New replacement with lots of pics

Dave0176

The old boiler was an 11 year old 150,000 btu Utica with single 2" copper riser and header that he fed into a 2-1/2x2x3" bushed down to 2" on the bull, bullhead tee. Owner told told me the heat never worked well, the third floor radiator didn't get hot unless he turned the tstat waaay up, then they roasted in the first floor. The porch was enclosed and the old plumber talked him into a hot water loop off the boiler, which he ran wrong, no bypass loop, only one flo control.

I did the best I could, was inspired by jstar with the header build. The boiler is a Williamson GSA 125,000 BTU (Weil McLain EG40) I ran a 3" header with two 2-1/2" risers, a 2" equilizer, one 2-1/2" main and one 2" main, used two No. 2 and one No. 1 Gortons on the main return.

Here it is on the first fire up almost done, just have finish

Dave0176

Well those pic didn't work lol

Dave0176

This one sideways I give up

Dave0176

More

Robert O'Connor_12

Did you bush the supply tappings down to 2"?
I thought that boiler came with 2- 3" connections on top.

Dave0176

Robert O'Connor said:

Did you bush the supply tappings down to 2"?
I thought that boiler came with 2- 3" connections on top.

Bushed supply tappings down to 2-1/2"

gerry gill

i like it..thats a first rate install.

Dave0176

Two 2-1/2" supply tappings on that boiler give 13.08 FPS steam exit velocity.

Paul_11

Nice work.
I'm sure it will produce dry steam.
my velocity chart shows that You could have done the piping with two 2" risers (14.88fps) in each and one 2.5 " header with 20.92fps

I also install a 10" or 12" nipple after the second riser ties in before I install a takeoff. I think it allows the steam to settle down a little bit after the two risers come together.

This would also let you install a full size 90 degree elbow aiming straight down to the equalizer before you reduce to 2"

I also install the vertical pile to the take off ones size bigger that the overhead

Dave0176

gerry gill said:

i like it..thats a first rate install.

From Gerry Gill, now that's a compliment, I've seen your site and work. Thank you

Steamhead

That's as good a drop header as I've seen. Does the aquastat on the HW loop work well in that location?

Dave0176

Steamhead said:

That's as good a drop header as I've seen. Does the aquastat on the HW loop work well in that location?

Well I'm soon to find out, it's right after the pump and flo control on the supply side.

Dave0176

I have to admit my 6 yo son did help me build the header. He had to at least try to tighten a fitting all while I supported the 36" pipe wrench, since it probably weighs more then him lol. He'll be there with me in the future.

Dave0176

BTW monster tape is awesome, I will use it on everything in the future. I used that combined with Mega Lock.

Dave0176

Finished

gerry gill

Its as good as it gets! just an outstanding job. I don't see anything to improve upon. Well Done!

Dave0176

As you can see that horizontal pipe running under that window is well below the "A" Dimention, so I ask the owner does he get water hammer there, he says yes, so I explain that horizontal run should've just dripped straight down and made a wet return as the old dry return was replaced because it ran down the middle of the basement and was very low. They had good intentions but failed to understand the A Dimention.

He doesn't want to replace it anyway, so I said call me when you get tired of the banging, I'll fix it.

nicholas bonham-carter

Keeping the pressure low (6ounces or lower) would keep the returns from backing up to the level of that pipe, and trying to fill it with water from the boiler, starving it.--NBC