As I pointed out in the opening post, I had an ageing heating system consisting of cord wood and oil boilers in series. At oine point the previous owners added an outdoor wood boiler to the system along with the two existing appliances. Needless to say, the system had been modified, added to, deleted from and retrofit over the years leaving behind a plumbing schematic resembling a bowl of pasta. We wanted to get the most of the new pellet system which meant cleaning up the old plumbing and updating it to a more efficient, neater layout. I have some plumbing skills but not to the level required for this job so I engaged the services of a close friend who was more than skilled enough, and lucky for me; willing to spend the weekend. I was also fortunate enough to be able to purchase the materials wholesale from the plumbing supply store which also made it lighter on the wallet.
I should mention that the plumbing supply stores used by the plumbing and heating companies often don't (or won't) sell to the general public. However, some of them do have "pipe and fitting" accounts designed for the do-it yourself" types. It is worth the time to check into these companies if you have a large job ahead. I priced the copper between my supply store and the local Lowes. I was surprised that there was at least 10% difference on most items and up to 25% savings on others.
My friend provided me with a parts list of the materials we would need for the job and added in extra supplies to limit the inevitable trips for unexpected fittings. If you don't live close to the parts stores take this piece of advice; Buy extra. You can always take them back. Nothing slows down a project like stopping to run to the store for a fitting. Oh, and make sure you know what time the stores close too. I learned this the hard way.
We spent most of the weekend updating the plumbing and piping. We installed new multi-speed hyrondic circulators that would allow additional adjustments to the system if needed. The old circulators were still good and we were able to re-purpose three of them. This also left me a spare just in case. I learned that ball valves (shut offs) are your friend. We put in lots of them so if a circulator failed or a pipe burst or the system had to be otherwise worked on it could be done without draining a huge portion of the system. It added a little extra cost to the project but now a quarter turn on two levers is all it takes and the system can be up and running again in no time.
We were fortunate to be able to connect the plumbing to the new Kedel boiler as it had been delivered a few days prior. We connected the pipes but did not flow any water into it. Nor did we connect any of the electrical components. This was done so there would be no questions as to warranty coverage of the unit. My father-in-law ran a 220 circuit from my panel to the area of the boiler and I ran a wire for the remote shut off switch but these were left for my installers to connect.
So after a good weekend of work, a few "oh shit" moments and a lesson in humility with a torch and solder, (not to mention a few adult beverages in the evenings), the job was done. New plumbing and modern controls in place. With the number of sweated joints we completed a few leaks were expected. To our surprise not a drop of water leaked from the joints.
So to recap:
Shop around for the best prices for pipe and fittings
Have a qualified friend who knows the plumbing code help
Buy extra fittings
Get a refresher on soldering pipe (before starting project)
Make sure your wife knows if she wants hot water she may have to shower elsewhere.
Now, we just had to wait three days for Kedel and Daigle Oil Company to come do the commisioning of the boiler.
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