Mystery water leak - excess water take up problem

I had to create a new profile to post. My account was lost to the ages. Can't even find what my ancient credentials were. I've sought advice here before. Learned about lots of things, including balancing steam systems. Have several steam books, including one from Dan. Learned about EDR and all that, just to get a working running stable system that behaved well.

The near boiler piping is nearly all iron pipe. The copper line was in an extension at the far end of the house. I added a radiator to a bathroom, because it was a tad too cold there in the winter. Like 5-8 degrees colder than the bedroom. My plumber, who smelled like maryjane at times, put in copper from the far end of the main to the radiator. This was decades ago. Like I said, I had to replace it due to his poor workmanship. His solder joints didn't even wick all the way around, never mind flow into the socket joint. Mine were soldered correctly.

When this 2013 boiler was put in, I asked for a drop header. I showed the installer (not the MJ plumber) a picture from Burnham, and he did it. It's not exactly what most here recommend, but the installer did not want to deviate from a Burnham diagram. This old piping system has a bull head tee, but the devil you know is often better than the devil you don't. Besides, that would have required a whole lot more money.

I checked the copper lines while the system was building steam a few minutes ago. I don't see any evidence of leaks, at least where it enters the wall from the basement. Like I said when the copper failed previously, it was wet there. It is not wet.

Surprisingly, can't find any photos of this system. I will go take a couple. Be back soon. I'll need to set up a light there, it's a bit gloomy today.

Seems one of them doesn't view for me. I did three. I see two.

Down by the burner, there's no evidence that there was water. Cracked/clogged tubes near the top in the boiler?

Water/dampness is due to the HW heater change out. It's slowly drying out in the pit.

I'm in Nashua, NH. The EDR I posted is based on Dan's book, for 7 radiators, and calculated for 3 radiators, using the instructions, based on the size, length and number of tubes. I got 404.1.

The boiler says it is 454 sq feet of steam. So it's not a horrible mismatch with the EDR. I made sure of that last time. (2013).

There are only two companies listed in NH, in Find a Contractor, and neither have descriptions that seem to indicate they know anything about steam. I had a licensed master plumber do my HW heater, and it was very clear he knew NOTHING about steam. His ideas about pressure, and even his terminology, meant to me he would not be a good candidate for the job. He was very nice, and he did a good job on the HTP indirect heater replacement, but he knew nada about steam. I'd like someone who knows more than me, a lot more, because my knowledge is really restricted to some book learning, and the school of hard knocks…

I'll search some more for a contractor.

When I figure out how to do this, I'll try "slowly" over filling the boiler to look for a leak. I suppose this would be the confirming test. There's no underground returns, or anything like that. It's all in plain view. (By figuring out, I mean, how do I get rid of the water from the boiler, once the test is over…)

A few days, I'm comfortable with, 2-1/2 weeks, not so much. My grandparents house froze up when they went in Florida. I visited their house after it froze. Pretty much everything was ruined, boiler block broken, pipes broken, ice everywhere, washing machine, toilets, dishwasher, you name it, totally wrecked. Made an impression on me.

Knock on wood, the LWCO and water feeder are still working. But, if you've lived long enough, or you are a contractor, you've seen them fail, I have. I've had multiple LWCO failures, some benign, some catastrophic. Burned out the o-rings on a Weil McLane, due to the LWCO failing and the block going red.

Their standard warranty is 10 years (as of 2024). I will look to see if I have an earlier copy of it. Maybe it is better.

Got a third contractor to come tomorrow. Will be a busy day. One of them is a "preferred contractor" listed by Burnham. I'll ask if it a replacement of just the cast iron block is plausible.

Hopefully between the three contractors there is something that makes sense.

I was going to ask if there was a DIY option, but I stopped myself. I want this to have some sort of "regulatory" approval, by some agency. DIY won't do that, and may detract value from the house, even though it works.

A replacement boiler may not require a permit. Repairs/replacement similar in nature usually are not permitted. Like replacing shingles on a roof. No permit required. A total new heating installation would require a permit. In any case, the contractor needs to contact the city for all that stuff, as required. I should verify what I said, by calling the city, as they are the relevant authority. When we get closer, I'll do just that. We will pull all the required permits, they are a tiny part of the job.

Any movement of gas line plumbing or additions to gas lines, definitely require a permit (and inspection plus a leak test). They are quite serious about that in my city. About 10 years ago, down the street a bit, there was a house explosion from NG. No one there, no one hurt. House was flattened, due to all the walls rapidly leaving the foundation at once. Not complaining about any gas permits, after seeing the aftermath of that.

Not in my city, at least for a roof. I asked. They said no permit required, as long as you are not changing your roof line.

However, it wouldn't surprise me at all for for a boiler… Will find out soon enough.