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

As an intern, heading out of state for a task as daunting as measuring over 25 coils was no small feat. However, I've had the privilege of learning from James Filauro, our seasoned Account Manager based in the New York tri-state area. His guidance has equipped me with the skills and confidence necessary to handle such projects under his supervision.

This particular assignment involved measuring and replicating aging coils located within large air handling units (AHUs) at the DFAS facility in Maine. These coils, originally manufactured in 1991, featured older designs with cast iron headers that had seen three decades of continuous operation. Over time, these headers began to show signs of wear, including rust and corrosion, which posed risks of leaks and potential water damage. Additionally, these outdated steel headers often led to reduced water flow, making the tubes more prone to clogging with sediment in the chilled water loop. To address these issues, we decided 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. Unlike steel, copper is less susceptible to severe corrosion over time, ensuring longer-lasting performance. Furthermore, should any issues arise down the line, copper headers can be easily repaired using a brazing rod—a significant advantage over old steel headers, which are notoriously difficult to fix, if not impossible. Another benefit of copper is its ability to prevent mold and mildew buildup on the headers, which can lead to unpleasant odors and compromise indoor air quality.

During the measurement process, I adhered to best practices, paying close attention to details such as header-to-header center dimensions and connection center-to-center dimensions while meticulously documenting all measurements in my workbook. By the third AHU, I detected a recurring pattern in coil fin heights and lengths, allowing me to efficiently match duplicate coils across various units without needing to re-measure each one extensively. This insight greatly streamlined our workflow and saved valuable time.

After successfully measuring more than 25 coils, I felt a sense of accomplishment as I packed up my tools and returned to the office to finalize the coil designs and complete the detailed CAD drawings. Reaching this milestone didn’t happen overnight; it took months of observation, learning, and skill development. It was incredibly rewarding to witness firsthand how far I’ve come in my career through opportunities like this one.

Nationwide Coils boasts one of the largest and most comprehensive databases of commercial HVAC coil drawings in the industry. We specialize in replicating any make or model of OEM coils. If you ever need assistance with your next project, feel free to reach out via email for a quote.