1 | WEATHERIZATION ASSISTANCE PROGRAM STANDARDIZED CURRICULUM – August 2010 eere.energy.gov Combustion Appliances WEATHERIZATION ENERGY AUDITOR SINGLE FAMILY WEATHERIZATION ASSISTANCE PROGRAM STANDARDIZED CURRICULUM – August 2010
1 | WEATHERIZATION ASSISTANCE PROGRAM STANDARDIZED CURRICULUM – August 2010 eere.energy.gov
Combustion AppliancesWEATHERIZATION ENERGY AUDITOR SINGLE FAMILY
WEATHERIZATION ASSISTANCE PROGRAM STANDARDIZED CURRICULUM – August 2010
2 | WEATHERIZATION ASSISTANCE PROGRAM STANDARDIZED CURRICULUM – August 2010 eere.energy.gov
COMBUSTION APPLIANCES
Learning Objectives
By attending this session, participants will:
• Understand the basic principles of combustion, distribution and venting and be able to recognize safety-related problems.
• Understand the health and safety issues related to combustion equipment.
• Know the basics of visual and diagnostic combustion appliance safety and efficiency inspection.
• Know the test procedures for vented and non-vented appliances.
• Understand the relationship between combustion safety problems and poorly designed or non code-compliant vent systems.
• Understand worst case Combustion Appliance Zone (CAZ) Testing.
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COMBUSTION APPLIANCES
We test to assure:• Health and safety.
• Building integrity.
• Comfort.
• Energy efficiency.
Why Test Combustion Appliances?
Photo courtesy of New River Center for Energy Research and Training (NRCERT)
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Combustion BasicsCOMBUSTION APPLIANCES
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The Combustion Triangle
Requirements for Combustion (burning):
COMBUSTION APPLIANCES
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COMBUSTION APPLIANCES
Complete Combustion Results in:
Triangle of Combustion Products
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COMBUSTION APPLIANCES
Complete Combustion Occurs….• When all the fuel is burned with sufficient oxygen
to produce carbon dioxide and water vapor.
Complete Combustion
Combustionby-products
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COMBUSTION APPLIANCES
CO Occurs When:• The ratio of fuel to oxygen is either too high to
permit the complete formation of CO2 or.........
• The temperature is too low to permit complete burning to occur.
Caused by:• Too much fuel for the amount of oxygen.
• Not enough oxygen for the amount of fuel.
• Not enough heat (flame impingement).
Carbon Monoxide from Incomplete Combustion
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COMBUSTION APPLIANCES
Combustion, Distribution & Venting
Return Air
Main Burner
Supply Air
Vent
Combustion Gases
Dilution Air
Heat Exchange
r
Gas Valve
Combustion Air
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COMBUSTION APPLIANCES
What do we inspect on combustion appliances?• Chimney safety.
• Vent pipes.
• Wiring.
• Heat exchanger.
• Distribution systems.
• Combustion air.
What to Inspect - Visual
Photo courtesy of PA Weatherization Training Center
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COMBUSTION APPLIANCES
Fuel Leak Testing #1
Use a calibrated gas leak detector to locate fuel leaks.
Photo Courtesy of NRCERTBacharach
www.bacharach-inc.com
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Fuel Leak Testing #2
Test all joints, valves and fittings.
Use soap bubbles to confirm a leak.
Photos Courtesy of NRCERT
COMBUSTION APPLIANCES
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COMBUSTION APPLIANCES
Fuel Leak Testing #3
Gas leak detector forgas and propane.
Visual inspection and the personal sniff test for fuel oil.
Photos Courtesy of NRCERT
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COMBUSTION APPLIANCES
Photos Courtesy of NRCERT
• Is insulation on wiring missing or deteriorated?
• Is the heating system on its own circuit?
• Are wires properly clamped, connected and enclosed?
Inspection – Wiring
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Clearance to Combustibles
Oil and Wood Gas
Single wall 18” Single Wall 6”
Double Wall Super Six, Dura Vent 6” Double Wall
B-Vent or B-W Vent 1”
Manufactured Chimney 2” or Per Manufacturer Instructions
Photo Courtesy of NRCERT
COMBUSTION APPLIANCES
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COMBUSTION APPLIANCES
• NFPA-54 states that combustion air must be provided for any combustion zone where the collective fuel input exceeds 1,000 Btu per 50 cubic ft.
• Make-up air can be provided from outdoors or from other zones of the building.
Combustion Air
Photo Courtesy of NRCERT
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Change out the furnace filter and educate the client about checking it periodically.
Filter Replacement
Photo Courtesy of NRCERT Photo Courtesy of PA Weatherization Training Center
COMBUSTION APPLIANCES
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Blower Maintenance
Clean the blower.
Photo Courtesy of NRCERTPhoto Courtesy of
PA Weatherization Training Center
COMBUSTION APPLIANCES
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Rust on the draft hood of a natural gas furnace is evidence of severe
spillage of flue gases.
Soot stains at the inspection port of an oil fired boiler indicate the
need for a tune up.
Combustion Safety Problems
Photos Courtesy of PA Weatherization Training Center
COMBUSTION APPLIANCES
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COMBUSTION APPLIANCES
What do we test on combustion appliances?• Fuel leaks.
• Fuel input rate.
• Sufficient combustion air.
• Worst case draft.
• Carbon monoxide.
• Combustion efficiency.
What to Test – Diagnostics
Photo Courtesy of NRCERT
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Combustion AnalyzerBacharach, www.bacharach-inc.com/fyrite-tech.htm
Combustion analyzers should be able to measure:• Flue gas oxygen content.
• Flue gas temperature.
• Ambient temperature.
• Flue gas carbon monoxide.
• Combustion efficiency.
• Flue gas carbon dioxide content.
• Flue Gas air-free or as measured CO content.
Testing Equipment - CriteriaCOMBUSTION APPLIANCES
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Draft Gauge
Smoke Tester (for Oil)
Selected Testing Equipment
Inspection Mirror
Digital Probe Thermometerhttp://www.omnicontrols.com
COMBUSTION APPLIANCES
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If you’re not testing, you're guessing!
Testing Equipment
Photo Courtesy of NRCERT
COMBUSTION APPLIANCES
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Unvented Space Heaters
Unvented space heaters release all of their combustion byproducts into the home. In addition to carbon dioxide and water vapor, compounds of carbon monoxide, excess air, and sulfur dioxide will be present.
Photos Courtesy of NRCERT
COMBUSTION APPLIANCES
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Visual Assessment – Space Heaters
WPN 08-4: Space Heater Policy• No Wx work allowed where unvented gas or
liquid fuel space heater is primary heat source.
• Strongly encourages removal and replacement of such heaters with vented, code-compliant heating systems prior to weatherization.
• Input rating at or below 40,000 BTU/hr.
• MVR guidelines apply.
• WAP funds may only replace primary heating system, e.g. unvented with vented, code-compliant system. May not replace unvented space heaters left in home as secondary units with code-compliant unvented units.
• Mobile home: must be vented outside.
Photo Courtesy of NRCERT
COMBUSTION APPLIANCES
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COMBUSTION APPLIANCES
Why Test Gas Cook Stoves?• Elevated Levels of CO
are Common.
• People often use them as a heat source.
• CO Kills.
• Knowledge implies action.
Cook Stove Testing
Photo Courtesy of NRCERT
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COMBUSTION APPLIANCES
Gas Cook Stove Testing - Stove Top
Test each range top burner for CO.
Hold probe 6” above flame and measure the CO content in
ambient air.
A portable flue section concentrates combustion byproducts for an accurate
CO measurement.
Photos Courtesy of NRCERT
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COMBUSTION APPLIANCES
Gas Cook Stove Testing - Oven
Insert the probe of the analyzer into the oven vent and read the CO
content after the oven has warmed.
Prepare the oven for a test by removing stored items, aluminum foil, etc.
Photos Courtesy of NRCERT
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Furnace Testing Protocol
Furnaces must be tested to assess:• Safety (fuel leaks,
clearances, etc.).• Flue gas temperatures.• Oxygen (O2) or Carbon
Dioxide (CO2).• Carbon Monoxide (CO)
levels.• Draft.• Condition of the heat
exchanger. Photos Courtesy of PA Weatherization Training Center
Open ended duct
Single wall flue for oil heat.
COMBUSTION APPLIANCES
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Furnace Testing Methods - Visual
Check for:• Dirt and debris.
• Burner alignment.
• Soot, evidence of flame roll-out.
• Heat-exchanger condition.
• Vent pipe and roof termination.
• Gas or oil leaks.
• Wiring condition.
• Condition of air filter.
Cracked Heat Exchanger
COMBUSTION APPLIANCES
Photo Courtesy of NRCERT
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Heat Exchanger Leakage Testing
Test Methods:• Look for flame damaged areas
on the heat exchanger.
• Look for rust on the burner ports.
• Measure flue gas concentration before and after blower starts.
• There should be no more than 1% oxygen change when the blower starts.
• Observe change in draft, CO or flame when blower turns on.
• Look for flame damaged areas on the heat exchanger.
Photo Courtesy of NRCERT
Damaged area of heat exchanger
COMBUSTION APPLIANCES
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COMBUSTION APPLIANCES
• Use a strong light and an inspection mirror.
• Is the heat exchanger rusty?
• Are there cracks?
Inspection – Heat Exchanger
www.bacharach-inc.com
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COMBUSTION APPLIANCES
• Find the worst case depressurization in the CAZ.
• Under worst case conditions conduct:- Spillage Test
- Draft Test
- CO Test
• Perform at the time of the audit and at the end of each work day.
• Deactivate appliances until hazard is fixed
Worst Case Combustion Safety Testing
Conduct these tests for vented systems only!
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COMBUSTION APPLIANCES
• Record outdoor temperature.
• Clean dryer lint filter and furnace filter.
• Deactivate all combustion appliances.
• Close all exterior doors and windows.
• Open interior doors containing exhaust fans.
• Close all other interior doors.
Setting Up Worst Case Conditions
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COMBUSTION APPLIANCES
• Record the pressure difference of the CAZ with respect to outdoors using a manometer.
• Operate all exhaust devices.
• Record the pressure difference of the CAZ with respect to outdoors.
• Conduct CO, spillage, and draft tests under worst case conditions.
• Open and close interior doors (including door to CAZ).
• Repeat for all other vented appliances.
• Return dwelling, exhaust fans, and combustion appliances to normal settings.
Conducting a Worst Case Test
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Test for Spillage
Photo Courtesy of PA Weatherization Training Center
No spillage after 1 minute of operation.
Smoke stick at draft diverter.
COMBUSTION APPLIANCES
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COMBUSTION APPLIANCES
Spillage– Test at vent openings, i.e. dilution air openings,
barometric damper, with smoke.Draft
– Test in vent connection between last opening in vent connect and chimney.
– Oil burners – Test over fire in combustion chamber.
CO– Test at appliance breech, between appliance and first
opening in vent connect or directly above heat exchanger.
– Condensing gas appliances – Test at vent termination.
Spillage, Draft and CO
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Atmospheric Furnace
CO, Draft and Steady State Efficiency
80+ Induced Draft Furnace
Figures courtesy of Corporation for Ohio Appalachian Development (COAD)
Draft
CO
CO & Draft
COMBUSTION APPLIANCES
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90+ Condensing Furnace
CO and Draft Test Locations #1
Floor Furnace
Figures courtesy of COAD
Draft
COCO & Draft
COMBUSTION APPLIANCES
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CO and Draft Test Locations #2
Fuel Oil Furnace Barometric Damper
Figure courtesy of COAD
DraftCO
Photo courtesy of NRCERT
COMBUSTION APPLIANCES
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Outdoor Temperature
Appliance < 20 °F 21-40 °F 41-60 °F 61-80 °F > 80 °F
Gas fired furnace, boiler or water heater with atmospheric draft
-5 Pa-0.016IWC
-4 Pa-0.02IWC
-3 Pa-0.012IWC
-2 Pa-0.006IWC
-1 Pa-0.004IWC
Oil fired furnace, boiler or water heater with atmospheric draft
-15 Pa-0.06IWC
-13 Pa-0.053IWC
-11 Pa-0.045IWC
-9Pa-0.038IWC
-7 Pa-0.030IWC
Minimum Acceptable DraftCOMBUSTION APPLIANCES
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APPLIANCE Suggested CO Action Levels
Gas furnace, boiler, or water heater 100 ppm, as measured
Unvented gas space heater 200 ppm, air free
Oil-fired furnace, boiler, or water heater 100 ppm, as measured
Gas cook stove: Range-top burner 25 ppm, as measured
Gas cook stove: Oven 100 ppm, as measured
Carbon Monoxide Action LevelsCOMBUSTION APPLIANCES
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COMBUSTION APPLIANCES
Solve excessive depressurization or inadequate draft:• Repair chimney obstructions, disconnections, or leaks.
• Properly size the vent, connector, or liner.
• Install a metal chimney liner and/or a wind-rated chimney cap.
• Seal leaks in the return ducts of the CAZ.
• Balance supply and return air by adding new returns, or by adding passive return air openings to the main body of the house.
• Reduce capacity of large exhaust fans.
• Provide make-up air for dryers and exhaust fans.
• Provide combustion air inlet to CAZ.
Combustion Safety Problems - Fixes
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Open Returns
Photo Courtesy of PA Weatherization Training Center
Open Return
Disconnected Draft Hood
COMBUSTION APPLIANCES
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Measuring BTU Input
• Turn on only the unit to be measured. Others should be off.
• Time one revolution of smallest dial, and compare to a calibration chart.
• Any discrepancy with the rated input should be within 10% of the input rating.
Clocking the Gas Meter
Photo courtesy of NRCERT
Time one revolution of smallest dial
COMBUSTION APPLIANCES
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What’s Wrong with this Picture?
Photo Courtesy of PA Weatherization Training Center
From Furnace
From Hot Water Tank
To Chimney
COMBUSTION APPLIANCES
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COMBUSTION APPLIANCES
Chimney and Vent Connectors
Chimney
Combustion gases mixed with room air
Vent
Gas Heating Applianc
e
Draft Hood
Water Heate
r
Draft Diverte
r
Dilution Air
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COMBUSTION APPLIANCES
A Venting System should:• Carry all combustion byproducts to outdoors.
• Establish draft quickly.
• Be properly sized with minimal restrictions.
• Have long durability (corrosion resistance).
• Not overheat surrounding materials.
• Have adequate make up air.
Venting Systems
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COMBUSTION APPLIANCES
Chimneys and Vents
Photo Courtesy of PA Weatherization Training Center
From Hot Water Tank
Chimney
Single Wall Vent
From Furnace
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COMBUSTION APPLIANCES
• Masonry chimneys.
• Type B vents – double wall, round.
• Type B-W vents – double wall, oval.
• Type L vents – more heat, corrosion resistant.
• Single wall metal – interior only.
• Plastic pipe vents – low temp condensing furnaces.
Vent Types
Photo courtesy of NRCERT
Masonry Chimney and B-Vent
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COMBUSTION APPLIANCES
• Vent gas temperature.
• Heat loss from the vent.
• Height of the venting system.
• Capacity of the venting system.
• Restrictions in the venting system.
• Ambient temperature.
• Negative pressure in the CAZ.
Factors That Affect Vent Operation
See a problem here?
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COMBUSTION APPLIANCES
Chimney Specifications
Masonry chimney is too short.
Photo Courtesy of PA Weatherization Training Center
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COMBUSTION APPLIANCES
Chimneys and vents should:
• Be connected and unblocked.
• Not have holes in the chimney or vent.
• Have a sound liner.
• Rise no less than 1/4” per linear foot in the direction of the outlet.
• Extend at least 3’ above the highest point at which they pass through the roof.
• Be the appropriate type and size for the combustion appliances.
• Be at least the same diameter as the exhaust port of the combustion appliance.
Chimneys and Vents #1
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Chimneys and Vents #2
Chimneys and vents must not be blocked and must have no holes in the chimney or vent.
Missing cleanoutBlocked chimney
Photos Courtesy of PA Weatherization Training Center
COMBUSTION APPLIANCES
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Hole in Vent ConnectorImproper Slope
Chimneys and Vents #3
Hole in vent connector.
Photos Courtesy of PA Weatherization Training Center
Improper slope.
COMBUSTION APPLIANCES
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No Vent Connector.Reduced vent connector out of compliance with code.
Chimneys and Vents #4
Reduced vent connector.
Photos Courtesy of PA Weatherization Training Center
No vent connector.
COMBUSTION APPLIANCES
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Water Heaters
Burn marks above the burner compartment are evidence
of flame roll out.
Spillage of flue gases or insufficient draft is often a result of an
improper installation such as this.
Photos Courtesy of PA Weatherization Training Center Photos Courtesy of NRCERT
COMBUSTION APPLIANCES
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Testing Water Heaters #1
Atmospheric Hot Water Tank
Test for draft above the draft diverter.Figure courtesy of COAD
Test for CO on both sides of the baffle
Photo courtesy of NRCERT
COMBUSTION APPLIANCES
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Test for CO directly into the breech of the unit on both sides of the baffle that runs up through the center of the tank.
On start up, time the amount of spillage. Then test draft above the draft diverter. Spillage should not exceed 1 minute.
Testing Water Heaters #2
Photos courtesy of NRCERT
Draft diverter
COMBUSTION APPLIANCES
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Photos courtesy of NRCERT
Chimney LinerCOMBUSTION APPLIANCES
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COMBUSTION APPLIANCES
• Understanding the basic principles of combustion, distribution, and venting will enable the auditor to recognize safety problems.
• Health and safety issues related to combustion equipment are some of the most important aspects of auditing a home.
• Visual and diagnostic combustion appliance safety and efficiency inspections, and worst case CAZ testing reveal potentially dangerous situations and guide retrofit strategies.
• Practice appropriate test procedures for vented and non-vented appliances.
• Understanding the relationship between combustion safety problems and poorly designed or non-compliant vent systems is important to finding solutions.
Summary