Strange noises from forced hot water heating system

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mathfogie

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I have strange noises in one part of my heating system.
It is forced hot water, Peerless boiler, Beckett burner, installed about 1990,
replacing a builder's special.
In 2012, I had a contractor split the first floor zone into two zones.
The original layout had several baseboard radiators on interior walls as well
as the the usual exterior walls. The result is a mixture of copper and
plastic pipes in the basement.
The water district replaced the meter about a week before the noise started.
There are gate valves on both sides of the meter.
The noise is in only one zone but it has several sounds.
One sound is a gurgle, something like a brook running rapidly over stones.
Perhaps it is like a lot of air in the line, but I can't imagine how it got there.
I searched for signs of a leak and did not find any.
The valve that could shut off the automatic refill is open.
The second sound seems like it could be something rotating,
perhaps a bearing failing in a motor or pump.
If so, that would be one of the units installed in 2012.
The third sound is like metal being dragged across another piece of metal..
All of the sounds seem to come from near the radiator that is closest to the boiler,
on the source or hot side, furthest from the pump on the return side.
One or more of the sounds, usually all of them, happen most of the time when the
thermostat calls for heat, but not all of the time.
Usually the noise stops before the burner turns off.
Ideas about cause and cure are needed. Thanks.
 

rjbphd

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What the pressure on the system? If the pump in on the return side, that alone can contributes noise in system due to improper piping setup. . Got any pictures?
 

mathfogie

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What the pressure on the system? If the pump in on the return side, that alone can contributes noise in system due to improper piping setup. . Got any pictures?
I do not know about the pressure in the system.
There is a pressure reducing valve just downstream from the meter.
It does not have a meter and has not been touched for several decades.
There is an expansion tank on the output side of the boiler. It also has no meter.
There is a pressure gauge on the front of the boiler.
Now it reads about 8 psi, but I have not watched it during a burn cycle.
There is heat in all three zones.
What kind of improper setup should I look for?
I have no pictures now, but I can take some.
What pictures would be helpful?
 

rjbphd

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Pictures of your boiler setup would helps the experts trouble shoot. .. the pressure should be at least 12 lbs. . If for any reason to call for service, make sure the person is a HYDRONIC HEATING expert, not just some plumber because it's piping or forced air guy because it's heating. .
 

Dana

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At 8psi at the boiler in a basement a radiator more than 18.5' above the pressure would be at negative pressure, and pulling air in. At 8psi there is also a much greater liklyhood of cavitation at the pump impellers and a higher prospect of flash-boil at the heat exchanger (though it'll probably sound more like fizz or hiss at first, but as the pressure drops it will be making banging sounds.)

Assuming the pressure gauge is correct, the system pressure at idle (no burning, no pumping, boiler at some idling standby temp) needs to be raised to 12psi, but unless it's a 3 story it usually doesn't need to be more than 15psi at tepid-idle.
 
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