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I have a 1979 Dunkirk natural gas steam boiler that was originally installed incorrectly. There is no header and the tappings have been reduced in size with bushings. The Hartford loop is very close to the steam production. When the steam comes out it hits a bullhead tee.
The boiler has been working this way for a very long time but has these problems: very bouncy water line, water being forced out of the boiler into the mains (wet steam) and water hammer in the Hartford loop. Because of these problems the system has to be run with a lot of extra water.
I would like to reconfigure it with a 3" header, 2" equalizer and two risers one for each distribution main. The Hartford loop will be on the other side of the boiler. I plan to do this work myself after the heating season ends. I've been doing all of my own plumbing with some help from plumbers in my family. Last summer I replaced the wet return which was leaking badly.
My question for the forum is it possible to do all this work including removing the bushings from the boiler tappings without breaking the boiler? If I do break it I'm prepared to buy a new boiler but wanted to try this approach first. Do I have a chance at success or is this just a terrible idea? Any tricks for taking the bushings out? I imagine it will be similar to taking the spud out of a radiator which I have done previously.