Commercial Gas Engineers Cheshire & Liverpool | Complete Heating System Repair Guide
- Chris Welford
- 5 days ago
- 7 min read
Case Study: Space 3 Fitness, Winsford | DD Wilson Gas And Heating Engineers
Published: December 2025
The Real Cost of Dormant Commercial Heating Systems: A Case Study
What happens when you take over a commercial premises and discover the heating system has been completely dormant for a decade? This was the challenge facing the new owners of what will become Space 3 Fitness in Winsford, Cheshire. As experienced commercial gas engineers serving Cheshire and Liverpool, we've helped countless businesses revive their heating systems and avoid costly downtime.
In this comprehensive guide, we'll walk you through exactly what to check before calling a commercial gas engineer—and share the real-world case study of how our team brought a 1,168kW dormant heating system back to life.
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The building, formerly a DW Sports facility, had been standing empty with its heating infrastructure untouched since the previous operators vacated. Two industrial boilers rated at a combined 1,168kW had been sitting silent, and nobody knew whether they could be brought back to life.
DD Wilson Gas And Heating Engineers was called in to assess, service, and certify the commercial heating system. Our lead engineer, Stephen Boardman, took charge of the project.
Why Commercial Heating Expertise Matters: UK Industry Context / Commercial Gas Engineers Cheshire Liverpool
Finding qualified commercial gas engineers in the UK is becoming increasingly difficult. The industry faces significant workforce challenges that directly affect businesses needing specialist heating services.
UK Gas Engineering Workforce Statistics
Statistic | Source |
~130,000 Gas Safe registered engineers in UK | HHIC / Parliamentary Evidence 2024 |
Average age of Gas Safe engineers: 45.4 years | Gas Safe Register 2023 |
50% of gas engineers are over 55 years old | Gas Training & Assessment Centre |
49% of gas engineers are sole traders | ONS Labour Market Stats 2023 |
UK needs 225,000 additional construction workers by 2027 | CITB Construction Skills Network 2024 |
Job postings for gas engineers increased 18.7% YoY | Reed Jobs Data Q1 2024 |
22.4 million UK homes connected to gas grid | National Grid 2024 |
The Gas Safe Register, working with industry bodies including the Heating and Hotwater Industry Council (HHIC) and the Chartered Institute of Plumbing and Heating Engineering (CIPHE), consistently highlights a shortage of qualified engineers, particularly in commercial heating and boiler servicing.
Commercial gas qualifications require additional training beyond domestic certification. Engineers must demonstrate competence across specific commercial categories covering larger pipework, higher gas volumes, complex controls, and industrial appliances. The majority of Gas Safe-registered engineers hold only domestic qualifications.
The Equipment: Two 584kW Hoval Cosmo Boilers
This was not a standard domestic boiler job. The plant room housed two Hoval Cosmo commercial boilers, each rated at 584kW, giving a combined heating capacity of 1,168kW (approximately 1.1MW). These units had been installed around 2005. While twenty years might seem old for a domestic boiler, a commercial heating plant of this quality is built for longevity. Hoval boilers are designed for demanding applications and can operate reliably for decades when properly maintained. The heating system fed a network of pipework and pumps powering an Air Handling Unit (AHU). This industrial setup draws in fresh air, passes it across heated coils, and distributes warm air through ducting across the entire building.
The Challenge: A Building Management System Frozen in Time
When any heating system sits dormant for a decade, problems are inevitable. The first obstacle Stephen encountered was not mechanical but digital.
The Building Management System (BMS), the computerised brain that controls when boilers fire and how the system operates, was completely unresponsive. The modem was fried and displaying dates from 2001. Without the BMS functioning, the boilers would not start through regular operation.
The Engineering Solution
Stephen used insulated tools to trace the wiring diagrams and manually bridged the contactors and relays. This bypassed the non-responsive BMS and allowed the mechanical systems to be tested independently.
This diagnostic approach required detailed knowledge of commercial heating control systems and the ability to work safely with high-voltage components while maintaining gas safety protocols.
The Compliance Issue: Undersized Purge Point
At DD Wilson, getting heating systems working is only part of the job. Systems must also be compliant with current gas safety regulations.
During inspection of the 4-inch gas main, Stephen identified a critical regulatory failure. The purge point, the valve used to clear air from the gas line during commissioning and testing, was undersized.
Requirement | Detail |
The Rule | Purge point must be at least 25% of main pipe diameter |
What We Found | 4-inch main pipe with ½-inch purge valve (12.5%) |
Required Size | 1-inch purge valve minimum |
Action Taken | Component failed on safety standards; flange replacement scheduled |
Commercial gas safety cannot be compromised. The purge point failed on safety grounds, and arrangements were made to replace the flange with the correct 1-inch valve.
The Result: Heating Restored After a Decade
After servicing the burners, checking the flue gases (which were running at a safe 105°C), and getting the pumps moving, the moment of truth arrived.
The burners fired up. Water temperature gauges began to climb. The fans in the Air Handling Unit roared to life. For the first time in a decade, warm air was flowing through the building.
The system was subsequently issued with a CP17 Commercial Gas Safety Certificate, confirming it met all current safety requirements.
Project Summary
Location | Winsford, Cheshire (Former DW Sports, becoming Space 3 Fitness) |
Equipment | 2x Hoval Cosmo 584kW boilers (1,168kW total) + Industrial Air Handling Unit |
System Age | Installed c.2005 (~20 years) |
Downtime | 10 years dormant |
Lead Engineer | Stephen Boardman |
Certification | CP17 Commercial Gas Safety Certificate issued |
Commercial Gas Qualifications: Why They Matter
This project required an engineer with specific commercial Gas Safe qualifications. Stephen Boardman holds both domestic and commercial certifications across multiple categories.
Commercial Qualifications (Gas Safe Verified)
Direct Fired Air Heating Appliances (Natural Gas & LPG)
Indirect Fired Air Heating Appliances (Natural Gas & LPG)
Overhead Plaque & Tube Heaters (Natural Gas & LPG)
NON DOM Testing & Purging up to & over 1m³ (Natural Gas & LPG)
First Fix Commercial Pipework (Natural Gas & LPG)
Indirect Fired Water/CH Appliances (Natural Gas & LPG)
Domestic Qualifications
Central Heating (Natural Gas & LPG)
Cookers and Range Cookers (Natural Gas & LPG)
Fires/Space Heaters (Natural Gas & LPG)
Water Heaters (Natural Gas & LPG)
Combustion Performance Analysis (Natural Gas & LPG)
Pipework (Core) - Natural Gas & LPG
Building Regulations competencies
These qualifications are registered with the Gas Safe Register and can be verified online. Commercial categories require additional training and assessment beyond domestic certification.
Why DD Wilson for Commercial Heating Projects
DD Wilson Gas And Heating Engineers Ltd has been serving Liverpool, Wirral, and the North West since 1998. Unlike many heating companies that operate as one-person businesses with domestic-only qualifications, DD Wilson maintains a team of engineers with both commercial and domestic credentials.
Team Capacity: With multiple Gas Safe registered engineers, DD Wilson can take on larger commercial projects and provide faster response times than sole traders.
Commercial Credentials: DD Wilson holds Gas Safe registration 583586 with qualifications covering 30+ categories across domestic and commercial work for both natural gas and LPG.
Track Record: Over 3,000 five-star reviews on Trustatrader, with commercial clients including schools, nurseries, care homes, offices, and leisure facilities.
Frequently Asked Questions
What is a CP17 certificate?
A CP17 is a Commercial Gas Safety Certificate required for non-domestic gas installations. It confirms the gas system has been inspected and meets current safety requirements. Businesses must ensure their gas installations are certified by a qualified commercial gas engineer.
Can a dormant commercial heating system be restarted?
Yes, in many cases. Commercial boilers and heating plant are built for longevity and can often be recommissioned after extended periods of inactivity. However, a full inspection and service by a qualified commercial gas engineer is essential before any restart attempt.
What is a Building Management System (BMS)?
A BMS is a computerised control system that manages heating, ventilation, and other building systems. It controls when boilers fire, monitors temperatures, and can optimise energy usage. When a BMS fails, it can prevent the entire heating system from operating.
How do I find a qualified commercial gas engineer?
Check the Gas Safe Register (gassaferegister.co.uk) and verify the engineer holds specific commercial categories, not just domestic qualifications. Commercial work requires additional certifications for larger pipework, higher gas volumes, and industrial appliances.
What areas does DD Wilson cover for commercial heating work?
DD Wilson serves a 40-mile radius from Liverpool, covering Merseyside, Wirral, Cheshire (including Chester and Winsford), Lancashire, and parts of Greater Manchester. See our coverage map.
What is the purge point 25% rule?
Gas safety regulations require that purge points (valves used to safely clear gas lines) must be at least 25% of the diameter of the main pipe they serve. A 4-inch pipe requires a minimum 1-inch purge valve.
How often do commercial gas installations need safety checks?
Commercial gas installations should be inspected annually by a qualified commercial gas engineer. Regular maintenance helps identify potential issues before they become safety hazards or cause system failures.
Need a Commercial Heating Partner?
Don't let heating failures cost you business. Whether it's a school, factory, office, or leisure facility, DD Wilson has the expertise and experience to handle complex commercial heating challenges. With 27+ years in the industry and Gas Safe registration for 30+ commercial categories, we're your trusted partner.
DD Wilson Gas And Heating Engineers Ltd
Family-run since 1998 | Gas Safe Registered 583586 | Over 3,000 Five-Star Reviews
Call: 0151 739 8945
⚡ Ready to Get Your Commercial Heating System Working Again? Request a free assessment from our certified commercial gas engineers today. No job is too complex—from dormant systems to compliance certification, we handle it all.
