Ray Wohlfarth: The Boiler Room

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"According to the ASHRAE HVAC Applications Handbook, the estimated life of an air-to-air heat pump or a rooftop unit is 15 years while a boiler life expectancy is between 24-35 years, depending on the boiler type. So, you will install two heat pumps or rooftop units for every boiler. Where do you think those old units will end up?" I ask the class.

The students in the dormitory started complaining of headaches and nausea. When the number of students with the same symptoms kept rising, the administration knew something was wrong. The maintenance department dispatched a service technician to investigate.

On the older hydronic systems, replacing the existing boiler with a new one was pretty straightforward. The installer connected the new boiler to the existing flue, piping and electric. The newer high-efficiency boilers are much different and require some additional planning.

Troubleshooting hydronic systems can be challenging, as the pipes are hidden behind walls. Your imagination has to help you “see” the routing of the piping. 

An electrician walked into the equipment room to diagnose and repair an electrical problem in the school. 

It was such a simple project; replace the old cast iron boiler with a new condensing boiler. You knocked it out in a few days. 

When troubleshooting a hydronic system, the piping layout is often confusing. To understand the system, I sometimes sketch the piping to help me visualize the flow of water. 

Sherlock Holmes has always been one of my favorite fictional characters. I envied how he would notice each detail and use every one of his senses to solve the crime. 

The owner asked for a bid to replace her 35-year-old cast iron boiler which was still operating. She had two requirements: Redundancy in the event of a boiler malfunction and lower fuel costs for the building.

When I look at any replacement hydronic boiler project, my tenet is always to assume the existing system is installed improperly. I like to pretend I am a famous detective, such as Sherlock Holmes, and my job is to uncover the hidden mistakes.