Repair collapsed combustion chamber in gas boiler?

Unknown

Jen_3

Repair collapsed combustion chamber in gas boiler?

Hi - Our pilot light wouldn't stay on so we called our gas supplier to get the boiler serviced. He said the following: "Heater condemned. Collapsed combustion chamber steel + fiber refractory. A non-repairable defect exists. Heater requires replacement." We will only be in this house for about 4 more years, and we really can't afford to pay the 5800-6800 quotes we're getting to replace the gas boiler. Is it possible to repair or replace a collapsed combustion chamber? Thank you for your help!

Jen_3

Repair collapsed combustion chamber in gas boiler?

Hi - Our pilot light wouldn't stay on so we called our gas supplier to get the boiler serviced. He said the following: "Heater condemned. Collapsed combustion chamber steel + fiber refractory. A non-repairable defect exists. Heater requires replacement." We will only be in this house for about 4 more years, and we really can't afford to pay the 5800-6800 quotes we're getting to replace the gas boiler. Is it possible to repair or replace a collapsed combustion chamber? Thank you for your help!

Mitch_4

refracrories

are usually in oil fired boilers. Do you have a gas fired conversion burner in an oil unit? If the problem is the refractory, they can usually be replaced. If the Heat exchanger is itself is beyond repair, you can get new heat exchangers. Unless you have an antique, Heat exchangers are usually available, but the repair is not cheap. It is usually better (if you have an "oldie") to replace it.

If yours is a conversion burner, you can get a unit designed to run on natural gas, give you better efficiency, and it will improve your position in terms of raising your asking price when you go to sell the place. Take out a home equity line of credit to finance, and you will save money with a better efficiency unit, and improve the resalability of the property.

Good luck.

Mitch

M. Whale

collapsed fire box

Haven't come accross a fire box in a converted boiler that can't be repaired or replaced yet! It does take some effort to find the tech with the right skill set and motivation however, and he/she probably won't be the youngest member of the team.

Boiler replacement is what we would recommend also. it does add significantly to the value and marketability of the home.

Jen_3

an update

First let me emphasize that I really don't know much about this (I'm a homeowner), though this site has been very helpful in providing an education! I greatly appreciate all of your help and advice!

The boiler is made by Weil McLain, and says CP No. 167686 on its tag. The model# is CGM-6, and it is series 6. The house was originally built in 1901, and the plumbers today mentioned that the house probably originally was heated by coal. They showed me where the flue had been shored up with cement to cover the original opening where the coal ash would have been removed. There is a gas inspection tag dated 1977 hanging on the gas pipe. I moved into the house in 2001, and don't know how old the boiler is.

I don't know how to tell if we have a gas fired conversion burner in an oil unit... I would gladly look if you could tell me what to look for. It runs on natural gas.

After taking off the front panel and then a second door that conceals the pilot (it has a hole through which you light the pilot when it is out), if I look at the left side of what I assume is the combustion chamber I can see a large metal plate that has an approximately 4 inch diameter hole in it. It has a "punched out" appearance and is surrounded by a dark purple/rust color - though it appears "blown out" as opposed to flat, which is what I would expect from metal that had rusted. The metal on the outside of the boiler has clearly been exposed to heat, as the paint is changed from its usual army green color to a grey, which I presume is due to heat contact.

I'm having trouble finding a diagram to point me to the refractory, so I'll describe what I see. If I remove the front door of the boiler I see an interior box within the exterior box. Between these two boxes is some kind of fiber - it looks like loose fiberglass to me, but I could be wrong. It looks to me like a steel and fiber "sandwich," so I presume this is what he was referring to. If this isn't the refractory please let me know what I should be looking for.

I hope this description helps. I will definitely consider replacing the boiler, particularly if the repair cost reaches several thousand dollars. However, if this still sounds like something that is worth repairing, I would greatly appreciate advice on how to go about locating someone who might be able to repair it. What questions should I ask when I call people? Should I call plumbers, or would the appropriate technician be listed under a different type of business in the yellow pages? Or if you know someone - I live in a suburb just a few miles north of Boston, MA. They can contact me at jonesjen@hotmail.com.

Thank you again for all of your help! - Jen

Ron Schroeder_2

I would suggest that you get a few more quotes on a new cast iron boiler. I know that you have no heat now but try not to look too desperate.

Is it a single zone system?

Jen_3

3 zone system

It's a 3 zone system - Thanks for the advice!

Ron Schroeder_2

Make sure that your quotes are consistant. New zone valves or not. New pumps or not etc.

John Mills_3

Not a relic

Certainly a modern boiler and meant for gas. I was picturing an old oil boiler with conversion burner too.

I don't see many boilers but can't help thinking this could be fixed for a fraction of the price of replacing. Check the find a professional section of this site and call one of the guys in your area or contact Weil-McLain for a suggestion on someone who will fix it for you instead of just wanting to replace.

Jen_3

differences in quotes

Thank you so much for your advice. The quotes are quite different, actually - while they have all said it's important to replace all of the valves, circulation pumps, etc there were two major differences: the more expensive company wants to install a "Chimney Liner, 6' x 35' kit, 2 appliances" and "Power Combustion make-up air," but the less expensive company did not think that was necessary. The paperwork for the more expensive company mentions that the chimney liner and make-up air are required to meet applicable codes. Both of these companies spent no more than 5 minutes in our home - they didn't go on the roof or take anything apart to look at the chimney. However, the less expensive company warned me that it's possible that the electrician might need to change out my 3 thermostats at a cost of $200/thermostat... does that sound right? I always thought thermostats were all the same... we installed programmable thermostats a year ago and didn't have to make a choice in terms of installing type a vs b thermostat.

I appreciate all of your advice! I will contacting some of the professionals listed on this site to see if I can find someone who is able to repair the boiler.

Jen_3

The problem is with the base insulation!

Hello again -

I just spoke to Weil McLain, and she said that this unit doesn't have a combustion chamber (apparently the first contractor was wrong). I described the problem to her and she said the problem is in the base insulation, so I should be looking for contractors for that kind of a repair. Does this change your advice at all? Thank you again!

Glenn Harrison_2

Jen, I'm a tech in the Chicago area,

and I just recently had a customer who went through a similar situation. I was called out for a cleaning as part of a real estate sale. Upon opening the boiler, I found pieces of the burner insulation or refractory, laying on the burners. This had caused the boiler to become plugged with soot. This was a Weil McLain gas boiler about 30 years old. I called our supplier on the spot,who then called W.M. who informed us that the refractory material was no longer available. Now this insulation or refractory is very important as it keeps the flames and heat of the flames within the burner compartment. This refractory has to be able to absorb extremely high temperatures. I believe you said there are burn marks on the cabinet of your boiler. If so, you can see where this is so vital. It literally protects the flame from burning through the sides/back of the boiler and causing a house fire. So the question is, is the insulation available for your specific boiler. If it is, then you need to find someone who will accept the liability of changing it. Keep in mind that this can be time consuming, and also may not be able to be done if the metal base of the boiler is burned through or damaged. If the insulation is not available, then you might be able to find someone who will replace the insulation with a generic replacement, but most likely you will not based on the fact that the contractor would be accepting all liability for rebuilding the burner compartment. If it can't be replaced, then you must replace the boiler.

M. Whale

insulated boiler base

We have changed the insualted base on another manufactuerers boiler (almost idnetical to WM). assuming WM will provide it (no one will stock it)it is very possible. But, it is time consuming and takes 2 techs as the cast heat exchager is very heavy and must be removed. look for a full day and possibly some repiping.

agian, skill set and motivation

good luck