Pressure Relief Valve Leaking (Please Help!!!)

[acechapman01]

This was from my reddit post, but I am not getting any responses so hopefully I can find some help here!
Here is the original post for my water boiler (Utica Boiler Model number MGB-100J):
In the summer I removed a radiator from my house in order to reinstall flooring. I refilled the system and then bled the radiators from top to bottom. After air came out of all but one radiator at the 2nd floor of the house, I realized that I needed I needed to repressurize the system to 12 psi (from the instruction manual guidance). I used the lever (pink arrow) on the pressure reducing valve to fill the system up to 12 psi and then pushed it down just until I no longer heard water flowing. I re-bled the system and water came out of all the radiators. I had run the boiler 3 times for about 40 Mins before realizing that the i needed to set the pressure. Since setting the pressure I have run the heat 4 times for a least an hour per time and then today for about 3 hours. When I went to the basement to check the furnace the pressure relief valve was leaking water to I immediately turned off the heat and the boiler. About 1 gallon of water came out when it was totally done dripping and the pressure went back to zero. While the water was dripping into the bucket I pushed the lever on the pressure reducing valve down in the event that it might let some pressure out. It didn't do anything so I put it back to where it originally was. The pressure gauge (after calling utica boilers they said this is not the original one) has 2 sets of numbers on it and I've been using the top set of blue numbers (blue arrow) (between 0 and 20) when I set the PSI. My question is- do I need to repressurize the system or should I let it cool and see if it will run since the excess water drained out of it or should I re-bleed and then repressurize the system to maybe a lower number? Thank you for your help!
Update:
Below is the recommended course of that was suggested to me and I did all of the steps:

• Remove all water pressure.
• Check expansion tank bladder pressure and make sure it’s 15psi. Add/remove pressure so it’s 15psi. Replace if unable to do this.
• Pressurize the system again using the auto feed (pink arrow). Make sure it raises pressure to 15psi. Adjust the nut on top to achieve 15psi. If unable to do this, replace the auto feed valve. Do not add by moving the lever.
• Bleed the radiators.
• Turn the heat on.
• Monitor pressure. If relief drips while below its pressure set point (on its tag), replace the relief.

The pressure relief valve did not leak after doing these steps, however I only had the heat running for about 1 hour. This morning I put the heat on for about two hours and the pressure relief valve was leaking. The only thing I did differently was use 12 psi as the starting pressure since that is what the boiler instructions as well as the expansion tank say to do. The expansion tank was around 6 psi and I used a tire pump to fill it to 12 psi and used the nut on the pressure reducing valve to adjust the pressure to 12 on the boiler and I get the lever on it down. I also tested it by pushing on the the valve that the air pump connects to and only air (NO WATER) came out. Also, when I knock on it, it has a hollow sound. The other thing I did was to give the top of the pressure relief valve a few taps with a hammer since I know that they don't always seal right after being open. However, none of this worked since water was once again leaking from the pressure relief valve. It appears to be leaking where it connects to the elbow joint as well as leaking out of the opening where water is supposed to come out of. My immediate thought is to replace the the pressure relief valve so I ordered a new one that will be here next week. It is definitely not soldered on but there is some sort of blueish colored paste (maybe) where it is connected but from what I have read I can just use Teflon tape to wrap around the threads. Also, when replacing it, do I need to drain the entire boiler? I can't seem to find a concrete answer on this. If I need to drain the entire boiler the then system will need to be re-pressurized so after draining it should I adjust the bolt on the pressure reducing valve so it is more open or could I use the lever on it to fill the system since it would be completely drained at the time? Any help is greatly appreciated. Thank you.

 

[John Gayewski]

Do you have a gauge that works anywhere so you can actually look and see the system pressure status?

 

[Sponsor]

 

[acechapman01]

Do you have a gauge that works anywhere so you can actually look and see the system pressure status?

I bought a water pressure gauge and I assume I need to attach it to where you drain the boiler (red knob close to the floor) and then turn on the water. My boiler is set to 12 psi so I assume if the water pressure gauge reads higher then my psi gauge is off and I need to drain some water out of the boiler until the water pressure gauge reads 12 psi