Leak Test Chiller - Carrier AquaEdge 19XR series Start-Up, Operation And Maintenance Instructions Manual

BOLT SIZE
(IN.)
LOW CARBON STEEL
MINIMUM
1
/
4
5
/
16
3
/
8
7
/
16
1
/
2
9
/
16
5
/
8
3
/ 105
4
7
/ 140
8
1 210
1
1 / 330
8
1
1 / 460
4
3
1 / 620
8
1
1 / 740
2
5
1 / 1010
8
3
1 / 1320
4
7
1 / 1630
8
2 1900
1
2 / 2180
4
1
2 / 3070
2
3
2 / 5120
4
3 6620
WARNING
Do not use air or oxygen as a means of pressurizing the
chiller. Mixtures of HFC-134a and air can undergo
combustion.
Due to regulations regarding refrig-
Leak Test Chiller —
erant emissions and the difficulties associated with separating
contaminants from the refrigerant, Carrier recommends the
following leak test procedure. Refer to Tables 11A and 11B for
refrigerant pressure/temperature values.
1. If the pressure readings are normal for the chiller
condition:
a. Evacuate the holding charge from the vessels, if
present.
b. Raise the chiller pressure, if necessary, by adding
refrigerant until pressure is at the equivalent satu-
rated pressure for the surrounding temperature.
Follow pumpout procedures in the Transfer Refrig-
erant from Storage Tank Vessel to Chiller section,
page 91.
WARNING
Never charge liquid refrigerant into the chiller if the pres-
sure in the chiller is less than 35 psig (241 kPa) for HFC-
134a. Charge as a gas only, with the cooler and condenser
pumps running, until this pressure is reached, using
PUMPDOWN LOCKOUT and TERMINATE LOCK-
OUT mode on the PIC II. Flashing of liquid refrigerant at
low pressures can cause tube freeze-up and considerable
damage.
c. Leak test chiller as outlined in Steps 3 - 9.
Table 10 — Bolt Torque Requirements, Foot Pounds
SAE 2, A307 GR A
HEX HEAD
NO MARKS
MAXIMUM
4 6
8 11
13 19
21 30
32 45
46 65
65 95
150
200
300
475
660
885
1060
1450
1890
2340
2720
3120
4380
7320
9460
SAE 5, SA449
SOCKET HEAD OR HEX
WITH 3 RADIAL LINES
MEDIUM CARBON STEEL
MINIMUM MAXIMUM
6 9
13 18
22 31
35 50
53 75
75 110
105 150
175 250
265 380
410 580
545 780
770 1,100
1,020 1,460
1,220 1,750
1,670 2,390
2,180 3,110
2,930 4,190
3,150 4,500
4,550 6,500
5,000 7,140
8,460 12,090
11,040 15,770
2. If the pressure readings are abnormal for the chiller con-
dition:
a. Prepare to leak test chillers shipped with refriger-
ant (Step 2h).
b. Check for large leaks by connecting a nitrogen bottle
and raising the pressure to 30 psig (207 kPa). Soap
test all joints. If the test pressure holds for 30 minutes,
prepare the test for small leaks (Steps 2g - h).
c. Plainly mark any leaks that are found.
d. Release the pressure in the system.
e. Repair all leaks.
f. Retest the joints that were repaired.
g. After successfully completing the test for large
leaks, remove as much nitrogen, air, and moisture
as possible, given the fact that small leaks may be
present in the system. This can be accomplished by
following the dehydration procedure, outlined in
the Chiller Dehydration section, page 71.
h. Slowly raise the system pressure to a maximum of
160 psig (1103 kPa) but no less than 35 psig
(241 kPa) for HFC-134a by adding refrigerant.
Proceed with the test for small leaks (Steps 3-9).
3. Check the chiller carefully with an electronic leak detec-
tor or soap bubble solution.
4. Leak Determination — If an electronic leak detector indi-
cates a leak, use a soap bubble solution, if possible, to
confirm. Total all leak rates for the entire chiller. Leakage
at rates greater than 0.1% of the total charge per year must
be repaired. Note the total chiller leak rate on the start-up
report.
5. If no leak is found during the initial start-up procedures,
complete the transfer of refrigerant gas from the pumpout
storage tank to the chiller. Retest for leaks.
68
SAE 8, SA354 GR BD
HEX HEAD
WITH 6 RADIAL LINES
MEDIUM CARBON STEEL
MINIMUM MAXIMUM
9 13
20 28
32 46
53 75
80 115
115 165
160 225
260 370
415 590
625 893
985 1,410
1,380 1,960
1,840 2,630
2,200 3,150
3,020 4,310
3,930 5,610
5,280 7,550
5,670 8,100
8,200 11,710
11,350 16,210
15,710 22,440
19,900 28,440