Heavy Corrosion on GJ Union ?

bigugh_4

> Hey guys-<BR>
> <BR>
> Ever seen anything like this before? <BR>
> (pics below I hope)<BR>
> <BR>
> Peerless 61-04 Boiler <BR>
> installed 1/98 by a supposed <BR>
> "professional".<BR>
> <BR>
> Ground Joint 2" union between <BR>
> boiler outlets on bottom starts corroding <BR>
> immediately, but never leaks visibly.<BR>
> <BR>
> 8 years <BR>
> later, I just got done chipping out a 20 foot <BR>
> trench in the poured basement floor to replace a <BR>
> wet return that's older than I am... and it was <BR>
> leaking for at least a heating season.<BR>
> <BR>
> Bring <BR>
> everything back up online, and now the boiler <BR>
> makes pressure, and so now that cruddy union is <BR>
> leaking, dripping, making a mess.<BR>
> <BR>
> Great. I've <BR>
> got a lot of pipes to back out, including the <BR>
> equalizer and the wet return. Okay.<BR>
> <BR>
> But what <BR>
> in heck caused that much corrosion, and only <BR>
> there? The 2" GJ is so bad I doubt I can spin <BR>
> any of it apart. But even the short nipples are <BR>
> corroded, all the way back to the tees and the <BR>
> flanges are eaten off of them. We're talkling <BR>
> porus, all the way through. I tapped (gently!) <BR>
> with a wrench a they sound dull and hollow. <BR>
> Everything else seems okay.<BR>
> <BR>
> I don't understand <BR>
> why it was only in this area, as everything else <BR>
> on the system looks fine. I thought maybe cheap <BR>
> Chinese fittings, but everything else was new '98 <BR>
> and Ward brand castings.<BR>
> <BR>
> Ever seen rot like <BR>
> this, and so localized? Can anyone suggest why? <BR>
> Thought maybe it was flue vapor dropping out or <BR>
> something, but only the fittings near the floor <BR>
> rotted, nothing else.<BR>
> <BR>
> I also don't understand <BR>
> why my "professional" chose to fit the rear <BR>
> outlet with a 2" to 1 1/2" reducing elbow, and <BR>
> reducing tees, rather than plumbing it just like <BR>
> the front outlet with all 2" stuff, like Peerless <BR>
> and God intended.<BR>
> <BR>
> Now's the time to do <BR>
> everything right, I suppose. My arms are still <BR>
> sore from the chop gun. At least it's not cold <BR>
> in NY yet.<BR>
> <BR>
> Love this site and the help. Thanks <BR>
> for your input-<BR>
> <BR>
> -steve <BR>
<BR>

S.A. McChesney

Heavy Corrosion on Steam Boiler GJ Union

Hey guys-

Ever seen anything like this before? (pics below I hope)

Peerless 61-04 Boiler installed 1/98 by a supposed "professional".

Ground Joint 2" union between boiler outlets on bottom starts corroding immediately, but never leaks visibly.

8 years later, I just got done chipping out a 20 foot trench in the poured basement floor to replace a wet return that's older than I am... and it was leaking for at least a heating season.

Bring everything back up online, and now the boiler makes pressure, and so now that cruddy union is leaking, dripping, making a mess.

Great. I've got a lot of pipes to back out, including the equalizer and the wet return. Okay.

But what in heck caused that much corrosion, and only there? The 2" GJ is so bad I doubt I can spin any of it apart. But even the short nipples are corroded, all the way back to the tees and the flanges are eaten off of them. We're talkling porus, all the way through. I tapped (gently!) with a wrench a they sound dull and hollow. Everything else seems okay.

I don't understand why it was only in this area, as everything else on the system looks fine. I thought maybe cheap Chinese fittings, but everything else was new '98 and Ward brand castings.

Ever seen rot like this, and so localized? Can anyone suggest why? Thought maybe it was flue vapor dropping out or something, but only the fittings near the floor rotted, nothing else.

I also don't understand why my "professional" chose to fit the rear outlet with a 2" to 1 1/2" reducing elbow, and reducing tees, rather than plumbing it just like the front outlet with all 2" stuff, like Peerless and God intended.

Now's the time to do everything right, I suppose. My arms are still sore from the chop gun. At least it's not cold in NY yet.

Love this site and the help. Thanks for your input-

-steve

bigugh_4

Corrosion ?

Do I see soot spillage upon the boiler jacket? Could thehr be some products of combustion coming from under the boiler? That and a weep leak on the GJ union and walla a nasty situation for the iron its made of. Just brainstorming here!

Unknown

I bet

the ends of the union are just a tad shy of mating or not exactly in line , and the union was leaking very slightly from day 1 . I know making that union up in that tight spot is pretty tough .

Another thought is that the nipples were tightened , they saw the union was too far apart , so they backed off on the nipples , loosening them to make up the slack . It seems too isolated to be anything other than a thread or union leak .