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Boiler replaced - Boiler trap removed
I'm hoping someone here can lend a little advice on a problem project I have been drawn in to. I have done a fair amount of work on residential steam heating systems and boiler replacements in the past but I do not consider myself a steam expert by any means. I have a basic understanding of the operation of the system I am now trying to repair but I don't have enough knowledge to feel confident in a repair.
My customer had their old oil fired steam boiler replaced with a new gas fired steam boiler by another contractor several months ago and claims it has not worked since the day it was put in. The other contractor has been making attempts at finding a fix but with no luck. From the descriptions of the old system that the customer has been giving me, it appears that there was originally a boiler return trap in the system. The installing contractor removed it during the course of the installation and replaced it with a new F&T trap. A dry return pipe, which is the return from all of the radiators, enters this trap then exits and is piped straight into a return tapping of the boiler. Another return pipe, which originates from the end of the supply main, comes in low and is piped into a Hartford loop and into a return tapping on the other side of the boiler. All of the piping near the boiler, both supply and return, has been replaced with copper and there are no check valves left in the system.
My suppliers have told me there is no possibility of getting my hands on a new boiler return trap. From researching as much documentation as I've been able to get my hands on, it appears the system will never operate properly without it. My thought process has been that I could probably reengineer this system with a receiver and condensate return pump but I don't want to make this expensive leap without some input from those with more knowledge of this design then I have. Does anyone have any experience with boiler return traps and what to do with the systems if they are removed?
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