Heating Help

Boiler block cracks

My Burnham V903 steam boiler has cracked twice since it was new in 2004, once in 2006 and again a month ago. Attached are photos of the near boiler piping.

Why?

Your pictures didn't come through, they have to be jpg format and cannot be huge files.

Do you know why these boilers have failed long before their time? Does your water have high chloride content or do you have a leak somewhere that is causing a lot of water to be added to the boiler?

Bob

Boiler block cracks

There does not seem to be a water leak. The water pH is 9-10, but I don't know about the chloride content. The boiler is 30% oversized - don't know if that matters.

Trying photos again.

oooo

Lot's of problems with the near boiler piping. The two risers are going into the Tee from opposite sides, The equalizer is in the wrong place, the Hartford loop should be as short as possible at the equalizer connection, but appears to be 12" +.

The way the risers are piped to the header may be causing a lot of stress on the boiler as things expand and contract. Check the manufacturers instructions.

Boiler block cracks

Attached are the manufacturers instructions. I don't know why my 903 has two risers like the larger boilers, but the piping does not follow the instructions I can see how the riser - header piping could cause stress. What problems would the incorrect equalizer location and long Hartford loop cause?

ah

Yes, per the manufacturers instructions only 1 - 3" riser is needed, two won't hurt. The equalizer helps keep the steam drier. Where it is located, steam at speed could easily shoot water right past it. The way it's piped it looks more like a drip, used to remove excess condensate before it gets to the header. In that case you don't have a true equalizer line.

A long Hartford Loop can be prone to steam hammer if the water level drops.

Looks like

2 risers are 2" maybe only 1 1/2" If they are 2" they are 25% too small if one 3" is called for. Small pipe means high speed steam sucking water out of the boiler. The piping on the returns makes it hard for the water to come back to the boiler. Active waterlines make for boiler cracks, to keep it simple.