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Rotted Steam Boiler - Replacement

JStarJStar Posts: 2,668Member
This time, the leak wasn't WM's fault (wink wink). Major deterioration most likely caused by copper/dielectric reaction, and a general lack of bad advice for proper maintenance.

Installed (our favorite) Smith/Carlin combo. Upsized drop header, which is unfortunately hard to see in the pictures. Upgraded main vents.

I've also seen something for the first time on this job. A supply pipe, nearly 50% blocked by sludgy clay sediment. A few spots of this main were also rotted right through because of poor pitch allowing condensate to settle in one spot. The pipe was obviously changed at least one time before. But, of course, the pitch was never corrected.

Thanks to Rod for helping our customer, via email, with doing the proper research and asking the right questions for this job. She sung your praises the whole time.


  • JStarJStar Posts: 2,668Member

    If you're wondering what that Honeywell relay is doing...we installed  WiFi capable t-stat that requires a common wire back to a 24V transformer. The Honeywell R8845U relay provides a true common terminal, AND provides a control fuse. Love that part!
  • SWEISWEI Posts: 7,356Member
    Nice work as usual

    Love those copper steam accelerators they added...
  • SteamheadSteamhead Posts: 12,726Member
    That W-M installation

    was a perfect example of "You Can't Fix Stupid".

    That single 2-inch riser probably sucked all the water out of the boiler. Then the feeder came on and overfilled it, and on the next cycle it lifted even more water up into the main, carrying sludge with it. All that fresh water being fed eventually rotted out the boiler and likely the steam main too.

    Fortunately the right contractor corrected the situation.
    All Steamed Up, Inc.
    "Reducing our country's energy consumption, one system at a time"
    Steam, Vapor & Hot-Water Heating Specialists
    Oil & Gas Burner Service
    Baltimore, MD (USA) and consulting anywhere.
  • JStarJStar Posts: 2,668Member

    Water was definitely leaving the boiler on a regular basis. You'd figure that a 3" boiler tapping, and a 3" header fitting would lead somebody to believe that a 3" pipe should connect them. Well, that's if you figure a lot of things about the previous installer.

    There was also a number of contractors who were trying to convince the homeowner that a conversion burner would be a good fit on this boiler. They said the detrioration wasn't a problem.

    I think we'll be going back to clean this boiler a few times duing the first month of heating season.
  • gerry gillgerry gill Posts: 2,896Member
    Wow Joe,

    That clogged pipe is really something! i hadn't seen that on a steam pipe either..glad she found you to get it all squared away.

    Serving Cleveland's eastern suburbs from Cleveland Heights down to Cuyahoga Falls.

  • RodRod Posts: 2,067
    Very Nice Job!

    Just got a chance to look over the pictures after a 2 ½ weeks vacation in the Maine north woods. A really nice installation, Joe. You really out did yourself ! The detail work, like the bell reducers on the risers to the mains, is superb!  Your customer is really happy!
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