Burst heating coil
Burst heating coil
(OP)
I have a heating coil 138/115 Deg C flow & return temperatures, design conditions. It is only 2 weeks old and recently burst at a support strap connecting the the flow and return header.
Before the incident under low load condition the return temperature was going back at 40 deg C. Is this normal and ok?. The control valve was only approximatly 10% open during this time maintaining off coil conditions smothly.
The coil supplier doesnt think the water should be going back so low and has blamed this on the controls system.
I am trying to figure out the thermodynamics of the coil re LMTD etc...and figure out why the coil burst.
Please help!!
Before the incident under low load condition the return temperature was going back at 40 deg C. Is this normal and ok?. The control valve was only approximatly 10% open during this time maintaining off coil conditions smothly.
The coil supplier doesnt think the water should be going back so low and has blamed this on the controls system.
I am trying to figure out the thermodynamics of the coil re LMTD etc...and figure out why the coil burst.
Please help!!





RE: Burst heating coil
RE: Burst heating coil
Sounds like the coil was not strong enough to take the high temperatures.
RE: Burst heating coil
Do not now if it was internal or external steress. The fracture was only a pin hole. It failed where the support strap connects to the hot pipe and happened at the back of the strap. The hot pipe header is supported off the ground at low level but it was at the strap at high level where the damage was done. There is also a strap at low level but no damage here. There is no excessive vibrations and the coils were factory tested. The freeze stat was calibrated. This happend during mild low load conditions.
Can someone tell me if leaving water temperatures of 40 degC which is less than design leaving at 115 is typical. The coil supplier says NO. I tend to disagree especially when all other coils in the plant vary weel below the figure of 115 deg C.
I am trying to understand the Q=UxAxLMTD equation.???????
RE: Burst heating coil
Where is the control valve located? If in return, then there may be chances that coil got damaged due to high pressure.
Regards,
RE: Burst heating coil
I think your wrong there. Assume the load goes from say
15 % to 0% (no load). Then the control valve starts closing. Isnt the leaving water temperature going to approach the entering air temperature if there is no load??
Its a strange one alright.
RE: Burst heating coil
A pin hole, to me, more often points to either corrosion, or a factory defect. Anyone who installs piping systems will tell you that occassionally you see a pin hole leak on new piping and fittings that can only be attributed to a problem in the manufacturing process. Usually these problems are discovered on hydro testing of a new system, but some develop later.
Two questions - What is the piping material? Is the leaking pipe in the airstream, or out of it?
---KenRad
RE: Burst heating coil
It was most probably a defect in the material (i.e., supplier's liability). Swarf in the water ways or inadequate chemical water treatment might have had a role (client's responsibility), but failure in two weeks sounds too fast for this. I think I'd investigate getting it brazed in-situ, which would minimize the down-time and save everyone the grief of dismantling and shipping it back to the suppliers. I'd get the supplier's faxed written agreement to this, so that it won't affect their warranty.
I suspect they'll want to minimize their costs and will probably agree; if they value your custom, they may offer to pay. If it happens again I'd expect a new coil, unless some other cause is identified. If they won't entertain it, just buy a new coil from another supplier, it will probably be cheaper than the time you'll spend in investigating and arguing.
RE: Burst heating coil
Mr. Whoops, I am trying to prove that having lower return water temps is normal in HVAC. The coil supplier is using the low water temp in his defence and said it went out of specifications of 115 deg C return.
Mr. quark reckons it should not go below 115 Deg C, the design return water temp.
Who is right??
RE: Burst heating coil
He may be, but it seems to be a very feeble defence. It's a red herring; it is not relevant to the defect. You need to ask them to explain how a low return temperature could possibly cause a pin hole in their coil. If they can explain it, I'd really like to know their explanation.
I think that the equation you need is;
Q = m x c x dT
(m x c x dT)air = (m x c xdT) water
Q (kW) energy transferred
m mass flow rate (kg/s)
c specific heat capacity of the fluid, air or water (kJ/kg degC).
The control valves work by reducing the water flow rate through the coil, whether it's a 2-port valve or 3-port diverting valve. The 3-port valves maintain a constant mass flow rate by diverting a portion of the water flow around the coil and back into the return.
RE: Burst heating coil
i dont know the relationship between the U value and the flow rate. Low flow rate decreases the U value of the coil (thermal coefficient, by how much I dont know. You probably want to know it results in a lower LMTD (log mean temp difference)
RE: Burst heating coil
A copper strap welded to the flow and return header at the top and bottom of the coil exist for structural reasons , so I am told by the supplier.
The coil was rated at 138/115 degC only, also according to the supplier. But with current low load conditions we have return water temps at 40 degC. Should not be, according to the coil supplier, lets blame the controls company.
The hot water in the flow pipe caused it to expand or move at a higher rate than the cold return and pulled on the low temp return pipe becasue of the hugh temp difference and caused the pipe to fracture at the strap wels on the strap at high level. This is probably true but no excuse for the coil to burst. It seems the coil is not robust. Any structural elements of the coil should be flexible enough to carry varing temps. The coil supplier say it was only tested to 138/115 deg C
I need to know for sure if at low load 40 degC water is normal, even thogh it is well below the design of 115 degC
pleas help!!!
RE: Burst heating coil
Any other condition will cause the coil to fail?
So when the coil was made, fresh off the assembly line, was it at those conditions? Was it at those conditions when it was transported to your site? When it sat on site waiting to be installed? Did the manufacuturer ever consider that the system might be shut down, like during the summer?
Tell your supplier that he is full of BS. You can even tell him that I said so if you think it would help.
The control system may or may not be working correctly, but that is not relavant to the failure.
RE: Burst heating coil
I regret I can't prove this, it's beyond my maths, which was fairly shaky when it was in regular use.
The low water return temperature does seem to be predictable from the Q = U x A x LMTD equation.
U and A are constants.
Q is the variable and so the LMTD term must be varied by the control system to give the required value of T(air off).
The LMTD term is a function of 4 temperatures, i.e., T (air on), T (air off), T (water on), T (water off).
Of these T (water on) is a constant.
T (air off) will, I think, probably have relatively minor variations.
T (air on) varies with the outside conditions and T (water off) seems to be the only term that can be controlled to compensate for the changes in T(air on).
T (air on) will go up in mild conditions, so I'd expect T(water off) to go down.
Anyone out there who's more mathematically talented & can show this with some equations?
Even if you can prove this to your own satisfaction, I expect the suppliers will argue black is white to avoid liability. If the temperature differential had caused the failure, I'd have expected a tear at the strap. I still can't see how the stress could cause a pin-hole. It was probably weld contamination, maybe they had the new guy doing the brazing that day.
RE: Burst heating coil
Actually the U is a variable too. It decreases with low water flow rate (low load) so there lies the difficulty in trying to prove the LMTD goes away down during low load conditions. If we knew how much the U value changes with flow it would be easier to prove then.
RE: Burst heating coil
HVAC68
RE: Burst heating coil
ww
Such a big temperature diffrential could have caused a thermal shock to the coil resulting in failure.In my opinion only a materials engineer is qualified to pass that judgement.
RE: Burst heating coil
You are right that I made an half baked statement and thanks for the correction. What actually I meant was a bit different but became oversmart
During low load condition(i.e keeping air flow constant and coil air inlet temperature high) hot water control valve should reduce the flow keeping the temperature difference constant(or within a close range). This is what my experience has been(not necessarily for others), both for cooling and heating coils. The reason for lower than designed return hotwater temperatures may be due to mall function of valve control system(high load but valve closing).
I also see less chances of failure due to water volume changes due to temperature. For ex. specific volume of water at 1150C is 0.00105588 m3/kg and at 400C it is 0.00100789 m3/kg. There is a difference of only 4.5%. The chances will be almost nill if we have the control valve in the outlet.
The pinhole seems to be totally a manufacturing defect and I concur with Whoops on this matter.
Regards,
RE: Burst heating coil
KB
RE: Burst heating coil
I wonder if the design units are incorrect? Should these values for the coil be in Fahrenheit? Another hint that there may be excessive supply temperature is that the HW coil control valve is 10% open. If controls are set right, a 10% open command might be closed or barely cracked. If temperature is being maintained during design conditions at 10% open, the supply may be way too hot.
To look into this further, could you give additional coil info? Design airflow? Design MBH? Design water flow?
RE: Burst heating coil
I wonder if the coil supplier looked at the installation site before he sold the coil? The pin hole failure sure sounds like a weld defect to me. Which wouldn't be caused by stress, thermal or mechanical.
Is this a replacement coil, or is it a brand new installation?
RE: Burst heating coil
RE: Burst heating coil
The quoted hot water temperatures are high. Yep, one can achieve these easily enough in a pressurized system. I've worked with such in the past. But where is THIS system installed, and why are they using a pressurized system? Pressurized systems, of adequate pressure to allow heating water temps as described, are expensive and generally only used when situation dictates it's use.
Next, coil manufacturer's claim that coil only tested and suitable for the ONE given supply and return temp, and may fail under any other condition is at best bogus and silly. How in the world do you do a startup and shut down if that's the case? Did they ship it to the site in a sealed and enviormentally controlled container to maintain temps within specs? That's ridiculous. Normal such a rating as they are arguing would be the conditions under which they can guarantee a specific performance of heat transfer. And is otherwise meaningless. It certainly can not reasonably mean that the coil will physically fail under any other circumstances whatsoever.
What are the coil manufacturer's instructions concerning warm up, cool down rates and times? In high performance, high energy systems, where thermal shock is a concern and issue, it is normal for equipment maker to provide specific operating info, stating something like "Do not allow equipment to warm up (or cool down)faster than 20 degrees per minute." Something to that effect. One sees these types of instructions commonly in high energy systems which damage due to overfast heating or cooling of system is expected to cause damage or shorten expected and design operational lifetime of equipment. Did coil manufacturer provide such instructions, if not, then they don't have much of a leg to stand on in their claims that the too low return temp damaged their coil. If they truly designed coil to such close (and flimsy) tolerances, they should've been clear about this. Actually, they should get into another line of business.
Now, that return temp you got is a problem. Shouldn't have caused the failure. One would expect that upon startup or shut down one might well see such a difference between supply and return. But that return temp shouldn't be "normal". That is, shouldn't occur normally during operation of properly designed and controlled equipment. I tend to agree with another poster that coil might be oversized. But, really, you haven't given much info for us to really know.
In my experience, which isn't all that great IMHO, there are questions here. Normally I'd expect that a coil that needs to have a specific supply and return water temp within some faily close tolerances, would achieve this by varying GPM, with control one control point looking at HW supply temp, keeping it steady. And another, the one for the coil, watching return temp and modulating to maintain that, as versus watching air temp. Another control of some sort, bypass damper or whatever, taking care of maintaining air temp parameters.
This is an interesting discussion. But raises a lot of questions in my mind.
In any event, pin hole leak as you describe sounds more like a manufacturing defect to me that anything else. ie Welder or brazer got a bit carried away with heat attaching strap, dug too deep into material of pipe. Thermal expansion and contraction, not unexpected ... quite normal, as one would get this in start up and shut down conditions even if everything else was working right, broke free strap and pulled away too thin spot on pipe.
Just my opinion.
In any event, that big of a deltaT shouldn't be during normal operations. Coil likely too big. Or maybe control valve on inlet, and inlet on top of coil? I've seen that screwup before.
RE: Burst heating coil
I've just picked up this thread and it seems like youv'e exhausted almost all avenues. However have you considered external forces. Is the coil piped up in such a way that it is not affected by external forces due to expansion.
If the pipework connecting on to the coil is subject to a large amount of expansion, there will be a lot of movement and stress generated which might affect the coil and cause it to burst??
Just a thought.
Friar Tuck of Sherwood
RE: Burst heating coil