Replacing a Shell and Tube Heat Exchanger? And Have the Model Number?

Replacing a Shell and Tube Heat Exchanger? Whether you’re dealing with an old TACO or Bell & Gossett unit, give us the model number and serial number to your heat exchanger and 9/10 times we can replace it!  If you’ve dealt with Shell & Tube Heat Exchangers in the past, you know that the shell portion of the Heat Exchanger can last 40+ years. You are also aware that the tubes and bundles usually cannot. When these bundles fail, the typical customer cannot wait 8-10 weeks for the OEM to get the requisite part manufactured and sent back. Capital Coil understands that quick turn-around time is essential, so we offer both 10 & 5 day shipments 12 months/year.Shell and Tube Heat Exchanger

There are 3 main types of shell & tube heat exchangers:

  • “U” Tube heat exchangers where it is possible to remove the entire bundle
  • Fixed tube heat exchangers where the tube sheet are welded to the shell and stationary and the bundle is not removable
  • Floating tube heat exchangers where one tube sheet is fixed and the other floats axially.  This tube bundle is also removable.

So what information do we require to get started on your replacement Heat Exchanger or Tubes & Bundles? As mentioned, if you have the model #, in most cases, we should be able to cross-reference that unit from our product library. Send that information to our sales department, and a member of our team will get back to you with a quote – simple as that.  In the rare cases when we cannot cross-reference your model number, we can provide blank drawings that specify what measurements we need and where they’re located on the unit.  Please see our product pages on REPLACEMENT TUBE BUNDLES and SHELL & TUBE HEAT EXCHANGERS for product specifications and blank product drawings.

Capital Coil has extensive expertise at replacing bundles and heat exchangers for emergency situations. We can easily get you information on performance, design and cost. Please give us a call for your next job. We look forward to working with on your next opportunity.

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Quick, Reliable & Uncommonly Fast

 Quick, Reliable & Uncommonly Fast

You have many choices when buying replacement coils and choosing a coil supplier. You could decide to diversify and work with numerous suppliers, based on a particular need. However, Capital Coil & Air can make your buying decisions a lot easier. We have been in the coil business for many years, and in this industry, we recognize what is important vs. what is irrelevant. That translates into us having good insight on what you need and how best to support you as a customer.

Quick

Coils today typically do not have much “preventative” maintenance done on them. Most everybody just waits until a coil fails and then worries about the problem at that time. And when coils inevitably fail, they fail during the times when you need them most; i.e. cooling coils failing in the summer and hot water coils breaking down in the winter. As a result, there is usually an urgency attached to most HVAC projects. Generally speaking, most jobs require some form of “quick-ship”. Capital Coil & Air gives you (4) different shipping options for all replacement coils. Our standard ship time is 3 – 4 weeks, but if you need your order faster, Capital Coil will accommodate that need. We do not want to have a “one and done” transaction. Capital Coil’s goal as a business is to have a customer base that we work with for 20 years, not 20 minutes. While we will do our best to give you the fairest price possible, you have to recognize that there is an additional premium associated with quick-shipments on replacement coils. However, you will never pay that premium if Capital Coil is late on manufacturing your order. We’ve built our business on quick-ships, and we hit 99% of all deadlines on orders the last two years. In other words, we rarely miss! We give you options, and you only pay for what you really need.

Reliability

Reliability encompasses so many things in the coil industry. For example, if you need a price today, and the sales rep takes (2) days to get back to you, that’s unacceptable and unreliable. If you require a drawing to help you design a job, and you are waiting for a week to have it returned? Again, not what Capital Coil considers reliable. If a coil supplier promises you a ship date and ships (2) weeks late? Once again, not reliable. Do any of the above issues sound familiar? It is easy to make extravagant promises, and companies do it all of the time. However, Capital Coil’s success rate on meeting and exceeding shipping schedules says more than any promise we can make. We believe in under-promising and over-delivering, not the reverse!

  • Capital Coil responds quickly to all inquiries for pricing, general information, and engineering assistance
  • Capital Coil manufactures high quality equipment in the U.S.A. and is AHRI Certified
  • Capital Coil’s years of experience will help you quickly pick the correct product for the correct application
  • Capital Coil provides accurate shipping dates, real-time tracking and common carrier information after your order has left our factory

We do all of the above to make everything in your life easier. Capital Coil holds itself to the highest standards for both reliability and customer service. In short, we want your experience with us to be professional and simple. Please call or email our sales department for any job – no matter how large or small. We greatly look forward to the opportunity to work with you on your next project.

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Tips on Hand Designation & “Counter-flow”

Are your water coils right hand vs. left hand?  Is it looking into the face of the coil or with the air hitting you in the back of the head?  What exactly is counter-flow and why is it important?  Are you completely confused by why right hand vs. left hand even exists?  Most manufacturers probably do not know or understand the technical reasons themselves.

First, let’s figure out what coils even need a hand determination.  Chilled Water Coils, Direct Expansion (Evaporator) Coils, and Condenser Coils are the only coils that need this figured on almost every job.  Hot Water Coils, Booster Coils, and Steam Coils rarely need this determination.  The reason for this is when the coils are only 1 or 2 rows deep, they can be flipped over.  When a chilled water coil is 3+ rows deep, hand determination is much more important because it needs to be counter-flow.  Most suppliers determine hand designation with the air hitting you in the back of the head….do you want the connections on the right or left?

Chilled Water CoilsYou’ve probably heard the term “counter-flow” countless times, but here’s the simplest explanation.  For peak performance, you want the air and the fluid traveling in opposite directions through the coil.  Is it the end of the world if your coils are not counter-flow?  The short answer is no, but you will lose anywhere from 12-15% of the output.  So if your coils are piped incorrectly, don’t expect to get the full performance.  Steam and hot water coils are 1 or 2 rows deep, so counter-flow is pretty much irrelevant.  However, it can make a big difference with any chilled water or direct expansion coils (3-12) rows deep.

We also get asked many times “what is the proper way to pipe coils?”  Put simply, steam coils should always be fed on the highest connection and the return on the lowest connection.  Water coils should always be fed on the lowest connection and returned on the top connection.

Hand designation and counter-flow are two pretty simple concepts when they are properly explained.  When dealing with a HVAC coil manufacturer, partner up with one who will walk you through the engineering and explain it along the way.  Capital Coil & Air has well over a decade of experience in handling pretty much any scenario that you may come across, so we want to be your coil resource for any and all projects. Please give us a try on your next job!

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Simple Strategies For Your Replacement Coil Buying Process

Roughly 100% of HVAC replacement coil shipments use some kind of trucking company or common carrier. There are occasions when the shipment is small enough to use UPS or FedEx, but the vast majority of HVAC shipments are sent by way of truck. Anyone who has frequently used freight companies has experienced damaged shipments and/or late arrivals. In our industry, these annoyances and inconveniences are typically written off as “the cost of doing business”. Think of the airline industry as an example. Our expectations have been reduced to point where we expect something to go wrong and are pleasantly surprised when the trip is smooth from start to finish.

Many folks might not know this, but the trucking industry in general is experiencing a gross shortage of drivers throughout the country. Some estimates have put this shortage of drivers as high as 50,000 throughout the country.

So what does this shortage mean for the HVAC industry? Put simply, it translates into complications and confusion for all involved.

  • Longer delivery times. For example, a delivery that used to take (3) days is now (5).
  • One major reason for the longer delivery times is that trucks now have many more stops than in years past. There are also many instances of more trips through connecting terminals as well.
  • More time on the truck usually equates to both “visible” and “hidden” freight damage.
  • The shipments become harder to track, and with fewer people at the trucking companies doing more work, shipments can and will get lost entirely.

Because the freight process is at the very end of the buying cycle, Capital Coil & Air has developed some simple strategies for the entire buying process that should help in avoiding many of the annoyances listed above. We’ve also added a very useful “hint” to counter longer freight delivery times.

  • Getting a price, delivery & accurate proposal from your vendor: Capital Coil responds to every quote request quicker than any of our competitors, and we are always willing to put that claim to the test. A (2) day delay in receiving your quote is the same as a (2) day freight delay on the back end.
  • Receiving your submittal drawings in a timely fashion: You need to approve these drawings, so once again, how is a (2) day delay in receiving approval drawings any different than receiving your order (2) days late?
  • Quick-Ships: As you’ve probably experienced numerous times in the past and/or present, other coil manufacturers seem to be consistently shutting down their quick-ship programs with little to zero notice for the customer. Why is this? Many manufacturers take on a glut of OEM business, or other large projects with small profit margins. In many cases they do this simply to keep the factory running during the slower periods of the year. This has the effect of delaying standard lead times, and in many cases, cancelling quick-ships altogether. It is very hard to do business with companies that make themselves unavailable when you need them the most.

Capital Coil NEVER shuts down our quick-ship programs, and we emphasize NEVER! Over the last (2) years, CCA has hit approximately 99% of all quick-ship orders.

  • Crating equipment to minimize freight damage.Steam Coils
  • Shipping on time: Simply put, we consistently ship when we say we’re going to ship.
  • Select a freight carrier that delivers to your area without interlining or stopping at several terminals: This is when freight damage is most likely to occur!
  • Pay the carrier fee for a guaranteed delivery date: Although seemingly not well-known, most carriers offer a guaranteed delivery date for a fee of $50-$100. Paying the fee will ensure that your order is now a “priority”, and most freight companies schedule deliveries based on these “priorities” first. If both your order and delivery are critical and time-sensitive, Capital Coil can help you with exploring these delivery options.

Capital Coil & Air will work with you throughout the entire buying and shipping process because you as the customer, deserve to work with a hands on manufacturer that will not turn its back on you once the order has been placed. Please give Capital Coil a try on your next project!

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Need A Replacement Heat Exchanger/Tube Bundle?

To begin with the obvious, shell & tube heat exchangers consist of a tube bundle surrounded and protected by a steel shell. While the shell can seemingly last forever, the tube bundle inside most certainly cannot. The tube bundle is not attached inside the shell, which means that the bundle can be removed if needed to be replaced. In other words, you can simply replace the tube bundle without having to replace the entire heat exchanger. A good comparison can be found with coils inside Air Handling Units (AHU’s). Due to erosion, corrosion or both, coils tend to fail before the entire AHU and subsequently need to be replaced. If everything is done correctly, the new coil should simply “slide” into the place of the old coil. The same is true of tube bundles in that ideally you want to be able to remove the old bundle, and slide in a replacement with little to no extra work. Capital Coil & Air is here to help you throughout the entire process.

Replacement Tube Bundle

The easiest route to ensure that the correct duplicate is built is to first try to cross-reference the model #. While you may not have that information at your fingertips, there is a very good chance that Capital Coil has already built that specific bundle, and/or has the ability to cross-reference whatever model that you are looking to replace. Simply send us a picture of the tag with the model & serial number, and we will do the rest.

Regarding tube bundles, the most common type of replacement bundle can be found in “U” tube type exchangers. These types of bundles are typically water/water or steam/water exchangers.

Steam/Water Bundles

When looking to duplicate a tube bundle, you HAVE to know the bundle’s correct diameter, as well as the diameter of the tubes in order to duplicate the tube area. Additionally, you must duplicate both the tube length and the flange on the bundle to match it up correctly to the shell.

Steam/Water bundles are rather basic in that water is in the tubes, with steam filling up the rest of the shell. Matching performance is almost never the problem, but matching up the dimensions is PARAMOUNT!!  

Water/Water Bundles

Water/water bundles really only differ from steam/water bundles in that there is now water on the shell side as well. Steam automatically fills the shellside, but water does need to be redirected back & forth across the bundle by a series of baffles that operate on GPM & water velocity. The baffles are also an integral part of the bundle, so if duplicated correctly along with the other physical dimensions, performance will not be an issue.  Once again, physical dimensions are PARAMOUNT!

How Can We Go Wrong?

The surest and most common mistake is not correctly matching up the bundle tubesheet to the rest of the exchanger. The tube sheets must fit between the head and the flange on the exchanger, and the bolt-hole pattern must also be an exact match. The bolts are inserted through all three parts simultaneously, and the pattern should match up with all three parts. Sometimes other tube sheets fit between the head and flange, but are also smaller in diameter. The bolts simply bypass the tube sheet and go around it. There needs to be a concerted effort to ensure that the tube sheet dimensions are correct and not too big. Additionally, the gaskets need to be sized and replaced correctly. 

Capital Coil & Air has an established track record of building tube bundles efficiently and quickly. And, in all probability, we already have information on whatever unit you need to get replaced. Like coils, replacing tube bundles usually has a level of emergency attached to it, so we offer multiple quick-ship options if needed. Please give us the opportunity to work with you on your next project, and let us help to take a lot of the guesswork out of your next project.

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