Site Bite: Measuring OEM coils for replacement at the Defense Finance & Accounting Service.

Being an intern often means tackling projects that feel like they're straight out of a textbook—only this one was anything but. My assignment? Traveling to Limestone, Maine, to measure more than 25 original equipment manufacturer (OEM) coils at the Defense Finance & Accounting Service (DFAS). While this might sound straightforward, it was a daunting task requiring precision and experience. Fortunately, I’ve been lucky enough to train under James Filauro, our seasoned Account Manager from the New York tri-state area. His expertise gave me the confidence and skills needed to take on this challenge alongside him.

Our mission today involved meticulously measuring and documenting the specifications of aging coils installed within large air handling units (AHUs). These coils, originally manufactured in 1991, feature outdated cast iron headers that have seen better days after three decades of continuous operation. Signs of wear, such as rust and corrosion, had begun to appear, leaving the headers vulnerable to leaks and potential catastrophic failures. Additionally, these older steel headers tend to restrict water flow, making the tubes more prone to clogging with sediment in the chilled water loop. To address these issues, we planned to replace the steel headers with higher-grade copper ones during the duplication process.

Copper headers are renowned for their superior efficiency and durability, especially in chilled water systems where they resist corrosion far better than steel. Should maintenance become necessary down the line, copper headers can easily be repaired using a brazing rod—a simple solution compared to the near-impossible repairs required for old steel headers. Furthermore, copper helps prevent mold and mildew buildup on the headers, ensuring cleaner air and improved indoor air quality within the building.

As I measured each coil, I adhered to best practices, carefully noting header-to-header center dimensions, connection center-to-center dimensions, and diligently recording all measurements in my workbook. After completing the first few AHUs, I identified a recurring pattern in the coil fin heights and lengths, allowing me to accurately match duplicate coils across different units. This saved significant time, as I only needed to confirm the dimensions of coils already confirmed as duplicates.

By the time I finished measuring over 25 coils, I felt a deep sense of accomplishment. Completing this project was no small feat, and it’s a testament to the months of training and development I’ve undergone under James’ guidance. Reaching this milestone in my internship has been incredibly rewarding, and I’m proud to have contributed to such a substantial project.

Nationwide Coils boasts one of the largest and most comprehensive databases of coil drawings in the industry. We specialize in replicating any make or model of commercial HVAC coil. For your next project, don’t hesitate to reach out—just email us for a quick quote!