At least they used black iron pipe.

Double D

What started out as a call to repair a system leak turned into a need for a boiler replacement. After briefly looking at the leak in the return line going into the boiler, I noticed there was water running down the front of the cast iron sections dripping down onto the burners and floor. After filling the boiler up to the header, I was able to confirm the boiler had a leak in the casting above the water line. I mentioned to the owner, you don't want the piping to your new boiler to look like this. Could I be any farther from the truth? He gave me the go ahead to post pictures here. I think he would be very interested in what everyone has to say. I told him I would give him the link if I get any response.

nicholas bonham-carter

That piping arrangement must have sent so much water up with the steam, that it’s amazing the boiler lasted this long.
It looks like a perfect use for a drop header configuration, which can mate more up easily, and effectively with the main supply going up.
The boiler doesn’t look ancient, so could there be other problems, such as bad town water, laundry products stored nearby, or a steam leak causing more fresh water to come into the boiler. Was it well sized for the EDR to begin with?—NBC

Steamhead

At least they drained the collision point into the equalizer. This may have been the piping for a previous boiler and whoever installed this one grafted it onto the old piping.

Is this a Vapor system?

Double D

@nicholas bonham-carter Drop header is exactly what I was thinking. Much easier than digging a deeper boiler pit. Although not ancient, the boiler is close to 40yrs old. The boiler and water heater are in a utility room with a washer and dryer with laundry products stored in the same room. The doors are solid but I did notice a fairly new fresh air intake. A couple of the radiator valves have been replaced over the years, some of the existing appear to be leaking from time to time but the only leak other than the boiler itself is on the bottom of an elbow on a return line, other than that the system is tight. I removed the failed Dole #5 and installed a Gorton 2. Total EDR is 270, if you add back in the radiator that was removed from the dining room the boiler is a perfect match.

@Steamhead This season I've seen my share of colliding headers but this is my first with its own drain. If you look at the age of the piping on the colliding header combined with the asbestos wrapped in duct tape together with the check valve on the return line, you can definitely see the connection to the boiler is much newer. Yes this is a vapor system with the Pressuretrol set for 3lbs.

lchmb

would be interesting to track usage after the replacement and repipe.

the_donut

More mistakes, more pressure.

Jamie Hall

Got to admit it's creative...

If it really is a vapour system, do something about the pressure. Like get a vapourstat and dial it down to about 12 ounces, for starters.

Double D

I had a vaporstat with me but since the boiler is leaking I figured it would be best to wait till the new boiler goes in. Most who bid this job will do a cut and slide. No doubt scrap the vaporstat that I install and use the pressuretrol that comes with the new boiler.

Sailah

Reminds me of a steer. That's all I got.

nicholas bonham-carter

In your proposal, you could draw attention to the fact of the improper piping having been the major cause of this earlier than normal boiler failure. Correcting that is even more important now with the thinner metal in today’s slightly more efficient boilers, and the necessity of following the manufacturer’s instructions for warranty reasons.
And they could learn of the joy of skimming, after lessons from you.—NBC

KC_Jones

Double D said:

Most who bid this job will do a cut and slide. No doubt scrap the vaporstat that I install and use the pressuretrol that comes with the new boiler.

If the owner reads this, I implore them to not do this. Please get someone to pipe this properly and get that system working it's best. You won't ever regret it.

It certainly is creative, but in this situation creativity is a bad thing.

Leonard

Painted HOT exhaust pipe ???
Wonder if it was latex

EBEBRATT-Ed

We all have seen piping much worse than that. I doubt the piping had anything to do with the boiler failure.

The header is big, and it's dripped it has a Hartford loop, he used both boiler tappings and it has swing joints

The collision is the only issue and since it's full size it probably didn't hurt operation much

nicholas bonham-carter

If this system is not fixed properly, we will see it here again from a new owner.—NBC