Frick LaZerWeld Plate Heat Exchangers Installation Operation and Maintenance Guide

Brand: Frick

Model: LaZerWeld Plate Heat Exchangers

Type: Installation Operation and Maintenance Guide

LaZerWeld Plate Heat Exchangers

THIS MANUAL CONTAINS RIGGING, ASSEMBLY, START-UP,

AND MAINTENANCE INSTRUCTIONS. READ THOROUGHLY

BEFORE BEGINNING INSTALLATION. FAILURE TO FOLLOW THESE

INSTRUCTIONS COULD RESULT IN DAMAGE OR IMPROPER

OPERATION OF THE UNIT.

Form 190.200-IOM (MAR 2018)

INSTALLATION - OPERATION - MAINTENANCE

File: SERVICE MANUAL - Section 190

Replaces: 190.200-IOM (MAY 2017)

Dist: 3, 3a, 3b, 3c

Please check www.johnsoncontrols.com/frick for the latest version of this publication.

190.200-IOM (MAR 2018)

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LAZERWELD HEAT EXCHANGER

INSTALLATION - OPERATION - MAINTENANCE

Indicates an imminently hazardous situation which, if not avoided, will result in death or serious

injury.

Indicates a potentially hazardous situation or practice which, if not avoided, will result in death or

serious injury.

SAFETY PRECAUTION DEFINITIONS

Indicates a potentially hazardous situation or practice which, if not avoided, will result in damage

to equipment and/or minor injury.

Indicates an operating procedure, practice, etc., or portion thereof which is essential to highlight.

DANGER

WARNING

CAUTION

NOTICE

Read this manual carefully before unpacking the equipment. Always observe the Safety Notes designated by the Warning

symbol listed throughout this manual.

Contents

GENERAL INFORMATION

Preface ...............................................................................3

How to contact Johnson Controls ...................................3

Warranty Information .........................................................3

New Semi-Welded Plate Heat Exchangers ......................3

Operating Principle ........................................................... 4

Standard design ............................................................. 4

Frame ............................................................................. 4

LaZerWeld – welded plate pairs ..................................... 4

In-line Filters ...................................................................5

General Safety Precautions ................................................5

Receiving of equipment......................................................5

Receiving check...............................................................5

Drawing Documentation ..................................................6

Assembly Details .............................................................6

General Arrangement Details ..........................................6

PHE Plate Arrangement Details .......................................6

Nameplate .......................................................................6

Handling .............................................................................7

Lifting ..............................................................................7

INSTALLATION

Foundation ......................................................................8

Space requirements ........................................................8

Connections ....................................................................8

Storage ..............................................................................8

Short Term Storage (less than 6 months) ........................8

Long Term Storage (more than 6 months) .......................8

OPERATION

Start-up and operation ......................................................9

Start-up ...........................................................................9

Operation ........................................................................9

Operational DOs And DON’Ts ..........................................9

Corrosion resistance ........................................................ 9

Shutting down .................................................................9

MAINTENANCE

Disassembly ....................................................................10

Cleaning ........................................................................10

Manual Cleaning ............................................................10

Cleaning-In-Place .......................................................... 11

Example of CIP Cleaning: .............................................. 11

Determination Of Correct CIP System ...........................11

Commissioning & Troubleshooting Do’s And Don’ts ......12

Reassembly ......................................................................12

LZW Return-To-Duty Testing Requiremnet Notice .......12

Maintenance & Inspection .............................................14

Maintenance Of In-line Filter ........................................15

Clean The In-line Filter In This Sequence: ..................... 15

Spare Parts – Identication And Ordering

Identication Of Spare Parts ..................................... 15

Storage of LZW Plate Heat Exchanger Gaskets .............15

Troubleshooting ...............................................................16

FACTORY ASSISTED FIELD SERVICE FORM

LZW Site Service Preparation Checklist: ..........................17

Field Testing of the Plate Heat Exchanger ........................18

NOTICE

The LZW Semi-Welded plate heat exchanger is an ASME pressure containing device.

The repair and refurbishment of pressure vessels is covered by the National Board of Pressure Vessel Inspectors

National Board Inspection Code (NBIC). Most Authorities Having Jurisdiction (AHJ) do not consider direct replacement

of plates and gaskets in a plate heat exchanger a “repair” and do not require inspection or application of the “R” stamp.

However, the AHJ where the unit is to be operated should be consulted for their interpretation of NBIC requirements.

There are also occasions where the customer or their insurance company demands the application of the “R” stamp,

even when the AHJ does not.

190.200-IOM (MAR 2018)

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LAZERWELD HEAT EXCHANGER

INSTALLATION - OPERATION - MAINTENANCE

Important!

In addition to this instruction manual, the following key

documents are included with your LaZerWeld™ plate heat

exchanger. In case of conict between this instruction

manual and the order and product documents, the order and

product specic documents take precedence.

• LaZerWeld PHE Plate Arrangement Drawing

• LaZerWeld Assembly Drawing which may be integrated

with the plate arrangement drawing

• Other Order-specic documentation

• Supplementary Instruction manuals dealing with specic

topics

Further details can be found in Section: “Receiving equipment”.

How to contact Johnson Controls:

Your nearest ofce is listed on our website: www.johnson-

controls/frick. There, you can also nd information regarding

our Service and Spare Parts offerings.

Thank you for choosing Frick equipment!

General Information

PREFACE

This manual has been prepared to acquaint the owner and

serviceman with the INSTALLATION, OPERATION and MAIN-

TENANCE procedures as recommended by Frick® Industrial

Refrigeration for the LaZerWeld Plate Heat Exchanger.

Proper performance and continued satisfaction with these

units is dependent upon:

CORRECT INSTALLATION

PROPER OPERATION

REGULAR, SYSTEMATIC MAINTENANCE

To ensure correct installation and application, the LZW unit

should be connected to a properly designed and installed

system.

NOTICE

Illustrations of LaZerWeld heat exchangers and

equipment presented in this manual serve as example

illustrations only in support of the instructions. Your

actual equipment may look different.

WARRANTY INFORMATION

New Semi-Welded Plate Heat Exchangers

WARRANTY and LIABILITY: LaZerWeld semi-welded plate

heat exchangers are warranted to be free from defects in

material and workmanship for a period of 12 months from

start of operation or 18 months from date of shipment unless

subject to an extended Warranty Protection Program offered

on the originally purchase date and specically stated in the

original order documents.

Any Warranty Protection is only valid when the LaZerWeld

plate heat exchanger is installed, operated, and maintained

according to the Frick® Industrial Refrigeration service

manual, Form 190.200-IOM. Any deviation from the

operating or service and maintenance instructions provided

in the service manual, at any location, by any individual or

company will void the protection coverage in full.

Buyer’s remedy for Warranty Protection Coverage pertaining

to Frick LaZerWeld heat exchangers shall be limited to the

repair or replacement, based on the opinion and option of

Frick Industrial Refrigeration and SPX Flow, of any product(s)

or part(s) which by examination are disclosed to be defective.

Warranty Protection Coverage does not include: (1) Any

labor; (2) Extraneous materials, such as test gases, etc; (3)

Other charges incurred associated with the removal, repair

or replacement of the defective part(s).

Warranty Protection Coverage shall be void if the equipment

has been subjected to: (1) negligence, abnormal conditions;

(2) abuse, alterations; (3) misuse, damaged due to other

failure(s) within the system; (4) chemicals attack, corrosion,

erosion; (5) excessive or cyclical pressures, vibrations; (6)

accidents, physical damage (in transit or after installation); (7)

misapplication or operation contrary to the manufacturer’s

recommendations

Any claims for defects must be made, promptly, in writing

using Frick form (190.200-FRM), completely specifying the

nature of such defects. Failure to do so shall constitute a

waiver of the claim. Labor associated with claim related

repairs must be performed by an authorized SPX Flow

service technician using OEM parts.

The Buyer must have written authorization, including a

Return Goods Authorization Number (RGA #), for the return

of any defective product(s) or part(s). This RGA # must be

clearly marked on the returned product(s) or part(s). Frick

and/or SPX Flow are not responsible for lost returns. The

freight charges associated with warranty parts and return

goods, both to and from the factory, are the responsibility

of the Buyer.

If the defective part(s) is not returned to Frick Industrial

Refrigeration or SPX Flow as dened on the RGA document

within 30 days from date of shipment of the replacement

part, the customer will be invoiced for the replacement part.

In the event that Frick Industrial Refrigeration fails to make

delivery or repudiate, Buyer’s sole and exclusive remedy shall

be repayment of that part of the purchase price therefore

paid by Buyer. In no event shall Frick Industrial Refrigeration

or SPX Flow be liable for damages in an amount exceeding

the amount of the purchase price paid for the product or part

concerning which a claim for damages arises. (Any right of

Buyer to consequential or incidental damages is excluded.

Any action for breach of warranty or otherwise for breach

of any agreement arising from our acceptance of an order

placed by Buyer, whether or not based on our quotation,

must be commenced within 12 months or applicable Frick

Warranty period after cause of action arises.) Any action

shall thereafter be barred.

*The full text of this warranty is available in document 020.160-W.

190.200-IOM (MAR 2018)

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LAZERWELD HEAT EXCHANGER

INSTALLATION - OPERATION - MAINTENANCE

OPERATING PRINCIPLE

Standard design

The plate heat exchanger consists of a number of thin

corrugated metal plates.

The plate corrugations form ow channels for the heat

exchanging uids and provide strength to the compressed

plate pack.

The plates contain ports for uid inlets, outlets and

interconnect passages as required.

Gaskets are attached to the plates, forming a seal between

the heat exchanging uids and the surroundings.

In the example shown here in Figure 1, the cold uid (blue)

enters at the bottom and the hot uid (red) at the top.

Figure 1 - Fluid Movement

Frame

The plates are clamped together to a predetermined

dimension by the tie bars between two thick metal slabs:

a stationary slab (head) and a moveable slab (follower).

Connections for the uid inlets and outlets can be made on

either slab. The plates are hung on the top bar and guided by

the bottom bar. An end column supports the top and bottom

bar ends. See Figure 2.

Figure 2 - Plate Clamping Design

Figure 3 - Welded Plate Pair System

LaZerWeld – welded plate pairs

LaZerWeld plate pair is a right- and left-hand plate laser

welded together to form a pair. This welded plate pair

system is particularly suitable for use with refrigerants such

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LAZERWELD HEAT EXCHANGER

INSTALLATION - OPERATION - MAINTENANCE

as ammonia and Freon or with other aggressive liquids that

could otherwise attack the gaskets in a conventional heat

exchanger plate. See Figure 3.

When the welded pairs are installed in a frame, each pair is

sealed by elastomeric seals.

NOTICE

A LaZerWeld plate pair cannot be separated for

inspection and cleaning. It is, therefore, important to

prevent fouling and clogging of the welded passage.

If fouling in the welded passage cannot be prevented, then

cleaning must be done by circulating a cleaning solution. It is

recommended that you contact a supplier of cleaning agents

for advice.

WARNING

The two sides of LaZerWeld PHE may have different

pressure and uid compatibility and therefore care must

be exercised in connecting the uids correctly.

WARNING

LaZerWeld PHE is not suitable for hygienic duties where

organic fouling is expected, for example, dairy products.

Figure 4 - LaZerWeld In-Line Filter

In-line Filters

For industrial applications involving bers or particles

which might foul the heat exchanger plates or block the

heat exchanger passages, a LaZerWeld in-line lter is

recommended. See Figure 4.

The LaZerWeld in-line lter is inserted in the uid inlet port

of the heat exchanger through an opening in the follower

and closed with a full-faced gasket blind cover. The in-line

lter mesh size is 2.5 mm (0.1 inch) for most models. A mesh

size of 2.0mm is required for LZW 650 and 1800 models, and

is recommended for LZW 115 and 360 models.

Where an in-line lter is purchased for an existing LaZerWeld

PHE, please check whether the follower is prepared for the

installation of an in-line lter. A replacement follower or

machining may become necessary.

LaZerWeld Plate Heat Exchangers are designed and

manufactured with due consideration and care for generally

accepted safety standards. As with any mechanical device,

the proper and safe performance of the equipment depends

on safe handling, operation, and maintenance.

GENERAL SAFETY PRECAUTIONS

WARNING

The following general safety precautions must be

followed in order to avoid personal injury or equipment

damage:

1. Always observe any applicable local and national safety

codes.

2. Always use appropriate protective gear, such as safety

gloves and safety shoes when touching and handling the

equipment.

3. Follow proper lifting procedures while handling the

equipment.

4. Never expose the equipment to heat, aggressive

chemicals or mechanical impact that can damage the

equipment.

5. Only qualied persons should handle and operate the

equipment.

RECEIVING OF EQUIPMENT

Receiving check

LaZerWeld Plate Heat Exchangers may be shipped fully

assembled and skid mounted. The PHE is normally mounted

on pallets and wrapped in protective plastic. Other wrappings

could be in open box or seaworthy packaging.

Prior to unpacking, check the packing for any defects and

the equipment for possible damage that might have occurred

during transportation. Any damage as a result of shipping

must be reported immediately. See Figure 5.

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LAZERWELD HEAT EXCHANGER

INSTALLATION - OPERATION - MAINTENANCE

Figure 5 - Check Before Unpacking

Figure 6 - Check the Equipment

Check the equipment according to the documentation

provided with the shipment. Any deviations must be reported

immediately. See Figure 6.

Drawing Documentation

The ofcial drawing that is included with the equipment:

including the following detailed elements:

• Assembly information (Figure 7)

• General arrangement details

• PHE Plate Arrangement information including parts listing

Figure 7 - Assembly Drawing

Assembly Details

The drawing provides information concerning overall

dimensions, bolt-down positions and a connection diagram

showing where external piping will be connected.

General Arrangement Details

This general arrangement detail provides the same

information, as the assembly detail plus additional customer

specied information. See Figure 8.

Figure 8 - General Arrangement Details

PHE Plate Arrangement Details

The plate heat exchanger is designed to perform a duty (or

duties) by arranging the number and type of plates required

in a specic sequence. This arrangement is represented

schematically by the plate diagram shown on the arrangement

drawing (Figure 9).

The drawing summarizes the plates and gaskets in the plate

heat exchanger design.

The summary includes plate types, angles, thickness and

material, along with gasket type, material and attachment

method (glued or clip in) and part no.

The assembly detail summarizes compressed plate pack

dimension, total weight and hold-up volume.

Figure 9 - Plate Arrangement Details

Nameplate

Identication of the equipment is printed on the nameplate

(mounted on the head or follower). When contacting Johnson

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LAZERWELD HEAT EXCHANGER

INSTALLATION - OPERATION - MAINTENANCE

Controls-Frick for service or spare parts, always refer to the

serial number on the nameplate (Figure 10).

Figure 10 - Nameplate

HANDLING

Lifting

If the plate heat exchanger is packed and transported lying

at on the head, great care must be taken during raising it, to

avoid sliding and impact of bending forces to the equipment

base or feet.

LaZerWeld Plate Heat Exchangers are provided with lifting

lugs or holes (Figure 12) for safe lifting and transportation

of the unpacked equipment. See Figure 11 - using followers!

When lifting an assembled heat exchanger frame, ensure

that the lifting point is above the centre of gravity of the

equipment.

WARNING

The lifting equipment must be in good condition and

should always be used in full compliance with the

specications and limitations given for the equipment.

Always maintain the minimum angle between the lifting

wires in order not to exceed the allowable wire tension.

The angle should not exceed 120° at any time. If the

ceiling height does not allow for safe lifting angle, dollies

or creepers can be used for moving the equipment.

WARNING

Always observe proper procedures for lifting and/

or moving equipment and qualied personnel for the

lifting and moving. Personnel must follow safe rigging

practices.

Indiscriminate use of fork lift trucks may damage the PHE in

critical areas.

See WARNING

concerning lifting

from follower!

Figure 11 - Lifting With Followers

WARNING

Lifting from the follower shown above is not acceptable

for some models and plate damage may result. Check

for warning signs on the follower supplied. Use

alternative lifting eyes, for example as shown below,

in those cases.

Figure 12 - Lifting Using Lifting Eyes

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LAZERWELD HEAT EXCHANGER

INSTALLATION

Installation

Foundation

The LaZerWeld Plate Heat Exchanger should be placed on

a solid foundation oor. If the unit is provided with feet,

the dimensions and placement of these are stated on the

assembly drawing.

Space requirements

Ensure that there is sufcient space around the plate heat

exchanger to separate the plate pack and to remove or insert

plates. The amount of free space required is stated on the

assembly drawing. See Figure 13.

Figure 13 - Space Allowance for Servicing

WARNING

Ensure sufcient space around the plate heat exchanger.

Connections

If the plate heat exchanger has liquid connections on the

follower, it is important that the compressed dimension is

checked against the drawing before the pipes are connected.

For easy disassembly and reassembly of the plate heat

exchanger, a pipe elbow should be used at all follower

connections.

The plate heat exchanger connections on the follower and

connector grids have little strength against pipe work or

nozzle loads. Such loads can arise for example from thermal

expansion. Proper care must be taken to avoid transfer of

such pipe forces and moments to the PHE.

STORAGE

Short Term Storage (less than 6 months)

The plate heat exchanger must be stored in a cool and

dry environment away from sunlight. It must be protected

from water and debris with a waterproof cover, while also

allowing for air circulation.

WARNING

Ozone-producing equipment, salt air and other corrosive

atmospheres must be avoided at all times.

Long Term Storage (more than 6 months)

The heat exchanger must be stored in a cool and dry

environment away from sunlight. It must be protected by

a waterproof cover against water and debris, however still

allowing for air circulation.

All connections must be closed to prevent water or debris to

enter the heat exchanger. Factory installed plugs or covers

may be used.

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LAZERWELD HEAT EXCHANGER

OPERATION

Operation

START-UP AND OPERATION

Start-up

WARNING

Start-up of the plate heat exchanger must be undertaken

slowly and smoothly to avoid any pressure shocks/

water hammering which might damage the equipment

or cause leakage.

Do not allow pressure changes of more than 10 bar (150

psi) per minute. Temperature changes may be harder

to control but ideally should be limited to less than 10

deg C (20 deg F) per minute. Cyclic hydraulic or thermal

conditions can cause serious damage to the PHE.

If the plate heat exchanger is provided with shutoff

valves at the inlets, these should be closed prior to

start-up and then opened slowly after pump start-up

Operation

The LaZerWeld plate heat exchangers are designed

according to predened temperatures, allowable pressure

drops, design pressures and uid compositions.

WARNING

Exceeding the design temperatures and pressures can

be harmful to the equipment and personnel, and must

be avoided.

Deviations from the designated uid composition may

cause corrosion of the plates and damage on the gaskets,

even if the deviations occur over relatively short time

periods.

Operational DOs And DON’Ts

1. Never charge liquid refrigerant into an evacuated heat

exchanger. This can cause the gaskets to chill to a point

where their elastic sealing properties are lost.

Generally, Paraprene (Chloroprene) gaskets remain exible

above -27°C / -13°F. Nitrile gaskets are exible above

-15°C / +5°F including Parator (Hydrogenated Nitrile). Low

Temperature Nitrile is exible above -45°C / -49°F. EPDM

gaskets are exible above -35°C / -31°F.

NOTICE

It is important to nd a way of charging the PHE with

gas rather than liquid.

2. Never freeze the gaskets on pump down.

3. Do not allow the process medium to freeze. Freezing

causes expansion and can lead to process side leaks and

gasket damage.

4. Do not allow any liquid refrigerant to remain in the heat

exchanger when the process channels will be cleaned-in-

place. Pump down to a procedure similar to the one attached.

There must be a fool proof method to ensure that CIP cannot

be activated while the PHE is charged with refrigerant.

Corrosion resistance

Before entering into operation you should assure that the

media do not exceed the corrosion resistance level of

the materials chosen for your Plate Heat Exchanger. Even

unprocessed water may contain such high level of corrosive

content (e.g. chloride content) that it may attack the plate

surface. A high temperature may accelerate the corrosion

process. Visit www.johnsonsontrols.com for more info.

Shutting down

The heat exchanger must be shut down slowly and allowed

to cool naturally to ambient temperature. Inlet valves, if

used, should be closed before closing the outlet valves.

If steam is used as a heating medium, it must be shut off rst.

In chilling duties, the cooling liquid must be shut down rst

to avoid freezing of the product.

WARNING

Sudden changes in the operating pressures and

temperatures should be avoided. Shock cooling of the

heat exchanger may cause leakages, due to sudden

contraction of the sealing gaskets.

All liquids should be drained from the heat exchanger after

shut down to prevent precipitation of products or scale build-

up. In the case of corrosive media, it may also be necessary

to ush with clean, noncorrosive water.

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LAZERWELD HEAT EXCHANGER

MAINTENANCE

Maintenance

WARNING

Never open the LaZerWeld plate heat exchanger until

the unit has cooled below 40°C (105°F).

Never open an LaZerWeld heat exchanger, which is

under pressure from any source.

Never open an LaZerWeld plate heat exchanger with

piping connected to the follower or connector grids.

DISASSEMBLY

Close the shutoff valves and drain the heat exchanger as

much as possible.

Disconnect any pipes connected to the follower.

Loosening and tightening of tie bars in the LaZerWeld

Medium and Small range plate heat exchangers can normally

be accomplished with ratchet wrenches/ spanners. Larger

units require hydraulic equipment or pneumatic/ electric

torque converters.

Measure and record the compressed dimension of the plate

pack before loosening the tie bars.

WARNING

As for any bolted vessel, bolts must not be slackened or

tightened indiscriminately, but approaching a cylinder

head sequence, balancing the opening on the right and

left throughout the process.

In the process below, dimension X is the initial compressed

dimension of the plate pack.

Loosen all tie bars in 3 mm increments to “X + 5%”, and

then remove only the 2 top and the 2 bottom tie bars in the

positions shown in the picture.

Loosen rest off the tie bars in increments of up to 6 mm to

“X + 10%”.

Top

Right

Side

Left

Side

Top

Bottom

Right

Side

Left

Side

Figure 14 - Large Units Figure 15 - Small Units

Order For Removing Tie Bars

For large or tall units ( where the distance between tie bars

labelled 1 and 3, exceeds 1200 mm, 4 ft), remove all tie bars

except 1 to 6. Loosen tie bars 1 to 6, moving in that order,

in increments of max. 25 mm until all tie bars become loose.

See Figure 14.

For smaller units, (distance between bars 1 and 3 is less than

1200 mm, 4 ft) remove all tie bars except 1 to 4. Loosen tie

bars 1 to 4, moving in that order, in increments of max. 25

mm until all tie bars become loose. See Figure 15.

When using hydraulic tightening units, ensure that each tie

bar is loosened equally during opening.

When the plate pack is fully released and the tie bars

removed, the heat exchanger can be opened by pushing the

follower back against the end support.

WARNING

For large units, block the follower into position, for

example by tying it to the end support, to provide extra

safety against accidental rolling of the follower during

maintenance.

Separate the plate pack carefully to avoid damaging the

gaskets or the plates.

CAUTION

Always wear protective gloves when handling plates.

Remove the plates by lifting them backwards and then

sideways off the top bar and then sliding out of the frame.

See Figure 16.

Figure 16 - Removal of Plates

Cleaning

The plate heat exchanger can be cleaned without opening

(i.e. cleaning-in-place) and manual cleaning.

Manual Cleaning

Manual cleaning is normally accomplished by washing down the

plates with a soft nonmetal brush, water and a cleaning agent.

See Figure 17.

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LAZERWELD HEAT EXCHANGER

MAINTENANCE

Figure 17 - Manual Cleaning Process

CAUTION

Cleaning agents must not be aggressive or corrosive

to the plates or the gaskets. If in doubt, contact the

cleaning agent supplier.

Cleaning agents should always be used according to safety

regulations and as specied by the supplier.

It is recommended to lay the plate on a at surface during

brush cleaning to avoid the risk of bending the plate.

If the heat exchanger is heavily fouled, care must be taken

to remove all debris from the gasket sealing surfaces when

the heat exchanger is reassembled. Any debris will most

likely lead to sealing failures. Do not forget that for glue free

gaskets, gasket sealing surfaces to be checked are at the top

as well as bottom surface of the gasket.

In many cases, fouling may be far too tenacious. LZW service

centers around the world may be approached for thorough

cleaning and inspection of the plate pack and regasketing.

Cleaning-In-Place

Cleaning in place (CIP) is accomplished by circulating a

suitable cleaning solution through the plate heat exchanger

instead of opening it.

CIP works best in the reverse direction of normal ow. Good

results are also possible with same direction ow and at

higher velocities than the product ow velocity.

The cleaning solution must be circulated at sufcient velocity

to ush out the product. Higher viscosity products generally

require higher velocity ushing to properly clean.

The cleaning solution must be able to dissolve the fouling on

the plates and great care must be taken to select a proper

cleaning solution that does not damage plates or gaskets.

Example of CIP Cleaning:

1. Drain product residues, cooling and heating media.

2. Rinse with cold or lukewarm water.

3. Circulate warm cleaning uid solution.

4. Rinse with warm water or warm water with softener added.

5. Rinse with cold or lukewarm water.

In simple cases cleaning can also be effected without circula-

tion but by pouring a cleaning uid solution into the system.

After some time of standing, ush the solution with clean water.

If the heat exchanger is to be out of service for a long time,

it is advisable to empty it, separate the plates, and clean

the unit. After cleaning, lightly re-clamp the plate pack and

cover it to protect from dirt and UV light. Please refer to

section 7.0 on Storage.

Determination Of Correct CIP System

The heat exchanger must be opened for inspection at regular

intervals. This is necessary especially during the initial start

up period, until experience has been gained on the effective-

ness of the cleaning regime. With these inspections, it will

gradually be possible to determine circulation times, tem-

peratures, and chemical concentrations with great certainty.

Insufcient cleaning is most often due to:

• Insufcient circulation rate.

• Insufcient cleaning time or temperature.

• Insufcient Concentration of the cleaning agent.

• Excessive periods of operation.

WARNING

Do not use chlorine-containing agents such as

hydrochloric acid (HCI).

Example of an acceptable solution for dairy applications and

AISI 316 plates and NBR gaskets:

• Oils and fats are removed with a water-emulsifying oil

solvent, e.g. BP-System Cleaner.

Organics and greasy coatings are removed with

Sodium hydroxide (NaOH) -max. concentration 2.0%

- max. temperature 85°C (185°F). 2.0% concentration

corresponds to 5.0 litre 30% NaOH per 100 litre water.

• Mineral scale deposits are removed with Nitric acid

(HN03)-max. concentration 0.5% - max. temperature

65°C (150°F). 0.5 % concentration corresponds to 0.58

litre 62% HN03 per 100 litres water.

CAUTION

Excess Nitric acid can seriously damage NBR and other

types of rubber gaskets.

• Nonorganic deposits can be removed by special

LaZerWeld Clean.

• Several alternatives to Nitric acid can be used, e.g.:

Phosphoric acid up to 5% and 85°C.

Recommended Limits for Process Side CIP or Sanitizing*

Chemical Concentration

MAX

Temperature

MAX ∆

Duration

MAX

Caustic Soda ∆1.00% 60°C 2 hrs

Nitric Acid 0.50% 60°C 2 hrs

Phosphoric Acid 5.00% 60°C 2 hrs

Sulphamic Acid

† 0.25% 60°C 1 hr

Hydrogen

Peroxide 1.00% 40°C 1 hr

* Never activate warm or hot CIP unless the refrigerant is

removed.

∆ Do not exceed 60°C ever with caustic soda in the presence

of Paraprene (neoprene) gaskets.

† Note that sulphamic acid solution must be freshly prepared

to avoid a change to sulphuric acid. If in doubt, check

compatibility of gasket material with cleaning chemical.

(Check with cleaning chemical supplier rst.)

190.200-IOM (MAR 2018)

Page 12

LAZERWELD HEAT EXCHANGER

MAINTENANCE

Commissioning & Troubleshooting Do’s And Don’ts

1. Always follow the instruction manual.

2. Check that tie bars are tight. Snug up to approximately

100 lb-ft. This equates to applying approximately a 70

pounds load at the end of an 18" arm wrench.

3. Do not open a heat exchanger for any reason unless the

following issues have been carefully evaluated. (It is only

intended to open these units at planned regasketing).

3.1 Elastomer gaskets may change their mechanical

properties when exposed to refrigerants, lubricants and

operating temperatures. Once a plate heat exchanger

is opened those gaskets may not t properly and seal a

second time. It is prudent to have a fresh set of gaskets

on hand before commencing service work.

3.2 Ensure that dust and debris cannot fall onto gasket

surfaces during opening and closing. Keep gaskets and

grooves clean.

3.3 Before opening the heat exchanger, document the

compressed plate measurement as indicated in Fig. 21

of this manual. If troubleshooting a leak, identify and

document the location of the perceived leak location.

Felt tip markers and pictures are excellent methods of

documentation.

3.4 The use of a sulfur stick is recommended for detecting an

ammonia leak. The burning sulfur will create a plume in

the presence of the leaking ammonia.

3.5 Special attention should be paid at the plate pack

extremities when checking for leaks. In other words,

• Seals between the rst plate pair after the head

• Between the rst plate pair and the second pair

• Between the last plate pair and the follower

• Between the last plate pair and the penultimate pair

• Both sides of the divider plate and neighboring pairs

3.6 With any follower connection leak, look for pipe forces

and moments which might cause follower deection

and leaks. Follower resistance to loads and moments is

limited.

3.7 When reassembling the plate heat exchanger, make sure

that the frame components are free of paint wherever

there is a refrigerant seal. i.e. around the ports in the

head, divider plates and follower. Some refrigerants,

particularly ammonia, degrade paint and can cause leaks.

3.8 If the follower plate has any port connection on it, special

care must be exercised to ensure that the frame port

rings align well with the plate port sealing surface. Use

a suitable technique to check alignment, e.g. engineer’s

blue.

3.9 It is necessary once an LZW heat exchanger has been

opened for service that it is then pressure and vacuum

tested prior to returning it to refrigeration duty. Please

follow the published factory recommendations for eld

testing.

4. Do not use superglue to attach the gaskets to the plates

for any reason. Avoid glue as far as practicable where

refrigerant seals are maintained, i.e. plate and frame port

rings. Some glues have chlorine compounds which can cause

plate cracking.

REASSEMBLY

Wipe the top bar clean with a soft cloth.

Apply suitable grease on the hanging surface where plates

will slide.

When replacing old plates, ensure that the new plates are

reinstalled in the correct sequence and orientation as stated

on the PHE Plate arrangement drawing.

CAUTION

Do not permanently bend or scratch the plates or

damage the gaskets during the installation. Some

plates must be carefully bent to install them.

Push the plates towards the head checking carefully that

they are correctly mounted.

When the plate pack has been correctly assembled, in most

models, plate edges will create a honeycomb (Figure 18). So,

check the edge of the plate pack for unusual patterns before

tightening the PHE.

Figure 18 - Correct Assembly Will Create a Honeycomb

Check the tie bars. Brush clean and grease over the working

lengths.

Once the plate pack has been carefully pushed towards the

xed head and then the follower is pushed against the plate

pack, then tie bar have to be placed in their positions

In the process shown in Figure 21, dimension X is the nal

intended compressed dimension of the plate pack.

NOTICE

It is important that any LZW plate heat exchanger that

has been opened for service be properly tested for

integrity before it is returned to duty. The Frick Service

Bulletin - 190.200-SB Heat Exchanger Field Service -

outlines the necessary steps to assure that the serviced

unit is ready to return to service.

LZW Return-To-Duty Testing Requiremnet Notice

190.200-IOM (MAR 2018)

Page 13

LAZERWELD HEAT EXCHANGER

MAINTENANCE

Top

Right

Side

Left

Side

Top

Bottom

Right

Side

Left

Side

Figure 19 - Smaller Units Figure 20 - Large Units

Order To Tighten Tie Bars

For Small To Mid-sized Units

(Distance between bars 1 and 3 < 1200 mm)

Compress plate pack in small increments, moving diagonally

from one tie bar to the next. Reach nal dimension X + 10%

by tightening bars 1 to 4 in the order given, in increments of

25 mm or less. Then add all left side and right side bars and

tighten all bars to dimension X+5% in increment of 6 mm or

less. Then add the 2 top and 2 bottom bars and compress in

3 mm increments to X. See Figure 19.

For Large Units

(Distance between bars 1 and 3 >1200 mm)

Compress plate pack in small increments, always moving

diagonally from one tie bar to the next. Reach nal dimension

X + 10% by tightening bars 1 to 6 in the order given, in

increments of 25 mm or less. Then add all left side and right

side bars. Tighten all bars to dimension X+5% in increment

of 6 mm or less. Then add the 2 top and 2 bottom bars and

compress in 3 mm increments to X. See Figure 20.

Figure 21 - Check X Dimension When Tightened

By using hydraulic compression tools 2, 4 or 6 bolts can

be compressed at the same time. The order of bolts and

increments must be the same as above.

It’s important that head and follower are kept parallel during

the compression work.

In this regard, compression must be measured at the top,

middle, and bottom sides. Measurements are to be taken

close to the tie bars. See Figure 21.

WARNING

Always tighten to full plate to plate contact, demonstrated

by sufcient force and within the dimensions permitted.

On the nameplate or the assembly drawing, you will

nd the minimum and maximum compressed dimension

of the plate pack.

In multisection machines, differences in pressures through

the sections can set up a concertina effect where higher

pressure sections open up by a few hundredths of millimetres

per plate and lower pressure sections close down (Figure 22).

Opening up of higher pressure sections can cause leakage of

that section. The robustness of the PHE is also linked with

the percentage division of plate counts in various sections.

Figure 22 - Pressure Differences

CAUTION

To ensure leak free operation in such applications, it

is even more important that the plates contact well

with each other. Well contacting plates are far more

resistant to the concertina effect. Always tighten to full

plate contact.

The concertina effect at minimum compressed dimension is

always very small and therefore the plate pack is more rigid

and robust against leakage.

Irrespective of new or old plates or a mix of new and old

plates, the plates must always be compressed to full contact.

Due to tolerances the full plate contact is attained between

maximum and minimum compressed pitch. Full plate contact

is indicated by rapidly raising compression force. See Figure

23 as an example.

190.200-IOM (MAR 2018)

Page 14

LAZERWELD HEAT EXCHANGER

MAINTENANCE

Gasket

Compressed

Gasket Compression

Max to Min Compression

Clamping Force

0% Plate Contact 100%

25%

Plate Pack Dimension

Figure 23 - Rapidly Rising Compression Force When Tight-

ening Plates

CAUTION

- Insufcient clamping force can cause leaking.

- For best rigidity of plate pack, tighten used plates to

the same dimension again.

- Never overtighten without written consent from

LaZerWeld as this can damage the ow plates.

Check the heat exchanger sealing before pipes on the

follower are connected.

After any service that requires the LZW heat exchanger to be

opened, follow the LZW Return to Service Bulletin (190.200-SB)

for pressure and vacuum testing.

Maintenance & Inspection

1. Routine Leak Check

In addition to normal inspection of a refrigeration plant,

conduct a leak check on the refrigerant side of the PHE using

nitrogen gas. The nitrogen gas should be laced with a trace

of the refrigerant for leak detection. The test is conducted at

10% above the operating pressure.

Evaporators Condensers

36 months from supply 12 months from supply

Then every 18 months Then every 12 months

*Evaporator: Leak check method: allow refrigerant in the

PHE to rise to ambient temperature during a shutdown and

check externally for leaks.

*Condenser and Desuperheater: Leak check method:

Remove refrigerant from the PHE. Isolate the PHE and use

nitrogen gas plus a minute trace of refrigerant gas or detector

gas. Test at a pressure no higher than 15% below the relief

pressure. Check for leaks externally. Do not conduct this test

with pure refrigerant.

2. Every 12 months, measure the compressed plate length

as indicated in gure 21 and record it for future comparison.

Also, check that each tie rod bolt has at least 100 ft lbs

torque to assure that all tie rods are participating in the

clamping force. Bolt torque to be checked only when both

sides of the heat exchanger are at or near 0 psig.

3. Regasketing

Unless the gaskets are inspected carefully by a Service

Engineer, regasketing must be carried out as follows:

IMPORTANT: Please read all footnotes following this table!

Max. (Actual) Operating

Temperature

Refrigerant Medium

Regasket After

These Years (1)

°C / °F YEARS

30°C / 86°F (2)

6.5 - Paraprene

6.5 - EPDM, NBR

6.5 - Low temp NBR

40°C / 104°F (2)

6 - Paraprene

6 - EPDM, NBR

5 - Low Temp NBR

50°C / 122°F (2)

5.5 - Paraprene

6 - EPDM

6 - HNBR

60°C / 140°F (2)

5 - Paraprene

5.5 - EPDM

5.5 - HNBR

70°C / 158°F (2)

4.5 - Paraprene

5 - EPDM

5 - HNBR

80°C / 176°F (2)

3 - Paraprene

4.5 - EPDM

4.5 - HNBR

90°C / 194°F (2)

2 - Paraprene

4 - EPDM

4 - HNBR

100°C / 212°F (2) 3.5 - EPDM

3.5 - HNBR

110°C / 230°F (2) 3 - EPDM

3 - HNBR

115°C / 239°F (2) (3) 2.5 - EPDM

2.5 - HNBR

125°C / 257°F (2) (3) (4) 2.5 - HNBR

TABLE FOOTNOTES

1. With elastomers stated. Count years from installation

of PHE, new plate pack or new gaskets, but no later

than one (1) year from delivery of PHE.

2. Extend by one (1) year at a time after each sound

leak check, beyond the schedule. Do not exceed

recommended re-gasket time by more than 3 years.

3. Do not exceed recommended re-gasket time by more

than 2.5 years.

4. For LZW 650 and LZW 800 units only.

General Notes:

Elastomer must be suitable for application and media

including the lubricant. Some lubricants can be

aggressive to elastomers and will shorten the expected

life considerably.

Spare gaskets: See the following gasket storage section.

c. Spare gasketed plates, not compressed in frame:

See the following gasket storage section.

190.200-IOM (MAR 2018)

Page 15

LAZERWELD HEAT EXCHANGER

MAINTENANCE

Gasket replacement

For ordering of spare parts and for re-gasketing, refer to

“Spare Parts” section on page 15.

In a small number of cases, gaskets may be attached with

glue. For the correct and important processes for removing

the glued gasket correctly and tting of new gaskets

correctly, consult LaZerWeld service.

Maintenance Of In-line Filter

The in-line lter where supplied needs to be cleaned at

regular intervals. The frequency depends on the content and

size of debris in the uid being ltered. An increase in the

pressure drop over the heat exchanger indicates the need for

cleaning (Figure 24).

Figure 24 - Clean the In-line Filter

Clean The In-line Filter In This Sequence:

1. Stop uid circulation pump.

2. Close valve on the lter side.

3. Drain the lter side.

4. Remove the full-faced gasketed blind ange on the

follower.

5. Carefully pull out the in-line lter through the follower.

6. Clean the lter with water and brush. Soap which is not

damaging to the lter material (AISI 316) may be used.

7. Before reinserting the in-line lter, it is recommended

that you ush any lose debris from the port where the

lter is installed.

8. Carefully reinsert the lter into the uid inlet port through

the follower.

9. Check that the full–faced gasket is in place on the blind

ange.

10. Place the blind ange on the follower.

11. Open the valve on the lter side and release air.

12. You may now start your circulation pump.

Spare Parts – Identication And Ordering

Identication Of Spare Parts

Each spare part of the LaZerWeld heat exchanger is allocated

a unique Item Number.

For gaskets and heat exchanger plates see Item Numbers on

PHE Plate arrangement drawing.

On some heat exchanger plates, the last four digits of the

item number are also stamped near one end of the plate.

On some gaskets, the part number may be moulded on the

gasket. Plate punch code and plate inversion – left and right

are shown in the picture here.

Plate handing is checked by which lower port will allow

ow into the channel. For the right hand plate, the right

hand lower port allows ow to enter or leave the channel.

Etc. See Figure 25.

Figure 25 - Plate Handing

Storage of LZW Plate Heat Exchanger Gaskets

Per ISO 2230, section 6.2, except for practical reasons, a

storage temperature up to 45°C/110°F is permitted.

•

Min. storage temperature: The minimum storage tempera-

ture is not limited, however, gaskets and gasketed plates

should not be handled at temperatures below 14°F [-10°C].

• To the extent practical, store the gaskets in a dark area in

an unstressed condition.

• Store the gaskets away from sunlight and ozone producing

equipment such as welding areas or electric motors.

•

Do not stack bundles of gaskets on top of each other. De-

stack bundles after receipt of gaskets, which may have

been shipped in a stacked condition to save shipping space.

Gasket stock rotation:

• The gasket inventory should be rotated based on

rst in/rst out sequence. This will help minimize the

deterioration by aging of rubber gaskets.

Elastomeric Gasket Storage Life

Gasket Polymer

ISO 2230 Storage By Customers

(1)

Nitrile, HNBR, Chloroprene

Group B 3 years

EPDM Group C 5 years

1. In permitted years from delivery, before use.

IMPORTANT: Storage years assume advice followed.

190.200-IOM (MAR 2018)

Page 16

LAZERWELD HEAT EXCHANGER

MAINTENANCE

TROUBLESHOOTING

Problem Possible Causes Suggested Solutions

1. Reduced heat

transfer

a. The inlet temperatures or ow

rates do not correspond to the

original design.

Correct temperatures or ow rates to design conditions.

b. Plate surfaces have become

fouled on either the product or

service side.

Open the heat exchanger and clean the plates or clean the plates (without

opening) by circulating a suitable cleaning agent or reverse ush to

dislodge debris.

c. Freeze-up. Correct temperatures or ow rates to design conditions.

2. Increased pressure

drop or reduced

ow rate

a. Plate surfaces have become

fouled on either the product or

service side.

See paragraph 1(b) above.

b. Debris is blocking the ow

channels.

Open the heat exchanger and clean the plates (see Section 6.0). Screens

or lters must be installed to prevent debris from entering the unit.

Reverse ush to dislodge debris.

3. Visible leakage a. Operating pressure exceeds the

rating of the heat exchanger.

Reduce the operating pressure to the rating of the heat exchanger. If the

unit continues to leak after the pressure is reduced, the plates or gaskets

might be damaged or gaskets aged and may require replacement.

b. The heat exchanger is not

tightened adequately for the

operating conditions.

Tighten the heat exchanger further in increments of .001 inch (0.025

mm) per plate, checking for leakage each time. Do not tighten below the

minimum dimensions given in the general arrangement drawing. If leaks

continue, see paragraph below.

c. Sealing surfaces of plates or

gaskets maybe damaged or dirty.

Open the heat exchanger and inspect the plates and gaskets. There must

not be any cuts, cracks, debris or at spots on the gaskets. Glue free

gaskets must not have any debris under the gasket. The plates must be

clean and free of heavy scratches or dents on both sides. Replace any

defective parts.

d. Chemical attack on the

gaskets.

Identify the source of chemical attack and correct either by eliminating the

corrosive agent or changing the material of the gaskets.

4. Cross-

contamination

a. Cracks in one or more plates.

These may be caused by

fatigue resulting from pressure

uctuations during operation.

Open the heat exchanger and inspect the plates. Replace the defective

parts. Identify the source of pressure uctuations and correct.

Dye-penetrant or alternative in situ testing may be required to identify

cracks in the plates. If this is the case, refer to Factory Service.

b. Holes in the plates caused by

corrosion

Identify the source of corrosion and correct by either eliminating the

corrosive agent or changing the material of the plates.

190.200-IOM (MAR 2018)

Page 17

LAZERWELD HEAT EXCHANGER

INSTALLATION - OPERATION - MAINTENANCE

FACTORY ASSISTED FIELD SERVICE

OF THE

LAZERWELD PLATE HEAT EXCHANGER

LZW SITE SERVICE PREPARATION CHECKLIST:

 A system refrigeration technician must be available for the scheduled service

 Notication of site specic safety requirements related to the heat exchanger work

 Leak location identied using the Service Request Form prior to arrival on site

 Identify the site decision maker who will be providing direction

 Have a site mechanic available to assist the heat exchanger service technician

 Shipped plates and gaskets located and available at point of use prior to arrival

 Site to be evaluated for safety; lock out/tag out must be in place

 The LZW system must be isolated and pumped down

 Air supply of 45 cfm at 90 psi available at point of use to operate pneumatic tools

 3,000 psi or greater power washer available if required to clean plates

 Work area identied for power washing

 Sufcient Nitrogen available to test plate pack (and connected system if not isolated)

 Vacuum pump available to reach to 2,000 micron of vacuum

INTRODUCTION

Successful eld service of the LaZerWeld (LZW) plate heat exchanger requires both diligent site preparation as well as adherence

to thorough service and testing procedures.

Frick publication 190.200-FRM LaZerWeld Service Request

along with the following information are provided to help

facilitate both.

All requests for factory eld service assistance should be

communicated using Frick publication 190.200-FRM, available

online or from the Frick Service Department.

FORM

NOTICE

The following site preparation and LaZerWeld service and testing recommendations are also

available as a separate single event checklist, Frick publication 190.200-SB, available online or

from the Frick Service Department.

190.200-IOM (MAR 2018)

Page 18

LAZERWELD HEAT EXCHANGER

INSTALLATION - OPERATION - MAINTENANCE

Steps Description Responsible Notes Init.

1Conrm that the most current LZW drawing is in hand. Refrigeration Con-

tractor

Measure the plate pack dimensions, compare to the drawing and docu-

ment the measurements. Please note that the nameplate information is

not always updated when a heat exchanger design is changed.

APV Heat Exchang-

er Service

3Verify the number of plate pairs in place before opening and record for

reference. Mark any suspect plates.

APV Heat Exchang-

er Service

4Mark any place the heat exchanger is leaking with tape or marker. APV Heat Exchang-

er Service

5Evacuate refrigerant from system. Refrigeration Con-

tractor

6Verify that lock out tag out procedures are in place. Refrigeration Con-

tractor

7If pipes are connected to the follower, the pipes are to be disconnected

from the follower by refrigeration contractor. All

Check to insure that plate heat exchanger is isolated from the chiller

package as much as possible using the installed valves. This applies to

both sides of the heat exchanger.

APV Heat Exchang-

er Service

9Check any available gauges to be sure the plates are at zero pressure

for all sections of the package before opening the systems.

Refrigeration Con-

tractor

10 Remove gauge or tting on both sides of plate heat exchanger to be

sure the plates are at zero pressure before moving to the next steps.

APV Heat Exchang-

er Service

Using a cross pattern similar to the closing procedure, as described in

the instruction manual, slowly open heat exchanger by loosening all

the tie bars equally in 1/8” increments for the rst 10% of compressed

dimension. For the remaining opening, loosen all the tie bars sequentially

in 1/4” to 1/2” increments until loose enough to remove the tie bars. For

more details consult the instruction manual.

APV Heat Exchang-

er Service

12 After the tie bars are removed slide the follower to the end support. APV Heat Exchang-

er Service

13 Rinse each plate as required being careful to avoid as far as practical

getting water into the welded pairs.

APV Heat Exchang-

er Service

Without removing the gaskets from the plate pairs, inspect each gasket

checking for cuts, wear or debris, including what may be under the

gasket.

APV Heat Exchang-

er Service

Remove each gasket that was marked prior to disassembly and carefully

inspect the gaskets and plates for deformation on both sides of the plate.

Retain the gaskets for inspection if required.

APV Heat Exchang-

er Service

GENERAL FIELD SERVICE NOTES

Do not attempt to adjust the tie bars while under pressure or under a vacuum.

Plate heat exchanges are limited to a gradual pressure changes of 150 psi per minute and temperature changes of 20°F per minute.

Consult the LaZerWeld Plate Heat Exchanger service manual and general arrangement drawing for diagrams or clarication.

Condenser/oil cooler 2-section heat exchangers: Never independently pressurize the oil cooler section as it may

lead to gasket displacement and leakage. It is imperative that the refrigerant condenser and the oil cooler be si-

multaneously pressurized preferably using the same pressure source. Similarly the coolant side of the two sections

must only be simultaneously subjected to pressure.

General caution about glue in refrigerant seal areas: The sealing surface of the port rings and the plate grooves

accepting these port rings, which seal the refrigerants, must stay free of adhesive. The legs extending from the

port rings are not sealing the refrigerant and adhesive, (examples: double sided tape, APV cement or Pliobond 30)

should be limited to such non-working areas. If there is an unusual need where the gasket ring will not t the plate

without glue assist, contact supervision and factory engineering for discussion and advice.

DO NOT PUT GLUE IN THE AREA MARKED YELLOW.

Date Location Service Tech Phone

FIELD TESTING OF THE PLATE HEAT EXCHANGER

190.200-IOM (MAR 2018)

Page 19

LAZERWELD HEAT EXCHANGER

INSTALLATION - OPERATION - MAINTENANCE

Steps Description Responsible Notes Init.

16 Check the gasket sealing surfaces on the faceplate and follower for paint,

remove any questionable paint.

APV Heat Exchang-

er Service

17 Wipe down each plate as needed and install replacement gaskets as

required.

APV Heat Exchang-

er Service

18 Install each plate as per the drawing. APV Heat Exchang-

er Service

19 After all the plates are installed check plate installation with the draw-

ing again.

APV Heat Exchang-

er Service

Start tightening the heat exchanger. Consult the LaZerWeld Plate Heat

Exchanger service manual for diagrams or clarication. The current plate

arrangement drawing is also required.

APV Heat Exchang-

er Service

Check the plate alignment and the repeating honey comb pattern of

the plate edges along the sides of the heat exchanger for indications of

incorrect plate orientation. Consult the LaZerWeld Plate Heat Exchanger

service manual for diagrams or clarication.

APV Heat Exchang-

er Service

Tighten the plate pack to the maximum dimension indicated on the unit

drawing for rst test with new plates and gaskets. If using new gaskets

with existing plates, use this formula(max dimension + dimension of plate

pack before opening) /2. If installing only a few new gaskets, go back to

the measured dimension prior to starting this service.

APV Heat Exchang-

er Service

23 Conrm the chiller package relief valve ratings. Document these ratings

on the service report.

Refrigeration

Contractor

24 Conrm all pressure gauges or transducers located within the pressure

test zone are of a suitable range for the return to duty pressure test.

Refrigeration

Contractor

25 Conrm all pressure vessels are sufciently rated for the test pressure

to be applied.

Refrigeration

Contractor

26 Manually open all automatic / manual valves required to do the test. Refrigeration

Contractor

27 Install calibrated pressure gauges on both the high and low sides of

the heat exchanger.

Refrigeration

Contractor

28 Access to the package must be limited to only necessary personnel. Refrigeration

Contractor

29 Ensure personnel have all required PPE (safety glasses, etc.). Refrigeration

Contractor

Connect dry nitrogen to high pressure side of plates. Increase the pres-

sure to 100 psi. (See condenser/oil cooler warning on page 1.) If no

leaks are present, open a system valve a very small amount to increase

the pressure 1-2 psi. This will introduce a small amount of refrigerant

to the plate high pressure side.

Refrigeration

Contractor

Pressurize the high (refrigerant) side of the unit to 85% of the MAWP

or 85% of the relief valve set pressure, (whichever is less) in 25 psi

intervals. There should be at least 5 minutes between each interval.

Refrigeration

Contractor

For the rst unbalanced test, increase the pressure to 85% of the work-

ing plate rating or 85% of the rating of the relief valve in the tested zone,

which ever is less for 60 minutes minimum. A loss of 1% pressure or

more during the test constitutes a failure. Permit pressure to stabilize

for 3 minutes before starting timer.

Refrigeration

Contractor

With the trace refrigerant gas in the heat exchanger check for leaks

using a sulfur stick or other appropriate refrigerant gas detector to

identify any locations of gas escaping the heat exchanger.

Refrigeration

Contractor

If the unit holds pressure and no escaping gas is detected, then proceed

with the next step. If the unit does not hold pressure, inspect all items

in the pressurized zone. This includes valves, anges and vessels sub-

jected to the test pressure. Once identied, depressurize the package

and make all appropriate repairs and begin the testing process again.

Refrigeration

Contractor

Release pressure from the high side of the heat exchanger until it

reaches twice operating pressure or 85% of the MAWP of the low side

of the heat exchanger, whichever is lower. Make note of this pressure

and make sure it does not increase during the next step.

Refrigeration

Contractor

FIELD TESTING OF THE PLATE HEAT EXCHANGER

190.200-IOM (MAR 2018)

Page 20

LAZERWELD HEAT EXCHANGER

INSTALLATION - OPERATION - MAINTENANCE

JOHNSON CONTROLS

100 Cumberland Valley Avenue

Waynesboro, PA 17268-1206 USA

Phone: 717-762-2121 • FAX: 717-762-8624

www.johnsoncontrols.com/frick

Form 190.200-IOM (2018-03)

Supersedes: 190.200-IOM (2017-05)

Subject to change without notice

Published in USA • 03/18 • PDF

March 2018 Form Revisions

p.3 –

Added some preface information

–

Added warranty information section

p.17 –

Added Factory Field Service Form (190.200-SB)

Steps Description Responsible Notes Init.

The second test is a balanced pressure test. Introduce nitrogen pres-

sure in to the low side of the heat exchanger being careful to limit the

pressure increase to a rate of 150 psi per minute. The balanced test

pressure should be done at the pressure identied in step #35 above.

While pressurizing the low side, monitor the high side pressure to be

sure it does not increase as noted above. A rise in high side pressure

during this procedure can be caused by plate exing. Relieve any ex-

cess pressure on the high side to maintain the balanced test pressure

on both sides.

Refrigeration

Contractor

Monitor pressure on both sides for 15 minutes. Inspect unit and check

for leaks. If no leaks (no visible change on the pressure gauge) pro-

ceed to next step. Permit pressure to stabilize for 3 minutes before

starting timer.

Refrigeration

Contractor

38 Allow the test pressure to be released from high side only down to less

than 5 PSI in a gradual and safe manner.

APV Heat Ex-

changer Service

For the second unbalanced test, add additional nitrogen to the low side,

if needed, after bleeding the pressure from the high side following the

balanced pressure test. Monitor pressure for on low side for 30 minutes.

Inspect unit and check for leaks. If no leaks (no visible change on the

pressure gauge) proceed to next step.

APV Heat Ex-

changer Service

40 Release pressure from low side. APV Heat Ex-

changer Service

With the tie bar threads correctly lubricated, check the torque of each

tie bar. For LZW-115 through LZW-800 the minimum is 100 ft-lbs on

each tie bar. Example: Approximately 70 lb on a 1 ½’ wrench arm.

For LZW-900 and larger models the minimum torque is 150 ft-lbs on

each tie bar.

APV Heat Ex-

changer Service

Evacuate both sides of the heat exchanger. It is recommended to draw

down to the 2000 micron level and hold with the pump running for 30

min. to assure a dry internal space and the accuracy of the next step.

Refrigeration

Contractor

43 With the vacuum pump off, hold the 2000 micron vacuum for 60

minutes. A vacuum rise of 500 microns or more constitutes a failure.

Refrigeration

Contractor

44 If vacuum test is successful, then proceed with next step. Otherwise,

make appropriate repairs and repeat entire test procedure.

Refrigeration

Contractor

45 Following the vacuum test, again check torque on tie bars. A minimum

of 100 ft-lbs is required on all tie bars.

APV Heat Ex-

changer Service

RETURN TO DUTY OF THE PLATE HEAT EXCHANGER

Introduce ammonia vapor via the suction line being sure the liquid is

drained from the low pressure side. Liquid ammonia is not to be in-

troduced into the plate heat exchanger at this time. The temperature

change would be too dramatic and it can cause the gaskets to chill to

a point where their elastic sealing properties are lost.

Refrigeration

Contractor

Once the proper operating pressure has been reached, liquid refrig-

erant can be introduced into the plates. Remember that plate heat

exchanges are limited to a rate of pressure changes of 150 PSI or less

and a temperature change of 20F or less per minute.

Refrigeration

Contractor

FIELD TESTING OF THE PLATE HEAT EXCHANGER

Frick LaZerWeld Plate Heat Exchangers Installation Operation and Maintenance Guide

Frick LaZerWeld Plate Heat Exchangers Installation Operation and Maintenance Guide

Frick LaZerWeld Plate Heat Exchangers Installation Operation and Maintenance Guide

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