Discover how to install and commission a gas booster safely and effectively, with insights from the Secomak manual and expert tips to avoid common mistakes.
Installing a gas booster isn’t just a matter of connecting pipework and flicking a switch. In manufacturing environments where precision, safety, and compliance are non-negotiable, getting the installation and commissioning process right is essential. From powering industrial burners, running multiple boilers, or keeping production lines moving, a Bio, town and natural gas booster supports the consistent pressure you need to operate efficiently.
This guide takes you through every stage of a successful gas booster installation, from pre-install checks to commissioning, maintenance, and troubleshooting. We’ll walk through best practices, legal requirements, and common mistakes to avoid, making certain your system is standard-compliant.
1. Introduction: Why Getting Gas Booster Installation Right Matters
Installing a gas booster is a critical step in any system that relies on reliable, pressurised gas flow, especially in sectors like manufacturing, food processing, energy, and commercial heating. When done right, it supports stable performance, energy efficiency, and long-term system health. When done wrong, it can lead to compliance issues, safety risks, and costly downtime.
As discussed in Episode 1: How to Choose the Right Secomak Gas Booster, choosing the right gas booster is the first step. The next step, installing and commissioning it correctly, is where many systems either excel or fall short.
This guide provides practical, step-by-step advice on installing a gas booster, what to prepare before installation, and how to avoid common mistakes. It also explains why gas booster commissioning should be done by a qualified professional, how standards like IGEM UP/2 and BS 8487:2007 & 2013 affect your setup.
2. Understanding the Role of a Gas Booster
A gas booster is a critical component of equipment used to increase the pressure of gas in situations where the existing supply pressure is too low for the application. In many industrial and commercial settings, especially those involving high-output burners, boilers, or ovens, Bio, town or Natural gas arrives at a pressure that’s insufficient to meet system demands. That’s where a gas booster comes in, boosting outlet pressure to meet process requirements. Secomak specialises in centrifugal gas boosters engineered for durability and consistent output across a wide range of industrial uses. These boosters are commonly installed in systems supporting:
- Boiler installation and upgrade projects
- Industrial manufacturing lines with continuous thermal loads
- Process heating systems in food and energy sectors
- Industrial housing buildings (Apartments) converting from commercial to residential increase demand for gas
To explore the range of available models and specifications, visit our Gas Booster Product Page or browse the full Technical Data & Manual to find the right solution for your application.
Whether upgrading existing infrastructure or planning a new system, understanding the purpose and placement of a gas booster is the first step toward safe and efficient integration.
3. Who Can Install vs. Who Can Commission?
One of the most important yet often misunderstood aspects of gas booster installation is the distinction between installation and commissioning. While both are essential to getting your industrial gas booster operational, they must be performed by appropriately qualified professionals to maintain compliance, safety, and system reliability.
Installation: The Role of a Gas Safe Registered Engineer
Under the Gas Safety (Installation and Use) Regulations 1998 (GSIUR), only a Gas Safe registered engineer is legally permitted to carry out gas-related installation work in the UK. This includes the physical installation of the gas booster, connecting the pipework, wiring in the electrical supply, and making sure the unit is installed according to manufacturer guidance and national safety standards.
To verify a technician’s registration and certification, consult the UK Gas Safe Register.
During this phase, the installer should also confirm that all installation conditions comply with IGEM/UP/2 – the industry standard for installation pipework in gas systems, including proper spacing from the gas meter, correct routing of pipework, and allowance for ventilation and maintenance access.
Commissioning: The Role of a Certified Gas Booster Commissioning Engineer
Once the physical installation is complete, the system must be commissioned, a critical process that verifies performance, guarantees safety, and brings the booster officially into service.
A qualified gas booster commissioning engineer must carry out this task. This individual typically holds a Commercial Gas Safety certification (such as the Commercial Core Gas Safety certificate or equivalent) and is trained to perform essential start-up checks, pressure tests, and flow verifications in line with safety standards.
Commissioning is not just about turning the system on. A proper gas booster commissioning includes:
- Verifying the correct direction of rotation
- Testing for leaks and safe shut-off
- Checking inlet and outlet pressures
- Validating booster performance under load
- Logging results for safety and compliance documentation
This process must also align with BS 8487:2007 & 2013, the British Standard governing the design and construction of gas boosters used with combustion equipment. You can view the standard here.
Why the Distinction Matters
It’s not just about compliance. It’s about safety, performance, and peace of mind.
A common misconception is that one qualified engineer can perform the installation and commission. Unless that person holds installation and commissioning qualifications, this approach is non-compliant and may void your insurance or warranties.
When a Secomak-approved engineer completes your gas booster commissioning, you benefit from an extended 12-month warranty, giving you 24 months of coverage. More importantly, your system will be aligned with the latest UK regulations and tested for long-term reliability.
For tailored advice or to book a commissioning visit, Contact Secomak Support and speak directly with our technical team.
4. Pre-Installation Planning: What to Check Before You Begin
Before a gas booster installation begins, it’s vital to plan thoroughly. Inadequate planning can lead to regulatory failures , poor performance, or even system downtime. Here’s what you need to evaluate before the first bolt is tightened.
Site Suitability and Environmental Conditions
Start by assessing the location where your gas booster will be installed. It should be:
- Well-ventilated: Avoid enclosed or poorly ventilated spaces to prevent heat build-up and gas accumulation.
- Accessible: Ensure there’s enough room for both installation and future servicing. Leave space around the unit to remove access panels and safe working zones. 1 metre surrounding the gas booster is what we recommend.
- Within temperature and humidity limits: Most Secomak gas boosters operate best in ambient temperatures between 5°C and 40°C and at stable humidity. Avoid locations with high condensation or extreme heat.
Electrical Supply and Power Readiness
The booster requires a stable electrical supply, usually single-phase or 3-phase, and the power characteristics must match the specifications provided in the Technical Data & Manual. Important checks include:
- Verifying the correct voltage and phase orientation
- Ensuring the panel includes a soft-start or variable frequency drive (VFD) if specified
- Confirming availability of a suitable isolator switch within reach of the booster
Pipework & Mounting Requirements
Gas boosters must be mounted correctly and connected with appropriate fittings to reduce vibration and improve long-term reliability. Best practices include:
- Using flexible connectors on both the inlet and outlet sides
- Installing anti-vibration mounts under the base plate
- Verifying all pipework is correctly sized (DN50, DN80, etc.) and free from stress or misalignment
- Keeping a suitable distance from the gas meter to prevent pressure fluctuations (as per IGEM/UP/2)
These steps are essential for meeting gas booster installation best practices and maintaining compliance with BS 8487:2007 & 2013.
Notify the Gas Transporter (14-Day Rule)
In the UK, it’s a legal requirement to notify your local gas transporter at least 14 days before installing any equipment that could significantly increase demand on the gas network, including an industrial gas booster.
This gives them time to assess the local network capacity and avoid pressure drops for other users. Your Gas Safe installer should handle this, but it’s ultimately the system owner’s responsibility to verify it’s done.
Taking the time to plan your installation properly avoids costly delays and supports a safe, compliant setup. If you’re unsure about site readiness or system compatibility, don’t guess. Contact Secomak Support for guidance tailored to your application.
5. Step-by-Step Gas Booster Installation Process
Once the site is prepared and the right booster is selected, it’s time to begin installing the gas booster. Following the correct process helps guarantee that your system safe, efficient, and ready for certified commissioning. . The following steps align with Secomak’s Installation & Maintenance Manual, available for download via our Technical Data & Manual page, and reflect gas booster installation best practices.
1. Mounting the Unit
Begin by positioning the gas booster on a solid, level surface that meets the environmental conditions outlined in your pre-installation checks.
- Use anti-vibration mounts to reduce noise and wear. These should be correctly spaced to support the unit’s weight and vibration profile.
- Make sure the mounting location allows full access to the booster’s side panels and motor assembly.
Tip: Avoid recesses or corners where airflow could be restricted.
2. Connecting the Pipework
Next, connect the gas inlet and outlet pipework. This must be installed with flexible stainless-steel connectors to account for vibration and thermal expansion.
- Confirm that pipe sizes (e.g., DN50, DN80) match the model’s specifications.
- Avoid sharp bends, tight elbows, or excessive fittings.
- Maintain sufficient straight runs before and after the booster to support stable flow.
- Install a manual isolation valve upstream of the booster for safety and servicing.
- Do not install too close to the gas meter—IGEM/UP/2 spacing requirements must be met.
Important: All pipework must be leak-tested and purged before electrical work begins.
Purging is the process of safely removing air or inert gases from the pipework before introducing gas. This ensures that the gas entering the system is free from contaminants that could affect combustion or create unsafe mixtures. It’s a critical step to prevent air-gas explosions and must be done by a qualified professional using appropriate purging methods, in line with gas safety regulations.
3. Setting Up Electrical Connections
Safe and compliant electrical wiring is essential for reliable operation.
- A qualified electrician should hardwire the booster using an appropriately rated cable and a 3-phase supply (unless otherwise specified).
- Confirm the correct phase rotation to ensure the motor spins in the proper direction. Incorrect rotation can damage the unit and reduce airflow.
- Integrate a soft-start unit or VFD (Variable Frequency Drive) to reduce start-up stress on belts and bearings.
Tip: After initial wiring, bump-start the motor to verify rotation direction before finalising connections.
4. Fitting Accessories and Safety Components
Secomak gas boosters are equipped with components for safety and compliance, including:
- Inlet and outlet pressure switches to provide automatic safety cut-out in over- or under-pressure conditions (Unless otherwise specified)
- Non-return valves, required to prevent backflow
- Duty/standby switchovers for systems using twin boosters
Follow the guidance in your Secomak package documents to install these components in the correct sequence and location.
5. Final Checks Before Commissioning
- Verify all fittings are tight and sealed
- Confirm system ventilation and electrical isolator position
- Attach all required safety labels and data plates
- Complete a basic continuity and insulation resistance check
Once these steps are complete, your industrial gas booster is ready for commissioning. Remember: commissioning must be performed by a qualified gas booster commissioning engineer. These are not the same person unless they are certified for both roles.
Need help navigating the setup or unsure if your configuration meets the standards? Visit the Gas Booster Product Page or Contact Secomak Support to speak with our technical team.
6. Common Installation Mistakes (and How to Avoid Them)
Even with the best intentions, gas booster installation can go wrong if critical steps are overlooked. These mistakes may seem minor during setup, but they often lead to long-term performance issues, increased maintenance needs, or worse—non-compliance with regulations like IGEM/UP/2 and BS 8487:2007 & 2013. Below are the most common missteps Secomak engineers encounter in the field and how to avoid them.
Mistake 1: Undersized or Incorrect Pipework
The issue: Running pipework too small or installed too close to the gas meter can cause turbulence, restriction, or pressure fluctuations that reduce performance.
How to avoid it:
- Always size pipework based on flow rate and pressure requirements.
- Maintain an appropriate distance from the gas meter (in line with IGEM/UP/2).
- Use straight pipe runs before and after the booster to stabilise the flow.
Mistake 2: Poor Access for Maintenance
The issue: Installing the gas booster in a tight or inaccessible space makes future servicing difficult or unsafe.
How to avoid it:
- Leave a clear working area around the booster, especially near panels, belts, and motor assemblies.
- Provide safe access to electrical isolation and pressure switches.
- Consider long-term servicing needs when choosing the location. (1 metre)
Mistake 3: Skipping Vibration Isolation
The issue: Omitting anti-vibration mounts or flexible connectors causes excessive mechanical wear and increased noise and can lead to fatigue failure over time.
How to avoid it:
- Always use Secomak-recommended anti-vibration mounts during installation.
- Fit flexible pipework connectors to absorb movement and thermal expansion.
- Review the best practices for gas booster installation outlined in the Installation & Maintenance Manual.
Mistake 4: Incorrect Electrical Wiring or Phase Rotation
The issue: Wiring the booster incorrectly or with the wrong phase order will cause the motor to spin in reverse, drastically reducing airflow and possibly damaging the impeller.
How to avoid it:
- Use a qualified electrician with experience in 3-phase equipment.
- Check rotation direction with a bump-start test before running the system continuously.
- Confirm soft-start or VFD settings are configured correctly.
Mistake 5: Missing Safety Notices and Documentation
The issue: Forgetting to apply safety labels or omitting required documentation can cause inspection failures and legal issues.
Secomak supplies stickers on the booster. However, the commissioner could add additional stickers when commissioning is complete.
How to avoid it:
- Apply all stickers and data plates provided with your gas booster.
- Document the installation in your site’s gas safety log.
- Submit required forms to your gas transporter in advance, especially under the 14-day rule.
Avoiding these pitfalls isn’t simply about ticking boxes. It will help extend the life of your equipment, protect your people, and guarantee that commissioning goes smoothly the first time.
For tailored guidance or installation checks, reach out to the Secomak team via our Contact Support page.
7. Booster Commissioning: What It Involves and Why It Matters
Once your gas booster installation is physically complete, it must be commissioned before it can legally and safely enter service. This final stage is not optional. Gas booster commissioning validates system performance, confirms compliance with UK gas safety regulations, and verifies that the booster operates exactly as intended.
Commissioning is a legal requirement and must be carried out by a certified gas booster commissioning engineer, distinct from the installer unless they hold both credentials.
What Commissioning Involves
A typical commissioning process for a gas booster includes a sequence of controlled tests, inspections, and adjustments to verify system performance and safety. The engineer will:
- Check the direction of motor rotation to affirm that airflow is correct
- Test the gas inlet and outlet pressures under normal and peak load conditions
- Perform leak detection tests using manometers or electronic detectors
- Verify the operation of pressure switches (inlet, outlet, and cut-off)
- Validate airflow and flow rates against specification
- Inspect electrical connections and verify soft-start or VFD settings
- Test system shutdown and reset procedures
These checks confirm your system meets Secomak recommendations, installation specs, and safety codes.
The Role of Documentation
Accurate documentation is a core part of the commissioning process. The commissioning engineer will complete a commissioning certificate that includes:
- Pressure and flow readings
- Electrical configuration and checks
- Confirmation of correct rotation
- Leak test outcomes
- Compliance sign-off with IGEM/UP/2 and BS 8487:2007 & 2013
This certificate forms part of your system’s safety file and may be required by insurance providers or auditors.
If the booster is commissioned by Secomak or one of our approved partners, you’ll also benefit from:
- An additional 12-month extended warranty (totalling 24 months)
- Verification that your setup aligns with Secomak’s technical recommendations
- A direct support channel for future service and troubleshooting
To book a certified commissioning engineer or to discuss commissioning support, contact Secomak Support.
Why Commissioning Can’t Be Skipped
Skipping or rushing commissioning risks more than just poor performance. It could result in:
- Breach of Gas Safety (Installation and Use) Regulations 1998
- System damage due to incorrect flow direction or over-pressure
- Voided warranties and invalid insurance coverage
- Increased risk of gas leaks or incomplete combustion
- Missed opportunities for tuning system efficiency
Commissioning is the critical final step—don’t cut corners. Book an expert through Secomak Support.
8. FAQs: Installation & Commissioning Best Practice
Installing and commissioning a gas booster is a technical process, and it’s natural to have questions, especially if you’re managing a new system or upgrading an existing setup. Here are some of the most common queries we receive, along with best-practice guidance to help you stay compliant and confident.
Can I install and commission the gas booster myself?
Only if you’re qualified to do both.
You must be a Gas Safe registered engineer to perform any gas installation work in the UK. Gas booster commissioning requires a qualified commissioning engineer, typically certified in Commercial Gas Safety. If you don’t hold both qualifications, these responsibilities must be split between two professionals.
We recommend using one of our engineers for full compliance and warranty coverage. Contact Secomak to arrange this service.
What should my inlet and outlet gas pressures be?
This depends on your booster model and system requirements. As a general guideline:
- Inlet pressure depends on the pressure at your gas supplier meter, your appliance demand, and how many boilers you have installed.
- Outlet pressure is appliance demand dependant. This depends on the application and the outlet pressure required from the appliance.
Exact values for our units can be found in the their technical specifications. Refer to the Installation & Maintenance Manual for pressure ranges by model.
My gas booster is vibrating too much—what should I check?
Excessive vibration is usually due to one of the following:
- Booster not mounted on anti-vibration mounts
- Missing or rigid pipework connections
- Incorrect belt tension or worn bearings
- Poor alignment or incorrect booster orientation
Addressing these early prevents premature wear and system noise. Refer to our Gas Booster Product Page for compatible accessories that reduce vibration.
What’s the difference between duty/standby and single booster setups?
A single installation uses one gas booster that runs continuously when gas flow is required.
A duty/standby setup uses two boosters, one active (“duty”) and one in reserve (“standby”). The standby unit automatically starts if the duty booster fails or requires maintenance.
For critical systems requiring zero downtime, duty/standby setups improve reliability and serviceability in high-demand environments.
When do I need a non-return valve?
Non-return valves (NRVs) are always required and must be installed after a gas booster. This helps in the following situations:
- Prevents backflow in shared supply systems
- Stops the risk of gas migrating backward during shutdown
- Duty/standby setups where boosters may cycle alternately
Secomak systems always include NRVs in their booster packages. Check your system design or contact our technical team for clarification.
If your question isn’t covered here, or you’d like system-specific advice, the best next step is to get in touch with Secomak Support. Our engineers are happy to help with planning, installation, or troubleshooting.
9. Helpful Tools and Resources
Getting a gas booster installation right involves more than just technical skill. It also requires access to the right information, tools, and expert support. Whether planning your first install or upgrading a legacy system, Secomak provides a full suite of resources to make the process easier, safer, and fully compliant.
Gas Booster Selector Tool
Not sure which industrial gas booster is right for your system?
Use Secomak’s Gas Booster Selector Tool to quickly identify the most suitable unit based on your flow rate, pressure requirements, and application type. This is a great starting point for specifying equipment for boiler installations, manufacturing processes, or commercial kitchens.
Start with Episode 1: How to Choose the Right Secomak Gas Booster for a guided breakdown of selection criteria.
Technical Data and Manuals
All technical documentation for installation, wiring, and performance specs is available online.
- Access full Installation & Maintenance Manuals
- View pressure ranges, flow rates, electrical data
- Download wiring diagrams and troubleshooting guides
Get everything you need from the Technical Data & Manual page.
Contact Secomak Support
Need advice on how to install a gas booster, system compatibility, or commissioning scheduling?
Our experienced support team is here to help with:
- Model recommendations
- Compliance queries (e.g., IGEM UP/2, BS 8487:2007 & 2013)
- Troubleshooting unexpected performance issues
- Warranty questions and commissioning bookings
Reach out to our team through the Contact Secomak Support page.
Having the right resources can save time, prevent costly mistakes, and validate that every part of your installation process meets the latest UK safety and performance standards.
10. Preparing for Long-Term Success: Post-Install Maintenance Tips
A correctly installed and commissioned gas booster is just the beginning. Regular maintenance is essential for long-term performance, energy efficiency, and safety. While Secomak boosters are built for durability, all mechanical systems benefit from proactive servicing, especially those supporting critical systems like boiler installations or manufacturing processes.
Below are key maintenance practices to keep your gas booster running at its best.
Schedule Regular Servicing
Routine servicing helps detect wear early and avoid costly breakdowns. As a rule of thumb:
- Visual inspections: Monthly
- Basic maintenance (belt tension, bearings, filters): Every 6 months
- Full service and pressure validation: Annually
This schedule may vary based on usage levels, environment, and booster type. High-use or high-humidity environments may require more frequent checks.
Check Belts, Bearings, and Connectors
Some of the most common serviceable parts include:
- Drive belts – Check for tension, cracks, and wear. Replace these belts every year.
- Bearings – Listen for noise and ensure they’re greased according to spec. Replace them every 5 years.
- Flexible pipe connectors – Inspect for signs of fatigue, corrosion, or gas staining. Replace these components every 5 years.
Replacing worn components promptly prevents performance dips and unplanned downtime.
Monitor Pressure Stability
Check that inlet and outlet gas pressures remain within the expected range for your annual inspection. Fluctuations could signal:
- System leaks
- Regulator faults
- Changes in site gas demand
- Obstructed pipework or filters
Maintaining consistent boosted outlet pressure is critical for combustion efficiency and system safety.
Keep Detailed Service Records
Document every service, inspection, and part replacement in a dedicated log. This helps with fault diagnosis and is also valuable for:
- Audits and compliance (e.g., Gas Safe inspections)
- Insurance claims
- Warranty support
If Secomak commissioned your booster, this also supports your extended 12-month warranty period.
What to Do If Your Booster Fails
If your gas booster stops working or shows signs of reduced performance:
- Isolate power and gas supply immediately.
- Check for tripped circuits or pressure switch faults.
- Inspect belts, connectors, and motors for visible damage.
- Consult the Technical Manual or contact Secomak Support for assistance.
Never attempt repairs beyond basic checks unless you are a qualified service technician.
Proactive care protects your equipment and supports safety, compliance, and long-term cost-efficiency. For tailored service plans or replacement parts, contact Secomak Support today.
11. Installing with Confidence
Installing a gas booster isn’t solely about complying with regulations. It’s about safeguarding your operations, improving efficiency, and securing long-term performance. From pre-installation planning to final commissioning, every step matters. Following gas booster installation best practices confirms that your system meets the high IGEM/UP/2 and BS 8487:2007 & 2013 standards and helps you avoid costly delays, safety issues, or performance shortfalls.
Remember:
- Only a Gas Safe registered engineer should perform installations
- Only a qualified gas booster commissioning engineer can legally and safely commission the unit
- A professionally commissioned booster from Secomak qualifies for an extra 12 months of warranty
- Long-term success depends on routine maintenance and accurate documentation
Secomak is here to support you at every stage, with tools, manuals, and expert guidance available on demand. Whether installing a gas booster for a boiler upgrade, a manufacturing line, or a commercial heating system, we can help you get it right the first time.
Need help or ready to get started? Contact Secomak Support today.
12. Coming Next in the Series: Understanding Gas Booster Technology
Now that you know how to install and commission your gas booster, our next article will explore the engineering behind them.
In the upcoming article, we’ll explore:
- How centrifugal impellers generate pressure
- The relationship between airflow, motor speed, and system resistance
- The science behind pressure lift and flow modulation
- How Secomak designs boosters for maximum durability and efficiency
Stay tuned as we break down the technology behind industrial gas boosters, giving you even more control and insight into your energy systems.
