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Participant

Join Date: Feb 2009
Location: Seattle, WA
Posts: 4

UVC Lamps and Cooling Coil Corrosion

02/12/2009 2:16 PM

Has anyone seen or experienced rapid metal corrosion and materials degradation in air handling units with UVC lamps installed downstream of the cooling coils?

I am working in a building that has been open since June of 2008 and there is severe corrosion taking place within the air handler at the cooling coils and on the stainless steel walls. UVC lamps were installed for air quality and to prevent microbial growth. All of the AHU's with UVC lamps installed have this corrosion, one AHU without the lamps does not have any corrosion.

Materials testing results showed high concentrations of chlorine on the copper header and oxides. The cooling coil aluminum fins are being eaten away. The main theory appears to be that the high volume of condensate generated during the cooling season is becoming acidic to the point that it is corroding the metal. The source of the chlorine appears to be some from the marine air into the building which approximately 1 mile from the ocean in Seattle, WA and from the PVC jacket on the chilled water piping insulation inside the air handler. Also, the UVC seems to be accelerating the process.

Engineers, the manufacturer, manufacturer's rep and UV lamp supplier all state that they have never seen this happen before.

Can somebody convince me that this is the only installation of this kind in the country?

I apologize the pictures I have were not able to be uploaded.

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Guru

Join Date: Dec 2005
Posts: 1602
Good Answers: 19
#1

Re: UVC lamps and cooling coil corrosion

02/12/2009 2:52 PM

I have no experience with UVC lamps, but UV from sunlight can accelerate PVC breakdown in certain types of PVC. It is dependant on the inhibitors used in different types of PVC. Not all PVC is created equal. Don't ask me why, but there are a lot of variations in the "PVC" family of plastics. In this case, I am not surprised to hear that UVC lamps are suspected in degrading the PVC jackets and leaching out Cl or other nasties.

I am also not surprised about the effects of marine air on uncoated HVAC coils. I was on a facility condition inspection near Jacksonville FL. Uncoated coils 1/2 mile from ocean were severely corroded after 16 months. Coils with epoxy or Heresite coatings were in good condition. There are firms that specialize in coating coils with a variety of materials. Also, larger equipment manufacturers are aware of this issue and will offer it as an option if they know where the equipment will be supplied. I am a bit surprised that the people you are discussing this in the Seattle area are unfamiliar with the effects of marine air on equipment.

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Participant

Join Date: Feb 2009
Location: Seattle, WA
Posts: 4
#4
In reply to #1

Re: UVC lamps and cooling coil corrosion

02/13/2009 9:45 AM

Thank you for the reply. What is confusing about the marine air is that the AHU without UVC uses the same air with no affects. Also, all other AHU's around the facility (this a large hospital) have no corrosion. The UVC seems to be the only common denominator.

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Guru

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#5
In reply to #4

Re: UVC lamps and cooling coil corrosion

02/13/2009 9:52 AM

Check out Rorshach and Strider6 responses, I gave them both "good reply" votes. Especially check grounding of equipment and stray currents, this can cause a lot of corrosion issues.

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Participant

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#6
In reply to #5

Re: UVC lamps and cooling coil corrosion

02/13/2009 9:55 AM

I agree, I am reading one of the articles right now. I think the grounding is a good lead.

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Power-User

Join Date: May 2007
Posts: 225
Good Answers: 4
#2

Re: UVC Lamps and Cooling Coil Corrosion

02/13/2009 2:36 AM

marine atmosphere can cause severe corrosion on many materials, in your case seems that the corrosion in affecting different materials at the same time (copper, aluminum, stainless steel). In HVAC unit there is a typical form of corrosion, formicary corrosion, that causes several problems.

maybe you've to investigate in this direction..

http://www.pdhcenter.com/courses/m133/m133content.pdf

hope this can help u

s

corrosion prevention

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Join Date: Jan 2008
Location: Spring, Texas
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#3

Re: UVC Lamps and Cooling Coil Corrosion

02/13/2009 9:15 AM

Other than what was noted before with the breakdown of PVC due to UV light, I cannot think of any other reason why the light would accelerate corrosion. Could there be a galvanic cell caused by (or enhanced by) stray current leakage into the ductwork from the UVC lamp ballasts? Make sure that the ductwork is grounded well at the lamp connections to prevent that. It only takes a couple of volts to really eat up aluminum.

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Participant

Join Date: Feb 2009
Location: Seattle, WA
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#7
In reply to #3

Re: UVC Lamps and Cooling Coil Corrosion

02/13/2009 9:56 AM

I think the ground is a good lead. Of course the manufacturer of the PVC is saying that the insulation is UV resistant but that may mean sunlight vs. UVC lamps.

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Active Contributor

Join Date: Dec 2008
Posts: 13
#8

Re: UVC Lamps and Cooling Coil Corrosion

02/15/2009 10:31 PM

Hi Jqsmc,

I also had the same problem. That why cause my rivet rusting for holding the AHU ducting inside the AHU connect with the fan . Now i know why my screw rust inside AHU. Thank for the information.

So how u solve ur AHU problem ?

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jgsmc (3); Ried (2); Rorschach (1); strider6 (1); Tan (1)

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