 25 491
rated above 3 MW output the tapping size for safety 353 to 440 32 802
valves shall be calculated in accordance with 4.1.3. 441 to 528 40 1 135
4.1.2 Provision of safety valves 529 to 732 50 2 050
733 to 1 142 65 3 210
4.1.2.1 Where the safety valve (or valves) is 1 143 to 1 640 80 4 540
supplied or fitted by the boiler manufacturer it shall
1 641 to 3 000 2 × 80 8 180
be in accordance with BS 6759-1, sized and fitted in
accordance with 4.1.2.2 and 4.1.3 and set to lift at a Qv = 2(0.329pAKdr) (1)
pressure not higher than the boiler design pressure
(see 1.2.1). where
NOTE 1 It is important that, when safety valves are fitted by Qv is the rating of the safety valve, in kW;
other than the boiler manufacturer, the safety valves meet the
requirements of 4.1.2. p is the maximum absolute relieving pressure,
NOTE 2 For recommendations regarding the installation [(boiler design pressure × 1.10) + 1], in bar;
provisions for safety valves see A.2.
A is the minimum flow area, in mm2;
Table 1 — Tapping sizes for safety
valves Kdr is the derated coefficient of discharge.

Rated output Nominal tapping size NOTE This equation is based on equation 18 of
BS 6759-1:1984, but includes 100 % vent allowance for vent
kW sizes in accordance with Table 3.
Up to 264 R¾ 4.1.3.3 For unvented hot water systems, the
265 to 352 R1 minimum flow area, A, of safety valves shall be
353 to 440 R 1¼ determined using equation (2).
441 to 528 R½ Qv = 0.329pAKdr (2)
529 to 732 R2
733 to 1 142 R 2½ where
1 143 to 1 640 R3 Qv is the rating of the safety valve, in kW;
1 641 to 3 000 2×R3 p is the maximum absolute relieving pressure,
4.1.2.2 The safety valve (or valves) shall be fitted [(boiler design pressure × 1.10) + 1], in bar;
vertically and attached directly to the boiler or, if A is the minimum flow area, in mm2;
this is impracticable, by means of the shortest Kdr is the derated coefficient of discharge.
possible straight length of pipe arranged vertically
and having an internal diameter no less than the 4.1.4 Setting of safety valves
bore of the valve, or an internal cross-sectional area Safety valves shall be set at the boiler operating
not less than the aggregate area of all valves pressure + 0.7 bar. In no case shall the safety valve
mounted upon it, and used solely for the purpose be set higher than the design pressure of the boiler.
without any intervening valve or cock.
4.1.3 Sizing 4.2 Vent pipes
4.1.3.1 The nominal bore of the safety valve shall be Boilers shall be provided with a tapping for a vent
not less than 20 min. pipe unless the flow pipe connection is located in a
4.1.3.2 For open vented hot water systems, the sizes position at the top of the boiler that permits
of safety valves shall be not less than those given in satisfactory venting (see A.3).
Table 2 or for valve sizes not covered by Table 2, the Any tapping for a vent pipe shall be of a size not less
minimum flow area A shall be determined from than that specified in Table 3.
equation 1.

© BSI 07-1999 5
BS 779:1989

Table 3 — Tapping sizes for vent pipes 4.4 Pressure gauges

Rated output Designated tapping size The boiler shall be provided with a tapping for a
kW pressure gauge.
Below 60 R1 NOTE Where a pressure gauge is provided it should be so sited
that it is clearly visible and can be replaced without draining the
60 to 150 R 1¼ boiler system. The gauge should indicate the pressure in bars or
151 to 300 R 1½ metres head of water.
301 to 600 R2
4.5 Temperature gauges
For rated outputs above 600 kW the designated
tapping sizes for vent pipes (to the nearest R size) The boiler shall be provided with a tapping for a
shall be calculated as follows: temperature gauge.
R size = 0.083 ×ÆQ NOTE Where a temperature gauge is provided it should be
fitted at or near the boiler outlet and should indicate the
where temperature of the boiler flow water in degrees Celsius. The
temperature gauge should be so sited that it is clearly visible and
Q is the boiler rated heat output (in kW). can be replaced without draining the boiler system.
NOTE For recommendations regarding the installation
provisions for vent pipes see A.3.

4.3 Emptying valves or cocks

The boiler shall be provided with a tapping,
connected to the lowest water space for the fitting of
an emptying valve or cock.
NOTE The size of the tapping should be chosen having regard
to the water content of the boiler. The time required to empty the
boiler should not exceed 30 min.

6 © BSI 07-1999
 BS 779:1989

Section 5. Combustion equipment

5.1 General 5.3 Liquid fuel firing

When the boiler combustion equipment is supplied
by the boiler manufacturer it shall comply
with 5.2, 5.3 or 5.4, as appropriate.
NOTE It is important that, when combustion equipment is
supplied by other than the boiler manufacturer, the combustion
equipment is in line with the boiler manufacturer’s
recommendations and complies with the appropriate standards.
5.2 Solid fuel firing
Equipment using underfeed stokers shall comply
with BS 749.
Liquid fuel firing equipment shall comply with
BS 799-3 and BS 799-4.
NOTE For recommendations regarding oil firing installations
reference should be made to BS 5410-2.
5.4 Gas firing
Gas firing equipment shall comply with BS 5978
and BS 5885, as appropriate.

© BSI 07-1999 7
BS 779:1989

NOTE The figures show the basic elements which classify the system. Details of pumps, valves and tanks in the make-up supply
will vary according to the system design and are not shown.
Figure 1 — Heating system categories

8 © BSI 07-1999

Section 6. Automatic controls and electrical
installation
NOTE The installation of electrical wiring for electrical
equipment on boilers complying with this standard, and
associated electrical equipment, e.g. motors, mains voltage
operated controls and components, should be in accordance with
the recommendations of Appendix B.
6.1 Automatic controls
6.1.1 General
Boiler automatic controls when supplied by the
boiler manufacturer either separately or as an
integral part of the boiler shall comply with 6.1.2
to 6.1.4.
NOTE 1 When supplied by other than the boiler manufacturer
it is important that the automatic controls comply with 6.1.
NOTE 2 Unless close manual supervision can be guaranteed at
all times the boiler is in service, it is essential for safety reasons
that at least the following automatic controls are fitted on the
boiler, or as part of the firing equipment, or on the system, as
appropriate.
For convenience in detailing the requirements for
automatic controls, hot water boiler systems shall
be classified into four categories (see Figure 1):
Category A — Static head systems open to
atmosphere;
Category B — Closed pressurized systems with
separate gas cushioning
pressurizing vessels and
provision for make-up water;
Category C — Sealed pressurized systems with
separate diaphragm or bladder
type pressurizing vessels and
provision for make-up water;
Category D — Continuously pumped
pressurized systems with
provision for make-up water.
6.1.2 Basic controls
In the event of the following circumstances arising,
automatic controls shall shut off the fuel supply to
boilers using gaseous or liquid fuels, and shut off the
air supply and, if necessary, the fuel supply to firing
equipment using solid fuels:
a) failure of the main flame or pilot flame on
boilers using gaseous or liquid fuels;
b) failure to ignite the fuel within a
predetermined time on boilers using gaseous or
liquid fuels;
c) failure of a forced or induced draught fan or of
an automatic flue damper;
d) when the temperature of the water at or near
the boiler flow outlet rises to a preset value at
least 17 °C below the temperature of saturated
steam which corresponds to the pressure at the
highest point in the circulating system;
e) when the water level in the pressurizing
equipment in a category B system falls to a preset
value below the normal operating level;
© BSI 07-1999
BS 779:1989
f) when the pressure in category B, C or D system
falls to a predetermined pressure below the
specified operating pressure;
g) when the pressure in a category C system
increases to within 0.35 bar of the safety valve
set pressure.
In the case of a) and b) the control provided shall be
of the lock-out type requiring manual resetting.
NOTE In the case of e) this should also cause an audible alarm
to sound.
In f) the predetermined pressure shall be at a level
which will ensure that the water does not reach
boiling point in any part of the system whilst the
working temperature is maintained.
In g) the safety valve set pressure shall be such that
it will not allow the design pressure of any part of
the boiler to be exceeded.
6.1.3 Independent overriding controls
Automatic controls for all categories of boilers shall
include independent overriding controls which cut
off the fuel supply to oil or gas burners or cut off the
air supply and, where required, the fuel supply to
solid fuel firing equipment in the event of one or
more of the following circumstances arising:
a) when the temperature of the water at or near
the boiler flow outlet rises to a predetermined
temperature providing a margin below the
temperature of saturated steam corresponding
with the pressure at the highest point of the
circulating system above the boiler;
b) when the water level in the pressurizing
equipment of a category B system falls to a
predetermined level, below the normal operating
level, lower than that indicated in 6.1.2 e).
The controls in the case of a) and b) shall lock out the
firing equipment and be of a type which requires
manual resetting.
In the case of a) for oil or gas fired boilers the margin
shall be at least 6 °C and for solid fuel fired boilers
be at least 10 °C.
NOTE In the case of solid fuel firing, the heat should be
dissipated from the fuel bed as quickly as possible. The means of
achieving this will depend upon the type of installation
concerned.
6.1.4 Boilers using mixing valves
Where mixing valves provided by the boiler
manufacturer are used to blend return water with
flow water, solid fuel fired boilers shall serve at least
one circuit which is independent of the mixing valve
and which is capable of dissipating residual heat in
the fuel bed when the mixing valve closes against
the boiler, e.g. during mild weather, otherwise a
heat dissipation thermostat which will override the
mixing valve control in the event of excessive
temperature rise, shall be fitted in the boiler flow
line.
9
BS 779:1989

Section 7. Inspection and marking

7.1 Inspection c) rated continuous output, with the number of

Each boiler or boiler section shall be hydraulically
tested in the presence of a responsible
representative of the manufacturer and/or the
inspecting authority.
NOTE The manufacturer should furnish the purchaser with a
certificate for such a test when required (see Appendix D).
7.2 Marking
Each boiler complying with this standard shall be
durably and clearly marked with the following
particulars:
a) manufacturer’s identification mark;
b) the number and date of this British Standard,
i.e. BS 779:19893);
sections to which the output refers;
d) the name and address in the UK of the
manufacturer or of his agent (where applicable);
e) the boiler type, name and or serial number,
with identification of more detailed variations or
modifications by, for example, suffix or prefix,
serial number, batch number or date of
manufacture, etc.;
f) the maximum permissible water-side working
pressure (in bar);
g) the maximum permissible flow temperature;
h) whether boiler combustion equipment is
supplied.

3) Marking BS 779:1989 on or in relation to a product represents a manufacturer’s declaration of conformity, i.e. a claim by or on
behalf of the manufacturer that the product meets the requirements of the standard. The accuracy of the claim is therefore solely
the responsibility of the person making the claim. Such a declaration is not to be confused with third party certification of
conformity, which may also be desirable.

10 © BSI 07-1999

Appendix A Installation provisions
A.1 Erection and site tests
A.1.1 Boilers when erected from sections in
accordance with the manufacturer’s instructions
should be capable of withstanding for a period
of 30 min hydraulic pressure of 1.5 times the
maximum operating pressure (see 3.1.3.2).
A.1.2 Before this test is carried out, appropriate
steps should be taken to isolate the boiler from any
parts of the system that are not designed to
withstand the specified test pressure.
A.1.3 The manufacturer should supply, on request,
leading dimensions for installation purposes
(see Appendix D).
A.2 Safety valves
A.2.1 Where the boiler is connected to a system not
capable of withstanding the boiler design pressure,
provision should be made to protect the system at its
own permissible working pressure, since the safety
valve is fitted to protect the boiler only and full
discharge will only be achieved at its maximum
design pressure.
A.2.2 In the case of a boiler plant consisting of more
than one boiler, providing each boiler cannot be
isolated from the common flow, one safety valve and
one vent pipe located in the common flow will suffice
provided that they are sized to suit the full capacity
when all units are operating together.
A.2.3 The discharge pipe from the safety valve
should be self draining and terminate in a visible
position where discharge will not result in hazard to
any person.
A.3 Vent pipes for open vented systems
A.3.1 Single boiler installations should be fitted
with an open vent pipe which rises continuously by
the shortest practicable route to the venting point.
A.3.2 Multiple boiler installations should be fitted
with either a common open vent pipe, or individual
open vent pipes rising continuously by the shortest
practicable route to the venting point.
When vent pipes are connected to a common vent
pipe, the cross-sectional area should be equal to the
total cross-sectional area of the individual pipes.
A.3.3 Each vent pipe should be sized according to
the maximum rated output of the boiler(s) it is
intended to protect. The minimum pipe sizes to be
used for rated outputs up to 600 kW should be in
accordance with Table 4.
© BSI 07-1999
BS 779:1989
Table 4 — Minimum open vent pipe sizes
Rated output Minimum bore Nominal sizea
kW mm DN
below 60 25 25
60 to 150 32 32
151 to 300 38 40
301 to 600 50 50
a
Steel pipe sizes complying with medium or heavy quality of
BS 1387.
For rated outputs above 600 kW, the minimum
cross-sectional area of the vent pipe(s) bore,
A (in mm2), should be calculated as follows:
A = 3.5 × Q (3)
where
Q is the boiler rated heat output (in kW).
A.3.4 Vent pipes should not be fitted with isolating
valves. Three way escape valves of the type ensuring
flow to vent or drain with no possibility of blocking
in intermediate positions may be used.
Appendix B Electrical installation
B.1 General
Any fixed electrical installation within a building or
fixed structure, housing a boiler constructed in
accordance with this standard, should be designed
and installed in accordance with the current edition
of the Institution of Electrical Engineers
“Regulations for Electrical Installations” where
these apply. Although directed at fixed installations
in buildings these regulations may provide guidance
on wiring of electrical equipment on boilers. In
situations where these Regulations do not apply,
then appropriate standards of design and
installation should be employed to ensure an
equivalent standard of electrical safety.
B.2 Environment
B.2.1 All insulation, wiring, electrical accessories
and components should be so selected and installed
as to be suitable for the temperatures, dusts, and
degrees of moisture likely to be encountered when in
use.
B.2.2 All vertical ducts or enclosed trunkings,
containing electrical wiring, which exceed 5 m in
length should be fitted with internal barriers to
prevent air at the top of the duct reaching
unacceptably high temperatures.
B.2.3 All wiring, insulation, electrical accessories
and components should be protected from damage
due to the ingress of oils, water or other matter.
11
BS 779:1989
B.2.4 All wiring, insulation, electrical accessories
and components should be protected against
damage due to impact, abrasion or chafing.
B.2.5 Rubber insulation should not be used on firing
equipment, or where oil contamination is
foreseeable, due to the deleterious effects of heat
and oil.
B.2.6 Where vibration is present, mineral insulated
cables should-only be used after careful
consideration.
Appropriate protective measures against the effects
of vibration on these cables should be taken where
they are installed.
B.3 Accessibility
B.3.1 All electrical components should be installed
in such a manner that they may readily be removed
for testing, fault isolation, maintenance purposes, or
replacement. The installation should be such as to
require the minimum dismantling of other parts.
B.3.2 All electrical controls should be installed such
that they are easily accessible at all times to those
persons requiring such access.
B.3.3 Where firing controls or equipment are
required to be opened for maintenance or inspection,
suitable insulated flexible cables enclosed in flexible
conduit should be used.
B.4 Transient overvoltages
The levels of transient overvoltage need to be
assessed and the necessary electrical protective
measures taken particularly where
mineral-insulated cables are used.
B.5 Wiring installations
B.5.1 All electrical wiring should be adequately
supported throughout its length.
B.5.2 Wiring should not be secured to removable
inspection or enclosure panels.
B.5.3 All wiring should be installed clear of abrasive
surfaces, rough edges and hot surfaces.
B.5.4 All wiring should be provided with further
mechanical protection where necessary. This may
take the form of trunking or conduit
(rigid or flexible).
B.5.5 All bends in wiring should comply with the
recommendations of the wiring manufacturer with
regard to minimum radius of bends.
B.6 Bonding, earthing and earth terminals
B.6.1 Any electrical component, other than a
class II or SELV component, associated with the
boiler is to be provided with an earth terminal and
be marked N or M.
12
B.6.2 The boiler installation is to be provided with a
main earthing terminal clearly marked N or M.
The marking should not be on components which
can be removed. Where necessary a copper earthing
bar is to be connected to this earthing terminal. The
terminal should be of sufficient size to cater for the
maximum earth fault current likely to flow in the
installation.
B.6.3 All component earthing terminals are to be
connected to the main earthing bar by the use of
single core insulated flexible cables with sheaths
coloured green and yellow. The terminations may be
lugs, spades or other appropriate methods of
termination, secured by nuts and bolts or other
proprietary fasteners.
B.6.4 All metal parts, frames, supports, enclosures,
covers, etc., of the boiler installation should be
bonded to each other and be connected to the main
earth terminal in such a manner as to ensure
efficient and effective earth continuity.
B.7 Testing
B.7.1 The complete wiring installation should be
tested for insulation resistance, polarity and earth
continuity. To measure insulation resistance a d.c.
voltage not less than twice the nominal voltage of
the circuit concerned (r.m.s. value for a.c. supplies)
is to be applied provided that the test voltage need
not exceed 500 V d.c. for installations rated up
to 500 V, or 1 000 V d.c. for installations rated
above 500 V up to 1 000 V. The insulation
resistance to earth should not be less than 1 M7
with all poles or phases bonded together. When
measurements are made between conductors or
poles the value of the insulation resistance is not to
be less than 1 M7.
The earth continuity resistance should be of such a
value that it will ensure correct operation of the
electrical protective device, e.g. fuse or
circuit-breaker, for any earth fault on the
installation.
B.7.2 All associated electrical equipment,
e.g. motors, mains operated controls and
components, should be tested to prove correct
operation and safety in use.
B.7.3 Any electrical components provided by and
assembled and connected by the boiler
manufacturer are to be tested to prove insulation
resistance, polarity and earth continuity in
accordance with B.7.1 after installation.
B.7.4 Where the purchaser/user of the boiler is
responsible for carrying out the electrical
installation, the boiler manufacturer should provide
detailed instructions as to how the installation is to
be made and provide a detailed test procedure in
order to prove the completed installation.
© BSI 07-1999

Appendix C Information to be
supplied by the purchaser
The following information is to be supplied by the
purchaser at the time of enquiry:
a) the required boiler output (kW);
b) the type of fuel;
c) the operating pressure and temperature;
d) electrical supply details;
e) any special specification requirements.
NOTE If the purchaser requires that the boiler is
independently inspected, the purchaser should indicate to the
Inspecting Authority any special statutory or other regulations
with which the boiler is required to comply.
© BSI 07-1999
BS 779:1989
Appendix D Information to be
supplied by the manufacturer
The following information is to be supplied, on
request, by the manufacturer:
a) a copy of the report of the boiler performance
test (see 1.3);
b) for boilers supplied without combustion
equipment, any relevant details or
recommendations regarding suitable combustion
arrangements (see section 5);
c) those leading dimensions associated with the
location, installation and fixing of the boiler
(see A.1);
d) a copy of the certificate of the hydraulic
pressure test or tests (see 7.1).
13
14 blank
 BS 779:1989

Publications referred to

BS 21, Specification for pipe threads for tubes and fittings where pressure-tight joints are made on the
threads (metric dimensions).
BS 749, Specification for underfeed stokers.
BS 759, Valves, gauges and other safety fittings for application to boilers and to piping installations for and
in connection with boilers.
BS 799, Oil burning equipment.
BS 799-3, Automatic and semi-automatic atomizing burners up to 36 litres per hour.
BS 799-4, Atomizing burners over 36 litres per hour and associated equipment for single and multi-burner
installations.
BS 845, Methods for assessing thermal performance of boilers for steam, hot water and high temperature
heat transfer fluids.
BS 845-1, Concise procedure.
BS 855, Specification. Welded steel boilers for central heating and indirect hot water supply
(rated output 44 kW to 3 MW).
BS 1113, Specification for design and manufacture of water-tube steam generating plant
(including superheaters, reheaters and steel tube economizers).
BS 1179, Glossary of terms used in the gas industry.
BS 1387, Specification for screwed and socketed steel tube and tubulars and for plain end steel tubes suitable
for welding or for screwing to BS 21 pipe threads.
BS 1452, Specification for grey iron castings.
BS 1580, Specification for Unified screw threads.
BS 1846, Glossary of terms relating to solid fuel burning equipment.
BS 1894, Specification for electrode boilers of riveted, seamless welded and cast construction for water
heating and steam generating4).
BS 1971, Specification for corrugated furnaces for shell boilers4).
BS 2789, Specification for spheroidal graphite or nodular graphite cast iron.
BS 2790, Specification for design and manufacture of shell boilers of welded construction4).
BS 2869, Fuel oils for non-marine use.
BS 3643, ISO metric screw threads.
BS 3643-1, Principles and basic data.
BS 3643-2, Specification for selected limits of size.

BS 4947, Specification for test gases for gas appliances.

BS 5410, Code of practice for oil firing.
BS 5410-2, Installations of 44 kW and above output capacity for space heating, hot water and steam supply
purposes.
BS 5885, Automatic gas burners.
BS 5978, Safety and performance of gas-fired hot water boilers (60 kW to 2 MW input).
BS 6759, Safety valves.
BS 6759-1, Specification for safety valves for steam and hot water.
BS 6880, Code of practice for low temperature hot water heating systems of output greater than 45 kW.
BS 6880-3, Installation, commissioning and maintenance.
BS 7190, Method for assessing thermal performance of low temperature hot water boilers using a test rig.

4)
Referred to in the foreword only.

© BSI 07-1999
BS 779:1989

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