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upsell Corrosion Protection to extend Product Life in Harsh Conditions PDF Print Email
Friday, December 07, 2018 12:05 PM

Upsell Corrosion Protection to Extend Product Life in Harsh Conditions

LOUISVILLE, KY – Hope springs eternal and so does coolant from a corroded tube. Corrosion is a natural process and can be responsible for a lot of heat exchange replacement work, especially in coastal climates. In coastal areas, moisture and salt wreak havoc resulting in metal deterioration on heat exchangers. For you it is business, for your business customers it can mean serious downtime and loss of production. For Se-Cliff Coatings, a NARSA member since 1974, helping you help your customers with their corrosion issues is what they do.

Sometimes too much of anything turns ugly. Case in point are those customers who have to operate businesses and even emergency equipment in briny atmospheres. Extending heat exchange product life cycles is what corrosion protection is all about. Adding a few months, maybe a year to the life of radiators or coil can add up.

The people out for the recent NARSA HD Conference here at the Marriott East had a great opportunity to learn a little more about corrosion from Tom Clifford, sales director North America and Europe for Se-Cliff Coatings, LLC. He also pointed to the opportunities that heat ex- change specialist’s business can help its customers by supplying products that have improved corrosion protection.
One can never prevent metal corrosion completely but there are products readily available that can reduce and retard the effects of corrosion. Corrosion begins immediately as new metal products like heat exchangers are exposed to the elements.

Tom shared some slides on where corrosion occurs and there are no surprises that the severe areas are coastal. One slide showed that all coasts were swathed in red (severe) and that the Cape Kennedy/Fort Pierce region of Florida has the highest rate of corrosion for HVAC systems in the U.S.

Tom pointed to other areas that may be corrosion contributors: salt, magnesium, coal mining; steel factories; high road salt areas; agricultural markets; petrochemical plants; marine; and food processing.

From a sales and marketing point of view, Tom said the case for corrosion protection on metal parts in general would include:

  • less engine wear, longer engine life;
  • less maintenance to the engine;
  • continued engine performance and power;
  • maintain near-original fuel-use levels;
  • maintain low particulate emissions levels;
  • less emergency failure, less downtime;
  • reduced interruption of production, profits;
  • much less total failure and reduced replacement costs of units and labor;
  • a value added product that solves an expensive maintenance issue.

He listed several exterior coating technologies that are currently available. They include: paint, Copon and other specialized paints; powder coating, Heresite, E-Coat (Electrodeposition) which his company uses, and spray hydrophilic. Tom also addressed a list of his suggested criteria to consider when choosing a technology. That list includes:

  • Corrosion retardant properties that meet all pertinent ASTM standards for salt water, and/or the specific application contaminants with no propensity for corrosion creep to occur.
  • Electrochemical and physical adhesion properties that meet applicable ASTM standards for cross-hatch adhesion.
  • Coverage – 100% guaranteed in writing.
  • Durability, flexibility.
  • Impact resistant capable of handling in-field abuse and power washing.
  • Consistent, reproducible coating thickness – no matter the core’s geometry or base metals used.
  • Zero bridging between fins and/or between louver edges.
  • High edge cove rage.
  • Green technology – can units be repaired and discarded safely (NSA Approved)
  • Military approval.
  • Warranty against defects or failure to protect against corrosion.
  • Cost competitive and efficient.
  • Supplier adheres to appropriate ISO process/production standards.
  • Minimum loss of heat transfer rate of less than 1% of capacity to transfer heat.
  • Minimum loss in air pressure drop.The coating should not significantly retard airflow rate as it passes through heat exchanger.

Tom explained the E-Coat process that his firm uses in Texas, Kentucky, New York, Michigan and Italy. E-Coat is a method of painting that uses electrical cur- rent to deposit paint. It is a highly efficient and automated process. Paint deposition is regulated by voltage and it has the ability to coat interior cavities without bridging fins or louvers.

This process works on new product only (clean, unpainted cores). The product must be able to withstand a 385°F process. Product can be copper, aluminum or steel. Other considerations include turn-around time (5 to 7 day typical) and the supply of a reusable shipping box or container.

For more information, go to: www.corekote.com. NARSA members are reminded that they can find this and the other presentations from the 2018 NARSA HD Conference (as well as all of the HD Conferences) in the NARSA Member Center at www.narsa.org.

 
Bradley edgar asks “How’s Your Aftertreatment Treating You?” PDF Print Email
Friday, December 07, 2018 09:25 AM

Bradley Edgar asks “How’s Your Aftertreatment Treating You?”

LOUISVILLE, KY – News updates, trends, market projections, innovations, design and new cleaning techniques, it doesn’t get any better for the DPF crowd assembled for the HD Conference here in September. Dr. Bradly Edgar of Red Fox Resources returned to the NARSA podium after his debut last year in Buffalo with a presentation chock full of knowledge.

Bradley Edgar has been involved in emissions for twenty-plus years and holds a Ph.D. in mechanical engineering with focus on combustion, heat transfer and air pollution. His best asset is his ability to deliver technical and business information in a manner that is easily understandable.

Among the news items, certainly booming truck sales is at the top of every truckers list. Since the meeting, ACT Research says over the past 12 months Class 8 orders have totaled 503,500 units. The last record year was 2006, when the build reached 376,000 units. That is good news. Really good news is that all have diesel emissions aftertreatment systems.

Maybe not such good news is that all the truck makers have electric truck programs in the works.

Brad also pointed out that now gasoline particulate filters are in production in Europe for light duty vehicles. He said these gasoline particulate filters (GPFs) are very similar in design and function, but smaller.

He pointed out the “sweet spots for service” are the larger trucks with serviceable DPFs which he estimated to be 2.6 million engines in 2018 but projected to reach 12.5 million by 2027 when the market reaches maturity. He told them, “Future trends . . . are here.” That includes:

  • more compact designs;
  • DOC, DPF and SCR integrated into single package;
  • SCR is becoming more effective;
  • SCR catalysts may be coated on DPF;
  • extended cleaning intervals with better oil control;
  • sensors and On-Board Diagnostics continue to improve.

He went on to provide a detailed look into the evolution of the technology, differences in the designs, and the fundamental concepts of cleaning. His comments on thermal and air-cleaning included:

  • Temperature ramps and ranges
    • (212-572°F): coolant, water, oil, fuel starts to evaporate
    • (1100-1200°F): soot oxidizes
  • Watch outs
    • Vaporized fluids are smelly and can create a mess
    • Too much soot, or oil soaked DPF can ‘runaway’ and lead to overheating, melting or fire
    • Load parts so they can entrain air (vertical is best)
  • Multiple steps and sequence can be important
    • Blow-Bake-Blow again: First blow cycle removes excess carbon
    • Bake-Blow-Bake again: Ash plugs can trap carbon and keep oxygen from getting to soot
  • Weigh parts before and after each step - Measuring weight/flow at each step is good practice
    • Lots of soot: could be engine problem - Lots of ash: oil control or too long between cleaning
    • Lots of oil/coolant: leaking/failed turbo, fuel injector, EGR cooler
  • Pay attention and take good notes
    • There is a learning curve

Adding perspective to the DPF development, Edgar provided a brief history. From 1980 to 2000, engine makers considered a number of different designs which resulted in a variety of materials and regeneration strategies were considered. He said the earliest applications were in underground mining.

By the 2000’s, the wall flow filter be- came the design of choice. It was also around then that California and EPA sponsored voluntary and regulated retrofit pro- grams. By 2007, the level of permitted particulate matter was reduced by 90% and that meant DPF technology would be required. DPF regeneration was based on catalyst technology with engine management. In 2010, NOx mandated reductions insured that urea SCRs were required. DPF regeneration became easier.

DPF design has settled. Materials used include: cordierite, silicon carbide, aluminum titanate. Leading manufacturers include: Corning, NGK and Ibiden.

Dimensions are from 6 to 13 inches in diameter with lengths from 6 to 15 inches, and cell density of 200-300 cells/in2 (cpsi). Today’s DPFs feature high filtration area per volume, high filtration efficiency (98 per- cent of particles), low pressure drop, high melting point, low thermal expansion, and can be coated with catalyst. According to Edgar, wall flow designs seemed to be here to stay for a while.

Serviceable DPFs are fastened with gas- kets and seals. Filters for Class 4-6 are more difficult to clean and in some cases non- serviceable. Filters for Class 2-4 engines, are not designed for cleaning. DPF clean- ing basic tools and processes include:

  • Heat to oxidation temperature of carbon (baking);
  • Reverse backflow of compressed air (blow);
  • Aqueous cleaning: water jet, flush/irrigate, ultrasonic;
  • Combination of methods usually required.

Edgar outlined current filter diagnostics in play which include:

  • Scale for weight;
  • Flow bench for pressure drop;
  • Pin test for cell blockage;
  • Ultrasonic device for cracks;
  • Borescope;
  • Light test.

Edgar pointed to the parts and service opportunities that cleaning can provide. They include: service revenue; aftermarket DPF/DOC sales; replacement parts sales (DPFs, gaskets, clamps); upstream engine work; and income from parts recycling.

 
Global Cost of Corrosion Over $2 Trillion PDF Print Email
Friday, December 07, 2018 09:16 AM

Global Cost of Corrosion Over $2 Trillion

MANITOWIC, WI – In the radiator business, the name Heresite is recognized by many as a reddish brown coating that is used to retard corrosion. Heresite is more than that. It is a company with global reach that provides corrosion solutions for a host of industries with a number of different products and processes.

Brand awareness is one of the reasons that Peter Hellman be- came the fourth owner of the company founded in 1935. He also saw potential in the corrosion protection business. Hellman improved processes, people and formulations, including reducing lead times from 6-8 weeks down to 2 weeks. According to Hellman, the annual worldwide cost of corrosion is over $2 trillion, which represents 3% of the world’s GDP. In the U.S., the annual cost of corrosion due to direct damage, increased maintenance and downtime is approximately $1 trillion.

Peter said about 90 % of their business is coating for heat transfer equipment which they have been doing since ‘60s. Markets they serve include HVAC and commercial refrigeration heat transfer coils and unitary/rooftop equipment; industrial pro- cess equipment like compressor rotors, valves, pump housings; radiators and industrial process coolers, charge air coolers, fin fan coolers, intercoolers; and air fume handling equipment such as fans, blowers, fume hoods, louvers.

Heresite was a first-time NARSA HD Heating and Cooling Conference exhibitor at the recent event in Louisville. Peter said that they are looking to increase awareness and business among radiator shops and manufacturers.

Demand for their coatings are the usual high salinity coastal regions and in environments exposed to high humidity, corrosive chemicals and fumes. Typical markets include: wastewater treatment plants, refineries, chemical plant, telecommunications and data centers, fossil fuel power plants, food processing facilities, airports, oil drilling platforms, as well as convention centers, and hotels.

They offer several different basic ways for protection. They can do it for you at their Wisconsin plant with Heresite’s P-413 baked phenolic epoxy. They also have products that can be spray-applied in the shop with their VR-514 air dry phenolic. An aerosol version of this product (VR-514t) is also available for smaller jobs and touch-ups. The third option is to use one of their 12 certified applicators, four of which are located in the United States. Heresite is active in 30 different countries including Canada, France, Italy, Mexico, South Korea and Dubai.

Peter said that they have one spray application for shop applications today (VR-514) and they will be releasing another soon (ES- 600). ES-600 will premiere at the January 2019AHR Show in Atlanta, GA. Other coatings include high bake phenolics for industrial applications such as tank liners.

Interesting note is that one of the certified applicators is Rahn Industries which has history with NARSA back into the ‘70s. Bill Han was the CEO and Rahn at the time was a leading supplier of automotive aftermarket air conditioning condensers. Rahn was a regular advertiser in the “Automotive Cooling Journal” which was renamed “The Cooling Journal” 15 years ago. Today Rahn Industries is a HVAC/refrigeration coil manufacturing company.

In marine/salt air applications the corrosion factors include chloride (salt spray, marine fog), humidity and sunlight.

For wastewater treatment, sources for corrosion include: acidic gases (hydrogen, sulfide, and ammonia), low pH condensate, and humidity.

Industrial urban markets corrosion factors are nitrogen and sulphur oxides, acid rain, low pH condensate, potential particulate chlorides, sulfates, sulfuric acid and carbon compounds. Protection from ammonia and nitrogen compounds, organic acids, sulfur and formic acids.

Sources of corrosion in food processing is from sanitizing chemicals, disinfectants, fumes and humidity. Transit and mining corrosion factors include: magnesium chloride, sodium chloride and hydrogen sulfide. Heresite works with customers to recommend the best process and coating. Corrosive environment considerations include:

  • Corrosive agent(s) and estimated concentrations;
  • Type of exposure (fume, splash, immersion);
  • Operating environment (temperature and humidity);
  • Coil type and construction (cold water, evaporator coil, steam coil. Is condensation likely to occur? Materials – copper tube, aluminum fin);
  • Coating experience (has the customer used a coating for this previously? What were the results?).

For more information, go to: www.heresite.com.

 
NARSA Mobile Heat Transfer Pavilion at AAPEX to Spotlight Innovation, Knowledge and Opportunity PDF Print Email
Tuesday, October 09, 2018 08:33 AM

NARSA Mobile Heat Transfer Pavilion at AAPEX to Spotlight Innovation, Knowledge and Opportunity

LAS VEGAS, NV – Oct. 9, 2018 – The NARSA Mobile Heat Transfer/Heating/Air Conditioning Pavilion at AAPEX returns as the global marketplace for service replacement parts and everything heat exchange, including finished products, manufacturing machinery, materials and supplies. AAPEX represents the $740 billion global automotive aftermarket industry and will take place Tuesday, Oct. 30 through Thursday, Nov. 1, at the Sands Expo in Las Vegas.

“The Pavilion, Tuesday’s Customer Appreciation Night, and the Thursday AAPEXedu session on Heat Exchange Fundamentals and Market Trends will provide buyers and sellers of cooling system and a/c products with three great ways to connect to the market,” said Wayne Juchno, NARSA Executive Director

This global showcase will provide a target-rich environment for suppliers and buyers alike. Products will be available for high-volume automotive and light-duty vehicle applications to sources for one-off, custom-engineered heat exchangers. For a listing and map of who’s who of heat exchange to be found at the NARSA Mobile Heat Transfer/ Heating/ Air Conditioning Pavilion at AAPEX 2018, visit www.aapexshow.com.

NARSA also will participate in this year’s AAPEXedu program with a session led by Juchno on “Automotive and Truck Heat Exchange Product and Market Fundamentals and Update,Thursday, Nov. 1, 10 a.m. - 11 a.m., The Venetian, Marco Polo 704. Juchno will be joined by Olivier Martina, Sales Director Global Engine Cooling Flat Rolled Products with Aurubis. Mr. Martina will focus on global trends.

Aurubis, founded in 1866 in Hamburg Germany has celebrated its 150-year anniversary. As a multi metal leading global producer of copper and copper alloyed products, Aurubis serves all segments of industry from architecture [roofing, facade], power electronics, connectors and cooling applications where copper and copper alloyed are used.  The company employs more than 6,400 people in over 20 countries on three continents.  They produce more than 1,140,000 tons of copper products annually. 


In addition, the annual Cooling System Appreciation Reception will be held on Tuesday, Oct. 30 beginning at 6 p.m. at Harrah’s Las Vegas. Open to AAPEX registered buyers of cooling system products, the Cooling System Appreciation Reception offers a low-key atmosphere to network with many of the NARSA member exhibitors and fellow industry professionals. To find out how to attend this event, go to www.narsa.org.

The AAPEX online registration fee is $40 through Friday, Oct. 12. To register, visit aapexshow.com/attendee.

AAPEX 2018 will feature more than 2,500 exhibiting companies displaying the latest products, services and technologies. More than 47,000 targeted buyers are expected to attend, and approximately 162,000 automotive aftermarket professionals from 135 countries are projected to be in Las Vegas during AAPEX 2018.

AAPEX is a trade-only event and is not open to the general public.

About AAPEX
AAPEX is co-owned by the Auto Care Association and the Automotive Aftermarket Suppliers Association (AASA), the light vehicle aftermarket division of the Motor & Equipment Manufacturers Association (MEMA). For more information, visit www.aapexshow.com or e-mail: [email protected] On social media, follow AAPEX at #AAPEX18.  

About NARSA
The International Heat Transfer Association is a trade association founded in 1954 whose members provide heat exchange products and services for transportation and industry, including manufacture, distribute, and design of thermal management products. NARSA creates opportunities for its members through innovation, vision and knowledge. For more information, visit www.narsa.org or call (724) 799-8415.

 
NARSA Names Aaron Morrow, General Manager of Johnson Mfg. Co. 36th President PDF Print Email
Tuesday, October 09, 2018 08:27 AM

NARSA Names Aaron Morrow, General Manager of Johnson Mfg. Co. 36th President 

PRINCETON, IA – Aaron Morrow, general manager of Johnson Mfg. Co., has been elected president of NARSA – The International Heat Exchange Association. Aaron becomes the 36th president in the Association’s 64-year history. The members of the Board of Director elected him at its annual Fall meeting which was held in conjunction with the Heavy Duty Heating and Cooling Conference in Louisville, KY.

Aaron Morrow holds a Bachelor of Science Degree in Chemical Engineering and a Masters in Business Administration from the University of Iowa. Aaron and his wife, Lisa and two-year-old daughter, Lucy, reside in Davenport, IA.

Said F. Larry LePrevost, executive vice president at Johnson Mfg. Co., “It has been my absolute pleasure working with Aaron. His organizational skills and leadership have led to his recent appointment as Johnson’s new General Manager. NARSA will both benefit, and enjoy working with Aaron as well.”

Said colleague and NARSA leader Pat O’Connor, VP of Sales and Marketing at Johnson, "I first introduced Aaron to NARSA and encouraged him to get active when I was president. I nominated him as a director. I think he will be a great asset for the Board and wish them all continued success with building our organization." Pat was NARSA president from 2012 to 2014 and a long time active member of the board. Pat retired from the NARSA board two years ago.

His term as NARSA resident will end in 2020. In addition to his volunteer work with NARSA, Aaron is a classroom volunteer with Junior Achievement of the Heartland, serves on the Board of Directors for Acacia Fraternity at the University of Iowa, the Alumni Advisory Board for the University of Iowa Chemical Engineering Dept., and is a member of the Ancient Free and Accepted Masons.

Also elected to the NARSA Board were: David Bienvenu, Radiator Service Co., Chairman of the Board; Robert Duran, Cooling Systems Caribe, First Vice President; Kyle Rickermann, Affton Radiator, Second Vice President; Roland Ewert, Thermal Solutions Manufacturing, Treasurer; and Rafael Taveras, Industria Core S.A., Director.

 
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