Case Study: We Need These Coils on a (5) Day Quick-ship

In late June, Capital Coil received a call from a Trane office in Ohio regarding quick-ship availability. One of Trane’s top customers had an urgent need for (12) large chilled water coils with stainless steel casing. The problem/hurdle that they were encountering was that they needed all (12) coils to be built and ship out of the factory in (5) business days. Completion of the whole project was 100% contingent on them receiving the coils in their specified time-frame. An additional complication was the fact that July 4th was the following week, and they needed to have the coils ship prior to the holiday.

Trane shopped the project around to different manufacturers, but not one could guarantee to ship in (5) days. Some manufacturers waffled and claimed that they could have them built in (6) or (7) days, but not one could guarantee to ship in (5) days. A sales rep in that same Trane office, who had worked with Capital Coil previously, suggested that his co-worker reach out to us to see what we could do. After speaking with Trane’s project manager, we immediately contacted our head of production to make sure that we had the capacity to complete all (12) coils in the required (5) days. She assured us that we had the materials and manpower on-hand to get them all built and ship on time. We agreed to accept the project and began work on the coils immediately.

Due to the size of the project, as well as it’s time-sensitivity, we had multiple calls daily with our factory to ensure that everything was proceeding on schedule. We then gave Trane daily status updates, so they were constantly informed of everything from the brazing of the coils to entering the final testing phase. Chilled Water Coil

As promised, all (12) coils were built correctly and shipped out in the required (5) days. Our logistics team was then in constant communication with the freight company to make sure that the delivery was on schedule. And just like during the production phase, we passed daily tracking updates along to Trane, so they knew where their coils were at all times and when they could expect delivery. All (12) chilled water coils arrived on July 3rd with zero freight damage, and the project was completed on time!

A company as large and influential as Trane can have their coils built by anyone, but Capital Coil was the only manufacturer that could guarantee to have their coils built and shipped by a required date. Additionally, in working so closely with Trane throughout the whole process, they were kept up-to-date in real time from the start of production to final delivery.

Capital Coil offers a level of service that you won’t get with other manufacturers. When we guarantee to ship by a certain date, we stand by that guarantee, or you do not pay!

 

Trane’s project manager’s comments to Capital Coil upon completion/delivery:

“This will help us get a jump on this project prior to the big event taking place next week! 

I will make sure to share your information with others across our great lakes region about our experience with your company, so that they know we have THIS option to go to for our coil needs. THANK YOU ALL!!”

Top 5 Reasons Commercial HVAC Coils Prematurely Fail

Capital Coil & Air has come across virtually every scenario over the years in which a commercial HVAC coil had to be prematurely replaced, and we have since created an easy guide targeting the main reasons HVAC Coils prematurely fail.

  • Coil Plugging: If you are not changing filters and/or your commercial HVAC coils are not properly cleaned in a timely manner, your coil will actually begin to act as a filter. When dirt builds up on the coil, that blockage prevents heat transfer and can cause an approximate 20% to 40% drop in performance. Dirt adds to the coil resistance and can be a primary cause for your coil to fail prematurely.
  • Vibration: When your HVAC coils are installed near a moving piece of equipment, vibration can occur and cause leaks. You can tell if vibration is the main cause if leaks are near the tube sheet and look like they are slicing through the tube. If/when that happens, the coils should be isolated from the rest of the system to prevent vibration from causing damage. One way to combat this is by oversizing the tubesheet holes, but many manufacturers will not do this. Condenser Coils are usually the most common victims of vibration.
  • Corrosive Environment: This applies to both the air in the environment and inside the tubes. For instance, if there is a corrosive element in the air, it will eat away at the copper tubes; whether you have 0.020” wall or 0.049” wall. This is very common in coastal areas where there may be salt in the air. To keep the costs down from going to a stainless steel or cupro-nickel coil, we usually suggest coating the HVAC coils. Coatings are almost always within your budget, and its application will only add about a week to the overall lead time. Steam condensate and untreated water can cause corrosion within the tubes of HVAC coils as well. If you have a steam coil that has failed before the one year warranty, there’s a great chance that corrosive agents are in the steam, and it’s eating away at the copper tubes.
  • Freeze-Ups: Most people think that when HVAC coils freeze, the water or condensate laying in the coil freezes into ice and it expands causing the tubes to bulge and eventually spring leaks. What really happens is that the coil will freeze in multiple areas simultaneously, and it’s the pressure between these areas that cause the tubes to swell and eventually burst. These are very easy to spot as the leaks will run the length of the tube rather than around the tube.  ALSO be very careful when considering “freeze-proof” coils!  If you remove 5-6 inches from the fin length to make the “freeze-proof” application fit, your coil’s performance will suffer considerably. 
  • System Design: You would be amazed to learn how many HVAC coils were never designed properly for their systems. If there is a design problem, replacing the coil will only waste time and money; while you have done nothing other than duplicate the previous problem. A little known fact in the replacement market is that a high percentage of all our projects are because the coils were built incorrectly or were never designed correctly in the first place. In some cases, owners attempt to improve the coil’s performance by adding additional rows. Most however do this without taking into account the air pressure drop or fluid pressure drop that comes with it.

When dealing with an HVAC coil manufacturer, try to 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 and can help you diagnose whatever problem that you are experiencing correctly the first time. We look forward to working with you on your next project!

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Syracuse University Athletic Dome Renovation

Capital Coil & Air prides itself on its ability handle all jobs – large or small! We quote anywhere from 25-50 projects/day, and there is typically a very diverse mixture of equipment and overall size & scope of projects that need to be engineered and quoted. The majority of our business comes from repeat customers because they know that we treat every job and request with the same importance – regardless of size. Today’s newsletter highlights one of our largest jobs to date to illustrate the fact that Capital Coil has the ability handle any job…no matter the size and scope.

Capital Coil has long understood that your businesses and customers depend on fast responses, fast engineering, fast shipping, and top-quality products. Again, whether it’s (2) small hot water duct-coils that you need overnighted, or banks of chilled water coils, Capital Coil wants you as our customer to be satisfied that you got a “fair-deal” with us on each and every job.

The Syracuse University Dome (SU Dome), in Syracuse, NY underwent an extensive renovation at a cost of $205 million. The old roof was air-inflated/supported and was replaced with an updated design-frame roof. As part of the total renovation, the building also changed out it bathrooms, Wi-Fi, LED lighting, and entire HVAC system. As part of the renovation, Capital Coil was asked to build (64) chilled water coils as a part of the air conditioning renovation project.Capital Coil

Modular Comfort Systems, located in Syracuse, contacted Capital Coil & Air during the planning and budgeting phase of this project. Modular Comfort Systems is a large and highly respected HVAC Representative in central New York State. After purchasing coils from CCA, they re-sold those same coils, as well as other HVAC equipment to the also very highly respected Burns Bros. Mechanical Contractors – also located in Syracuse. Burns Brothers has been working in HVAC, plumbing and process piping for more than 100 years. Both of these companies are the types of companies that Syracuse University would entrust with such an important and high-profile job.

Capital Coil built (64) free-standing chilled water coils in sizes ranging from (33” x 93”) – (33” x 118”). All (64) coils are (8) rows with 304 stainless steel casing, increased tube wall thickness of .035”, with connections built and oriented at 90 degrees to facilitate ease of piping. The coils have all been highly engineered and are exactly correct for this application/project. Each coil weighs over 1,000 lbs, so Capital Coil split up the total order into (2) separate shipments, two weeks apart, in order to help the contractor receive the delivery.

The point of this case-study is to show how proud Capital Coil & Air is to have been tasked with building coils for such a high-profile project. Capital Coil is also proud to have worked with professional organizations like Modular Comfort Systems and Burns Brothers Mechanical. But regardless of the size of the project, you’ll receive the same attention and support as anyone else who reaches out for our assistance. Please contact us as we look forward to working with you on your next project!!

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5 Work Day Quick-Ships on HVAC Coils – Why Capital Coil does it right

Day 1 – 38% of all orders sent to Capital Coil are on some kind of quick-ship, whether it be on a (5 day, 10 day, or 15 day). We enter the order immediately so that all departments in the plant have the project in their systems and are ready to move on it right away. The coil isQuick-Ships engineered, routing sheets are sent to the shop floor, and everybody now knows what needs to be built. 

Day 2 – Sheet metal casings are cut and sized, headers and connections are fabricated, while tube sheets are fabricated.

Day 3 – All tubing and fins are cut, stamped and assembly begins. You can see what the coil will look like upon final assembly at this point. Coils can be seen sitting on assembly tables.

Day 4 – Tubes are then expanded into the fins, and keep in mind that this is not a short process. Headers are then brazed to the tubes, and if there are return bends, they are connected. The coil is completely assembled and moved to the testing tank. The coil is tested under water for 20 minutes at 550 PSI. About 3% of coils have small leaks someplace in the brazing and are sent back to braze again.

Day 5 – The coil is crated and sent to shipping for routing to the customer. Then most importantly, your coil will be shipping in the guaranteed (5) days.

As you can see by this description, with quick-ships, there is not a lot of room for error in the timing and shipping with OEM HVAC replacement coils. We’ve been doing this for a while now, and we’ve had an approximately (97%) success rate fulfilling all quick-ship requests. We offer quick shipments 365 days per year, with both (10) day shipments & (15) day shipments also available for lower premiums.

diagram 

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Cooling Coils & Moisture Carryover

Moisture carryover is present on cooling coils where dehumidification happens.  Many people do not think it’s a problem…until you have moisture running down ductwork or spewing all over the inside of an air handler. If you’ve ever experienced that then you probably know all of these rules regarding moisture carryover.

  • Entering air temperatures of 80/67 of return air in the Northeast carry far less moisture than an outside 95/78 entering air temperature in Florida. Outside air always has more moisture. Cooling Coils

    -Your location plays a part as well. The drain pans will absolutely have be sized differently. Florida’s will be much larger in size.

  • Fin design is irrelevant when it comes to moisture carryover. Whether you have copper corrugated fins, or aluminum flat fins, plate fins or even the old fashioned spiral fins, none of it has any effect on moisture carryover.
  • Lastly, be careful when installing a new chilled water or DX (Evaporator) Coils in a system. Many end users like to increase the airflow on older coils because those old coils can act like filters, the fins are covered in dirt/dust and you’re not getting the same airflow through the coil. This dirt on the coil also semi-prevents moisture carryover. When that brand new chilled water coil is installed, the airflow might be higher than that of 550 ft/minute, which of course will cause moisture carryover problems. 

Please give us a call with any questions about your coil, your system or its design. Capital Coil is here to help you avoid situations like the one described in this post, and we would love for the chance to work with you!

 

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Guidelines For Air Velocities

The height, length and resulting air velocities greatly figure in everything in determining the size and performance of a coil. Step # 1 in determining the size and performance of a coil is dependent upon understanding face & air velocities of air across the coil. Whether you use CCA’s coil selection program to help size the coil, or you are replacing an existing coil; the height, length and resulting velocity determine everything.

Hot Water Booster Coils

air velocities

Every coil has a specific, optimum velocity, so you want to make sure you are within 30% (+ or -) of that number. For example, booster coils have an optimum velocity of 800 ft/minute. That means that you can drop your velocity to 600 ft/minute, or conversely, increase the velocity to 1,000 ft/minute. The duct velocities are almost always higher, which means that you will need to transition to a larger coil. Try to get to as close to 800 ft/minute as possible, while sizing your coil to make the transition as easy as possible. Everything with coils is a balancing act.

Hot Water & Steam Coils

Like booster coils, hot water and steam coils should also have face velocities at approximately 800 ft./minute. Both steam & hot water coils have only sensible heating, which is why their face velocities can be the same. Face velocities ultimately control the coil’s cost, so 800 ft./minute really is a heating coil’s “sweet spot”.

If you are purchasing an air handler unit, oftentimes the heating coil is smaller than the cooling coil because the face velocities on heating coils can exceed those of cooling coils. Due to water carry-over, cooling coils cannot exceed 550 ft/minute, while heating coils only deal with sensible heat.

Chilled Water & DX Coils

Due to the limited face velocities of cooling coils, your choices are more limited. With cooling coils, your face velocity must be somewhere between 500 ft./minute-550 ft./minute. Remember that when dealing with cooling coils, you are dealing with both sensible and latent cooling, so the coil is wet. When you exceed 550 ft./minute, water carry-over occurs past the drain pans.

If you are purchasing an air handler unit, you probably will not have worry about the coil’s face velocity as most coils come pre-sized at the acceptable face velocities. Fan coils also come pre-sized with the correct CFM’s. However, if you are replacing an existing cooling coil, the face velocity must remain at or below 550 ft/minute!!

 Air Stratification Across The Coil

Air does not travel equally across the face of a coil. If you were to divide a coil into (9) equal sections, like a tic-tac-toe board, you would see a high percentage of air travelling through the center square, rather than the corner squares. In a perfect air flow scheme, 11% of the air would travel through each of the 9 squares, but that is not what happens. Because more air travels through the center of the coil, you want to avoid putting a fan too near the coil. Due to central air flows, most systems are draw-thru, rather than blow-thru. This is also why you want to avoid installing your coil near any 90 degree angles/turns in the ductwork. Avoid any situations that contribute more than the “natural” air stratification to help ensure your coil is at maximum efficiency.

In some situations involving cooling coils, you will have water carry-over even when the coil is sized correctly. How can this happen? Think about the tic-tac-toe board again. Air velocities are exceeding 700 ft./minute in the coil’s center, while the corners are around 300 ft./minute. This cannot and will not work.

Coils do not have any moving parts. They simply react to the air across the outside of the coil and whatever is running through the inside of the coil. Coils are 100% a function of your entire system, as well as the installation in general.

Capital Coil & Air is here to help with any coil selections that will help avoid costly missteps that lead to wasted time and money. Call us on your next project, we greatly look forward to working with you!

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Chilled Water Coils – Circuiting Made Easy

Chilled Water Coil

Circuiting chilled water coils is one of life’s great challenges in the coil business. You’re bound to run across folks with years of experience in the industry that can not effectively explain this concept. While not the most exciting of subjects, the necessity of circuiting chilled water coils can not be overstated. Capital Coil & Air has attempted to simplify the idea of circuiting as much as possible.

For starters, circuiting chilled water coils is ultimately up to the performance of those coils. Circuiting is really a balancing act of tube velocity and pressure drop. In other words, think of a coil as a matrix. Each coil has a specific number of rows, and a specific number of tubes within each row. For example, a chilled water coil might be 36 inch fin height and 8 rows deep. The coil has 24 tubes in each row, and multiplied by 8 rows, there is a total of 192 tubes within the coil. While you can try to feed any number of tubes, there are only a few combinations that will work.

    • Feeding 1 tube – you will be making 192 passes through the coil, which will essentially require a pump the size of your car to make that process work.
    • Feeding 2 tubes – equates to 96 passes, and your pressure drop will still be enormous.
    • Feeding 3 tubes – 64 passes, which is still too many.
    • Feeding 4 tubes – See above.
    • Feeding 5 tubes – Impossible as 5 does not divide evenly into 192 (passes).
    • Feeding 6 tubes – Still constitutes far too many passes, which again leads to additional pressure drop.
    • Feeding 7 tubes – Same rule for feeding 5 tubes.
    • Feeding 8 tubes –  Same rule for feeding 6 tubes.
    • Feeding 24 tubes – This feed consists of 8 passes, which is in the ballpark, and with a pressure drop you can live with.
    • Feeding 32 tubes – 32 tubes will see 6 passes. You might see a slight decrease in performance, but it’s off-set by a continuously better pressure drop.
    • Feeding 48 tubes – The magic combination, as 4 passes typically elicits the best performance and pressure drop simultaneously.

 

Rule #1: The number of tubes that you feed must divide evenly into the number of tubes in the chilled water coil.

Rule #2: The chilled water coil must give you an even number of passes so that the connections end up on the same end.

Rule #3: Based on the number of passes, you must be able to live with the resulting pressure drop. Acceptable tube velocity with water is between 2 and 6 ft. per second.

You’re bound to run into different terminologies depending on the manufacturer. More times than not, the different verbiage confuses more than it clarifies. However, understanding the basic tenets of chilled water coil circuiting will remove much of the perceived difficulty.  

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Frozen Steam Coils: How Do You Prevent This?

Regardless if you have steam coils or steam distributing (non-freeze) coil, you can freeze ANY coil.  When freezes happen, everyone immediately looks to the steam coil as the cause.  When in fact, there are numerous reasons that must be looked at well before the coil.

Freezes generally happen in older systems, however if your new system is not maintained properly or correctly installed, your steam coil can and will freeze.  For instance, you’d be surprised at how many times dampers are left open, controls fail, freezestats don’t work, etc.Steam Coils

In a Standard Steam or Steam Distributing Coil, a freeze-up can occur when condensate freezes within the tubes of the steam coil.  The two most common reasons for freezing steam coils are the steam trap and the vacuum breaker.  The function of steam trap is to remove the condensate as soon as it forms.  Condensate usually collects in the lowest part of the coil.  If your steam trap isn’t installed properly, that condensate will lay in the coil and it will inevitably freeze as soon as it sees outside air.  The vacuum breaker also helps clear the condensate, minimizes water hammers, and helps with uneven temperatures. This must be installed on the control valve and always above the steam trap.

Unfortunately, there are no ways to determine exactly where your steam coil will freeze.  And a common misnomer is that the condensate turns to ice and the expansion is what causes the tubes of the coil to pop.  In reality, it’s the pressure that builds up between freeze points.

Here’s couple tips in your coil design that can help prevent your standard steam and steam distributing coils from freezing:

  • Standard steam coils should NEVER see any outside air below 40 degrees.  If it does, steam distributing is the only way to go!
  • 5/8” OD Steam distributing coils over 72” long are recommended to have a dual supply
  • 1” OD Steam distributing coils over 120” long are recommended to have a dual supply
  • Make sure your steam coil is pitched if possible.  This slopes the condensate to the return connection making it easier to remove the condensate

Give Capital Coil & Air a try on your next project. Our engineering, pricing and service is the best in the industry!

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Are Your Quick-Ships Shut Down When Needed Most???

Why are quick-ships so important??

Christmas season is in full-swing, and your current coil supplier has suspended all Quick-Ships with little to zero notice to its customers. Does that sound familiar these days? Additionally, the clock is ticking to complete those projects that need to be done by the end of the year. In this industry, this scenario is when “Quick-Ship” availability is an absolute must. Right now, the vast majority of coil manufacturers are scrambling to complete standard orders on regular lead-times, and if by dumb-luck they are able to temporarily offer any type of expedited build, the added premiums are so astronomical that very few customers can afford to use those options.

If you need a new coil, your first inclination will probably be to call the OEM. But more times than not, they are not flexible or nimble enough to handle your emergency within an acceptable time-frame. Quick-ships are generally based on emergency conditions, and that is precisely the worst time to discover that your regular supplier has suspended Quick-Ships.

So why do so many manufacturers seem to get so overwhelmed at various point every year? In short, 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’s primary duty as the leading OEM replacement coil manufacturer is to fill in those gaps and work with you to help alleviate any emergencies. Whether you need a coil in (3) weeks, or (5) days, Capital Coil has got you covered.

Capital Coil does not try to be all things to all customers, and we’re most comfortable “staying in our lane”. Our #1 goal is to ensure that we have multiple quick-ship options open all year around…even if that means turning away an order to ensure sure that our Quick-Ships are ALWAYS available!!  Quick-ships

Because Quick-Ships make up such a substantial portion of our overall business, Capital Coil has hit 99.9% of our quick-ship requests over the last (2) years. An unfortunate forklift mistake makes up the other .1%. Throughout the first 6 months of 2022, approximately 80% of all orders were/are quick-ships, and they have either all been completed on time, or are 100% on schedule.

An RFQ that sits on a desk unanswered is useless to everyone involved. If you need a quote, you’ll have your price and any required submittals that same day. It really is that simple and easy! Working with Capital Coil will remove many, if not all of the annoying and unannounced shut-downs that come with other manufacturers, so please let us help you when you need it the most!

 

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OEM Replacement Coils: Repair or Replace???

When considering OEM replacement coils, there are multiple reasons why coils can fail prematurely. Sometimes, OEM Coils simply freeze and can never be repaired. Other times, the coil was selected incorrectly, which in turn, made the coil significantly underperform. Many times, there is substantial corrosion or something else in the system that causes the coil to fail. However, most coils, when selected correctly, and in systems that are properly maintained, can last anywhere from 10-30 years!  10-30 years is also a pretty wide range, and there are many variables in how long you can expect a coil to perform. Factors, such as ongoing maintenance, air quality, and water/steam quality all have an effect on a coil’s lifespan.

OEM Replacement Coils

Reasons Why Coils Fail Of Old Age

  • While the coil’s tubes are considered the primary surface, 70% of all coil performance is performed by the finned area on a coil, which is known as the secondary surface. The fin/tube bond is easily the most important manufacturing feature in any coil. Without the bond between the tubes and fins, the coil could never properly function. Like all things however, over time the fin/tube bond becomes less efficient with constant expansion and contraction. While the construction of the coil, as well as the fin collars, does not allow the fins on the coil to move, that fin/tube bond naturally weakens a coil’s life over time after installation. Because of this, it is not a stretch to say that a coil is easily 30% less efficient after (20) years.
  • Cleaning coils often pushes dirt to the center of the coil, and this occurs even more so on wet cooling coils. Just remember that coils can become great air filters if not properly maintained. The BTU output of any coil is in direct proportion to the amount of air going through the coil. If you decrease the CFM by 20%, you are also decrease the BTU’s by 20%!
  • Cleaning agents often corrode aluminum fins. Since every square inch of fin surface matters in performance, corrosion of the fin surface is always detrimental to the coil’s performance.
  • Many times, there are coil leaks simply because of old age. No coils are immune to erosion. You might find the brazing in the tubes, as well as the brazing in the header/tube connections failing over time. Steam can be both erosive and corrosive under higher pressures. Water travels through the coil at 2 – 5 ft/second, so erosion is an enormous part of coil failure, regardless of how well-maintained. Erosion is always there, whether you realize it or not.
  • Water/steam treatment and the corrosive effects of bad steam/water can all be causes of coil failure…which then necessitates the need for a reliable manufacturer for OEM replacement coils.

So What Is The Solution?

Some coils can last 5 years, and some coils can last 30 years. As you have read, there are numerous factors that contribute to a coil’s life. In the end, there will most likely have been multiple attempts to repair that coil to make it last as long as possible. The depressing news is that most of these “Band-Aid” attempts do not work well. The most likely outcome is that you are buying a new coil anyway, so why waste the time and money on a temporary solution?

Coil failure is a “pressure event”, which is a fancy way of saying that a coil is leaking. We’ve listed some of the most common repair methods that you are likely to come across:

  • Drop leaking tubes from the circuit: Keep in mind however that every dropped tube reduces the coil’s performance by triple the surface area of the tube that is dropped. Again, while ok in the short-term, this is simply another “Band-Aid” fix. Over time, your energy costs will rise exponentially, and you will probably end up buying a new coil anyway.
  • Braze over the existing braze: As mentioned above, erosion has caused the original braze to fail, so all that you are really doing is pushing the pressure to another braze, which will then begin to fail as well.
  • High Pressure Cleaning: This method bends the fins, further restricts the airflow, and pushes dirt more to the center of the coil, which can never be adequately cleaned.

The real reason why coils need to be replaced rather than repaired is due to energy costs. If your coil is not operating near desired levels, you’ll need to increase the energy to make it work at its peak performance. Energy increases might be slight at first, but they are guaranteed to continue to rise over time. For example:

  • Somebody adjusts the fan drive for higher speeds, higher CFM’s and higher BTU’s.
  • Someone adjusts the boiler; the water and steam temperatures are higher.
  • Someone adjusts the chiller (1) degree higher for colder water to the chilled water coil.

Whichever method is used, performance begins to suffer and adjustments to the system occur. These adjustments cost energy efficiency and ultimately, money!

If you have ever experienced repairing a coil, then you know it is labor intensive and typically will not work as a permanent solution. With very few exceptions, repairs should be seen as nothing more than temporary until you’re able to replace that coil!

Capital Coil & Air has seen every “repair” method used, as well its inevitable outcome, so instead of putting yourself through that, call Capital Coil and allow us to be your coil replacement experts.

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