2020-8 TechPres Safarz

Upcoming Code Changes
ASME CSD-1, NFPA 85, and NFPA 87
Prepared for:
National Board – State Chiefs Meeting
Presented by:
Jason Safarz
Date:
08 October 2020
Jason Safarz | 2020-10-08 Streng vertraulich! Alle Rechte bei Karl Dungs GmbH & Co. KG, auch für den Fall von Schutzrechtsanmeldungen. Jede Verfügungsbefugnis, wie Kopier- und Weitergaberecht, bei uns. 1
Strictly confidential! The company Karl Dungs GmbH & Co. KG is the exclusive holder of all rights, also in case of patent application. All rights reserved, including copy and circulation.
About Jason Safarz – Regional Sales Manager
Background:
• Mechanical Engineer
• 20+ years on the combustion industry including both boilers and process equipment (ovens/furnaces)
Memberships/Codes/Standards:
• ASME CSD-1 Current Vice Chair, 6 years as Chair, >15 years on committee
• NBIC Part 2 – Inspection Subgroup and Subcommittee
• UL STP’s (Standard Technical Panels)
• CSA B149.3 – Alternate
• NFPA 37 – Alternate
Disclaimer: Any Standards and Codes discussion is the opinion of Dungs; all changes being presented may
change as public reviews are completed and final edits/changes are made prior to publication.
Agenda of this e-Training
PART 1
Overview of Boiler Combustion Standards &
PART 1 Coverage (inc. Thermal Fluid Heaters)
PART 2
PART 2
ASME CSD-1 Board Approved Changes
US Standards for
Boiler PART 3 PART 3
Combustion NFPA 85 Overview
Systems
PART 4
PART 4 NFPA 87 Board Approved Changes
PART 1
PART 1
Overview of Boiler Combustion Standards & Coverage
(inc. Thermal Fluid Heaters)
General Considerations - Standards
■ Requirements for US and Canadian markets on gas systems are different in requirements and
applicability NB-370 https://www.nationalboard.org/ViewAllSynopses.aspx
■ Standards revised every 4-5 years
■ Not all components can or need to be approved – A Fully FM / UL / CSA gas system is most likely not
possible… “Labeled and Listed”
■ Alternative allowed constructions are common (e.g. VPS vs POC, Over-Pressure Protection solutions,…)
Streng vertraulich! Alle Rechte bei Karl Dungs GmbH & Co. KG, auch für den Fall von Schutzrechtsanmeldungen. Jede Verfügungsbefugnis, wie Kopier- und Weitergaberecht, bei uns. 5
Jason Safarz | 2020-10-08 Strictly confidential! The company Karl Dungs GmbH & Co. KG is the exclusive holder of all rights, also in case of patent application. All rights reserved, including copy and circulation.
Main Standards for Gas Systems
ASME and ANSI, UL, CSA
■ Smaller packaged and labeled/listed boilers
NFPA Standards
■ Usually more stringent on gas trains than other standards
■ Most requested
Additional Guidelines – Insurance Linked

■ FM Property Loss Prevention Data Sheets
■ Global Asset Protection Services LLC (XL Gaps – Ex IRI)
Additional Requirements – Location Specific

■ e.g. New York City “Blue-Book”
■ e.g. State of Massachusetts Board of Plumbers and Gas-Fitters
Additional Requirements:
■ Hazardous Locations (NEC 500)
■ IFGC: International Fuel Gas Code
Boiler Codes & Standards
Code/Standard Current Ed. Application
ASME CSD-1 2018 Controls and Safety Devices for Automatically Fired Boilers
- Input less than 12,500,000 Btu/hr (3,663 kW)
NFPA 85 2019 Boiler and Combustion Systems Hazards Code
- Input of 12,500,000 Btu/hr (3.7 MW) or greater
NFPA 87 2018 Recommended Practice for Fluid Heaters
- Thermal heaters with fluid under pressure, indirectly heated (combustion or
electric source)
API 556 2019 Instrumentation, Control, and Protective Systems for Fired Heaters and Steam
Generators
CSA B149.3-15 2015 Code for the field approval of fuel-related components on appliances and
equipment
- Fuel-related components and accessories on an appliance using gas,
downstream of the manual shut-off valve
TSSA-FA-2016 2016 TSSA Field Approval Code
Main Standards - OEM Equipment
OEM Equipment Certifications / Listings
■ If an applicable standard exists, OEM’s need to get their standard products

certified/Listed through a Nationally Registered Testing Laboratory will make the
certification to the standard
• E.g. “UL 795 - Commercial-Industrial Gas Heating Equipment” used for
coffee roasters or commercial furnaces or commercial boilers– Commercial-
Industrial Gas Heating Equipment:
• E.g. “ANSI Z21.13/CSA 4.9, Standard for Gas-Fired Low Pressure Steam
and Hot Water Boilers” used for boilers typically under 5,000,000 Btu/hr
■ Or specific standards including gas trains’ designs can be used

• E.g. “ANSI Z83.4-2017/CSA 3.7-2017 - Non-recirculating direct gas-fired
heating and forced ventilation appliances for commercial and industrial
application”
■ Those standards have usually less demanding requirements on the gas system
than applicable NFPA standards
PART 2
PART 2
ASME CSD-1 Board Approved Changes
ASME CSD-1 Controls and Safety Devices for Automatically Fired
Boilers
Current: 2018 Edition

Effective Date: October 12, 2018
Future: 2022 Edition
Scope:
Applies to packaged and field erected automatically operated boilers directly fired with gas, oil,
gas-oil, or electricity with an input of less than 12.5 million Btu/hr.
CSD-1 History
• 1st issue April 29, 1977
• Historically addressed gap in boiler codes between listed boiler packages and NFPA 85 series
(>= 12.5 MMBtu/hr)
• Exclusions include: water heaters, direct gas-fired swimming pool heaters, acceptance by other
listings (such as ANSI Z21.13, UL 726, UL 834)
• Developed to address major perils and principal causes of accidents in boilers:

Loss of water Furnace explosions
Overpressure Over-temperature
Lack of controls Lack of safety devices
Lack of maintenance Lack of training
Failure to test devices Complacency of operator
Main Parts of CSD-1
CSD-1 Scope - Included
Part CG General
I. Boiler Type:
– Hot Water Part CM Testing and Maintenance
– Low Pressure Steam (<= 15 psig) Part CE Electrical

– High Pressure Steam (> 15 psig) Part CW Steam and Waterside Control
– Vacuum Part CF Combustion Side Control
– Modular
II. Fuels Installed: IV. Burner MMBtu/hr Input:
– Natural Gas – LP Gas/Air – Fuel Oil – 0 to 0.4 / 0.4 to 2.5 / 2.5 to 5.0 /
– Electric 5.0 to 12.5
– Other V. Pilot Type:
III. Burner Type: – Direct Spark-Hot Surface /
– Atmospheric/Natural Draft Continuous / Intermittent /
– Power/Mechanical Draft Interrupted
2022 CSD-1 Changes
Board Approved – Major Edits

• 12-1579 (CF-1000) VFD Drive on Combustion Air
• 11-1255 (CF-195 & CF-540) Automatic Stack Dampers
• 16-2379 (CE-110) Remote Shutdown Switches on Outdoors Boilers
• 08-643 (CG-440 & CG-500) Operational Testing & Reporting
12-1579 CF-1000 Requirements for the Use of Variable Frequency Drives
(VFD) - Abridged
CF-1010 VFD used on Combustion Air Fan
Boiler units that use a VFD to vary the speed of the combustion air fan shall comply with the following:
a) Purge - shall be as specified in Tables CF-2, CF-3 and/or CF-5, and
b) If used to modulate combustion air in response to changing fuel inputs, the VFD shall respond to the combustion control
system as part of the fuel-air-ratio control (FARC) system, and
c) An independent feedback signal shall be used to verify the fan or blower speed.
d) The independent feedback signal and the FARC system shall be labeled and listed for the VFD application by a nationally
recognized testing agency.
e) Direct Coupled arrangements may use motor speed as a measure of the fan/blower speed.
f) Errors between the directed fan or blower speed signal and the independent feedback signal of actual speed or air flow
shall result in a safety shutdown.
g) VFD’s shall not be used in applications where the combustion air fan is used to operate equipment such as an oil pump or
the atomizing air compressor.
12-1579 CF-1000 Requirements for the Use of Variable Frequency Drives
(VFD)
Exceptions:
1) CF-1000 does not apply to modulating controls that are certified as part of boiler units that are labeled and
listed by a nationally recognized testing agency or other organization that is acceptable to the authority
having jurisdiction.
2) CF-1000 does not apply to ratio-regulator controls.
3) CF-1000 does not apply to VFD applications that do not vary fan or blower speed in relation to firing rate or
changes in firing rate.
New Definitions:
Atomizing Air Compressor, Combustion Control System, Direct Coupled Fan/Blower, Fuel-Air-Ratio Control
System, Independent Feedback Signal, Ratio-Regulator Control, Variable Frequency Drive (VFD), Directed
Fan or Blower Speed Signal
11-1255 CF-195 and CF-540 Automatic Stack Dampers - Abridged
New Definition
Automatic stack damper. An automatically operated damper or shutter that is located downstream of the combustion chamber
and in the flue duct (boiler outlet, breeching, stack or chimney) with a drive mechanism that can open, close or modulate the
damper in response to boiler operation or stack draft variations.
CF-195 Automatic Stack Dampers (Gas Fired)

When an automatic stack damper is used, the following criteria shall apply:
a) The automatic stack damper shall be labeled and listed for the intended application by a nationally recognized testing
agency.
b) A means shall be provided to open such automatic stack damper to the high fire position before each light-off cycle is
initiated, and before the pre-purge period begins.
c) If a post-purge period is required or implemented, a means shall be provided to open the automatic stack damper to the
high fire position or maintain the automatic stack damper in the previous firing position.
CF-540 Automatic Stack Dampers (Oil-Fired)

Same language as CF-195
16-2379 CE-110 (b) (3)
CE-110 Electrical Requirements
CE-110 General
(b) A manually operated remote shutdown switch or circuit breaker shall be
located just outside the boiler room door and marked for easy
identification.
(1) Consideration should be given….
(2) Activation of the remote shutdown switch or circuit breaker shall

immediately shutoff the fuel or energy supply.
(3) For installations not in a boiler or equipment room, such as outdoors at

ground level or roof top, the manually operated remote shutdown
switch(es) or circuit breaker(s) shall be accessible and located at a safe
distance as defined by the authority having jurisdiction.
17-2617 and 08-643 CF-440 and CG-510
CG-440 Operational Testing
The manufacturer and/or the installing contractor, as applicable, shall make a testing report available as required by sections CG-441, CG-442,
CG-443, CG-444, and CG-510.
CG-441 Shop-Assembled Boilers — New Installations

(a) The manufacturer of shop-assembled boilers Manufacturers shall test and report per CG-510(a) on the operation of control systems and
safety devices installed in accordance with this Standard. Test conditions shall be as close to specified field conditions as feasible prior to
shipment from the manufacturer’s facility. Where production makes it infeasible to check each shop-assembled boiler unit individually prior to
shipment, the manufacturer shall follow a written inspection and quality control procedure by which the intent of this paragraph will be met.
(b) The installing contractor manufacturer’s representative or installing contractor shall, as part of commissioning the unit, test and report per
CG- 510(ba) on the operation of all control systems and safety devices installed in accordance with this Standard prior to release to the
owner/user.
CG-442 Shop-Assembled Boilers — Existing Installations

After replacing burners or controls, installing audible or visual alarms, status, or control wiring to primary flame safety controls, or after the boiler
unit is moved from its original installation location, the installing contractor shall test and report per CG-510(a) on the operation of all control
systems and safety devices installed in accordance with this Standard prior to release to the owner/user.
17-2617 and 08-643 CF-440 and CG-510
CG-440 Operational Testing Cont.
CG-443 Field-Assembled Boilers — New Installations

During commissioning of a new installation, manufacturers, their representatives, or installing contractors shall test and report per CG-510(b),
as applicable, on the operation of all control systems and safety devices installed in accordance with this Standard prior to release to the
owner/user.
CG-444 Field-Assembled Boilers — Existing Installations

After replacing burners or controls or after the boiler unit is moved from its original installation location, the installing contractor shall test and
report per CG-510(b) on the operation of all control systems and safety devices installed in accordance with this Standard prior to release to
the owner/user.
CG-500 CERTIFICATION AND REPORTING
CG-510 Certification and Reporting

(a) Manufacturers and/or installing contractors, as applicable, of shop-assembled boiler units covered by this Standard shall maintain a report
for each boiler unit or on for each category (type, size, or model) for of boiler unitsunit. For boiler units less than or equal to 400,000 Btu/hr (117
kW) for gas, or less than or equal to 3 gph (11.4 L/h) for oil, a report shall be maintained on each category (type, size, or model).
(b) Manufacturers and/or installing contractors, as applicable, of field-assembled boiler units covered by this Standard shall maintain a report
for each boiler unit or for each category (type, size, or model) for each boiler unit.
2022 CSD-1 Changes – Minor Edits
• 18-1288 (CW-120 & CW-140) AHJ Acceptability for Blowoff Location
– Added “acceptable to AHJ” language
• 15-2910 (CW-140) Miniature Boiler Clarification

– 1 LWCO device for high-pressure miniature steam boilers
• 18-1283 SI Conversions & Significant Figures

– i.e. 1 100kPa to 1.1 MPa
– 1.86 m2 to 1.9 m2
• Definition Changes: 16-2380, 15-2880, 16-1732, 17-2618 SEE APPENDIX
PART 3
PART 3
NFPA 85 Overview
NFPA 85 Boiler and Combustion Systems Hazards Code

Effective Date: November 25, 2018
Future: 2023 Edition (Fall 2022 Revision Cycle)
Scope:
Applies to single and multiple burner boilers, stokers, and atmospheric fluidized bed boilers with
an input of 12.5 million Btu/hr or greater. Pulverized fuel systems at any input. Fired/unfired
steam generators used to recover heat from combustion turbines (HRSGs) at any input.
NFPA 85 Scope - Included
Fuels Include (Sec. 1.1.4 through 1.19)
• Natural gas
• Other gas w/ calorific and other characteristics similar to natural gas.
• Fuel oil
• Simultaneous firing of gas and oil
• Pulverized coal
• Wood
• Refuse-derived fuel (RDF)
• Municipal solid waste (MSW)
• Other solid fuels
Exceptions (1.1.3)
NFPA 85 does not cover process heaters used in chemical and petroleum manufacture in which the steam
generation is incidental to the operation of a processing system.
NFPA 85 Scope - Included
• All boilers (packaged and field assembled) greater than or equal to 12,500,000 Btu/hr input.
• Each Chapter addresses a specific style of boiler:

– CH 4 – Fundamentals (applies to all unless otherwise noted)
– CH 5 – Single Burner
– CH 6 – Multiple Burner
– CH 7 – Atmospheric Fluidized Bed
– CH 8 – Heat Recovery Steam Generators (HRSGs)
– CH 9 – Pulverized Fuel Systems
– CH 10 – Stokers
PART 4
PART 4
NFPA 87 Board Approved Changes
NFPA 87 Standard for Fluid Heaters

Effective Date: August 21, 2017
First year as a Standard
Future: 2021 Edition
Recent Editions: 2011 First Edition, based upon NFPA 86 (Recommended Practice)
2015 (Recommended Practice)
Scope:
Applies to fluid heaters and related equipment with an input exceeding 150,000 Btu/hr. Includes thermal
and process fluid heaters, new and altered/extended existing equipment, where:
 Fluid is flowing under pressure
 Fluid is indirectly heated
 Release of energy from combustion of an electric source occurs within unit
NFPA 87 Standard for Fluid Heaters - Exclusions
Exclusions:
1. Boilers covered by ASME CSD-1 and NFPA 85
2. NFPA 86 Class A, B, C, and D ovens and furnaces
3. Fired heaters and petroleum refineries and petrochemical facilities designed:
 API STP 560 – Fluid Heaters for General Refinery Services,
 API RP 556 – Instrumentation and Control Systems for Fired Heaters and Steam
Generators, and
 API RP 2001 – Fire Protection in Refineries
4. Fired heaters commonly called reformer furnaces or cracking furnaces in petrochemical
and chemical industries
5. Occupies space or comfort heating air
6. LP-Gas vaporizers designed and installed to NFPA 58
7. Listed equipment with heating system total input not exceeding 150,000 Btu/hr (44 kW)
SR-12
Added terms related to the safeguarding

of solid fuel combustion and provide
clarification and standardization for
manufacturers of solid-fuel-fired fluid
heaters.
SR-16
The first draft rev created unintended
consequences (e.g., absence of parallel
language for oil fire burners to CSD-1, logic
to the presence of POC on SSOVs). The
result was a significant increase in the Btu/hr
capacity threshold for SSOVs including pilot
systems as compared to those in the
existing 2018 edition.
2021 NFPA 87 – Minor Edits
SR-8
Ball valves are not acceptable due to ability to
trap fluid when closed (thermal expansion risk)
SR-10
Clarification on conflicting req’s between Chapter 10 and Chapters 1-9, 11
SR-11
Terminology change from “oven” to “combustion chamber”
Streng vertraulich! Alle Rechte bei Karl Dungs GmbH & Co. KG, auch für den Fall von Schutzrechtsanmeldungen. Jede Verfügungsbefugnis, wie Kopier- und Weitergaberecht, bei uns.
2021 NFPA 87 – Minor Edits Cont.
SR-15
New definition for “blanket gas”
SR-17
Piping materials and joining methods alignment with NFPA 54 under 6.2.6.
ASME CSD-1 vs. NFPA 87 – Conflict
NFPA 87 8.2.1 The requirements of Chapter 8 shall not apply to thermal fluid heaters with fuel input ratings
less than 12,500,000 Btu/hr (3.7 MW) that conform with ASME CSD-1, Controls and Safety Devices for
Automatically Fired Boilers, or with UL 795, Standard for Commercial-Industrial Gas Heating Equipment.
Chapter 8 is the heating system safety equipment and application. Several items are not covered by CSD-1
including PLC/Safety PLC’s, software, stack excess temperature, and fluid excess temperature.
Take-Aways:
 ASME CSD-1 service limitations are for automatically fired boilers (steam
and water) and burner assemblies and burners field-installed is
automatically fired boilers.
 By definition a thermal fluid heater is not a boiler and as such is not

covered by ASME CSD-1
RESOURCES AVAILABLE:
ASME CSD-1 Connect NFPA Website: nfpa.org
https://cstools.asme.org/csconnect/Committ
eePages.cfm?Committee=L01400000 85 https://www.nfpa.org/codes-and-standards/all-codes-and-
standards/list-of-codes-and-standards/detail?code=85
87 https://www.nfpa.org/codes-and-standards/all-codes-and-
standards/list-of-codes-and-standards/detail?code=87
Appendix
Additional Supporting Information
CSD-1 Appendix: 12-1579 CF-1000 VFD Definitions
Atomizing Air Compressor: an air compressor that supplies air to the oil nozzle for the atomizing medium.
Combustion Control System: those control systems that includes the ability to provide safety shutdown and the Fuel-Air-Ratio
control system
Direct Coupled Fan/Blower: the fan or blower is mounted to the motor shaft and mechanically secured.
Fuel-Air-Ratio Control System: a system that manages the flow of combustion air, fuel and other support systems to support
modulating firing rates.
Independent Feedback Signal: a signal indicating the speed of the fan or blower, that can be read by the combustion control
system and used to compare actual fan or blower speed to the required fan or blower speed.
Ratio-Regulator Control: a fuel control valve that modulates the fuel flow as a ratio of the combustion air flow.
Variable Frequency Drive (VFD): a control that can vary the speed of an electric motor. This is intended to include all forms of
motor speed control, including Variable Speed Drives (VSD), Pulse Width Modulated (PWM), Electronically Commutated (EC) or
Brushless DC (BLDC) or any other type of motor speed control.
Directed Fan or Blower Speed Signal: a signal developed by the Fuel-Air-Ratio control system to regulate fan or blower speed as
part of the combustion air flow requirements.
CSD-1 Appendix: Other Definitions Added
boiler, hot-water: a hot-water heating boiler, hot water supply boiler, or high-temperature water boiler.
(a) boiler, hot-water heating: a boiler in which no steam is generated and from which hot water is circulated for heating
purposes, then returned to the boiler operating at a pressure less than or equal to 160 psig (1 100 kPa gage) or a
temperature less than or equal to 250°F (120°C) at or near the boiler outlet.
(b) boiler, hot-water supply: a boiler that furnishes hot water to be used externally to itself at a pressure less than or equal to
160 psig (1 100 kPa gage) or a temperature less than or equal to 250°F (120°C) at or near the boiler outlet.
(c) boiler, high-temperature water: a water boiler intended for operation at pressures in excess of 160 psig (1 100 kPa)
and/or a temperatures in excess of 250°F (120°C).
fuel train; a series of valves, regulators, and controls, between the burner and the source of fuel, all fuel piping, tubing,
fittings, valves, devices, and components, that regulates and controls the flow of fuel , that from the inlet of the manually
operated shutoff valve, which isolates all main fuel line controls from the fuel supply, to the burner.
Safety Device: Any device that acts, or initiates action, to cause the boiler to remain in, or revert to, a safe state.
2 Valves with Proof-of-closure
NFPA 85:2019 – Single Burner Boiler required.
Main Safety Valves (W/ POC)
Low Pressure Switch
High Pressure Switch
– Manual Reset Valve Proving System
– Manual Reset
Valve Proving System

Main Safety Valves – W/POC
Normally Open Vent Valve
– Half-Pipe Size – Primary
option instead of VPS
All Pressure switches required to be

manually reset
Jason Safarz | 2020-10-08 Strictly confidential! The company Karl Dungs GmbH & Co. KG is the exclusive holder of all rights, also in case of patent application. All rights reserved, including copy and circulation. 37
NFPA 85:2019 – Multiple Burner Boiler (Simplified) Vent Valve
Header Vent Valve

Main Safety Valve
2 Valves with Proof-of-closure Normally Open Vent Valve

required + Header – Half-Pipe Size – Only
Option
Jason Safarz | 2020-10-08 Strictly confidential! The company Karl Dungs GmbH & Co. KG is the exclusive holder of all rights, also in case of patent application. All rights reserved, including copy and circulation. 38
Thank you very much for your attention!
Jason Safarz Karl Dungs Inc.

3890 Pheasant Ridge Dr. NE
Suite 150
Regional Sales Manager Blaine, MN 55449, U.S.A.
Phone 763-582-1700
Fax 763-582-1799
Mobil 612-222-7171
jsafarz@karldungsusa.com
www.dungs.com/usa/

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Upcoming Code Changes

ASME CSD-1, NFPA 85, and NFPA 87

applicability NB-370 https://www.nationalboard.org/ViewAllSynopses.aspx

■ Standards revised every 4-5 years

possible… “Labeled and Listed”

Additional Guidelines – Insurance Linked

Additional Requirements – Location Specific

OEM Equipment Certifications / Listings

■ If an applicable standard exists, OEM’s need to get their standard products

■ Or specific standards including gas trains’ designs can be used

Current: 2018 Edition

Future: 2022 Edition

• Developed to address major perils and principal causes of accidents in boilers:

– Low Pressure Steam (<= 15 psig) Part CE Electrical

Board Approved – Major Edits

2) CF-1000 does not apply to ratio-regulator controls.

CF-195 Automatic Stack Dampers (Gas Fired)

CF-540 Automatic Stack Dampers (Oil-Fired)

(2) Activation of the remote shutdown switch or circuit breaker shall

(3) For installations not in a boiler or equipment room, such as outdoors at

CG-441 Shop-Assembled Boilers — New Installations

CG-442 Shop-Assembled Boilers — Existing Installations

CG-443 Field-Assembled Boilers — New Installations

CG-444 Field-Assembled Boilers — Existing Installations

CG-500 CERTIFICATION AND REPORTING

CG-510 Certification and Reporting

• 15-2910 (CW-140) Miniature Boiler Clarification

• 18-1283 SI Conversions & Significant Figures

• Definition Changes: 16-2380, 15-2880, 16-1732, 17-2618 SEE APPENDIX

Current: 2019 Edition

Future: 2023 Edition (Fall 2022 Revision Cycle)

• Each Chapter addresses a specific style of boiler:

Current: 2018 Edition

Future: 2021 Edition

Added terms related to the safeguarding

 By definition a thermal fluid heater is not a boiler and as such is not

Valve Proving System

All Pressure switches required to be

Header Vent Valve

2 Valves with Proof-of-closure Normally Open Vent Valve

Jason Safarz Karl Dungs Inc.

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