Galvanic Corrosion

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SELECTION GUIDE:

ENVIRONMENTAL CORROSION
PROTECTION

COMMERCIAL PRODUCTS:
CONDENSER COILS AND COOLING/HEATING COILS

ALUMINUM-FIN/COPPER-TUBE COILS
COPPER-FIN/COPPER-TUBE COILS
PRE-COATED ALUMINUM-FIN/COPPER-TUBE COILS
E-COATED ALUMINUM-FIN/COPPER-TUBE COILS
E-COATED COPPER-FIN/COPPER-TUBE COILS

Carrier Corporation
Syracuse, New York

March 2005
TABLE OF CONTENTS

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . .3 Field Applied Coatings . . . . . . . . . . . . . . . . . . . .12


E-Coated Material and Chemical Resistance . . . .12
WHAT CAUSES CORROSION? . . . . . . . . . . . . . . .4
Galvanic Corrosion . . . . . . . . . . . . . . . . . . . . . . . .4 SELECTION SUMMARY TABLES . . . . . . . . . . .14
General Corrosion . . . . . . . . . . . . . . . . . . . . . . . . .5 Protection Option Selection . . . . . . . . . . . . . . . . .14

IDENTIFICATION OF POTENTIALLY COIL MAINTENANCE AND


CORROSIVE ENVIRONMENTS . . . . . . . . . . . . . .6 CLEANING RECOMMENDATIONS . . . . . . . . . .18
Coastal / Marine . . . . . . . . . . . . . . . . . . . . . . . . . .6
Industrial . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 RELIABILITY TESTING /
Combination Marine / Industrial . . . . . . . . . . . . . .7 QUALITY ASSURANCE AT CARRIER . . . . . . . .18
Urban . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 Moist SO2 Chamber . . . . . . . . . . . . . . . . . . . . . . .18
Rural . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 Steam Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Localized Environment-Corrosivity Salt Spray Tests . . . . . . . . . . . . . . . . . . . . . . . . . .18
of the Surroundings . . . . . . . . . . . . . . . . . . . . . . . .7 Kure Beach Studies . . . . . . . . . . . . . . . . . . . . . . .18
Cyclic Corrosion Testing . . . . . . . . . . . . . . . . . . .18
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . .8 Prohesion™ Cycle Test Results Comparison . . . .18

CORROSION PROTECTION OPTIONS . . . . . . . . .9 APPENDIX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20


Condenser Coils . . . . . . . . . . . . . . . . . . . . . . . . . .9 E-Coating Chemical Resistance Guide . . . . . . . .20
Cooling / Heating Coils Standard
Coil Construction . . . . . . . . . . . . . . . . . . . . . . . .11

INTRODUCTION

Corrosion is costly. By definition, corrosion is the If units are improperly applied or left unprotected,
destruction or deterioration of a metal or alloy these units can experience rapid corrosion from
through chemical, physical, or electrochemical reac- exposure to aggressive elements. However, meas-
tion with the environment. As applied to HVAC ures can be taken to identify potentially corrosive
equipment, exposure to various elements in the environments prior to equipment selection. With
environment can lead to localized and/or general this information, the best-suited coil protection can
corrosion of heating and cooling coils. Improperly be applied to minimize the harmful effects of corro-
protected coils in corrosive areas can lead to prema- sive elements and ensure long equipment life.
ture performance degradation, unsightly surface
conditions and, under the most severe conditions, This guide will assist in the selection of appropriate
equipment failure. This can be costly to the cus- coils and long-term product solutions in potentially
tomer and result in lost sales caused by the percep- corrosive environments by describing:
tion of poor product quality. Fortunately, corrosion
can be minimized in most cases with proper coil • What causes corrosion
protection. • How to identify potentially harmful
environments
Commercial equipment that may be susceptible to • How to select proper coil protection
corrosion includes:
Rooftop Units With this information, intelligent equipment selec-
Air-Cooled Chillers tion decisions can be made to optimize the level of
Air-Cooled Condensing Units corrosion protection and maintain the highest level
Remote Air-Cooled Condensers Make-Up of long-term equipment quality.
Air-Handling Equipment
3
WHAT CAUSES CORROSION? includes aluminum oxide build up around the tube
surface and within the fin pack, flaking aluminum
Corrosion takes on many forms. The most common fins, fins falling from the coil surface in thin sheets
forms of corrosion, as applied to HVAC equipment, and total removal of the aluminum fin material.
are known as galvanic and general corrosion. Each
of these corrosion types can lead to equipment fail-
ure. As a result, special attention will be given to CORRODED
ALUMINUM
each of these types of corrosion. FIN

Galvanic Corrosion
AIRFLOW
When dissimilar metals are in contact in the pres-
ence of an electrolyte, a reaction occurs. This reac-
tion is known as galvanic corrosion. There must be
a metallic couple between two or more dissimilar
metals in the presence of an electrolyte. Without any Fig. 2. Galvanic corrosion begins.
one of these ingredients, galvanic corrosion will not
occur. Bi-Metallic Construction

The standard coil is manufactured from copper


Galvanic corrosion of copper tube/aluminum fin tubes mechanically bonded to aluminum fins. This
heat exchanger coils results in fin degradation, bond creates a classic bi-metallic couple necessary
which may ultimately lead to the destruction of the for galvanic corrosion. An electrolyte in the pres-
coil. Galvanic corrosion of the unprotected coil ence of the copper-tube and aluminum-fin couple is
begins at the bi-metallic couple between the copper sufficient to initiate a corrosion reaction. However,
tube and aluminum fin. Because the aluminum is elimination of the bi-metallic couple can eliminate
less noble than copper, the aluminum material cor- galvanic corrosion. This can be accomplished with
rodes. Figure 1 shows a typical standard coil prior to an all copper coil (elimination of the dissimilar met-
attack from galvanic corrosion. als; one of the necessary factors for galvanic corro-
sion to occur) or through isolation of the two metals
ALUMINUM FIN with a protective coating. The protective coating
will create a barrier between the metallic couple and
COPPER TUBE
the electrolyte to prevent galvanic corrosion (elimi-
nation of the electrolyte; one of the necessary con-
ditions for galvanic corrosion). Another method of
LOUVERED AIRFLOW
FIN
reducing galvanic corrosion is through insulating
ENHANCEMENT the copper from the aluminum through the use of a
pre-coated aluminum fin. This breaks up the electri-
cal contact between the copper and the aluminum
(elimination of the electrical contact of the dissimi-
Fig. 1. Standard coil construction.
lar metals; one of the necessary conditions for gal-
vanic corrosion).
As galvanic corrosion begins in the standard coil
construction, the aluminum fin deteriorates starting The Electrolyte
at the copper/aluminum interface (Figure 2).
Corrosion of the aluminum fin continues until coil Electrolytes are electrically conductive solutions.
performance is adversely affected due to the oxide Common electrolytes may include chloride contam-
buildup at the copper tube/aluminum fin interface inants from sources such as seawater, road salts,
which creates thermal resistance or severe visual pool cleaners, laundry facilities and household
deterioration results. Common visual deterioration cleaning agents. These electrolytes are typically

4
sodium or calcium chloride compounds. Other rele- CLEAN
UNCONTAMINATED COPPER
vant contaminates that may be present include sul- ATMOSPHERE TUBE
fur and nitrogen compounds, from the combustion
of coal and fuel oils.

The most common sources of chloride contamina- REFRIGERANT


tion are marine and coastal environments. Sea spray,
mist, and fog contain tiny droplets of salt water that
can be transported more than several miles by ocean
breezes and tidal currents. It is not uncommon to Fig. 3. Clean copper tube.
experience salt-water contamination many miles
from the coast. As a result, protection from ocean-
borne electrolytes in inland areas may be necessary. METAL
CONTAMINATED OXIDES
ATMOSPHERE FORM
General Corrosion

General corrosion is the degradation of metal caused


by a reaction with the environment, such as oxida- REFRIGERANT
tion and chemical attack of the metallic surface.
Since general corrosion consumes metal and forms
metal oxides, unsightly surface conditions result.
For example, copper is susceptible to attack from Fig. 4. Oxidation begins.
sulfur containing gases. The result is the formation
of a non-protective layer on the material surface.
The copper fins will often become very brittle, with
PROLONGED EXPOSURE TO TUBE
the corrosion product being non-adherent to the cop- SEVERELY CONTAMINATED INTEGRITY
per metal surface. Unprotected metal will continue ATMOSPHERE FAILS
to react with the contaminant and corrode. Under
severe, prolonged conditions, the metal continues to
corrode until the integrity of the equipment is jeop-
REFRIGERANT
ardized. Unprotected copper in polluted industrial
environments can lead to failure of the refrigeration
system. Sulfur and nitrogen based electrolytes in
combination with chloride environments are often Fig. 5. Tube failure.
the cause of accelerated corrosion of copper.

Failure of a contaminated copper-fin coil can result


from fin degradation and ultimate loss of tube
integrity. Furthermore, surface tarnish on copper,
such as black, red, green, brown, or yellow deposits,
lead to the perception of poor quality.

General corrosion of copper due to a contaminated


environment is illustrated as follows. A clean copper
tube in an uncontaminated atmosphere maintains
system integrity (Figure 3). However, in a contami-
nated atmosphere, metal oxides begin to form on the
copper tube (Figure 4). Prolonged exposure to a
contaminated atmosphere results in tube failure
(Figure 5).
5
IDENTIFICATION OF POTENTIALLY should be considered when the potential for coastal
CORROSIVE ENVIRONMENTS contamination exists:

A corrosive environment must be clearly identified • Is the unit near the ocean? Visit the proposed
and understood before proper coil protection can be installation site. How far away from the ocean is the
selected. In addition to proper coil protection, indoor site? Are the prevailing winds from the ocean? If so,
air quality codes and generally accepted practices the potential for severe coastal corrosion should be
must be addressed. Corrosive environments may expected and appropriate protection is required.
have a detrimental effect on indoor air quality.
• Is there corrosion on exterior structures, other
Potentially corrosive outdoor environments include HVAC equipment, or other equipment? Look around
areas adjacent to the seacoast, industrial sites, heav- the installation site and surrounding areas. If there is
ily populated urban areas, some rural locations, or evidence of corrosion, chances are high that corro-
combinations of any of these environments. In air- sive contaminates exist and suitable protection is
handling applications, some indoor environments required.
such as swimming pool areas, water treatment facil-
ities, and industrial process areas can produce corro- Industrial
sive atmospheres.
Industrial applications are
Local environments must also be considered; close associated with a host of
proximity to laundry facilities, diesel-burning diverse conditions with the
devices/exhaust piping, sewer vents, traffic, etc. can potential to produce various
also lead to premature failure of improperly selected corrosive emissions. Sulfur
equipment. and nitrogen containing con-
taminants are most often
Coastal / Marine linked but not limited to to
industrial and high-density
Many emerging HVAC markets urban environments. Combustion of coal and fuel
have a majority of their popula- oils release sulfur oxides (SO2, SO3) and nitrogen
tions located in coastal areas. oxides (NOx) into the atmosphere. These gases accu-
This leads to an increased number mulate in the atmosphere and return to the ground in
of air conditioning applications the form of acid rain or low pH dew.
located in corrosive environ-
ments. Not only are industrial emissions potentially corro-
sive, many industrial dust particles can be laden with
Coastal or marine environments are characterized by harmful metal oxides, chlorides, sulfates, sulfuric
the abundance of sodium chloride (salt) that is car- acid, carbon, and carbon compounds. These parti-
ried by sea spray, mist or fog. Most importantly this cles, in the presence of oxygen, water, or high
salt contamination can be carried many miles inland humidity environments can be highly corrosive.
from the coast. Even if the HVAC equipment is a
substantial distance from the ocean, corrosion from Note: These particles/contaminates can be carried
salt contamination can still occur if the equipment is for many miles.
not properly protected.

Distance from the ocean, prevailing wind direction,


relative humidity, wet/dry time and coil temperature
will determine the severity of corrosion in the
coastal environment. As a result, the following
6
Combination typically not required beyond the standard
Marine/Industrial aluminum fin/copper tube coil construction.
Salt-laden seawater mist, Sometimes, however, rural environments contain
combined with the harmful high levels of ammonia and nitrogen contamination
emissions of an industrial from animal excrement, fertilizers, and high con-
environment, poses a severe centrations of diesel exhaust. These environments
threat to the life of HVAC should be handled much like industrial applications
equipment. The combined with E-coated coil protection.
effects of salt mist and
industrial emissions will Localized Environment -
accelerate corrosion. This Corrosivity of the Surroundings
environment requires superior corrosion resistant
properties for air-conditioning components to main- All of the above environments are subject to
tain some level of product quality. Complete encap- “Micro-Climates” which can significantly increase
sulation of the coil surfaces is recommended. the corrosivity of the environment. Care should be
E-coated copper-fin coils should be considered. taken to ensure that the localized environment sur-
rounding the HVAC equipment does not contain
Urban contaminates that will be detrimental to the coil. For
example, if the equipment placement was near a
Highly populated areas gen- diesel loading area, although the general area where
erally have high levels of the building may be located may meet the scope of
automobile emissions and a coastal or marine environment, the localized ele-
increased rates of building ments that surround the equipment may actually
heating fuel combustion. classify the application as industrial and protection
Both conditions elevate sul- of the coil should be planned accordingly.
fur oxide (SOx) and nitrogen
oxide (NOx) concentrations. Situations to consider when determining the level of
Corrosion severity in this corrosivity of the localized environment:
environment is a function of the pollution levels
which in turn depend on several factors including Proximity to:
population density for the area, emission control and • Sea water
pollution standards. • Automobile traffic
• Bus traffic
Any HVAC equipment installed near to diesel • Truck traffic
exhaust, incinerator discharge stacks, fuel burning • Power plants
boiler stacks, areas exposed to fossil fuel combus- • Factories
tion emissions, or areas with high automobile emis- • Breweries and food processing plants
sions should be considered an industrial application. • Wastewater treatment plants
E-coated aluminum-fin coils would be the only • Dumps and incineration plants
acceptable protection in these environments. • Cruise ships and shipping traffic
• Swampy areas (rotting vegetation)
Rural
Contributing factors such as:
A rural environment typically is unpolluted by • Prevailing wind direction
exhaust and sulfur containing gasses. Typically a • Acid rain (sources may be hundreds of miles away)
rural environment is sufficiently inland that contam- • Humidity levels
ination and high humidity from coastal waters are • Time of wetness
not present. Protection in these environments is • Condensation
7
INSTALLATION

The following situations also contribute to the level


of corrosivity of the localized environment:

• Laundry vents or exhausts


• Dryer exhausts
• Laundry rooms
• Exhaust vents

• Diesel tank locations


• Diesel loading areas
• Diesel boiler rooms/exhausts
• Proximity close to cooling towers where
carry-over is possible

• Close proximity to sprinkler systems


(where over-spray is possible)
• Kitchen exhaust vents
• Sewer exhaust vents
• Areas where insecticide will be utilized
• Areas where fertilizers are applied
• Pools/Hot tubs
• Chemical/cleaner storage areas
• Loading docks
• Bus loading areas

8
CORROSION PROTECTION OPTIONS Aluminum fin stock is coated with a baked-on
epoxy coating prior to the fin stamping process
The highest level of product quality can be assured (Figure 7). Coating of the fin material prior to the fin
when the right protection is applied. The choices stamping process is known as “pre-coating.” The
available on Carrier’s commercial products offer the pre-coated fin material is then stamped to form a
right protection for many aggressive environments. wavy fin pattern for optimum thermal performance.
The wavy design can be recognized by the
Condenser Coils vertical corrugation on the fin face. Vertical corru-
gations increase the fin’s effective surface area and
Standard Coil Construction
further enhance heat transfer properties.
The standard condenser coil has copper-tubes INSULATING BARRIER
BETWEEN THE
mechanically bonded to aluminum-fins with lou- FIN AND TUBE

vered enhancements. Figure 6 shows a cross-section ALUMINUM FIN


WITH EPOXY
of a copper tube and several aluminum fins. High PRECOATING

thermal efficiency is achieved through direct metal-


COPPER TUBE
lic contact between the tube and fin. Fin louvers
improve the fin’s heat transfer capabilities. As a
result, maximum thermal performance is achieved
with this high efficiency coil design provided there
is no corrosion. Fig. 7. Pre-coated coil assembly.

The standard coil generally provides the highest per- A thin layer of inert epoxy precoating material insu-
formance for non-corrosive environments. (e.g., lates the dissimilar metals of the coil from one
non-polluted Rural Environments). Application of another. As a result, the electrical connection
this coil in any environment containing corrosive between the copper and aluminum is broken, thus
constituents is not recommended due to the likeli- preventing galvanic corrosion. In mild coastal envi-
hood of visible deterioration resulting from corro- ronments precoated coils are an economical alterna-
sion. tive to E-coated coils and offer substantial corrosion
protection beyond the standard uncoated coil.

Copper-Fin Coils
ENHANCED
ALUMINUM
FIN Copper-fin coils eliminate the bi-metallic bond
found on standard fin coils (Figure 8). A copper
COPPER TUBE
wavy fin pattern, void of louvered enhancements, is
mechanically bonded to the standard copper tube.
All copper tube sheets are also provided to enhance
the natural resistance of all copper construction. A
protective Mylar strip installed between the coil
Fig. 6. Standard coil construction.
assembly and sheet metal coil support pan further
protects the coil from galvanic corrosion.
Pre-Coated Aluminum-Fin Coils

Pre-coated aluminum-fin coils have a durable epoxy Copper-fin coils are priced higher than aluminum
coating applied to the fin. This design offers protec- precoated fin coils, since material costs for copper
tion in mildly corrosive coastal environments, but is are greater than aluminum. However, coastal corro-
not recommended in severe industrial or severe sion durability in an unpolluted marine environment
coastal environments. can be substantially improved over the standard or
precoated coil construction, since the bi-metallic
construction is not present.
9
SINGLE METAL
BOND BETWEEN
ultra clean. The water bath rinses residual dust and
FIN AND TUBE
contamination away in preparation for the E-coating
COPPER FIN
process. The fundamental principle of electrocoat-
ing is that the materials with opposite electrical
MYLAR STRIP
COPPER TUBE charges attract each other. An electrocoating system
SEPARATES
COIL FROM applies a DC charge to the coil immersed in a bath
GALVANIZED
COIL SUPPORT
COPPER TUBE
SHEET of oppositely charged epoxy molecules. The mole-
cules are drawn to the metal, forming an even, con-
tinuous film over the entire surface. At a certain
Fig. 8. Copper-fin coil assembly. point, the coating film insulates the metal, stopping
the attraction, and preventing further coating depo-
Copper-fin coils provide increased corrosion resist- sition (self-limiting nature of the coating process).
ance in coastal environments where pollution
sources are not present. Copper is generally resistant The final rinse bath removes and recovers residual
to unpolluted coastal environments, since a natural coating material to ensure a smooth coating and
protective film is formed to passivate the copper minimizes process waste. A precisely controlled
surfaces. Furthermore, a mono-metal bond exists oven bake cures the coating uniformly to ensure
between the tube and the fin. However, uncoated consistent adhesion on all coil surfaces. Finally, a
copper coils are not suitable for polluted coastal UV protective topcoat is applied to shield the finish
applications or industrial applications, since many from ultraviolet degradation and to ensure coating
pollutants attack copper. The use of uncoated copper durability and long life.
in these applications is not appropriate and must be
avoided to ensure long coil life. E-coated alu-
minum-fin coils should be considered for such
applications.

E-Coated Aluminum-Fin Coils

E-coated coils provide superior protection against


many corrosive atmospheres with the exception of
formic acid and nitric acid environments. For a com-
plete listing of the chemicals to that the E-coat is
resistant, please refer to the appendix. Degreasing E-Coat Oven Bake

Water Rinse Final Rinse UV Topcoat


E-coated aluminum-fin coils have an extremely
durable and flexible epoxy coating uniformly Fig. 9. E-coat process.
applied over all coil surfaces for complete encapsu-
lation from exposure to the contaminated environ- This creates a smooth, consistent and flexible coat-
ment. A consistent coating is achieved through a ing that penetrates deep into all coil cavities and cov-
precisely controlled electrocoating process that ers the entire coil assembly including the fin edges
bonds a thin impermeable epoxy coating on the spe- (Figure 10). The process in conjunction with the
cially prepared coil surfaces. coating material results in a less brittle, more
resilient and more durable coating without bridging
Electrocoating is a multi-step process that ensures between adjacent fins than previous phenolic coat-
ultra clean coils are properly coated, cured and pro- ings. E-coated coils provide superior protection in
tected from environmental attack (Figure 9). This the most severe environments.
process includes complete immersion degreasing to
remove contamination and ensure all surfaces are
10
Flexible, consistent Cooling/Heating Coils Standard
and durable epoxy Coil Construction
coating. Fills all coil
cavities and covers The standard cooling/heating coil (water, steam, or
fin surface and Direct Expansion) has copper-tubes mechanically
edges.
bonded to non-lanced aluminum-fins with a wavy
pattern embossed on the fin face. The fin pack is
Aluminum Fin assembled with galvanized steel tubesheets and coil
case. This assembly has classic galvanic corrosion
Copper Tube components with multi-metal bonds between the
fin-and-tube and tube-and-tubesheet.
Fig. 10. Magnification of E-coated aluminum-fin
copper-tube coil. In cooling applications, condensate accumulates on
the coil surfaces when dehumidification occurs. Wet
E-Coated Copper-Fin Coils coil surfaces resulting from condensation in the
presence of a contaminated airstream will lead to
E-coated copper-fin coils have the same durable and galvanic corrosion if not properly protected.
flexible epoxy coating uniformly applied over all
coil surfaces as the E-coated aluminum-fin coils Potentially corrosive airstreams may not be suitable
(Figure 11). However, these coils combine the natu- for building occupants. If a contaminated airstream
ral resistance of all copper construction with com- can lead to corrosion, special consideration with
plete encapsulation from the E-coat process. E-coat- respect to indoor air quality and potentially harmful
ed copper-fin coils should be specified for side effects to building occupants is recommended.
environments with harsh coastal conditions.
Copper-Fin Copper-Tube Coils
E - COATING
Much like the all-copper condenser coil, all-copper
ALL COPPER cooling/heating coils eliminate the bi-metallic bond
CONSTRUCTION found on standard coils. A copper fin with wavy pat-
tern is mechanically bonded to the standard copper
tube to ensure a single-metal assembly. Most air-
handling equipment is available with stainless steel
tubesheets and coil cases to improve the corrosion
MAXIMUM PROTECTION
IN SEVERE COASTAL, durability of the entire coil assembly. As a result, the
INDUSTRIAL OR A potential for corrosion is reduced since bi-metallic
COMBINATION OF
BOTH ENVIRONMENTS couples can be reduced within the coil assembly.
SIDE VIEW FRONT VIEW
E-Coated Coils
Fig. 11. E-coated copper/copper coil.
E-coated coils have the same E-coating as the con-
denser coils (see Condenser Coils section on page
9). All E-coated coils have a durable and flexible
epoxy coating uniformly applied over all coil sur-
faces, including tubesheets and coil cases. The coat-
ing provides a barrier between the coil surfaces and
the corrosive effects of the atmosphere to prevent
contamination of the coil surfaces. Since cooling/
heating coils are not exposed to the potentially
harmful ultraviolet rays from the sun, the UV top-
coat is unnecessary.
11
In considering E-coated coils, it is important to also • Inconsistent coating thickness can minimize or
consider the effects of moisture carryover. Moisture negate coating protection. Recommended coat-
carryover occurs when accumulated condensation is ing thickness cannot be ensured with field appli-
blown from the coil surface during cooling coil cation on multiple row coils. Film thickness
applications. The extent of carryover is a function of measurements are generally overlooked.
airstream velocity across the coil, fin spacing, fin
geometry and material of construction. When • The coil must be void of corrosion prior to field
E-coating is applied to a cooling coil, carryover will application of the coating. Encapsulation of
occur at lower coil face velocities. existing corrosion makes the coating ineffective
Recommendations shown in Table A should be con- by leading to continued deterioration and coat-
sidered when selecting chilled water or DX coils to ing delamination.
ensure moisture carryover will be prevented.
E-Coated Material and Chemical Resistance
Table A
Maximum Recommended Face Velocity (FPM)* Chemical resistance of the E-coating material is
described in the appendix, “E-coating Chemical
Fin Spacing
Resistance Guide.” Application of an E-coated coil
(FPI) Aluminum-Fin Copper-Fin E-coated Coil
should only be considered when the contaminant is
8 650 500 500
listed in the Appendix guide. If the E-coating is
11 650 425 425
NOT resistant to the contaminant listed or if the
14 575 375 375
contaminant is not listed in the appendix, applica-
FPI - Fins per Inch FPM - Feet per Minute tion in this environment is not recommended.
*External fouling on cooling coils will adversely affect the max- Contact your Carrier representative for further guid-
imum recommended face velocities. Data based on clean coils
with proper filtration and periodic cleaning of coil surfaces. ance.

Field Applied Coatings

Most field applied sprayed-on coatings generally do


not provide sufficient protection in corrosive envi-
ronments. Possible reasons for poor performance:

• Coil cleanliness is crucial for proper adhesion.


Adequate field cleaning techniques are general-
ly overlooked.

• Field application cannot ensure continuous coat-


ing of coil surfaces on multiple row coils. It is
difficult to ensure uniform coating quality
throughout the depth of the fin pack.

• Interior coil surfaces remain untreated when


sprayed-on from unit exterior (often spray appli-
cators cannot reach deep into the coil assem-
blies, leaving inconsistent coating).

12
Common industrial contaminants which are resisted
by the E-coated coils are shown in Table B.

Table B
Industrial Contaminants
Potential
Color of
Chemical Type of Industry/ Source of Corrosion
Contaminant Symbols Application Contaminant (on copper)*

Sulfur Oxides SO2 Pulp, Paper & Lumber Plants Process Emissions Black
SO3 Incineration Facilities Products of Combustion Blue
Fuel Burning Power Generation
Diesel/Gasoline Engine Operation

Nitrogen Oxides NOx Pulp, Paper & Lumber Plants Process Emissions Black
Incineration Facilities Products of Combustion Blue
Fuel Burning Power Generation
Diesel/Gasoline Engine Operation

Chlorine & CI2 Cleaning Agent Processing Process Emissions Brownish


Chlorides CIx Water Treatment Facilities Water Disinfection Yellow (Non-
Salt Mining/Processing Process By-Products hydrated)
Swimming Pool Agents Green (hydrated)

Ammonia & NH3 Chemical Industries Process Emissions Black


Ammonia Salts NH4 Fertilizer Manufacturers Process By-Products
Waste Water Treatment Facilities Waste Digestion
Agriculture Animal Waste & Fertilizers

Hydrogen H4S Waste Water Treatment Facilities Sludge Processing Black


Sulfide

* Discoloration is an indication of potential problems. However,


identification of contamination sources based on color may be
misleading.

13
SELECTION SUMMARY TABLES
(TABLES C-H)

Protection Option Selection

Clearly identify the operating environment for the


intended installation. Determine the severity of each
environmental factor associated with the installation
site. Choose the protection option based on the most
severe environmental factor anticipated for the
given site. As an example: the site is on the coastline
and the condenser coil is facing the ocean, but there
is not noticeable corrosion on other equipment. An
E-coated Aluminum-Fin Copper-Tube option is rec-
ommended. Always choose the option for the most
severe environmental factor.

Table C
Coastal Environment Protection Option

Severity of Environmental Factors


Low Severe
Distance from Coast
Inland Coastline
Direction of Prevailing Winds
From Coast to Unit From Unit to Coast
Corrosion Present on Other Equipment
Coil Option None Present Noticeable Corrosion

Standard: Aluminum-Fin / Copper-Tube X NR NR NR NR


Copper-Fin / Copper-Tube ACC ACC X NR NR
Pre-Coated Aluminum-Fin / Copper-Tube ACC X NR NR NR
E-Coated Aluminum-Fin / Copper-Tube ACC ACC ACC ACC X
E-Coated Copper-Fin / Copper-Tube ACC ACC ACC ACC X

ACC - Acceptable application with corrosion


protection in excess of required level
X- Recommended Option
NR - Not Recommended

Note: Environments immediately adjacent to diesel exhaust,


incinerator discharge stacks, fuel burning boiler stacks, or
areas exposed to fossil fuel combustion emissions should be
considered a Combined Coastal/Industrial application.
Recommendations presented for Industrial and Combined
Coastal/Industrial Environments should be followed.

14
Table D
Industrial Environment Protection Option
Severity of Environmental Factors
Low Severe
Contaminant Concentration*
0 ppm 100 ppm
Corrosion Present on Other Equipment
Coil Option None Present Noticeable Corrosion

Standard: Aluminum-Fin / Copper-Tube X NR NR NR NR


Copper-Fin / Copper-Tube NR NR NR NR NR
Pre-Coated Aluminum-Fin / Copper-Tube ACC X NR NR NR
E-Coated Aluminum-Fin / Copper-Tube ACC ACC X X X
E-Coated Copper-Fin / Copper-Tube NR NR NR NR NR

ACC - Acceptable application with corrosion


protection in excess of required level
X- Recommended Option
NR - Not Recommended
* “E-Coating Chemical Resistance Guide”, appendix.

Table E
Combined Coastal/Industrial Environment Protection Option

Severity of Environmental Factors


Low Severe
Distance from Coast
Inland Coastline
Direction of Prevailing Winds
From Coast to Unit From Unit to Coast
Corrosion Present on Other Equipment
Coil Option None Present Noticeable Corrosion

Standard: Aluminum-Fin / Copper-Tube X NR NR NR NR


Copper-Fin / Copper-Tube NR NR NR NR NR
Pre-Coated Aluminum-Fin / Copper-Tube ACC X NR NR NR
E-Coated Aluminum-Fin / Copper-Tube ACC ACC X X X
E-Coated Copper-Fin / Copper-Tube NR NR NR NR NR

ACC - Acceptable application with corrosion


protection in excess of required level
X- Recommended Option
NR - Not Recommended
* “E-Coating Chemical Resistance Guide”, appendix.

15
Table F
Urban Environment Protection Option

Severity of Environmental Factors


Low Severe
Pollution Levels/Population Density
Low High
Corrosion Present on Other Equipment
Coil Option None Present Noticeable Corrosion

Standard: Aluminum-Fin / Copper-Tube X NR NR NR NR


Copper-Fin / Copper-Tube NR NR NR NR NR
Pre-Coated Aluminum-Fin / Copper-Tube ACC ACC X NR NR
E-Coated Aluminum-Fin / Copper-Tube ACC ACC ACC X X
E-Coated Copper-Fin / Copper-Tube NR NR NR NR NR

ACC - Acceptable application with corrosion


protection in excess of required level
X- Recommended Option
NR - Not Recommended

Note: Environments immediately adjacent to diesel exhaust,


incinerator discharge stacks, fuel burning boiler stacks, or
areas exposed to fossil fuel combustion emissions should be
considered a Combined Coastal/Industrial application.
Recommendations presented for Industrial and Combined
Coastal/Industrial Environments should be followed.

16
Table G
Advantages/Disadvantages of Protection Options

Coil Option Advantages Disadvantages

• High Thermal Efficiency • Limited Corrosion Protection


• Lowest Cost capability in corrosive applications
Standard Coil
• Light Weight

• Low Cost • Reduced Thermal Efficiency


Pre-Coated Coil • Galvanic Decoupling • Limited Protection Capabilities
• Inappropriate in severely
corrosive environments

• Corrosion Durability in unpolluted • Highest Cost


marine environment • Greatest Weight
Copper/Copper
• Effective Thermal Performance • Not effective in some
• Mono-metal Construction marine/industrial environments
• Lower velocity limits require coil
to receive optimum airflow in
cooling coil application
• Unexpected Corrosion due to
local pollutants

• Flexible, Consistent, Durable • Higher Cost


• Superior Corrosion Protection • Greater Weight
E-Coating
• Complete Coil Encapsulation
• Creates Barrier between all coil
surfaces and corrosive environments

Table H
Comparison of Protection Options with Standard Aluminum-Fin Copper-Tube Coil
Corrosion Thermal
Coil Option Cost Availability Protection Weight Performance

E-Coated Copper Fin ---- - ++++ -- -

E-coated Aluminum Fin --- - ++++ - -

Pre-coated Aluminum Fin - = ++ = -

Copper Fin -- = + -- =

+ Superior to Standard Coil


= Equal to Standard Coil
- Less Favorable to Standard Coil

Note: More than one + indicates factor is significantly better than standard coil;
more than one - indicates factor is significantly less favorable than standard coil.

17
COIL MAINTENANCE AND Kure Beach Studies
CLEANING RECOMMENDATIONS
Coils and equipment are exposed to a coastal envi-
Routine cleaning of coil surfaces is essential to ronment at a facility run by the LaQue Center for
maintain proper operation of the unit. Elimination of Corrosion Testing in Kure Beach, NC. The atmos-
contamination and removal of harmful residues will pheric conditions are monitored at this site where
greatly increase the life of the coil and extend the exposures have been done over the years at 80-ft or
life of the unit. 800-ft distances from the mean tide line. The testing
performed here allows Carrier to determine actual
RELIABILITY TESTING/QUALITY performance of corrosion protection methods in a
ASSURANCE AT CARRIER coastal environment. The results obtained from test-
ing at the beach are used to develop accelerated lab-
As part of Carrier’s commitment to continuous oratory methods to simulate coastal environments
product improvement and quality assurance, many and to test methods for preventing corrosion.
tests can be performed to determine the level of cor-
rosion protection for specific applications and Traditional salt spray testing has been performed
environments. according to the neutral salt spray test ASTM
Specification - B117 which uses a continuous 5%
Moist SO2 Chamber salt fog at 35 degrees C. This has been the accepted
corrosion test method for more than 80 years, but
Moist SO2 testing is typically accomplished in what good correlation between the test results and corro-
is referred to as a Kesternich Chamber. The purpose sion seen in actual atmospheric exposures has sel-
of this cyclical testing is to simulate industrial dom been found. New test methods involving cycli-
atmospheres by introducing a known volume of SO2 cal exposures are being developed which can be
gas and exposing material to this while simultane- better correlated with actual atmospheric exposure
ously controlling the humidity at a high level for results.
8 hours. This is followed by an ambient condition
dry cycle of 16 hours. Cyclic Corrosion Testing

Steam Tests Carrier utilizes a cyclic Corrosion Tester for


enhanced testing capabilities at the LaQue Center.
The steam test was developed at Carrier to rapidly The Q-fog Model CCT600 is used to obtain more
evaluate the quality of various coatings. This test realistic corrosion performance results than can be
exposes coated metal panels to steam generated by obtained from traditional steady-state exposures.
a distilled water bath and heaters for various lengths
of time. Generally the exposure period is 48 hours, Carrier’s use of the cyclic Corrosion Tester allows
however, additional testing has been performed over accelerated testing methods to be developed more
other lengths of time to determine the total time to quickly. The chamber is able to run various pro-
blister (a measure of the adhesive properties of a grammed cycles such as the Prohesion™ cycle, GM
coating to a substrate). exposures (GM9540PLB), Japanese automotive
cycles, Japanese acid rain cycles, and many other
Salt Spray Tests cyclic tests deemed necessary to provide meaningful
corrosion data.
Typically, salt spray testing is done according to the
ASTM Specification - B117. This cycle exposes Prohesion™ Cycle Test Results Comparison
material to continuous salt fog commonly between
500 and 2000 hours in duration. This is The corrosion performance of a baseline bare coil, a
strictly a comparative test as it does not correlate pre-coated coil, three (3) post-coated coils and an
well to actual atmospheric exposure. E-coated coil have been evaluated through
18
Prohesion testing. This test subjects the coil to cycli-
cal exposure to highly corrosive solutions and regu-
lated drying time to simulate severely corrosive
environmental conditions.

After 1000 hours of cyclical exposure, the corrosion


performances of the coils were evaluated by visual
examination and through heat transfer measure-
ment.

The heat transfer performance factor G* is used to


evaluate the thermal performance of the coils. G*
shows a change in implied performance for a coil
compared to a baseline coil’s new implied perform-
ance. The higher G* value, the better the thermal
performance.

Figure 12 shows the thermal performance results


after exposure for 1000 hours. It can be seen that
E-coated coils have the best performance for this
type exposure. The other coil coatings fall well short
of the E-coat performance.

Thermal Performance
Thermal After After
Peformance 10001000
HourHour
Prohesion TestTes
Prohesion
1.10
Bare Coil
E-Coat:
E-Coat: No Effect
effect on
on Thermal
Thermal
Performance
Performance After 1000Hour
After 1000 HourExposure!
Exposure!
Precoated
1.00 Coil
G*
Thermal Performance Factor G*

Coating 1

0.90 Coating 2

Coating 3

0.80
E-Coated
Coil
Thermal

0.70

0.60

0.50
0 1000
Exposure Time (Hours)

Fig. 12. Prohesion test results.

19
APPENDIX Note: All data, statements, and recommendations
are based on research conducted by the E-Coat man-
E-Coating Chemical Resistance Guide ufacturer and are believed to be accurate. However,
no guarantee of accuracy can be made and Carrier
The coating materials used for E-Coat will with- Corporation assumes no liability as a result.
stand exposure to many corrosive atmospheres with
the exception of formic acid and nitric acid. The
E-Coat material is resistant to fumes from the chem-
icals listed below. However, Carrier does not rec-
ommend direct coil immersion service for any of
these chemicals. The chemical resistance guidelines
were determined by a 24-hour spot test exposure of
the chemical listed at ambient temperature condi-
tions. Resistance was determined for these chemi-
cals at the concentrations identified.

Since resistance is dependent upon the application,


environment, type of protection, and other factors,
your Carrier Representative should be consulted for
recommendations.

E-Coat is resistant to the following fumes:


Acetone Fructose Ozone
Acetic Acid 99% Gasoline Perchloric Acid
Acetates (ALL) Glucose Phenol 85%
Amines (ALL) Glycol Phosgene
Ammonia Glycol Lither Phenolphthlaein
Ammonium Hydroxide Hydrochloric Acid 37% Phosphoric Acid
Amino Acids Hydrofluoric Acid 30% Potassium Chloride
Benzene Hydrogen Peroxide 5% Potassium Hydroxide
Borax Hydrogen Sulfide Propionic Acid
Boric Acid Hydrazine Propyl Alcohol
Butyl Alcohol Hydroxlamine Propylene Glycol
Butyl Cellosolve Iodine Salicylic Acid
Butric Acid Isobutyl Alcohol Salt Water
Calcium Chloride Isopropyl Alcohol Sodium Bisulfite
Calcium Ilypochloric Kerosene Sodium Chloride
Carbon Tetrachloride Lactic Acid Sodium Hypochlorite 5%
Cetyl Alcohol Lactose Sodium Hydroxide 10%
Chlorides (ALL) Lauryl Alcohol Sodium Hydroxide 25%
Chlorine Gas Magnesium Chloride Sodium Sulfate
Chloroform Magnesium Sulfate Sorbitol
Chromic Acid 25% Maleic Acid Stearic Acid
Citric Acid Menthol Sucrose
Cresol Menthanol Sulfuric Acid 25-85%
Diesel Fuel Methylene Chloride Sulfates (ALL)
Diethanolamine Methyl Ethyl Ketone Sulfides (ALL)
Ethyl Acetate Methyl Isobutyl Ketone Sulfites (ALL)
Ethyl Alcohol Mustard Gas Starch
Ethyl Ether Naphthol Toluene
Fatty Acid Nitric Acid 25% Triethanolamine
Fluorine Gas Olale Acid Urea
Formaldehyde 27% Oxalic Acid Vinegar
Xylene
E-Coat is NOT resistant to the following fumes:
Formic Acid • Nitric Acid

20
®

Copyright 2005 Carrier Corporation www.carrier.com 811-20062 Printed in U.S.A 03-05

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