Routine Boiler Maintainance leads to sputtering/suggestion to replace oil line... BS?

JEA2880

First time posting and not an expert so bear with me, seeking advice about whether or not I'm getting screwed by my oil company.

Company (good reputation, known for service but more expensive than others) performed annual routine maintenance/cleaning on my boiler that comes with service plan. After cleaning done, I noticed that there was intermittent sputtering that sounded like it was coming from oil tank and through the oil line to the boiler. This had never happened prior to maintenance. A second technician comes out a few days later from the same company and says he had to use 6 CO2 cartridges to clear the line and that it was clogging and needed to be replaced. I asked him why the issue directly coincided with the cleaning and he shrugged it off as a "coincidence". As a result, he said I need to replace my oil lines to fix the problem. After the second technician left things were working fine for a few days until just now I heard the sputtering again for the first time.

Does this sound like a legitimate problem and solution or am I getting screwed? I find it very hard to believe that the introduction of the problem was truly just a coincidence, and now the company wants more money for a problem that never existed prior to the routine check.

Here are some pics of the general setup - the lines go from the blue pipes attached to the tank and run across the ceiling to the boiler so at least there wouldn't be any destruction if they needed to be replaced. Does this sound like something that would actually fix the problem?

Any help or advice is greatly appreciated.

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mattmia2

Sounds like it is sucking up sludge from the tank.

EdTheHeaterMan

Those fuel lines look fairly new.  Within the past 10 years.  This problem deserves a letter to the fuel oil company owner, if it is a local family business (like my fathers company was in the 1990s) or the general manager of the oil company if it is owned by a mega supplier that buys up all the old mom and pop dealers.   Either way the letter should account for the fact that the burner did not have a sputtering problem for the 10+ years (you fill in the correct number here) of operation prior to the maintenance performed on (you provide the date here).  I can't help but think that this is not a coincidence as your technician from (second service call date) indicated.   As there are several options available to me, including other fuel providers. I would hope that you would provide me with a new evaluation as to the nature of my problem, to assure me that your technician is not just saying "NEW STUFF NEEDED" because they are not as familiar with this issue, as an experienced veteran of the oil burner service industry might be.  I'm sure you have a service manager or top technician that has more experience than the one that did the maintenance and the other tech that blew out the fuel lines.  

I am asking several experienced old timers on the HeatingHelp.com website for assistance in this problem, and some have asked about performing a test on the fuel system with a vacuum gauge, others have indicated that using CO2 cartridges to blow out fuel lines is not the best way to free up blocked fuel lines. And there is a very interesting long time oil burner man that has the tagline “After you do that expensive repair and you still have the same problem, What will you check next?”.  I wish to remain a loyal customer, however based on my experience over the last couple of days (weeks) I am not getting the warm fuzzy feeling about our professional relationship. 

Awaiting your prompt reply

Sincerely,

(You fill in the name and signature here)

Letters are better than voice communication because the emotion of hearing “are you calling me a liar” will not interrupt your thoughts the way a phone conversation will. And nobody uses the US Mail anymore, so getting a paper letter has a lot of impact here.   Second best is an email to the boss, but I like the paper letter idea. 

EdTheHeaterMan

Without getting too technical with the mechanics of your fuel system, It appears that you have a two pipe fuel line system that goes overhead to the burner. The next observation might be if there are a lot of tank bottom deposits in your tank, replacing the fuel lines in the exact configuration as they are now, will eventually end up with the same problem.  Then what will they do?  Say Oops, we should have told you that you need a new tank and chare you more.

From the looks of that fuel tank in the photo, it appears to have a slight pitch so the lower end of the tank is at the same end as the pickup and return line.  That would be a mistake in my book.  Also I can not see if the bottom opening has a valve for service or just has a plug. Without a valve, a proper tank maintenance procedure of draining off the bottom of the tank annually can not be completed.  So there are years of tank bottom deposits accumulated at the bottom of that tank where it will cause the most problems.   

As you can see from the illustration (the pitch is exaggerated) the lower end has more debris at the bottom and that is where the oil will be agitated causing the tank bottom deposits to mix with the oil and enter the supply pipe to the fuel pump. Putting the new pipes in the same location will not solve the problem. 

To solve the problem you need to have some oil drained each year during the regular maintenance, in order to remove any accumulation and draw off any water (from condensation, not water delivered by your dealer) on an ongoing basis.  Not after years of buildup causes a problem. 

I had 30+ year old oil tanks that did not have any sludge problems because I did tank maintenance each year.  And all that is needed is a valve on the bottom and a tub to catch the oil.  Within 30 seconds all the water from the previous year is gone and clean oil starts to flow. Close the valve and put a plug in the valve. Good to go for another year.     

JEA2880

Ed - very helpful insights, I really appreciate the thorough response.

Matt - appreciate the thought about sludge as well

Steamhead

@JEA2880 , does the house have natural gas service available? If so, it's time to make the switch. And you won't need a new boiler- that Weil-McLain WTGO will run nicely with a Carlin EZ-Gas burner.

HVACNUT

Are you sure the "intermittent sputtering" is originating from the tank? Seems more like it should be at the burner.

It's a 2 pipe setup, so you might hear oil returning to the tank, but that's not a sputtering sound. That's an enlarged prostate sound.

I find it hard to believe 6 CO2 cartridges were needed to clear the line, unless the pickup tube in the tank is 2 inches or less from the bottom and there's a ton of sludge in the tank. But even that wouldn't explain the sudden issue after maintenance. I also find it hard to believe an oil tech is using CO2 cartridges instead of a Push/Pull pump in 2024.

Try to catch the sputtering at the burner. There could be a suction leak that needs to be addressed. And what NEEDS to be addressed is NOT the oil lines themselves. Flares, valves, gaskets, filter canister, fittings, maybe. Not the copper.

Was a combustion report left? That's the information you want. What proof do you have that when the tech left, the burner was running properly with correct draft and 0 smoke? Ask them to kindly show you the proof if nothing was left.

EBEBRATT-Ed

They could have not replaced the filter cartridge correctly. The filter (looks like a General 1A25) has a main gasket, a gasket under the bolt that should be replaced as well. The gaskets used to come with the replacement filter.

The most likely thing is they created a suction leak while servicing the burner or filter.

They say a sludge problem. Have you had any issues with a plugged filter, nozzle or pump strainer before? If not I kind of doubt the sudden sludge problem.

If it is sludge, you could try having them drain the bottom of the tank as @EdTheHeaterman suggested.

The other temporary fix if it is sludge is to shorten the suction pipe where it goes to the bottom of the tank so it pulls clean oil.

How old is the oil tank? It does not look very old at all.

I would think a suction leak more likely than a sludge issue.

Big Ed_4

The last tech had problems clearing the oil lines….. Top feed tanks as Ed mentioned needs to be drained of collected water yearly . If not the tank will grow an algae inside .. Over time the sludge or algae waste product will build up on the bottom until it reaches the suction line and causes blockage . There are many fixes that will only buy you time …

To correct the problem …. Pump out the sludge and get on a future schedule of draining off any collected water . A load of kerosene after the tank cleaning would also be a good idea …

CLamb

If it is a sludge problem wouldn't it be visible in the filter?

EdTheHeaterMan

https://forum.heatinghelp.com/discussion/comment/1802194#Comment_1802194

I should think so. But there is no mention of the filter condition in the information provided. That evidence is long gone in a land fill somewhere by now.

Did you know that three 1A-25A used fuel oil filter cartridges make a great camp fire starter?