Melted parts on top of hot water heater

Water heaters only have a top and bottom thermostats which seldom go bad. Heating elements wear out most often. If you are running out of hot water too quickly kill the power drain the tank and remove bottom heating element using a special large socket. Visual inspection should tell you if it is melted. If it is ok check the top heating element. If the heater was on and the tank not full the top element will go first. Elements never operate at the same time

On a gas water heater?
http://waterheatertimer.org/How-to-troubleshoot-gas-water-heater.html#intellivent\

http://www.thetankatwaterheaterrescue.com/forums/forum3/

Gene

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It sounds like there is too much pressure in the hot water pipes. You can try adjusting the pressure. Do it a little at a time to see how much hot water is coming out. The only other thing I can think of is that there is a large delay between the switch and the water flow. meaning you will need to stop the water a while before you actually want the water to stop flowing.

Elisa Jed ' http://www.mccreeryhvac.com

Define melts cold line.

Sounds like the output fitting has melted inside and clogged up the output pipe. These couplings are one way valves to keep water from draining backwards when not in use to keep from burning elements. They are plastic inside. I would turn off water and replace those after a visual inspect if needed.

My guess is that you may have or have had a spider web or other debris in burner tube that caused flame to back up, thus burning some wiring but, have someone experienced check it and clean it. The wiring if not burned too bad may be able to be repaired/spliced.

Replace the melted part.

If tank is popping breaker, then the melted part has a short circuit.
http://waterheatertimer.org/How-to-troubleshoot-electric-problems-with-water-heater.html
When replacing thermostats, I usually replace both of them
http://waterheatertimer.org/How-to-replace-thermostat-on-electric-water-heater.html

There are 5 basic parts to electric water heater.
Electricity to water heater.
Upper thermostat
Upper element
Lower thermostat
Lower element
It sounds like electricity is good.
Elements are probably good if just replaced, but one of them could have a short.
Thermostat is melted, so replace it and see if it restores hot water.
If not, then take 40 minutes and do complete troubleshoot as shown in link above.

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Breaker may be defective and not clipping off when it overheats. More and more power keeps going through it and nothing to stop it. Or check the wiring on the heater itself to be sure they are connected right.

Many states building codes require a pressure regulator and expansion tank for hot water heater installation. Check the pressure regulator if you have one as this would only affect the hot water pressure. Adjust or replace. Rap the expansion tank like knocking hard on a door. Hollow sound is good. Dull thud means it needs to be replaced as it is filled with water.