Furnaces

Furnace types:
Flue Temperature

Type of Vent

Conventional (Cat. 1)
(max efficiency = 60%)

> or = 350F

Single wall or B-vent

(metal because the temperatures
are so hot)

Mid-Efficiency (Cat. 1)
(max efficiency = 80%)

275F to 350F

Single wall or B-vent

High-Efficiency (Cat. 4)
(min efficiency = 90%)

80F to 120F

System 636

Module 1
Personal Safety:
-attitudes that will help:
1) Courtesy
2) Attention
3) Safe Conduct
4) Posture
-factors that will affect a safe working environment:
1) Temperature and humidity conditions
2) Noise
3) Lighting
-safety aspects:
1) eye protection
-CSA-approved glasses or goggles
2) hearing protection
3) head protection
-must be CSA-approved
4) foot protection
-CSA-approved
5) respiratory protection
6) hand protection
*types:
-thermally-insulated gloves
-rubber/approved plastice treated gloves
-approved rubber gloves
-neoprene gloves
-when using a ladder: 1 ft horizontal for every 4 ft vertical
-protective equipment:
-fire extinguishers
-ventilation equipment
-vacuum systems
-exhaust systems
-special ventilating equipment
-electrical safety:
-use grounded plugs or double-insulated power tools

= hot surfaces
= acids and cleaning
chemicals
= electrical
= LPG (liquid propane gas)

-lockout:
Lockout-Tagout (LOTO)
-general safety rules:
1) No horseplay
2) Clean up
3) Do not place things where they can fall
4) Work with adequate lighting
5) Lift correectly
6) Use protective equipment
7) Tag and remove defective items
8) Report accident and injuries
9) Be aware of the state of your health
10) Do not work while impaired by alcohol or medication
11) Correct or report unsafe conditions immediately
-fire hazards:
-fire is also called combustion
*for it to exist: need three things:
1) oxygen
-remove it = starvation
2) fuel
-remove it = cool
3) heat for ignition
-remove it = smother
-Fire extinguishers:
-aim at base of fire
-inspect every year
Fire Extinguishers
Symbol Colour and Class

Type of Fire

Type of Extinguisher

A (green)

-involving ordinary
-ones that use the
combustibles (wood, cloth, heat-absorbing effects of
paper, rubber, most plastics) certain chemicals that slow
e.g. water ext. / halon ext. /
combustion
dry chemical ext.
B (red)

-involving flammable
vapours

-ones that prevent vapours

from being released
-ones that interrupt
combustion

-involving energized
electrical equipment

-ones that use

non-conductive
extinguishing agents
-A or B extinguishers can
be used when electrical
equipment is de-energized

e.g. halon ext. / dry chemical

ext. / C02 ext.
C (blue)

e.g. halon ext. / dry chemical

ext. / C02 ext.

D (yellow)

-involving combustible
metals (magnesium,
titanium, zirconium,
sodium, potassium)

-ones that use

heat-absorbing
extinguishing medium not
reactive w/ burning
materials
-sand can also be used

WHMIS:
-supplier WHMIS label must have following info.:
1) Product identifier (name of product)
2) Supplier identifier (name of company that sold it)
3) statement that an MSDS is avail.
4) hazard symbols
5) risk phrases
6) precautionary measures (how to be safe when using the product)
7) first aid measures
8) all text in English and French
9) WHMIS hatched border
-classes:
Class A: Compressed Gas
Class B: Flammable and Combustible Material
Class C: Oxidizing Material
Class D: Poisonous and Infectious Material
Division 1: Immediate and Serious Toxic Effects
Division 2: Other Toxic Effects
Division 3: Poisonous and Infectious Material
Module 2
Screws:
-identification:
1) outside thread diameter
2) number of threads per inch
3) length of screw
4) type of point
5) type of head
6

20

1/2

Type AB,

slotted hex

Cotter pins:
-used to secure circular shafts (keep something on an axle
(look kind of like bobby pins)
Bits:
-carbon bits = to drill into steel
-carbide bits = to drill into concrete
Temperature calculations:
C to F =
(C x 9) + 32
F to C =
(F 32) x 5
5
9

Module 3: Propane and Natural Gas

PROCESSING
PLANT
(separates methane,
butane, water,
odourless
petroleum, etc.)
natural gas

COMPRESSOR
STATION

CITY GATE
STATION
(mercaptan added)
odourless
(1500 to
2000 PSI)
<300 PSI

7WC to
60PSI

GAS WELL
(methane plus a lot
of other stuff)

COMMERCIAL
AND
RESIDENTIAL

INDUSTRIAL

Distro. of Natural Gas:

-through pipeline
-City Gate Station:
-gas reduced in pressure for local distro.
-ethyl mercaptan is added
-stored in subterranean caverns when there is low demand
*delivered locally at three different pressures:
Low pressure = 7WC to 14WC (older areas of cities w/ low-pressure systems)
Intermediate pressure = 2 to 60 PSI (residential and commercial)
High pressures = 60 to 125 PSI (industrial)
Distro. of Propane:
-in containers by rail, truck, etc.
-process:
Well head
Well head processing plant: gas is liquified and mercaptan is added
Shipped in containers to distributors
Uses of Natural Gas and Propane:
1) Residential
-space heating
-water heating
-ranges
-dryers
-fireplaces
-pool heaters
2) Commercial/Institutional
-space heating

-commercial cooking and laundry

-temp. heating at construction sites (propane)
3) Industrial/Agricultural
-space heating
-process ovens and dryers
-power generation
-welding
-crop drying and milk processing
Physical Properties:
-natural gas and propane = hydrocarbons (compounds of H and C)
-propane distilled from oil and natural gas
-natural gas is naturally occurring => drawn out of the well as a substance containing
mostly methane
-90% methane
-5% ethane
-other stuff
-characteristics of propane and natural gas:
1) colourless
2) odourless
3) tasteless
4) non-toxic
-propane also known as liquid petroleum gas (L.P.G.)
Mercaptan:
Natural gas: butyl mercaptan added at City Gate Station
Propane: ethyl mercaptan added at processing plant
*one pound of mercaptan is added to every 1 million cubic feet of gas
Chemical composition:
Natural gas:
-composed primarily of methane
METHANE is CH4
-H is lighter than C
Propane:
Propane is C3H4
-additional C atoms is what makes it heavier than natural gas
*the more C and H = the heavier the molecule
= the more heat value (greater BTUs/greater calorific
value)
= the more air you need for complete combustion
Properties of Natural Gas and Propane:
A) Relative Density (Specific Gravity)
= weight of a substance as compared to the known weight of another substance
Gaseous state: compare to air (specific gravity of air is 1)
Specific gravity of N.G.
= 0.6 (lighter than air)
Specific gravity of Propane gas
= 1.52 (heavier than air)
Liquid state: compare to water (specific gravity of water is 1)
Specific gravity of N.G. liquid
= 0.4 (lighter than water)
Specific gravity of Propane
= 0.5 (lighter than water)
B) Boiling Point
= temperature at which a liquid turns into a vapour

-water boils at 212F

Propane:
boiling point is -44F
N.G.:
boiling point is -258F
C) Expansion Factors
= when the temp. of a liquid increases, it changes to a vapour and expands
= this results in an increased pressure and volume (amount of a substance)
-liquid propane containers only partially filled to allow for expansion
*when you let vapour escape from a propane container, the pressure inside
changes which causes the remaining liquid to boil/vapourize
N.G. Expansion Factor:
expands 1 to 600 times
Propane Expansion Factor: expands 1 to 270 times
D) Heating Value (Heat Content)
= amount of heat energy released from the burning of one cubic foot of gas
(Calorific value)
(BTUs/ft3)
*1 BTU = amount of heat required to raise 1lb of water 1F
Propane heat content:
2520 BTUs per cubic foot
N.G. heat content:
1000 BTUs per cubic foot
(natural gas has fewer carbon and hydrogen atoms => it produces less heat
content per cubic foot of gas)
E) Minimum Ignition Temp.
= temperature at which an air/gas mixture will start combustion
Propane:
1200F
N.G.
900F
F) Limit of Flammability
= upper and lower ranges of the amount of gas in an air/gas mixture that will support
combustion (keep the fire burning)
Propane:
2.5% to 9.5%
N.G.:
4%
to 15%
G) Air to Fuel Ratio
= the ratio of air to gas required for complete combustion
Propane:
23.5 to 1 (23.5 cubic feet of air for 1 cubic feet of propane gas)
N.G.:
10
to 1
H) Max. Flame Temperature
= the maximum flame temperature that a gas can produce
*only occurs at perfect combustion
Propane:
3600F
N.G.:
3500F
I) Max. Flame Speed
= speed at which the flame front moves towards the air/gas mixture issuing from the
burner port
*depends on the amount of air
Propane:
32 per second
N.G.:
12 per second
Combustion Properties:
*combustion = the rapid oxidization of a fuel gas to produce light and heat
*oxidation = process where oxygen combines chemically with other atoms to form
oxides (e.g. rust = iron oxides -> slow form of oxidation)
-three components for ideal combustion:

1) Air (80% N, 20% O)

2) Fuel
3) Heat for ignition
-types of combustion:
1) Perfect Combustion (not the real world) of methane and air
(air is 2 parts O2 and 8 parts N2)
Air-Gas Mixture
Methane (CH4)
Air (2O2 + 8N2)

ignition causes
COMBUSTION

Flue Gases
Carbon Dioxide
(CO2)
Water vapour (2H2O)
Nitrogen (8N2)

-all products of combustion/flue gases hold heat

-N is not part of the reaction b/c it is inert (just passes through and holds heat)
2) Complete Combustion of methane and air
Flue Gases
Air-Gas Mixture
Methane (CH4)

Carbon Dioxide (CO2)

ignition causes
COMBUSTION

Air (2O2 + 8N2)

Water vapour (2H2O)

Nitrogen (8N2)

Excess Air (O2 + 4N2)

Excess Air (O2 + 4N2)

-the excess air is not needed for complete combustion

*it is a safety factor to avoid CO
-passes through combustion but still holds heat
-residential burners = 50% excess air
-in a furnace burner:

SECONDARY
AIR

PRIMARY AIR

GAS -->

THROAT
ORIFICE
PRIMARY
AIR
SHUTTER

MIXER
HEAD

AIR/GAS
MIXING
ZONE

INNER CONE
OUTER
-incomplete
combustion (CO, CONE

MIXING
BURNER etc. is present)
TUBE/
VENTURI PORT

-2ndary air is
drawn in to
complete
combustion

3) Incomplete combustion of methane and air

Flue Gases
Carbon Monoxide (CO)
Air-Gas Mixture
Methane (CH4)
Incomplete Air (O2 + 4N2)

ignition causes
COMBUSTION

Water vapour (2H2O)

Hydrogen (H2)
Nitrogen (4N2)

-air (and therefore oxygen) has been cut in half => not enough air for complete
combustion
-Combustion Air:
1) Primary Air
= air mixed w/ the fuel prior to actual combustion
2) Secondary Air
= air added after combustion to allow complete combustion
-Excess Air
= air added but not required for combustion
*buffer added to make sure there is enough air supplied for complete
combustion
*too much excess air...
...can carry away heat and therefore decrease efficiency
... can lower flame temperature and cause some incomplete combustion
-Dilution air is added at the draft hood for venting appliances
-products of combustion:
Complete combustion:
CO2 + Water vapour
+ heat + excess air
Incomplete combustion:
CO
+ Soot
+ Aldehydes
*the CO has carbon atoms which aren't completely burnt = will create soot
-unburned carbon seen as:
-yellow or white in a flame
-white residue on a heat exchanger
*aldehydes: have an acrid smell and create irritation in eyes and throat
-carbon monoxide (CO)
= the great imitator
-displaces oxygen in the blood
= similar to common flu, headaches, dizziness, nausea w/out fever
*characteristics
-colourless
-tasteless
-odourless
-combustible and explosive (flammibility range is b/t 12 and 74%)
-specific gravity is 0.96
-if CO concern is raised:
1) evacuate the area and/or
2) sample the air at a 5ft height as you approach potential source

Air Supply Requirements

(theoretical to complete combustion)
*the requirements:
1) Combustion Air
-required to complete combustion process
*two aspects:
I) Primary Air
-air that is mixed w/ fuel prior to ignition
-enters through air shutter around orifice
II) Secondary Air
-air supplied around the flame
*Primary Air + Secondary Air = COMPLETE COMBUSTION
2) Excess Air
-air supplied to combustion process in excess of combustion air to ensure
complete combustion
3) Dilution Air
-air which enters the draft control device to cool the hot flue gases
Total Air Requirement:
-Natural Gas: theoretical air requirements for a natural draft furnace:
For every cubic foot of gas that is burned (producing 1000 BTUs of heat), the air
required is...
1) Combustion Air = 10 cubic feet of air
Ratio = 10 air : 1 gas
2) Excess Air
= 5 cubic feet of air
Ratio = 5 air : 1 gas
3) Dilution Air
= 15 cubic feet of air
Ratio = 15 air : 1 gas
Total air requirement
= 30 CUBIC FEET OF AIR
-Propane: requires much more air
Flame types:
-determined by: (1) type of burner used and (2) type of fuel burned
-liquid fuels (oil) and solid fuels (coal, wood) can't mix the fuels as thoroughly as fuel
gases
-fuel gases can produce two types of flames:
1) Yellow or luminous flame
= when air is partially or not premixed w/ the fuel gas
*so: too much fuel gas and not enough air
-the yellow in the flame = result of glowing carbon particles
2) Blue or bunsen flame
= when fuel is premixed with air
*two cones are present, each a different shade of blue
-if orange is present = dirt in the combustion zone
Outer cone: where complete combustion occurs
-oxygen in the secondary air mixes w/ the incomplete products of
combustion
-if outer cone touches a cold surface = no quenching of combustion
process, b/c complete combustion has already occurred
-if inner cone touches a cold surface = incomplete combustion will result
because the temperature has decreased

Flame Lifting:
*occurs when:
1) the burner is over-fired (max. gas input exceeds the burner design)
2) too much primary air is used
-can be noisy
-flame cones may rupture, causing incomplete combustion
-more likely to occur when the burners are cold
Flashback:
= when gas/air mixture burns back towards the burner
*the flame burns back through the burner port to ignite the mixture in the burner head
-occurs when: gas/air flow velocity is less than flame speed
Propane:
*also called Liquefied Petroleum Gas (LP Gas/LPG) b/c it is stored and transported as a liquid
-is stored in 2 types of containers:
1) Cylinder
-designed, tested, fabricated by: Transport Canada, Department of Transport,
Canadian Transport Commission
-are filled by weight, measured in water capacity or pounds of water
e.g. WC240 = water capacity 240
= the capacity of the cylinder when filled w/ water
-to determine how much propane can be safely stored: mutiply by 0.42
-the largest cylinder manuf.ed = 1000lbs WC (420 lbs propane)
-relief pressure = 375PSI
2) Tank
-designed, tested, fabricated under the Boiler and Pressure Vessels Act (overseen
by TSSA)
-are filled by volume given in US gallons of water
-propane tanks are made for withdrawing both liquid and vapour
*vapour = left hand threads
*liquid = right hand threads
-relief pressure = 250 PSI
-filling a propane container:
-when heated, propane liquid expands
-propane liquid at 60F, filled to 80% will expand to 100% at 130F
-1 gallon of propane weights 5.1lbs
Module 4: Codes
Technical Standards and Safety Act:
-MCBS: Minister of the Consumer and Business Services = provincial minister ultimately
responsible for the admin. of the TSS Act
*monitors the TSSA
-TSSA: Technical Standards and Safety Authority
-Director's role = ensure the act, regulations and standards are administered
Testing Agencies:
1) Canadian Gas Association (CGA)
-test and certify appliances, equipment, components, and accessories
2) International Approval Services (IAS)
-test appliances, equipment, components, and accessories on behalf of AGA and CGA
3) Canadian Standards Association (CSA)

-accredited to test and certify appliances, equipment, components, and accessories

-can develop standards and codes
-has purchased CGA and IAS
4) Underwriter's Laboratories of Canada (ULC)
-approves venting in addition to other related things
5) Underwriter's Laboratories Inc. (UL)
-only approved if it says Ulc
6) Warnock Hersey (WH) and Equipment Testing Laboratories (ETL)
-both are operated by Inchscape Testing Services