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Leaking sections on steam boiler with copper header
I have an 8.5 year old Weil McLain LGB-6 steam boiler. The sections have begun to leak in about 4 areas in front. The header is made of copper without any swing joints or companion flanges. There is only one riser coming from one side of the boiler. When the boiler is first fired up after being cold, the sections begin to leak for about a minute until the sections heat up. The leaking appears to be coming from between the sections in at least one area. The sections appear rusted in front. The boiler locks out at times possibly from the flame sensor or pilot assembly getting wet. We have a metal trough built to divert some of the water drip away from the flame sensor. What is causing the leaking? Is the leaking because of bad seals? Is the leaking due to the copper header expanding when heated and thus pulling the sections apart because there are no swing joints or companion flanges? If a copper header is built, is it enough to have a swing joint or a companion flange, or are both needed in conjunction? Is it better to use a swing joint or a companion flange? Is it better to build a header out to steel with a swing joint? No additives have been used in the boiler that would have affected the rubber/composite seals that Weil-McLain uses between its boiler sections.