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Converting steam convectors to forced hot water
I searched around the last few days on this but did not find any thread addressing a few of my concerns.
Working in an old new England home with an existing steam system using copper convectors that are buried in the walls. Primarily on the first floor only...one on the second floor. Addition on second floor roughed for sf30 bb. The convectors have no vents on them. The system is piped in what I believe is a reverse return. There is a 1.5" supply header around the perimeter and a 1 1/4" return around the perimeter with each convector supply being 1" and the return 3/4". The return breaks into 4 vertical pipes with steam vents into the floor and back to the boiler.
We want to convert to fhw for several reasons...mostly to gain efficiency, run the superstor and use bb on the second floor.
My main questions are:
1. Boiler location is moving...20ft or so. What size piping should I plan on using to hit the existing supply and return for the first floor convectors. Should i pump away as we usually do now?
2. 3 convectors have to move outward (for the addition) about 12ft each. Can the mains stay in there current location, (old foundation location)? That would mean each supply and return to the 3 moved convectors would be 12ft or so. All are currenting right near the mains. I think this is ok as the water will be forced through no matter what right. I really don't want to reconfigure the main return and supply. Also planning on using the same size piping as on the other convectors. I am thinking iron on the convector side so that I can secure them nicely, then connect the two with wirsbo heat pex.
I tried to get the homeowner to change to bb for the first floor, had him convinced, and now he's back to keeping these convectors! It's a loosing battle.
Should I be worried about leaks in the existing piping ? Everything worked fine with the steam. I know I have to remove the steam vents on the return main.
Am I missing anything?
Thanks all, to date I have not performed a steam to fhw conversion so I want to make certain everything is going to work well.
The boiler I plan on using is a lochinvar, piped with a primary secondary, 3 zones...superstor, 1st convectors/iron piping with one 2nd floor convector, 2nd floor new bb
And a future. It is not ideal to Have the 2nd floor convector stay I realize...but it is in an existing section of the home that no one wants to get into the walls in. Otherwise I would put bb in there and tie it into the 2nd bb loop as it should be.
Thanks in advance!