WARM Program Combustion Safety Testing Field Training October 21, 2008 Holiday Inn Conference Center, New Cumberland, PA.

WARM ProgramCombustion Safety Testing

Field TrainingOctober 21, 2008

Holiday Inn Conference Center, New Cumberland, PA

Controversial and Confusing►Action Levels vary

►Terminology varies

►What do you do with unvented appliances?

►What do you do with coal stoves?

►How do you seal test holes?

►How far should WARM go to fix problems?

WARM Procedure

►Combustion safety testing has been required as part of the WARM program for many years.

►The procedure and action levels have recently been changed slightly.

Why Focus on Combustion Safety Now?

►Due to high natural gas and oil prices, more WARM customers have switched to using electric space heaters for their primary or sole heat.

►They then qualify for air sealing and insulation if their winter seasonal use is at least 2,000 kWh.

►But they likely have a gas water heater and may still use their fossil fuel heating system….

►So… if you air seal a home with a fossil fuel system, ……..

Why Now? ContinuedSo…..

►When air sealing or insulation is installed in a home with fossil fuel heating or water heating systems, the air exchange across the thermal boundary will (should) be reduced as part of the WARM installed measures.

►Any planned reduction in air flow (CFM -50Pa) means the combustion appliances must be checked BEFORE air sealing to be sure they are operating safely…. And they need to be checked AFTER air sealing to be sure they still operate safely.

Because…►Air is needed for proper combustion.►When air flow is restricted, combustion

appliances can be starved for air.►If a combustion appliance is starved for air, it

won’t burn properly and/or it pulls its combustion air down the flue and back-drafts.

►Back-drafting (spillage) is dangerous because the flue gasses contain CO and other bad things.

►We want to be sure the appliances operate safely.

Why Now? continued

Also, if a customer’s summer seasonal use is at least 2,000 kWh, they qualify for cooling load reduction measures, including insulation and air sealing measures. These customers may have fossil fuel heating systems and/or water heaters.

More Why Now?

►Utilities and other PA programs are requiring Energy Auditors and Field Technicians to be BPI Building Analyst 1 Certified.

►Following BPI Standards for combustion testing and safety makes sense in PA right now.

Which WARM Customers Get Combustion Testing?

Typical jobs:

►Defacto electric heat jobs

►Electric heat jobs with gas water heaters

►AC jobs receiving air sealing or insulation

Combustion Testing Includes:

►CO testing: ambient air, combustion appliance zone (CAZ), flues

►Gas leak detection

►Spillage and flame roll-out evaluation

►CAZ depressurization

►Draft evaluation

►Gas range testing

Combustion Safety TestingAudit Form Page 18

Combustion Safety Tests must be

performed if:

►Conventionally vented combustion appliances exist and

►Air sealing is done – to reduce cooling load or to reduce heating load

Audit Form Page

ProcedureCOMBUSTION SAFETY

SEPTEMBER, 2008This section includes specifications relating to combustion appliance

testing, related services and measures, and instructions for action when an unsafe condition is discovered.

COMBUSTION SAFETY TESTING PROCEDURE The WARM Program Service Delivery Contractors and QA contractors

must follow the most current Building Performance Institute (BPI) Combustion Safety Test Procedure for Vented Appliances and Combustion Safety Test Action Levels which served as a basis for this detailed procedure. For the purposes of this document, BPI’s Combustion Safety Test Procedure for Vented Appliances, dated 4/07, BPI’s Technical Standards dated 2/28/05, and BPI’s Combustion Safety Test Action Levels document dated 4/07 were used. …….

Action Levels

The Big PictureWhy Perform Combustion Safety Tests?

►When inadequate oxygen is present, in addition to CO2 being formed, Carbon Monoxide (CO) can be formed. This is our main concern.

►Carbon rich fuels, like Fuel Oils, can also lead to Carbon Particles, or Smoke, being produced.

Combustion DiagramThe ideal operating range is a setting with excess air.

Incomplete Complete

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Courtesy of Bill Spohn, Testo

Air Tight Building►Negative pressure

conditions in homes can create back-drafting of combustion appliances

►Common exhaust equipment (i.e. attic fan, bathroom exhaust, fireplace) can compete with the normal venting process of combustion appliances

Graphics © COAD 1996

Courtesy of Bill Spohn, Testo

Sometimes Things Go Backwards

►Back-Draft

►Flame Roll-Out

►Spillage

Graphic © Readers Digest

2001

Courtesy of Bill Spohn, Testo

Combustion Testing Video

►16 minute video demonstrating the combustion safety testing procedure

What is flue gas?

carbon

hydrogen sulfur

oxygen

nitrogen water

Oxygen(20.9%)water vaporNitrogen (79%)

Carbon dioxide CO2

Carbon monoxide CO

Sulfur dioxide SO2

O2 - balance

Nitrogen oxide NOx

Water vapor H2O

Smoke (oil systems)

fuel-residualashes

fuelair

How is it formed?

Courtesy of Bill Spohn, Testo

What is Carbon Monoxide ?►CO originates from incompletely (oxidized) burnt

carbon (fuel). ►It is very dangerous for human and animals,

because it prevents the absorbstion of oxygen in the blood stream.

►Reasons for the formation:- fuel rich mixture- Improper venting- too early cooling of the flame (1128 F)

CO is expressed in parts per million (ppm).

Courtesy of Bill Spohn, Testo

CO Sources►Fuel burning furnaces

and hot water heaters►Fuel burning boilers►Fuel burning space

heaters►Kitchen ranges & ovens►Auto emissions

Attached garages

►Fireplaces►Tobacco smoke

Courtesy of Bill Spohn, Testo

Characteristics of CO

►Odorless►Colorless►Tasteless►Mixes well in air

Does not stratify

Follows air flow in a structure

►Poisonous

Courtesy of Bill Spohn, Testo

CO Health Effects► 35 ppm NIOSH Permissible Exposure Limit – 8 hours► 200 ppm NIOSH Ceiling– 15 minutes► 200 ppm Slight headache with 2-3 hours► 400 ppm Headache within 1-2 hours► 800 ppm Sickness & twitching of limbs within 1-

2 hours; unconsciousness in 2 hours► 1,600 ppm Headache within 20 minutes; death

within 2 hours► 3,200 ppm Death in 30 minutes► 6,400 ppm Death in 10-15 minutes► 12,800 ppm Death in 1-3 minutes

Courtesy of Bill Spohn, Testo

CO Testing Fuel Burning Appliances

►Sample from entry of home to exit of home

►Sample around all un-vented appliances

►Sample before draft diverter of atmospheric devices

►Sample where you may suspect CO

Graphics © COAD 1996

Courtesy of Bill Spohn, Testo

Types of Furnaces ►Atmospheric – Natural Draft

Buoyancy Creates NEGATIVE Pressure in Flue

►Induced Draft Fan Creates NEGATIVE Pressure in Flue

►Power Draft –Power Vent Fan Creates POSITIVE Pressure in Flue

►Condensing Sealed combustion

Calculating Combustion Efficiency

Natural GasLight OilHeavy OilPropane

Wood

Ambient Temp(combustion air)

Oxygen O2

StackTemp

fuelAir Temp

The analyzer uses the oxygen and net temperature measurements in fuel specific equations to give the efficiency, CO2 and excess air readings.

Courtesy of Bill Spohn, Testo

Combustible Gas Leak Detection

Spillage, Flame Roll-Out, Backdrafting

Testing for CO in the Appliance

►Test undiluted CO

Testing Draft

Notice the hole in the boiler flue pipe

Testing Draft►Some combustion analyzers test for pressure as well as

CO. This one records pressure (draft) in Inches of Water Column, IWC

Testing Condensing Furnaces►Test under Steady State

Operating Conditions►Sample around burner (CO)►Sample efficiency in plastic

vent pipe (MFG or authority)►Or sample in stack termination

(CO)

Follow Manufacturer’s Specs

Graphics © COAD 1996

Courtesy of Bill Spohn, Testo

Venting Types Video

►17 minute Gas Venting video

Gas Appliance Categories►Cat. I fan-assisted gas appliance: negative pressure,

a high vent temperature avoiding condensation and an integral fan drawing combustion air through chamber

►Cat. I gas appliance: negative pressure, a high vent temperature,

►Cat. II gas appliance: –negative pressure, low vent temperature causing excessive condensation

►Cat. III gas appliance: –positive vent pressure in the vent , a high vent temperature

►Cat. IV gas appliance: - positive vent pressure in the vent low vent temperature causing excessive condensation

Courtesy of Bill Spohn, Testo

Unvented Appliances – Test Air-Free or Undiluted

►Gas RangesCO Hot-Pot

www.karg.com

►Gas Ovens

►Test CO Air free, undiluted

Courtesy of Bill Spohn, Testo

Range Top CO Testing

Sealing Test Holes

►For double wall (B-vent) flue pipes, letters from vent manufacturers say to use “high temperature, non-hardening sealant to plug the hole on the inner sleeve. Do the same for the outer sleeve, but cover with a patch of aluminum tape over the sealant”.

►For single wall flue pipes, use the same, or metal plugs.

What If A Test Fails?

►If a test fails before air sealing and/or insulating: follow procedure – no air sealing until the problem is fixed

►If a test fails after air sealing and/or insulating: follow procedure – fix the problem

Bonus Video

►6 minute Efficiency Video

What Information is Important?

►Combustion Efficiency 02, Temperature, Fuel

Reduce Fuel Cost - Savings

To determine Operating Condition

Diluting effects of excess air

(NO, NO2, SO2, CO)

Weight of pollutant (lbs/Mbtu)

• Carbon Dioxide (CO2)

• O2 Reference (3%, air free)

• Emission Conversions

• Excess Air Extra Air for Combustion

Courtesy of Bill Spohn, Testo

Typical Readings

►Gas Fired Power BurnersOxygen : 3 % - 6 %

Carbon Dioxide: 8.5 % - 11 %

Stack Temp : 275 ºF to 570 ºF

Draft: -.02WC to -.04WC in the Stack

Carbon Monoxide: <100 ppm (diluted)

Always Follow Mfr‘s Specifications

Courtesy of Bill Spohn, Testo

Typical Readings► Oil Fired Power Burners

Oxygen (cast iron cone): 4% - 7 % Oyygen (flame retention): 3%-6% Carbon Dioxide 10 – 12.5% Stack Temp (60-79 AFUE): 400 ºF to 600 ºF Stack Temp (80 plus AFUE): 330 ºF to 450 ºF Stack Temp (90 plus AFUE): Less than 125ºF Draft: -.02WC Overfire Carbon Monoxide: < 50 ppm (diluted) Always Follow Mfr‘s Specifications

Courtesy of Bill Spohn, Testo