combustion safety testing

125
Energy Efficiency Education Combustion Safety Testing 1

Upload: freja

Post on 11-Jan-2016

23 views

Category:

Documents


0 download

DESCRIPTION

Combustion Safety Testing. Your Instructor…. Brian Kumer Thermal Imaging Services, Inc. 1136 E. Brookview Lane Peoria, IL 61615 Cell: 309-251-1719 Office: 309-547-5000 [email protected] www.improvinghomeperformance.com or www.briankumer.com. Building Science Hot Line. - PowerPoint PPT Presentation

TRANSCRIPT

Page 1: Combustion Safety Testing

Energy Efficiency Education

Combustion Safety Testing

1

Page 2: Combustion Safety Testing

Energy Efficiency Education

Your Instructor…

Brian KumerThermal Imaging Services, Inc.

1136 E. Brookview LanePeoria, IL 61615

Cell: 309-251-1719Office: 309-547-5000

[email protected]

orwww.briankumer.com

2

Page 3: Combustion Safety Testing

Energy Efficiency Education

Building Science Hot Line

Illinois Home Performance Building Science

HOT LINE 866-395-1032 ext. 3

Free to homeowners, renters, contractors, anyone looking for unbiased advice on specific home

performance issues and improvements!

To learn more go to: www.illinoishomeperformance.org/hotline

3

Page 5: Combustion Safety Testing

Energy Efficiency Education

5

Todays Conversation… BPI’s new standards what that means to you Major changes related to combustion safety When will they become finalized (who knows) Equipment needed for testing Air-Free vs As-Measured CO readings Sources of carbon monoxide CAZ testing procedure Measuring ventilation through baht fans Measured CO limit changes CO exposure limits

Page 6: Combustion Safety Testing

Energy Efficiency Education

6

My Website…

www.improvinghomeperformance.comor

www.briankumer.com

Page 7: Combustion Safety Testing

Energy Efficiency Education

7

Largest Manometer in the World!

Page 8: Combustion Safety Testing

Energy Efficiency Education

8

Largest Manometer in the World!

24” wide x 44” tall Touch screen

DG700 manometer

Coming to a theater near you!

Page 9: Combustion Safety Testing

Energy Efficiency Education

• COSA Carbon Monoxide Safety Assoc.– Not for profit providing CO: Education, Training &

Certification www.cosafety.org

• GAMA Gas Appliance Manufactures Assoc. www.gamanet.org

• NFPA Nation Fire Protection Assoc.– Developed the NFPA 54 National Fuel Gas Code

www.nfpa.org

Useful Links

9

Page 10: Combustion Safety Testing

Energy Efficiency Education

10

Parking Lot Topics

Questions you may have about:1. Problem homes2. Testing procedures3. Interpreting results4. Test equipment5. Remediating problems6. Anything, really anything…

Page 11: Combustion Safety Testing

Energy Efficiency Education

11

Future Training Topics

1. Thermography (IR)2. Duct pressure testing3. Ventilation4. Multi-family Blower Door testing5. Whole House Air Leakage Control Installer6. Your thoughts?????

Page 12: Combustion Safety Testing

Energy Efficiency Education

12

Changes to the BPI Standards

• No CAZ depressurization limits• No draft measurement• No smoking the doors• No testing failed spillage under natural

conditions• No checking the air filter during CAZ• Not required to measure CO on both sides of

turbulator

Page 13: Combustion Safety Testing

Energy Efficiency Education

Effects ofCarbon Monoxide

in Our Lives

13

Page 14: Combustion Safety Testing

Energy Efficiency Education

What Causes Carbon Monoxide?

CO is produced by:

• Insufficient or excess combustion air (oxygen)

• Insufficient or excess fuel

• Flame impingement**When any part of the flame is reduced below

1,128º F, CO will be produced. 14

Page 16: Combustion Safety Testing

Energy Efficiency Education

16

Carbon Monoxide Sources..There have been carbon monoxide sources and carbon monoxide poisonings dating back to times when people lived in caves.Carbon monoxide is formed by the incomplete combustion of materials containing carbon and can be produced by virtually anything that burns. The more efficient the combustion process, the less carbon monoxide is produced.

Page 17: Combustion Safety Testing

Energy Efficiency Education

17

Cold Weather Carbon Monoxide Levels

The largest numbers of poisonings occur in winter when fireplaces, furnaces and boilers are being used to keep buildings warm.

Vehicles are also left idling more during winter. This creates circumstances that can easily cause carbon monoxide levels to rise within a vehicle and the surrounding area (such as a garage).

Page 18: Combustion Safety Testing

Energy Efficiency Education

18

Power Outages

Power outages increase the risk of rising carbon monoxide levels. Power outages and natural disasters greatly increase the carbon monoxide risk as people are placed in unfamiliar circumstances using unfamiliar equipment.

Page 21: Combustion Safety Testing

Energy Efficiency Education

Teak Surfing is be Deadly!

21

Surfers hold onto the teak platform to perform there surfing moves behind the moving boat with no life jacket. When they are overcome by CO they let go and sink into the water.

Teak surfing has been outlawed in several states.

Page 22: Combustion Safety Testing

Energy Efficiency Education

Ventless Water Heater????

22

Do you realize there is no difference between operating this gas water heater with no vent and operating a gas cook stove?

Stop Everything! Disable water heater

before leaving the house!

Page 23: Combustion Safety Testing

Energy Efficiency Education

3 Sources of Carbon Monoxide

1. Automobile exhaust 66%

2. Faulty heating appliances 33%

3. Fire – burning wood, smoking 1%

I would assume that the automobile exhaust incidences would increase due to Power-vented replacement furnaces less likely to cause CO poisoning Source: Illinois Department of Public Health

23

Page 24: Combustion Safety Testing

Energy Efficiency Education

The most vulnerable have the greatest risk of CO poisoning and they are…1. People with existing health problems

such as heart and lung disease2. Elderly3. Infants4. Children and pregnant women5. Smokers6. Small animals

Greatest Risk of CO Poisoning?

24

Page 25: Combustion Safety Testing

Energy Efficiency Education

Health Affects of CO Poisoning

When carbon monoxide is inhaled into the lungs and bonds with hemoglobin in blood, which forms Carboxyhemoglobin (COHb). This condition displaces oxygen in the blood stream and affects all major organs and muscles.

Carbon monoxide molecules bond with hemoglobin in blood over 200 times more easily than oxygen molecules. Suffocation occurs from the inside out.

25

Page 26: Combustion Safety Testing

Energy Efficiency Education

Symptoms of CO Poisoning

200 ppm Slight headaches, tiredness, dizziness, and nausea after 2-3 hours

400 ppm Frontal headaches within 1-2 hours, life threatening after 3 hours

800 ppm Dizziness, nausea and convulsion with 45 minutes.

800 ppm Unconsciousness within 2 hours. Death with 2-3 hours

1,600 ppm Headache, dizziness and nausea within 20 minutes. Death within

1 hour

3,200 ppm Headache, dizziness and nausea within 5-10 minutes. Death within

30 min.

6,400 ppm Headache, dizziness and nausea within 5-10 minutes. Death within

10-15 min.

26

Page 27: Combustion Safety Testing

Energy Efficiency Education

UL 2034 CO Detector Alarm Levels

Detector must ignore CO levels of 30 ppm or less for at least 30 days

70 ppm Unit must sound alarm within 60-240 minutes.

150 ppm Unit must sound alarm within 10-50 minutes.

400 ppm Unit must sound alarm within 4-15 minutes.

27

Page 28: Combustion Safety Testing

Energy Efficiency Education

CO Detector Comparison Test

28

Page 29: Combustion Safety Testing

Energy Efficiency Education

UL-2034 vs CO Experts

29

Page 30: Combustion Safety Testing

Energy Efficiency Education

Killer Water Heater…

1,200 ppm + tested before dilution with 100% spillage!

30

Notice the rust on the side of the di-electric fittings from the constant back-drafting

Page 31: Combustion Safety Testing

Energy Efficiency Education

Combustion Basics&

Measuring CO(As Measured & Air-Free)

31

Page 32: Combustion Safety Testing

Energy Efficiency Education

Combustion Appliance Zone

CAZCAZ is the air space surrounding your

natural draft or induced draft heating appliances

CAZ pressure testing lets us know what conditions the drafting equipment has to work in

32

Page 33: Combustion Safety Testing

Energy Efficiency Education

33

A natural draft furnace requires 15 cubic/ft of dilution air for every cubic foot of natural gas it uses.

1 cubic foot (cf) = 1,027 Btu 100 cubic feet (1 cf) = 1 therm

(approximate)

The operation of a 100k furnace for one hour is the equivalent of operating one

50cfm bath fan operating for one hour

Natural Draft Furnace

Page 34: Combustion Safety Testing

Energy Efficiency Education

Air + Fuel + Ignition = Heat

HEAT

IGNITIONFU

EL AIR

The Three T’s of Combustion

1. Time

2. Temperature

3. Turbulence

34

Page 35: Combustion Safety Testing

Energy Efficiency Education

Our Atmosphere

Our atmosphere is made of:

79% Nitrogen20.9% Oxygen

Nitrogen is an inert gas that will not react in the combustion process.

35

Page 36: Combustion Safety Testing

Energy Efficiency Education

36

What is Perfect Combustion?

For perfect combustion all 20.9% of the oxygen was completely used up during the combustion process and 0% of oxygen will be measured in the spent flue gases in the vent.

That would be considered perfect combustion.

A typical water heater or furnace would measure 6 to 8% oxygen.

Page 37: Combustion Safety Testing

Energy Efficiency Education

37

Excess Air

Excess air is the amount of air (specifically oxygen) in the combustion gases in excess of the exact amount needed for perfect combustion. When combustion is perfect, just the right amounts of fuel and oxygen are supplied to the combustion process so that all the oxygen is utilized - no oxygen remains in the combustion gases.

Page 38: Combustion Safety Testing

Energy Efficiency Education

38

“As Measured” vs “Air Free”

• There are two scales with which to measure CO: one is “As-Measured” and the other is “Air-Free.”

• As-Measured is the method used by most technicians today. The CO is measured from a sample of combustion gases with no regard for the amount of excess air diluting the CO concentrations.

Page 39: Combustion Safety Testing

Energy Efficiency Education

39

“As Measured” vs “Air Free”

The basic problem with the as-measured method is this: As the amount of excess air increases, the as-measured CO value falls for a given source strength of CO. In other words, the amount of excess air in the sample can significantly influence the as-measured value. This can cause a technician to mistakenly think that a hazardous burner is working properly. - Rick Karg

Page 40: Combustion Safety Testing

Energy Efficiency Education

40

“As Measured” vs “Air Free”

“As-Measured” – is a CO measurement made in a situation where there is no control of the combustion air entering the combustion chamber of an appliance. You could think of it as measuring the CO from an open flame on stovetop. You are measuring diluted flue gases.

The flue gases would then contain large quantities of oxygen (above approx. 15%). An example would be measuring the CO in an oven or the stovetop burners. As Measured CO is always lower than Air Free CO measurements.

Page 42: Combustion Safety Testing

Energy Efficiency Education

42

“As-Measured” vs “Air-Free”

Air-free measurement of CO takes account of the amount of excess air by incorporating an adjustment to the as-measured ppm value, thus simulating air-free (oxygen-free) conditions in the combustion gases. To do this, a reading of oxygen (O2) percentage is taken from the combustion gases along with the as-measured CO reading.

Page 43: Combustion Safety Testing

Energy Efficiency Education

43

“As Measured” vs “Air Free”

“Air Free” – is a CO measurement in the vent of a heating appliance where the volume of air entering the combustion chamber is somewhat controlled.

These flue gases would typically contain oxygen levels between 4% and 10%.

Page 44: Combustion Safety Testing

Energy Efficiency Education

44

“As Measured” vs “Air Free”

If air-free CO is determined with a single meter, the meter will have an integral electronic chip that will calculate the air-free level from as-measured CO ppm and O2 percentage.

Page 45: Combustion Safety Testing

Energy Efficiency Education

Calculating Air-Free CO

COAFppm = ( ) x COppm 20.9

20.9 – O2

COAFppm = Carbon monoxide, air-free

COppm = As-measured combustion gas carbon monoxide ppm

O2 = % of oxygen in combustion gas, as a percentage

CO = % of carbon monoxide in combustion gas, as a percentage

20.9 – 8% (O2) = 12.9 (20.9 ÷ 12.9) x 23 (CO) = 37 ppm air-free

Page 46: Combustion Safety Testing

Energy Efficiency Education

46

“As Measured” vs “Air Free”

This technician is measuring the CO in undiluted flue gases of this water heater.

This is an “Air-Free” CO measurement.

The instrument you will be using does have the Air-Free option. No math required!

Page 47: Combustion Safety Testing

Energy Efficiency Education

47

BPI CO Thresholds Page 12 7.8.5

Page 48: Combustion Safety Testing

Energy Efficiency Education

Venting Gas Appliances

48

Page 49: Combustion Safety Testing

Energy Efficiency Education

49

Venting Gas Appliances

Venting spent fuel gases to the outside of the home from combustion appliances can be done one of three ways:

1. Masonry chimney2. B-vent (metal double wall pipe)3. PVC pipe – high efficiency equipment only!

Page 50: Combustion Safety Testing

Energy Efficiency Education

Masonry ChimneyA masonry chimney may be constructed out soft brick and it may have a clay tile liner on the inside connecting the heating appliance to outside.

Chimneys most times are oversized and take a long time to warm up and promote draft. Installation of a a flue liner will correct this problem.

50

Page 51: Combustion Safety Testing

Energy Efficiency Education

B-Vent Flue

“B-vent” is a double wall vent pipe that is routed from the heating appliance or vent connector through the roof to the outside. Commonly referred to as a “flue”

51

Page 52: Combustion Safety Testing

Energy Efficiency Education

Vent Connector to Chimney

The vent connector is a single wall metal pipe connecting the heating appliance to the masonry chimney.

The vent connector must have a minimum of ¼” rise per foot!

52

Page 53: Combustion Safety Testing

Energy Efficiency Education

3 Types of Heating Appliances

1. Natural draft - has no fans to assist with exhaust (uses a draft diverter to create draft)

2. Induced draft – metal B-vent flue (80%)

3. Power-vent – PVC flue not sealed combustion

- Power-vent – PVC flue sealed combustion

53

Page 54: Combustion Safety Testing

Energy Efficiency Education

Natural Draft FurnaceThis type of furnace relies on stack-effect (convection) to vent the flue gases out of the home through the B-Vent or chimney.

Stopped manufacturing in 1978.

54

Page 55: Combustion Safety Testing

Energy Efficiency Education

80% Induced Draft FurnaceThis type of furnace utilizes an induced draft fan to start the venting process then relies on stack-effect (convection) to vent the flue gases out of the home through the B-Vent or chimney.

Started manufacturing in 1978.

55

Page 56: Combustion Safety Testing

Energy Efficiency Education

Induced Draft Fan

Induced draft fan pulls the gases out of the heat exchanger and gets the flue gases flowing into the vent connector. Once the flue starts warming, stack-effect takes over and draws the gases.

56

Page 57: Combustion Safety Testing

Energy Efficiency Education

High Efficiency / Power-Vent FurnaceOften called “Condensing Furnaces”. These furnaces have a second heat exchanger to extract more heat from the flue gases. The cool gases (115° max) condense in the flue pipe requiring PVC pipe for a flue.

Positive Pressure flue!57

Page 59: Combustion Safety Testing

Energy Efficiency Education

Hummmm…

59

The power-vented furnace (positive pressure vent) and natural draft water heater (negative pressure vent) can not be vented into the same flue!

Homeowners!

Page 60: Combustion Safety Testing

Energy Efficiency Education

What is Back Drafting?

The spilling of flue gases from natural draft or induced draft heating appliances into the home

High concentrations of CO flue gases going up the flue do not pose an immediate health problem?

60

Page 61: Combustion Safety Testing

Energy Efficiency Education

What Allows Gas to Flow Up & Out??

Answer: Convection / stack effect

Important: Until the vent is purged of the cold air from the flue or chimney the appliance will spill!

61

Page 62: Combustion Safety Testing

Energy Efficiency Education

The Flue is a “Vacuum Generator”

Negative CAZ pressure

Negative CAZ pressure

62

Page 63: Combustion Safety Testing

Energy Efficiency Education

Causes for Appliances to Back Drafting?• Excessive negative pressure in the CAZ• Poor flue design• No flue liner in masonry chimneys• Blockage in the flue• Orphaned water heater• Minimal rise of the flue

“Spillage”The definitive test for pass or fail

63

Page 64: Combustion Safety Testing

Energy Efficiency Education

Max. Vent Connector Length

The maximum horizontal vent connector length equals 1.5’ of run for each inch of connector diameter.

Example: 3”(dia. vent) x 1.5’ = 4.5’ length of vent connector

Never install a smaller diameter vent connector than the draft diverter outlet!

64

Page 65: Combustion Safety Testing

Energy Efficiency Education

Calculation for an Oversize Flue…

The flow area of the largest section of verticalvent or chimney shall not exceed 7 times the smallest listed appliance categorized vent area, flue collar area, or draft hood outlet area.

Example: DWH with a 3” diameter draft hood

Formula: R x R x ⫪ = area of a circle

1.5”(R) x 1.5”(R) x 3.14(⫪) = 7 sq”

7sq” x 7(7 times draft hood dia.) = 49 sq” 65

Page 66: Combustion Safety Testing

Energy Efficiency Education

Vent Pipe Area Chart

4” – 12.25” – 19.66” – 28.37” – 38.38” – 50.39” – 63.610” – 78.5

Vent pipe diameters

49 sq” is the max. area7” max. dia. vent

66

Page 67: Combustion Safety Testing

Energy Efficiency Education

Correctly sized flue liner heats up quickly and starts drafting almost immediately!

Why Installation of a Flue Liner?

Oversized masonry chimney hard to draft, cold and condensation on the inside, rotting of mortar joints, ect…

Installation of a flue liner run from the top down into the basement connecting the heating appliance to outside.

67

Page 68: Combustion Safety Testing

Energy Efficiency Education

Furnace Heat Exchanger (all furnaces)

A heat exchanger allows the transfer of heat (btu’s) from burning gases into the air stream flowing across the outside of the heat exchanger and into the home. The flue gases and the warmed air cannot mix.

68

Page 69: Combustion Safety Testing

Energy Efficiency Education

Cracked Heat ExchangerThis cracked heat exchanger can allow flue gases into the air stream flowing into the home. This condition is usually caused by lack of air flowing across the heat exchanger overheating the heat exchanger due to an air flow restriction to the furnace blower.

69

Page 70: Combustion Safety Testing

Energy Efficiency Education

Look for Flame Interference

At the time the blower turns on observe the burners for flame for interference.

Higher pressure air from the blower blows in through a crack in the heat exchanger and changes the normal appearance of the flame.

Have the assumed cracked heat exchanger verified by a professional!!

70

Page 71: Combustion Safety Testing

Energy Efficiency Education

Combustible Gas Leak Detection

71

Page 72: Combustion Safety Testing

Energy Efficiency Education

KaBoom……

72

Page 73: Combustion Safety Testing

Energy Efficiency Education

73

CGD (Combustible Gas Detector)

Location of the sensor. It takes about a minute

to warm up

On/Off – sensitivity adjustment

Batteries

Visual lighted sensitivity scale

Flexible wand

BPI refers to a gas leak detector as a “CGD”. This is the same CGD you will be using.

Page 74: Combustion Safety Testing

Energy Efficiency Education

74

Combustible Gas Leak Detection

7.5.1.2 In the absence of manufacturer instructions, perform gas leak testing as follows:

• Hold the wand of the CGD within an inch of the line, starting at the first joint closest to the outlet of the LP tank or natural gas meter outlet.

• Move the wand in a 360-degree circle around the entire joint at a rate of 1” per second.

• All connections thereafter shall be tested in the same manner.

Page 75: Combustion Safety Testing

Energy Efficiency Education

75

Combustible Gas Leak Detection

7.5.1.3 The gas leakage inspection shall include the following components:

• All accessible gas piping fittings from the outlet of the natural gas meter or LP tank to a point where the supply line connects to the gas valve of all appliances. Do not move appliances.

Page 76: Combustion Safety Testing

Energy Efficiency Education

Gas Leak DetectionCheck the gas meter and outdoor gas pipes for leaks.

Note: Natural gas is lighter than air. Hold the tip of your sniffer near the top of the pipe.

Propane is heavier than air. Holder your sniffer near the bottom of the pipe

76

To pinpoint gas leaks use soap and water.

Page 77: Combustion Safety Testing

Energy Efficiency Education

Personal Safety During Testing

77

Page 78: Combustion Safety Testing

Energy Efficiency Education

Combustion Safety – 4 Tests

1. Combustible Gas Detection

2. CAZ worst case test – entire house

3. Spillage – use smoke or mirror at diverter

4. CO – measured before dilution

78

Page 79: Combustion Safety Testing

Energy Efficiency Education

79

Safe Entry & Working Conditions

• Immediately upon entering the building, a sample of the ambient air shall be taken to determine the level of CO in the building by conducting measurements in the occupied space and including utility rooms.

• Gas leak detection: Indoor air shall be sampled in at least one location per floor of occupied space upon entering the home.

Page 80: Combustion Safety Testing

Energy Efficiency Education

80

Personal CO Monitors 7.3.3.1.1

The auditor shall comply with CO exposure action levels specified in the manufacturer’s instructions and, in any case, shall not proceed with work when time weighted average CO concentrations in the work environment exceed 50 ppm for one hour and/or 200 ppm for eight hours.

Page 81: Combustion Safety Testing

Energy Efficiency Education

81

Time Weighted Average (TWA)

The time weighted average (TWA) is the accumulated reading of the gas concentration since the monitor was turned on, divided by 8 hours.

Page 82: Combustion Safety Testing

Energy Efficiency Education

82

Indoor Ambient CO Levels

The following slides will state certain indoor ambient CO levels measured within the home.

This is not be confused with the CO levels measured in the ambient air at the time of testing heating appliances. The Stop Work level is 35 ppm. 7.8.1.1

Page 83: Combustion Safety Testing

Energy Efficiency Education

83

Ambient CO Below 9 ppm 7.3.3.2.2.4

If the CO instrument indicates ambient CO below 9 ppm, the auditor shall proceed with the audit.

Page 84: Combustion Safety Testing

Energy Efficiency Education

84

Ambient CO 9 – 35 ppm 7.3.3.2.2.3

If the instrument indicates an ambient reading between 9 ppm and 35 ppm, the auditor shall advise the occupant that CO has been detected and recommend that all possible sources of CO be checked and windows and doors opened. Where it appears that the source of CO is a permanently installed appliance, the appliance shall be inspected and the owner shall be advised to contact a qualified servicing agent.

Page 85: Combustion Safety Testing

Energy Efficiency Education

85

Ambient CO 36 – 69 ppm 7.3.3.2.2.2

If the instrument indicates an ambient reading between 36 ppm and 69 ppm, the auditor shall advise the occupant that elevated levels of ambient CO have been detected and recommend that all possible sources of CO be turned off immediately and windows and doors opened. Where it appears that the source of CO is a permanently installed appliance, the appliance shall be turned off and the owner shall be advised to contact a qualified servicing agent.

Page 86: Combustion Safety Testing

Energy Efficiency Education

86

Ambient CO 70 ppm or Greater 7.3.3.2.2.1

If the instrument indicates an ambient carbon monoxide level of 70 ppm or greater, the auditor shall immediately terminate the inspection, notify the occupant of the need for all building occupants to evacuate the building; the auditor shall immediately leave the building.

Page 87: Combustion Safety Testing

Energy Efficiency Education

Combustion Appliance Zone

Testing

87

Page 88: Combustion Safety Testing

Energy Efficiency Education

Monitor Your Breathing Zone

• Ambient CO shall be monitored at all times during the test. If measured CO levels exceed 35 ppm as measured at any time during the test, testing shall stop.

• You breath with your nose and mouth not your butt!

Abort if CO goes over 35 ppm!

88

Page 89: Combustion Safety Testing

Energy Efficiency Education

89

Condensed BPI Standards Version…

1. Close exterior doors & windows, turn off all exhaust fans and air handlers

2. Close all interior doors except doors to rooms with an exhaust fan or a return

3. Measure CAZ pressure WRT outside Record Pressure4. Turn on dryer (clean lint trap) and exhaust Record

Pressure5. Turn on air handler Record Pressure6. Open CAZ doors (check with smoke) Record Pressure7. Put CAZ into worst case condition for testing

Page 90: Combustion Safety Testing

Energy Efficiency Education

90

My Interpretation with BPI’s Input

Water heaterFurnace

0

-1.8-3.5

-3.9

15560

340105

4855

3222

200400

3118

Kitchen range hood flow rating is 400 cfm

0

Page 91: Combustion Safety Testing

Energy Efficiency Education

Water Heater(Warm vent)

Spillage &CO Testing

91

Page 92: Combustion Safety Testing

Energy Efficiency Education

92

Pre-spillage Test Checklist…

It would be a good idea to do the flowing items before you start testing:

• Observe vent design issues• Drill holes as needed while flue is still cool• Check for gas leaks

Page 94: Combustion Safety Testing

Energy Efficiency Education

Water Heater Spillage

• Fire appliance and check for spillage at the draft diverter in two places (min.) with smoke or a mirror starting with the smallest btu appliance first

• Appliance has 60 seconds to prove draft

94

Page 95: Combustion Safety Testing

Energy Efficiency Education

95

Check for Spillage Here

Water HeaterDraft Hood

Water Heater

Chimney

Check for spillage here

Check for spillage here

Vent Connector

Page 96: Combustion Safety Testing

Energy Efficiency Education

96

Spillage Testing – (Water Heater)

7.8.1.10 - Starting with the appliance with smallest BTU input rating, follow lighting instructions and place in operation. Adjust the thermostat or control so the appliance will operate continuously.

Abort if CO goes over 35 ppm!

Page 97: Combustion Safety Testing

Energy Efficiency Education

97

Spillage Testing – (Water Heater)

7.8.1.12 - Domestic Water Heater or Warm Vent• Spillage shall be assessed and CO Air Free

measurement of undiluted flue gas shall be taken at 1 minute of main burner operation and again at 2 minutes. CO Air-Free measurement of undiluted flue gas shall continue be taken at 1 minute intervals for a total of 5 minutes.

Page 98: Combustion Safety Testing

Energy Efficiency Education

98

Action Levels – (Water Heater)

7.8.1.12.1.1 - If spillage ends at 1 minute of main burner operation and CO Air Free level is at or below the CO thresholds established in Section 7.8.5, Table G.6 throughout testing period, no action is required.

Page 99: Combustion Safety Testing

Energy Efficiency Education

99

Action Levels – (Water Heater)

7.8.1.12.1.2 - If spillage occurs at 1 minute of main burner operation, but spillage stops at 2 minutes and the CO Air Free level falls to a point at or below the CO threshold established in Section 7.8.5, Table G-6 at the 5 minute interval, recommend that the appliance be serviced by a qualified professional.

Page 100: Combustion Safety Testing

Energy Efficiency Education

100

Action Levels – (Water Heater)

7.8.1.12.1.3 - If spillage occurs at 2 minutes and/or the CO Air Free level is above the CO thresholds established in Section 7.8.5, Table G.6 at 5 minutes of main burner operation, the auditor shall notify the homeowner that it is imperative the appliance be serviced immediately by a qualified professional.

Page 101: Combustion Safety Testing

Energy Efficiency Education

101

BPI CO Thresholds Page 12 7.8.5

Page 102: Combustion Safety Testing

Energy Efficiency Education

Test Next Bigger Appliance

• Cool the vent before testing the next higher btu appliance

• Let the Worst Case depressurization cool the vent or, turn the Blower Door on for a few minutes

• Test appliance for: spillage & CO under Worst Case conditions

102

Page 103: Combustion Safety Testing

Energy Efficiency Education

Furnace(Warm vent)

Spillage &CO Testing

103

Page 104: Combustion Safety Testing

Energy Efficiency Education

Natural Draft Furnace

Test here for CO in each chamberTest for spillage here

Measure CO in each port. Record highest level to compare to BPI Action Levels

104

Page 105: Combustion Safety Testing

Energy Efficiency Education

80% Induced Draft Furnace

80% Furnace1. Spillage2. CO

Where do you test for spillage and CO with this configuration of heating equipment?

105

Page 106: Combustion Safety Testing

Energy Efficiency Education

Direct Vent & Power-Vented CO Test

7.9 - If the outlet of the exhaust is accessible, include a CO test on all direct vented and power-vented appliances (without atmospheric chimneys).

No spillage test.

106

Page 107: Combustion Safety Testing

Energy Efficiency Education

107

Spillage & CO Testing – (Furnace)

7.8.1.11 - Cold Vent (Except Domestic Water Heaters)

• Spillage shall be assessed and CO Air Free measurement of undiluted flue gas shall be taken at 1 minute of main burner operation and again at 1 minute intervals for 5 minutes.

Page 108: Combustion Safety Testing

Energy Efficiency Education

108

Action Levels – (Furnace)7.8.1.11.1.5 - If spillage ends and CO Air Free level is at or below the CO thresholds established in Section 7.8.5, Table G-6: at 1 minute of main burner operation and remains at or below the CO threshold at 1 minute intervals for 5 minutes of main burner operation, no action is required. Note: If CO measurements continue to rise after 5 minutes of operation, the auditor shall advise the homeowner that the appliance must be serviced by a qualified professional.

Page 109: Combustion Safety Testing

Energy Efficiency Education

109

Action Levels – (Furnace)

7.8.1.11.1.6 - If spillage occurs and/or CO Air Free level is above the CO thresholds established in Section 7.8.5, Table G.6 at 1 minute of main burner operation, but spillage stops and CO Air Free level falls to a point at or below the CO threshold by the 5-minute interval of main burner operation, recommend that the appliance be serviced by a qualified professional.

Page 110: Combustion Safety Testing

Energy Efficiency Education

110

Action Levels – (Furnace)

7.8.1.11.1.7 - If spillage continues and/or CO Air Free level is above the CO thresholds established in Section 7.8.5, Table G.6 at 5 minutes of main burner operation, the auditor shall notify the homeowner that it is imperative the appliance be serviced immediately by a qualified professional.

Page 111: Combustion Safety Testing

Energy Efficiency Education

111

BPI CO Thresholds Page 12 7.8.5

Page 112: Combustion Safety Testing

Energy Efficiency Education

112

Measure CO Every Minute 1-5

1 2 3 4 50

20

40

60

80

100

120

73

103

54

2016

Measuring CO

Minutes

CO PPM

If the CO level is going over approx. 500 ppm pull out your probe to protect you combustion analyzer!

Page 113: Combustion Safety Testing

Energy Efficiency Education

What if You Fail the Spillage Test?

113

Page 114: Combustion Safety Testing

Energy Efficiency Education

What If Appliance Fails Spillage?

• “If” an appliance fails the 60 second spillage, test again under “Natural Conditions”

• If the appliance fails in Worst Case, but passes under Natural Conditions what could be the problem?

• If the appliance fails under both conditions what could be the problem

Not a BPI requirement!

114

Page 115: Combustion Safety Testing

Energy Efficiency Education

Birds Nest

115

Page 116: Combustion Safety Testing

Energy Efficiency Education

House Depressurization Chart

Present Condition

ImprovedCondition

-7 Pa Increased House Pressure

Source: The Energy Conservatory Blower Door Operators Manual – page 51

116

Page 117: Combustion Safety Testing

Energy Efficiency Education

117

Retro Make-up Air Damper MD6TU

(6”, 8” & 10”)

Range Hood Make-Up Air

Page 118: Combustion Safety Testing

Energy Efficiency Education

118

Testing Gas Ovens For CO

Page 119: Combustion Safety Testing

Energy Efficiency Education

119

Gas Oven CO

7.10.1.1 - Combustion cooking appliances shall be tested for ambient and vented CO using the testing procedures and action levels specified in the procedure detailed in Section 7.10.1.1.1.

**The following standard mentions how to measure of the stovetop burners. You do NOT have to do that.

Page 120: Combustion Safety Testing

Energy Efficiency Education

120

Gas Oven CO7.10.1.1.2.1 - With appliance off, inspect oven cavity and range-top exhaust vent for blockage with aluminum foil or other materials. 7.10.1.1.2.2 - With appliance off, inspect cooktop is free from grease build-up. 7.10.1.1.2.3 - With appliance on, measure CO above each burner and at the oven exhaust vents after 5 minutes of main burner operation. The CO should not exceed the threshold in Section 7.8.5, Table G.6.

Page 121: Combustion Safety Testing

Energy Efficiency Education

121

BPI CO Thresholds Page 12 7.8.5

Page 122: Combustion Safety Testing

Energy Efficiency Education

Oven Vent Location

122

Page 123: Combustion Safety Testing

Energy Efficiency Education

Typical CO Measurements From Ovens

123

Page 124: Combustion Safety Testing

Energy Efficiency Education

124

Test the Garage to House Connection

Page 125: Combustion Safety Testing

Energy Efficiency Education

Test the Garage to House Connection

With the home depressurized to -50.0 Pascals while standing in the garage test with smoke for possible connections to the house.

No supply or return ducts allowed in the garage! Use a separate heating system for the garage.

High priority air sealing!!

125