Partner for progress Certification Standards in North America for Gas Boilers and Water Heaters John Gorman – Technical Advisor – CSA International

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Partner for progress Certification Standards in North America for Gas Boilers and Water Heaters John Gorman Technical Advisor CSA International Slide 2 2 AGENDA General Issues Boiler Standards in North America Water Heater Standards in North America Installation Codes Gases used in North America Efficiency Requirements Boilers and Water Heaters Key Evaluations Pressure Vessels, Sanitation, Venting, Controls, Wiring/Electrical Components, Manuals/Markings, NOx, Production Line Testing Combination Type Heaters Slide 3 3 Standards Development and Maintenance General Issues Standards are in constant revision. Committees meet one or more times a year to revise standards Base standard plus to addendas (a and b addenda) are issued The standards have sections within them that identify requirements unique to either the United States or Canada CSA International is not a voting member of a standards committee. Provides technical support Suggests revisions to standards CSA America (standards division) is secretariat for the ANSI/CSA gas standards Slide 4 4 Standards in North America Gas- Fired Boilers ANSI Z21.13/CSA 4.9 Gas-Fired Low Pressure Steam and Hot Water Boilers Is used for certification in the United States and Canada Includes boilers with input ratings up to 12,500,000 Btu/hr (3660 kW) Only covers boilers with gas inlet pressure ratings not more than psi (35 mbar) Hot water boilers operate at or below 160 psi (11 bar) water pressure and 250 F (121 C) water temperature Requires compliance with ASME Boiler and Pressure Vessel Code, Section IV (Heating Boilers) Slide 5 5 Standards in North America Gas- Fired Boilers UL 795 Commercial-Industrial Gas Heating Equipment Certification in the United States only Commercial Boilers over 400,000 Btu/Hr (117 kW) Covers boilers with gas pressures greater that psi (35 mbar) CAN1-3.1 Industrial and Commercial Gas-Fired Package Boilers Certification for Canada only Commercial boilers with gas inlet pressures greater than psi (35 mbar) Slide 6 6 Standards in North America Gas- Fired Water Heaters ANSI Z21.10.3/CSA 4.3 Gas Water Heaters Volume III-Storage Water Heaters With Input Ratings Above 75,000 Btu/Hr, Circulating and Instantaneous Covers all instantaneous (Tankless) designs Used for Certification in both the United States and Canada Does not require ASME Section IV compliance ANSI Z21.10.1/CSA 4.1- Gas Water Heaters Volume I-Storage Water Heaters With Input Ratings of 75,000 Btu/Hr or Less Covers Residential Size Storage Tank Type Heaters Used for Certification in both the United States and Canada Slide 7 7 Installation Code Requirements ANSI Z223.1/NFPA 54 National Fuel Gas Code United States Only Local Codes may be different Used by CSA during review of instructions ASME CSD-1 Controls and Safety Devices for Boilers Required by many local code authorities Control requirements are different, Specially on boilers with input ratings over 400,000 Btu/Hr (117kW) Many manufacturers offer control packages for boilers being installed in regions where CSD-1 is required by code authority Slide 8 8 Installation Code Requirements CAN/CSA B149.1 Natural Gas and Propane Installation Code Canada Only Local/Provincial Codes may be different Used by CSA during review of instructions CAN/CSA B149.3 Code for Field Approval of Fuel- Related Components on Appliances and Equipment Used by agencies and code authorities to evaluate unlisted equipment in Canada Testing is not part of code. CSA International does not certify to this code. We provide field evaluation of unlisted equipment only Slide 9 9 Installation Code Requirements New York MEA Required by New York City to sell products CSA International prepares specialized reports California Energy Commission (CEC) Requires special listing of efficiency ratings for products being sold into their state. The minimum efficiency requirements are the same as the federal levels in the United States CSA International is an approved certification laboratory CEC website is: www.energy.ca.gov Slide 10 10 Gases Used in North America Natural Gas The standards identify natural gas with a nominal heating value of 1075 Btu/cuft (40.1 MJ/m3) and a specific gravity of 0.65. Tests are conducted using local utility supplied gas. Typical heating values may range from 1000 Btu/cuft to 1100 Btu/cuft. Typical Wobbe index values range from 45 to 51 MJ/m3. Additional tests for ignition and burner operation are conducted using Test Gas G Butane-Air or Test Gas H Propane-Air each with a 1400 Btu/cuft (52.2 MJ/m3) heating value. Slide 11 11 Gases Used in North America Liquefied Petroleum Gases Testing for compliance with LPG is conducted using Propane HD-5 with a nominal heating value of 2500 Btu/cuft (93.1 MJ/m3) LPG is a general term defined as a mixture of propane, propylene, butanes and butylenes. Propane HD-5 is defined as grade of LPG consisting of minimum of 90% liquid propane and a minimum of 5% propylene Additional tests for ignition and burner operation are conducted using Test Gas D Butane with a nominal heating value of 3200 Btu/cuft (119.2 MJ/m3). Certification on butane is not permitted by the water heater and boiler standards. Slide 12 12 Gases Used in North America Heating values used in North America are the gross or higher heating value of the gas corrected to 60 F (15.5 C) and 30 inches Hg (1016 mbar). Tests are conducted with normal inlet gas pressures adjusted the following: Natural Gas 7.0 inches w.c. (17.4 mbar) LPG 11.0 inches w.c. (27.6 mbar) Additional tests are conducted at reduced and increased inlet pressures Slide 13 13 Efficiency Requirements Gas Boilers Efficiency requirements for boilers are different for the United States and Canada. United States Boilers with input ratings of 300,000 Btu/Hr (88 kW) or more must comply efficiency requirements in the standard. Hot water boilers are tested to verify a combustion efficiency within 98% of the claimed efficiency of the manufacturer but not less than 80%. Additionally, a thermal efficiency may be conducted at the discretion of the manufacturer. -Combustion efficiency is based on a measurement of CO2 and temperatures in the flue exhaust. -Thermal efficiency is based a measurement of gas consumption and water flow over a specified period of time. It is anticipated that these requirements will soon be removed from Z21.13/CSA 4.9 due to recent requirements announced by DOE. Slide 14 14 Efficiency Requirements Gas Boilers United States Boilers with input ratings of 300,000 Btu/Hr (88 kW) or more must also comply with DOE regulations in 10CFR 31, Subpart E. This is not a mandatory test requirement to obtain CSA Certification. The test procedure identified in the regulation is the Hydronics Institute (HI) division of GAMA standard BTS-2000. The test conducted is a combustion efficiency test identical to the test required in ANSI Z21.13/CSA 4.9 The minimum efficiency required by the regulation is 80%. Slide 15 15 Efficiency Requirements Gas Boilers United States: Boilers with input ratings below 300,000 Btu/Hr (88 kW) do not require testing to the requirements in the Z21.13/CSA 4.9 standard. Certification is provided without any evaluation of efficiency. These models must comply United States of Department of Energy (DOE) 10CFR430. The test is identified in Appendix N to Subpart B of 10CFR430. The specific test protocol is contained in ANSI/ASHRAE standard 103-1993- Method of Testing for Annual Fuel Utilization Efficiency of Residential Central Furnaces and Boilers. Minimum federal level for hot water boilers is 80% Annual Fuel Utilization Efficiency (AFUE). Slide 16 16 Efficiency Requirements Gas Boilers United States: Boilers with input ratings under 300,000 Btu/hr (88 kW) must be provided with an EnergyGuide label in accordance with federal rule 16 CFR Part 305. The label displays anticipated operating costs on a yearly basis. The Federal Trade Commission website http://www.ftc.gov contains details of the label requirements. http://www.ftc.gov Boilers with input ratings under 300,000 Btu/hr (88 kW) are eligible for Energy Star rating provided that the Annual Fuel Utilization Efficiency (AFUE) is 85% or greater. Details on energy star are found on their website http://www.energystar.gov. Slide 17 17 Efficiency Requirements Gas Boilers Canada: Boilers with input ratings of 300,000 Btu/Hr (88 kW) or more must comply with the requirements in Z21.13/CSA 4.9 with the same requirements as specified for the United States. Boilers with input ratings less than 300,000 Btu/Hr (88 kW) must comply with CSA P.2 Testing Method for Measuring Annual Fuel Utilization Efficiencies of Residential Furnaces and Boilers. -Minimum Efficiency ratings are established by Natural Resources Canada (NRCan). Current minimum rating for hot water boilers is 80% Annual Fuel Utilization Efficiency. Their website is www.nrcan.gc.ca. -Compliance with this standard is necessary as part of certification of boilers in Canada. -An energyguide label is not required by the Canadian regulations. Slide 18 18 Efficiency Requirements Gas Water Heaters Efficiencies of water heaters are treated differently for the United States and Canada. United States: Not required for certification Instantaneous water heaters with input ratings or 200,000 Btu/Hr (58 kW) or less are subject to federal Department of Energy (DOE) Requirements, which are identified in 10CFR430. The test procedures are identified in Appendix E to Subpart B of 10CFR430. Minimum federal levels are expressed as an energy factor, which is the ratio of water consumption and energy consumption over 6 specific water draws. The current minimum level is 0.62 (0.0019 x rated storage volume in gallons) Slide 19 19 Efficiency Requirements Gas Water Heaters United States: Instantaneous water heaters with input ratings under 200,000 Btu/hr (58 kW) must be provided with an EnergyGuide label in accordance with federa