P l D i i Properly Designing A Boiler Exhaust SystemA Boiler Exhaust System

Common Problems Of Improperly Designed Boiler Exhaust Systems

Common Problems

Boiler Inefficiency

Flame Ignition Failure

Downtime

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Common Problems

Excess draft in the stack

Insufficient draft in the stack

FactorsFactors Improper breeching sizing

Improper stack sizing

Poorly designed ventilation systemPoorly designed ventilation system

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Important Criteria InStack System Design

Boiler Categorization

Stack Types

Stack Sizing

UL C tifi tiUL Certification

Materials Of Construction

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Boiler Categorization

Boilers are divided into four categories based on thepressure and temperature produced in the exhaust stackand the likelihood of condensate production in the ventand the likelihood of condensate production in the vent.

TIV

E

CATEGORY IICATEGORY I

NE

GAT CATEGORY II

APPLIANCECATEGORY IAPPLIANCE

VE

NON-CONDENSING CONDENSINGP

OS

ITIV CATEGORY IV

APPLIANCECATEGORY IIIAPPLIANCE

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Boiler Categorization

Category IA b il hi h i h i i

Category IIA b il hi h i h i iA boiler which operates with a non-positive

vent static pressure and with a vent gas temperature that avoids excessive condensate production in the vent.

(B V t T A)

A boiler which operates with a non-positive vent static pressure and with a vent gas temperature that may cause excessive

condensate production in the vent.(T BH)(B-Vent, Type A) (Type BH)

Category IIIA boiler which operates with a positive vent

Category IVA boiler which operates with a positive vent p p

pressure and with a vent gas temperature that avoids excessive condensate

production in the vent.(Type BH)

p ppressure and with a vent gas temperature

that may cause excessive condensate production in the vent.

(Type BH)( yp ) ( yp )

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Boiler Categorization

N C d i B ilNear-Condensing Boilers

Condensing BoilersCondensing Boilers

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Stack Types

Type B Gas Vents

•• Gas Appliance with Draft HoodGas Appliance with Draft Hood•• Gas Appliance with Draft HoodGas Appliance with Draft Hood

•• MasonryMasonry ChimneysChimneys

Liners

Type BH Gas Vents

• Most Cat II, III and IV boilers• Most Cat II, III and IV boilers

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Stack Sizing

Appliance category Altitude

Draft Draft

Appliance category

Power input

Altitude

Flue gas velocity

calculation based on criteria

calculation based on criteria

Type of fuel Flow restriction: tees, elbows, wyes, dampers, reducers

c te asuch as:c te asuch as: Flue gas temperature

Stack and breeching

Seasons(summer vs. winter)

A dStack and breeching diameter, height, length And more…

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Stack Sizing

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UL Certification

UL 103 (USA) / ULC959 (CAN)

Building HeatingAppliance Chimney

I t d d f ith d li id id ti l t d b ildi• Intended for use with gas and liquid residential type and building heating appliances which vent flue gases at a temperature not exceeding 1000ºF under continuous operating conditions with a maximum rated positive pressure of 60 inches W.C., as specified in the Chimney Selection Chart of the National Fire Protection Association Standard No. 211

• Can be installed in an unenclosed installation or enclosed in a noncombustible chasenoncombustible chase

• Also complied with a temperature test at 1700ºF for 10 minutes

• 1400ºF Chimney: same as above, but for flue gases at a

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temperature not exceeding 1400ºF

UL Certification

UL 1738 (USA) / ULC S-636 (CAN)

Special Gas Vents

I t d d t b t d di tl t th fl tl t f th C t• Intended to be connected directly to the flue outlet of the Category II, III and IV gas burning appliances, as defined by the National Flue Gas Code, ANSI Z223.1/NFPA 54, where the maximum continuous flue gas temperature produced does not exceed 550ºF with a maximum rated positive pressure of 15 inches W.C.

• Can be installed in an unenclosed or an enclosed installation made of combustible materials

• Also complied with a temperature test at 1700ºF for 10 minutes

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UL Certification

UL 1777 (USA) / ULC S-635 (CAN)

I t d d t b i t ll d i hi d t t il

Chimney Liners

• Intended to be installed in masonry chimneys used to vent gas or oil fuel fired residential type and building heating appliances where the maximum continuous flue gas temperature produced does not exceed 570ºF

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UL Certification

UL 1978 (USA & CAN)

I t d d f i i t ll ti f th l f k d

Grease Duct For Restaurant Cooking Appliances

• Intended for use in installations for the removal of smoke and grease laden vapors in commercial and industrial applications

• They are appropriate for continuous operation at temperatures not exceeding 500ºFexceeding 500 F

• Were evaluated in accordance with the Standard for Removal of Smoke and Grease-Laden Vapors from Commercial Cooking Equipment, NFPA 96Equipment, NFPA 96

• Also complied with an abnormal temperature test at 2000ºF for 30 minutes

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UL Certification

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Materials Of Construction

Installation-Ready Exhaust Systems

Structural

• Stainless steel (304 / 316 / 301 / AL29 4C)( )• Aluminized steel• ABS / PVC / CPVC / POLYETHYLENE• Galvanized steel

Insulation

• Air• Mineral fiber• Ceramic fiber

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Materials Of Construction

Freestanding Stacks

Structural

• Carbon steel• Cor-Ten steel• Stainless steel• Other materials per customer specifications

Insulation

• Per customer specifications

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Other Considerations

Installation-Ready Exhaust Systems

Draft control systems Dampers

N tiBarometric draft controls

Modulating draft systems

Negative pressurein the building

Air inletModulating draft systems

Draft inducer fans

Air inlet

Clearances for the boiler

Draft hoods Masonry chimney

Maximum length of breeching or stack

Other Considerations

Freestanding Stacks

Duct works and breeching systems Platforms and ladders

Concrete pad and footing design

FAA aircraftwarning system

Seismic calculations

Special anchoring

Wind loads

Lightening protectionSpecial anchoring Lightening protection

Special steel structural design

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Other Considerations

Local codes and regulations Special support requirements

Chemical and ASME and CWBthermal conditions certified products

Corrosion effects UL certified products

Special paint requirementsNeeds for related products: economizer, SCR products,

silencer, other

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Cleaver-Brooks Product Offering

Installation-ReadyExhaust Systems

Freestanding Stacks

Special Gas Vents

Chimney Liners

Grease Duct Products

cleaverbrooks.com/exhaustsolutions

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References

• CSA B149.1-10: Natural Gas & Propane Installation Code – Applies to the installation of Natural Gas & Propane Appliances & Equipment- http://www.csa.ca/cm/ca/en/standards

• NFPA -http://www.nfpa.org/categoryList.asp?categoryID=124&URL=Codes%20&%20Standards

• 211: STANDARD FOR CHIMNEYS, FIREPLACES, VENTS, AND SOLID FUEL-BURNING

NFPA 54: NATIONAL FUEL GAS CODE• NFPA 54: NATIONAL FUEL GAS CODE

• UL- http://www.ul.com/global/eng/pages/?noredirect

• UL103: Factory built chimneys-

• UL1738: Vent or chimney connector dampers for oil fired appliances• UL1738: Vent or chimney connector dampers for oil-fired appliances

• UL1777: Chimney liners

• ANSI Z21.86: Vented gas-fired space heating appliances- http://www.ansi.org/

• ASME STS-1 – 2011: Steel Stacks- http://www.asme.org/kb/standards

• ASHRAE- http://www.ashrae.org/standards-research--technology/standards--guidelines

• Manufacturer’s Operations and Maintenance Manuals• Manufacturer s Operations and Maintenance Manuals

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Eric GravelSales Manager

egravel@cleaverbrooks.com(450) 625-6060

clea erbrooks com/e ha stsol tions25

cleaverbrooks.com/exhaustsolutions

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