Boiler Condensation - How bad is this?

[camshaft]

I have 28 year old 37000 btu hw boiler with two circulators. Fired it up for the first time this season last week and after it was running for a bit (5 to 10 min) started hearing what sounded like drops of water hitting a very hot surface. Drops about once every 20 seconds or so.

Yesterday I surveyed the situation a bit closer and have found that there appears to be condensation forming on the cast iron heat exchanger (?) and dripping down onto the firebox. I have a couple of pics here

http://img267.imageshack.us/img267/9218/1000018fv8.jpg


http://img143.imageshack.us/img143/4008/1000027tr2.jpg

Now I have to admit that I have not run the boiler for a while like an hour or more and gone back to see if it has stopped or not. I will do so this weekend.

This is either condensation or a leak. Judging from the rust may be doing so for some time now, I am surprised if so as I am in the area of the boiler quite often and would have noticed previously.

Anyway the big issue for me is that I really need this boiler to go this one last season as I am renovating and adding onto the house in 2007, and the whole thing will be put to scrap.

Expert advice and opinion would be greatly appreciated.

[simpleman]

After 28 years its not rain shower so to speak.
Unless something has been change.
It looks to me like a section leak.Is this a castiron or a
steel boiler? I mean that almost looks like a block off.

What name brand of the boiler and model #.

[hvac1000]

Condensation correction. I use a valve and place it between the supply and return. I then allow the hot discharge to enter the cold return line. Adjust the valve until the problem goes away the take off the handle so no one tries to adjust it again.

[rich pickering]

Fin tube boiler? Sure looks like gaskets leaking.

[camshaft]

The boiler is a Rheem Hydronic Model number CBX 167 C.

I was wrong it is a 167,000 btu unit. Natural gas

Would it help if I posted some pictures of the whole unit?

[jpb2]

Water mixing will do the job But i preffer an aquastat ( close on rize) to power the pumps set at about 140 degrees. just my 2 pennys

[camshaft]

Guys,

What about my question. How serious is this and do you think it will get me through one more season? The dripping appears to stop after the boilers been running for a while. Thanks

[steamfitter, retired]

If this leak stops when the boiler water is up to temperature then it's not a major problem providing the drips don't interfere with the burner operation.

I've seen swimming pool heaters drip constantly and starting up a new hot water heater will do the same thing. If however the boiler leaks while it's cooled down and not running I would say it was a section seal, pin hole, gasket, rust or whatever. I think you would have noticed water on the floor over the summer if it was any of the above.

They do make stop leak products as a band aid but you would need a professional to install it.

[tinknocker service tech]

looks like you may have a leak somewhere in the boiler. It may be something external leaking down into the boiler but it sure looks like it has been going on for a while. The unit is 28 years old and imo you are looking to be replacing it soon. If you can see that much rust on the the bottom just amagin how much and what it looks like at the point of the leak. Iop i dout it is condensation with that much rust and if it were the condensation would clear up once the water is hot after ten or twenty minutes
Start getting prices

[Freezeking2000]

I see alot of condensation on boilers at start-up when the water temps are low or during the first few minutes of operation. This is the flue gas condensing in most cases and not a water leak.

[jpb2]

I was not really clear. the aquastat i propose is in addition to the standard one. The bulb should be put in a well on the discharge side thus keeping the pump off below 140 degrees and avoid condensation and the related prods

[swnoel]

I believe it's only condensate dripping from a boiler with cold water being heated and would suspect this has been going on for some time by the pix.

I agree if it doesn't effect the burner operation and has now stopped leaking it should be ok for a while.

You may want to consider relacing it just for efficiency purposes, 28 years old... I don't think it owes you anything and you maybe getting your warning that it's near time.

[rich pickering]

Went to rheems website. They don't show youe model, but they bought raypak, and raypak makes copper fintube boilers.

Post a pic of the other sides of the boiler.

If it is a fintube, the header gaskets are leaking. No problem to replace, just a pain. Make sure they use a high temp gasket.