Steam Boiler Install 112,000 BTU

First mistake: You reduced the steam piping from 2-1/2" to 2". This can cause wet steam, banging, reduced efficiency etc. See pages 9-10 of the boiler manual, here:

https://penncoboilers.com/sites/default/files/1305004%20PENNCO%2016%20IOM%20REV%20L.pdf

There seems to be this lingering perception that steam boiler piping should all be 2". This is dead wrong. You have to follow the instructions. Also, the manufacturer may not honor the warranty if something goes wrong and the instructions were not followed.

For more on this topic, get the following book:

https://www.heatinghelp.com/store/detail/the-lost-art-of-steam-heating-revisited

Not a fan of coming out of the side of the header.

You worked hard and obviously take pride in your work. The boys are right on their comments. I give you a C +. If you repipe the header and near piping, I'll give you the opportunity to score as high as an A. If it works fine and runs OK, you can leave it but you are taking your chances on the warranty not being honored. Since, you DO seem to care, I'd repipe if I were you. Mad Dog

Well it's kind of complicated @Steamhead as you know.

This is a 4 section Dunkirk design. It's the exact same as many other brands I believe, including Utica, which is probably the most commonly used brand for this design (at least around NJ).

Utica calls for a single 2" supply and header for the 3 and 4 section. Yes, Pennco calls for 2-1/2" which will no doubt be generally better, but this boiler will work fine with 2" as long as the water quality is reasonable (as I proved with my old boiler even though it had a garbage "vertical" header).

DaironHvacTech said:
> Cool. Didn't know if I went a half inch smaller on pipe it will cause problems. I been using 2" and everything been working fine. I'll start using 2 1/2 after this boiler.

@DaironHvacTech don't take the wrong lesson. The lesson is not to always use 2-1/2, the lesson is to read the instructions as Steamhead said. The instructions will tell you what to use for that size boiler from that manufacturer.

Also, stop painting your pipes. And stop buying Dunkirk boilers for your customers. Get a Peerless or Weil-McClain (or a WM off-label such as Williamson). Those side-outlet Dunkirk types are more prone to surging (which is probably why Pennco says to use a 2-1/2" pipe, so they don't get angry calls—the problem is this causes unnecessary expense for you and your customers. You will get more jobs if you don't have to quote 2-1/2" pipe for a 112kbtu input boiler.

Final questions @DaironHvacTech : How did you size that boiler? What was your skimming procedure? Once I know that I will give you a grade.

"we don't have issues" is confirmation bias as you and your partner well know 😃 You wouldn't have issues with 3" pipes either.

But I'm not sure what you are saying. Are you saying the Pennco is using different castings than Utica? Are you saying all of these boilers do better with a single tapping than with two tappings? Are you saying Utica is playing a bit fast and loose? (I can believe it) Thanks in advance for clarifying what you're saying, I greatly respect your opinion and experience.

Thank you sir, I was under the mistaken impression that all these Dunkirk style boilers were using the same Dunkirk castings.