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Emergency steam replacement

Dave0176
Dave0176 Member Posts: 1,176
edited November 2019 in Strictly Steam
The old boiler was a Weil-McLain EG50 and they unfortunately had sprung a leak on the wet return, this time the LWCO probe had failed due to lack of maintenance. In fact the old boiler not only was never skimmed, it was never properly cleaned. So the dry fire caused a gasket to burn up and the boiler was leaking. After measuring the radiators it was determined the old boiler was quite a bit oversized 300 EDR compared to the boilers 454 sq ft rating, so I installed an EG40. Took 16 hours but it’s done. I forgot to take before shots because I just jumped in, but the header was 2-1/2” but the main connections were done in copper, and one main was 2-1/2” but they downsized the supply to 2”, of course I ran it full size from the header.



DL Mechanical LLC Heating, Cooling and Plumbing 732-266-5386
NJ Master HVACR Lic# 4630
Specializing in Steam Heating, Serving the residents of New Jersey
https://heatinghelp.com/find-a-contractor/detail/dl-mechanical-llc

https://m.facebook.com/DL-Mechanical-LLC-315309995326627/?ref=content_filter

I cannot force people to spend money, I can only suggest how to spend it wisely.......
ethicalpaulSteamDoltDZoro

Comments

  • gfrbrookline
    gfrbrookline Member Posts: 727
    The first two pictures look like an amazing steam organ, the third confirms another perfect install.

    Well done!
    Dave0176Hap_Hazzard
  • ethicalpaul
    ethicalpaul Member Posts: 4,663
    Awesome job Dave! Do you carry all those fittings with you, or do you make a trip to the supply on your way there?
    1 pipe Peerless 63-03L in Cedar Grove, NJ, coal > oil > NG
  • Intplm.
    Intplm. Member Posts: 1,443
    Some very nice looking work there. And done in a emergency. Sixteen hours! Did you do this non-stop?

    Looks great.
    ethicalpaul
  • mikeg2015
    mikeg2015 Member Posts: 1,187
    Lots of pipe is a small space. Great work.
    ethicalpaul
  • Dave0176
    Dave0176 Member Posts: 1,176

    Awesome job Dave! Do you carry all those fittings with you, or do you make a trip to the supply on your way there?

    I have multiples of everything, mostly cast iron fittings except for some of the 3” fittings for the header. A job like this requires me bringing the big guns, the Ridgid 141 and stuff for pipe larger than 2”.
    DL Mechanical LLC Heating, Cooling and Plumbing 732-266-5386
    NJ Master HVACR Lic# 4630
    Specializing in Steam Heating, Serving the residents of New Jersey
    https://heatinghelp.com/find-a-contractor/detail/dl-mechanical-llc

    https://m.facebook.com/DL-Mechanical-LLC-315309995326627/?ref=content_filter

    I cannot force people to spend money, I can only suggest how to spend it wisely.......
    ethicalpaul
  • Dave0176
    Dave0176 Member Posts: 1,176
    Intplm. said:

    Some very nice looking work there. And done in a emergency. Sixteen hours! Did you do this non-stop?

    Looks great.

    Worked straight through, it’s the nature of the beast!!
    DL Mechanical LLC Heating, Cooling and Plumbing 732-266-5386
    NJ Master HVACR Lic# 4630
    Specializing in Steam Heating, Serving the residents of New Jersey
    https://heatinghelp.com/find-a-contractor/detail/dl-mechanical-llc

    https://m.facebook.com/DL-Mechanical-LLC-315309995326627/?ref=content_filter

    I cannot force people to spend money, I can only suggest how to spend it wisely.......
    JohnNYIntplm.DZoro
  • RayWohlfarth
    RayWohlfarth Member Posts: 1,232
    Wow nice looking project!
    Ray Wohlfarth
    Boiler Lessons
  • clammy
    clammy Member Posts: 2,912
    Nice work Dave I remember the 16 hours days from my younger days now we only do 1/2 days 12 hours no more then lol great looking job keep it up Peace and good luck clammy
    R.A. Calmbacher L.L.C. HVAC
    NJ Master HVAC Lic.
    Mahwah, NJ
    Specializing in steam and hydronic heating
    ethicalpaul
  • ethicalpaul
    ethicalpaul Member Posts: 4,663
    > @Dave0176 said:
    > (Quote)
    > Worked straight through, it’s the nature of the beast!!

    At least this time of year!
    1 pipe Peerless 63-03L in Cedar Grove, NJ, coal > oil > NG
  • ethicalpaul
    ethicalpaul Member Posts: 4,663
    > @Dave0176 said:
    > The old boiler was a Weil-McLain EG50 and they unfortunately had sprung a leak on the wet return, this time the LWCO probe had failed due to lack of maintenance.

    Wait! You mean the Hartford Loop didn’t do its job??! 😅

    Sorry I couldn’t resist
    1 pipe Peerless 63-03L in Cedar Grove, NJ, coal > oil > NG
    Intplm.Dave0176
  • Dave0176
    Dave0176 Member Posts: 1,176

    > @Dave0176 said:

    > The old boiler was a Weil-McLain EG50 and they unfortunately had sprung a leak on the wet return, this time the LWCO probe had failed due to lack of maintenance.



    Wait! You mean the Hartford Loop didn’t do its job??! 😅



    Sorry I couldn’t resist

    Actually Paul it did do its job of keeping water in the boiler, however with the low water cutoff inoperable there was nothing to shut down the burner, which in turn kept steaming off the water until it was bone dry.
    DL Mechanical LLC Heating, Cooling and Plumbing 732-266-5386
    NJ Master HVACR Lic# 4630
    Specializing in Steam Heating, Serving the residents of New Jersey
    https://heatinghelp.com/find-a-contractor/detail/dl-mechanical-llc

    https://m.facebook.com/DL-Mechanical-LLC-315309995326627/?ref=content_filter

    I cannot force people to spend money, I can only suggest how to spend it wisely.......
  • ChrisJ
    ChrisJ Member Posts: 14,398
    Dave0176 said:

    > @Dave0176 said:

    > The old boiler was a Weil-McLain EG50 and they unfortunately had sprung a leak on the wet return, this time the LWCO probe had failed due to lack of maintenance.



    Wait! You mean the Hartford Loop didn’t do its job??! 😅



    Sorry I couldn’t resist

    Actually Paul it did do its job of keeping water in the boiler, however with the low water cutoff inoperable there was nothing to shut down the burner, which in turn kept steaming off the water until it was bone dry.
    And that has been the point the entire time.
    Loop or not, 99% of the time the boiler will eventually dry fire anyway because no one pays attention until the house is cold.

    Single pipe quasi-vapor system. Typical operating pressure 0.14 - 0.43 oz. EcoSteam ES-20 Advanced Control for Residential Steam boilers. Rectorseal Steamaster water treatment
    ethicalpaul
  • ethicalpaul
    ethicalpaul Member Posts: 4,663
    edited December 2019
    I'd say the Hartford Loop's job is to prevent dry fire but I've been known to have odd opinions :sweat_smile:

    Could you tell from the condition of the pipes (or maybe you had a chance during your install to see it) how fast was the wet return leak? Did it go right down the drain, or did it pool on the floor and they saw it?

    And sorry for all the questions, but this topic interests me for some reason: How did they discover the failure? Did the dry fire cause smoke?

    If you're too busy to answer I totally understand, I'll ask you about it next time I see you :)
    1 pipe Peerless 63-03L in Cedar Grove, NJ, coal > oil > NG
  • Hap_Hazzard
    Hap_Hazzard Member Posts: 2,826

    How did they discover the failure? Did the dry fire cause smoke?

    I imagine when the boiler ran out of water to make steam with, the house started getting cold.
    Just another DIYer | King of Prussia, PA
    1983(?) Peerless G-561-W-S | 3" drop header, CG400-1090, VXT-24
  • ethicalpaul
    ethicalpaul Member Posts: 4,663

    How did they discover the failure? Did the dry fire cause smoke?

    I imagine when the boiler ran out of water to make steam with, the house started getting cold.
    Not sure about that this time of year and during a heat cycle. It must not take very long for a dry fire situation to turn ugly. There's no control to stop it, right? I wonder if it starts to make strange sounds.
    1 pipe Peerless 63-03L in Cedar Grove, NJ, coal > oil > NG
  • Hap_Hazzard
    Hap_Hazzard Member Posts: 2,826
    It would take a few cycles to go from the level of the Hartford loop to bone dry, and I imagine it might make some interesting noises. Maybe when the sections started getting red-hot the jacket started flexing and buckling. ;)
    Just another DIYer | King of Prussia, PA
    1983(?) Peerless G-561-W-S | 3" drop header, CG400-1090, VXT-24
  • ethicalpaul
    ethicalpaul Member Posts: 4,663
    I don't think it would necessarily take a few cycles, but even if it did, the boiler would keep generating heat and working fine until the water just about ran out so only the last cycle really matters (I say never having tried it).
    1 pipe Peerless 63-03L in Cedar Grove, NJ, coal > oil > NG
  • JUGHNE
    JUGHNE Member Posts: 10,564
    Tstat would not get satisfied so that would stay closed/on.
    No water to make steam pressure for P-trol operation so that would stay closed/on.

    Smoke detector is next.
    Hap_Hazzardethicalpaul
  • Dave0176
    Dave0176 Member Posts: 1,176
    edited December 2019
    @ethicalpaul
    The HO told me they were aware of the return pipe leak because it had been going off on low water. Apparently the leak got bigger and unfortunately the last instance the probe failed to sense the low water. She said she began to notice a smell of “fire” and called the fire dept. When they show up they noticed the boiler dry firing and shut it down. She said we’re going to try and use a pipe clamp to stop the leak temporarily, however it was too late. We’re actually going back in the spring to replace the entire wet return.


    @Hap_Hazzard
    Since it was a Weil-McLain it basically just burned up the return gaskets, I could not find any visible cracks in the boiler sections


    DL Mechanical LLC Heating, Cooling and Plumbing 732-266-5386
    NJ Master HVACR Lic# 4630
    Specializing in Steam Heating, Serving the residents of New Jersey
    https://heatinghelp.com/find-a-contractor/detail/dl-mechanical-llc

    https://m.facebook.com/DL-Mechanical-LLC-315309995326627/?ref=content_filter

    I cannot force people to spend money, I can only suggest how to spend it wisely.......
    ethicalpaul
  • Fred
    Fred Member Posts: 8,541
    Looks Great!
    ethicalpaul
  • ethicalpaul
    ethicalpaul Member Posts: 4,663
    Thanks @Dave0176 sounds like she acted fast and was very fortunate. Don't ignore those leaks, folks!
    1 pipe Peerless 63-03L in Cedar Grove, NJ, coal > oil > NG
  • BobC
    BobC Member Posts: 5,401
    Forty years ago I notice a "hot smell" in my back hall one summer day. so I went down the basement to see what was going on. The landlord had divided the basement with a wood wall with a doorway so you could access his side for the fusebox, etc.

    Everything seemed fine on my side but I could see a red glow on the other side of the wall. I went through and saw a large red spot on the back of his old Delco steam boiler. I killed the power and the boiler shut down, 5-10 minutes later a heard a load crack and that was the end of that old boiler.

    This was in 1979 and those 30-40 year old boilers did not have a LWCO safety on them. The boiler was used for hot water as well as steam so I assume it fired up to heat the domestic hot water.

    Bob
    Smith G8-3 with EZ Gas @ 90,000 BTU, Single pipe steam
    Vaporstat with a 12oz cut-out and 4oz cut-in
    3PSI gauge
    ethicalpaul